Dodge - Ram Srt-10 Pickup - Workshop Manual - 2004 - 2004

Factory Workshop Manual Make Dodge Model Ram Srt-10 Pickup Engine and year V10-505 8.3L (2004) 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation Alarm Module: Description and Operation The Sentry Key Immobilizer Module (SKIM) (1) is the primary component of the Sentry Key Immobilizer System (SKIS). This module contains a Radio Frequency (RF) transceiver and a central processing unit, which includes the Sentry Key Immobilizer System (SKIS) program logic. The SKIM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKIM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKIM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKIM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKIM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKIM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. The Sentry Key Immobilizer Module (SKIM) transmits Radio Frequency (RF) signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKIM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKIM also communicates over the Programmable Communications Interface (PCI) data bus with the Powertrain Control Module (PCM) for gasoline engines or the Engine Control Module (ECM) for diesel engines, the ElectroMechanical Instrument Cluster (EMIC) and/or a diagnostic scan tool. The SKIM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKIM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKIM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKIM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKIM. For added system security, each SKIM is programmed with a unique Secret Key code. This code is stored in memory, sent over the PCI data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKIM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKIM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKIM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a PCI data bus message from the PCM or ECM during SKIS initialization. In the event that a SKIM replacement is required, the Secret Key code can be transferred to the new SKIM from the PCM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKIM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKIM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On or Start positions, the SKIM transmits an RF signal to excite the transponder in the ignition key. The SKIM then listens for a return RF signal from the transponder. If the SKIM receives an RF signal with a valid "Secret Key" and transponder identification codes, the SKIM sends a "valid key" message to the PCM/ECM over the PCI bus. If the SKIM receives an invalid RF signal or no response, it sends "invalid key" messages to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKIM messages. It is important to note that the default condition in the PCM or ECM is an invalid key. Therefore, if no message is received from the SKIM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 7 The SKIM also sends electronic messages to the EMIC which control the VTSS indicator. The SKIM sends messages to the EMIC to turn the indicator on for about three seconds when the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKIM sends bus messages to keep the indicator off for a duration of about one second. Then the SKIM sends messages to turn the indicator on or off based upon the results of the SKIS self-tests. If the VTSS indicator comes on and stays on after the bulb test, it indicates that the SKIM has detected a system malfunction and/or that the SKIS has become inoperative. If the SKIM detects an invalid key when the ignition switch is turned to the On position, it sends messages to flash the VTSS indicator. The SKIM can also send messages to flash the indicator and to generate a single audible chime whenever the Customer Learn programming mode is being utilized. The SKIS will store fault information in the form of Diagnostic Trouble Codes (DTC's) in SKIM memory if a system malfunction is detected. For diagnosis or initialization of the SKIM and the PCM/ECM, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 8 Alarm Module: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Grasp the tilt steering column knob (2) firmly and pull it straight rearward to remove it from the tilt adjuster lever (1) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 9 8. Disconnect the wire harness connector (2) from the Sentry Key Immobilizer Module (SKIM) (1). 9. Remove the screw (3) that secures the SKIM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKIM. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 10 1. Position the Sentry Key Immobilizer Module (SKIM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKIM to the steering column housing. Tighten the screw to 2 N.m (20 in.lbs.). 3. Reconnect the wire harness connector (2) to the SKIM (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 11 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 N.m (20 in.lbs.) 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in.lbs.) 9. Align the tilt steering column knob (2) with the tilt adjuster lever (1) on the left side of the steering column and use hand pressure to snap it back into place. 10. Reconnect the battery negative cable. NOTE: If the SKIM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKIM and to program at least two Sentry Key transponders before the vehicle can be operated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations RKE Module Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 15 Module-Sentry Key Immobilizer (SKIM) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 16 Keyless Entry Module: Description and Operation When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 17 Keyless Entry Module: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 18 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster. 3. Remove remote keyless entry module (2) from instrument cluster (1). INSTALLATION 1. Install remote keyless entry module (2) to instrument cluster (1). 2. Install instrument cluster. 3. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations Right Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 22 Voice Activation Module: Diagrams Module-Hands Free C1 Module-Hands Free C2 Module-Hands Free C3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 23 Voice Activation Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel right side end cap. 3. Remove the mounting fasteners. 4. Disconnect the electrical harness connector and remove module. INSTALLATION 1. Connect the electrical harness connector and position module. 2. Install and tighten the mounting fasteners. 3. Install the instrument panel right side end cap. 4. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations > Page 28 Heated Mirror Relay: Description and Operation The heated mirror relay (1) is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns (2). The heated mirror relay is a electromechanical device that switches battery current through a fuse in the integrated power module (IPM) to the outside rear view mirror heating grids. The heated mirror relay is energized when the relay coil is provided a ground path by the control circuitry within the A/C-heater control. The heated mirror relay is located in the IPM in the engine compartment. The ISO-standard heated mirror relay is an electromechanical switch that uses a low current input controlled by the A/C-heater control to control the high current output to the outside rear view mirror heating grids. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the outside rear view mirror heating grids. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The heated mirror relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the heated mirror relay include: - Terminal (30) receives fused battery current at all times. - Terminal (86) receives a ground through the defogger relay control circuit only when the A/C-heater control electronically pulls the circuit to ground. - Terminal (85) receives fused battery current through an ignition switch output circuit only when the ignition switch is in the Run position. - Terminal (87) provides battery current to the heated outside rear view mirror grids through the heated mirror relay output circuit only when the heated mirror relay coil is energized. - Terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the heated mirror relay coil is de-energized. The heated mirror relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard relay and for complete heated mirror system wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations > Page 29 Heated Mirror Relay: Service and Repair NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for heated mirror relay location. REMOVAL 1. Disconnect and isolate the negative battery cable (1). 2. Remove the cover from the integrated power module (IPM) (2) located in the engine compartment. 3. Remove the heated mirror relay from the IPM. INSTALLATION 1. Position the heated mirror relay into the proper receptacle of the integrated power module (IPM) (2). 2. Align the heated mirror relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations RKE Module Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 33 Module-Sentry Key Immobilizer (SKIM) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 34 Keyless Entry Module: Description and Operation When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 35 Keyless Entry Module: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 36 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster. 3. Remove remote keyless entry module (2) from instrument cluster (1). INSTALLATION 1. Install remote keyless entry module (2) to instrument cluster (1). 2. Install instrument cluster. 3. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation Power Seat Control Module: Description and Operation The heated seat module (2) is also known as the Seat Heat Interface Module. The heated seat module is located under the drivers front seat cushion, where it is secured to a mounting bracket. The heated seat module has a single connector receptacle (3) that allows the module to be connected to all of the required inputs and outputs through the seat wire harness. The heated seat module is an electronic microprocessor controlled device designed and programmed to use inputs from the battery, the two heated seat switches and the two heated seat sensors to operate and control the heated seat elements in both front seats and the two heated seat indicator lamp Light-Emitting Diodes (LEDs) in each heated seat switch. The heated seat module is also programmed to perform self-diagnosis of certain heated seat system functions and provide feedback of that diagnosis through the heated seat switch indicator lamps. The heated seat module cannot be repaired. If the heated seat module is damaged or faulty, the entire module must be replaced. The heated seat module operates on fused battery current received from the integrated power module. Inputs to the module include a resistor multiplexed heated seat switch request circuit for each of the two heated seat switches and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements and sensors, and controls the ground for the heated seat switch indicator lamps. When a heated seat switch (Driver or Passenger) is depressed a signal is received by the heated seat module, the module energizes the proper indicator LED (Low or High) in the switch by grounding the indicator lamp circuit to indicate that the heated seat system is operating. At the same time, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. The Low heat set point is about 36° C (96.8° F), and the High heat set point is about 42°C (107.6° F). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an N-channel Field Effect Transistor (N-FET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the N-FET which de-energizes the heated seat elements. The heated seat module will continue to cycle the N-FET as needed to maintain the selected temperature set point. If the heated seat module detects a heated seat sensor value input that is out of range or a shorted or open heated seat element circuit, it will notify the vehicle operator or the repair technician of this condition by flashing the High and/or Low indicator lamps in the affected heated seat switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation > Page 43 Power Seat Control Module: Testing and Inspection If a heated seat fails to heat and one or both of the indicator lamps on a heated seat switch flash. If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate, test the heated seat switch. If the heated seat switch checks OK, proceed as follows. 1. Check the heated seat element. 2. Check the heated seat sensor. 3. Check the heated seat switch. NOTE: Refer to Wiring for the location of complete heated seat system wiring diagrams and connector pin-out information. 4. Using a voltmeter, backprobe the heated seat module connector, do not disconnect. Check for voltage at the appropriate pin cavities. 12v should be present. If OK go to Step 5, if Not, Repair the open or shorted voltage supply circuit as required. 5. Using a ohmmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK replace the heated seat module with a known good unit and retest system, if Not OK, Repair the open or shorted ground circuit as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation > Page 44 Power Seat Control Module: Service and Repair REMOVAL 1. Position the driver seat to the full rearward and inclined position. 2. Working under the driver front seat, remove the two heated seat module retaining screws. Due to the fact that the retaining screws are installed with the seat cushion pan removed, a small right angle screwdriver will be required to access and remove the screws. 3. Disconnect the seat wire harness connector from the connector receptacle on the back of the heated seat module. Depress the connector retaining tab and pull straight apart. 4. Remove the heated seat module from under the front seat. INSTALLATION 1. Position the heated seat module under the front seat. 2. Connect the seat wire harness connector on the connector receptacle on the back of the heated seat module. 3. Working under the driver front seat, install the heated seat module retaining screws. 4. Re-position the driver seat. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams Module-Heated Seats Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 48 Seat Heater Control Module: Description and Operation The heated seat module is also known as the Seat Heat Interface Module. The heated seat module is located under the drivers front seat cushion, where it is secured to a mounting bracket. The heated seat module has a single connector receptacle that allows the module to be connected to all of the required inputs and outputs through the seat wire harness. The heated seat module is an electronic microprocessor controlled device designed and programmed to use inputs from the battery, the two heated seat switches and the two heated seat sensors to operate and control the heated seat elements in both front seats and the two heated seat indicator lamp Light-Emitting Diodes (LEDs) in each heated seat switch. The heated seat module is also programmed to perform self-diagnosis of certain heated seat system functions and provide feedback of that diagnosis through the heated seat switch indicator lamps. The heated seat module cannot be repaired. If the heated seat module is damaged or faulty, the entire module must be replaced. The heated seat module operates on fused battery current received from the integrated power module. Inputs to the module include a resistor multiplexed heated seat switch request circuit for each of the two heated seat switches and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements and sensors, and controls the ground for the heated seat switch indicator lamps. When a heated seat switch (Driver or Passenger) is depressed a signal is received by the heated seat module, the module energizes the proper indicator LED (Low or High) in the switch by grounding the indicator lamp circuit to indicate that the heated seat system is operating. At the same time, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. The Low heat set point is about 36° C (96.8° F), and the High heat set point is about 42° C (107.6° F). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an Nm-channel Field Effect Transistor (Nm-FEET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the Nm-FEET which de-energizes the heated seat elements. The heated seat module will continue to cycle the Nm-FEET as needed to maintain the selected temperature set point. If the heated seat module detects a heated seat sensor value input that is out of range or a shorted or open heated seat element circuit, it will notify the vehicle operator or the repair technician of this condition by flashing the High and/or Low indicator lamps in the affected heated seat switch. Refer to Diagnosis and Testing Heated Seat System in Heated Systems for flashing LED diagnosis and testing procedures. Refer to Diagnosis and Testing Heated Seat Module for heated seat module diagnosis and testing procedures. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 49 Seat Heater Control Module: Testing and Inspection If a heated seat fails to heat and one or both of the indicator lamps on a heated seat switch flash, refer to Diagnosis and Testing Heated Seat System in Heated Seats for the location of flashing LED heated seat system diagnosis and testing procedures. If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate, test the heated seat switch. Refer to Diagnosis and Testing Heated Seat Switch in Heated Seats for heated seat switch diagnosis and testing procedures. If the heated seat switch checks OK, proceed as follows. 1. Check the heated seat element. 2. Check the heated seat sensor. 3. Check the heated seat switch. NOTE: Refer to Wiring for the location of complete heated seat system wiring diagrams and connector pin-out information. 4. Using a voltmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for voltage at the appropriate pin cavities. 12v should be present. If OK go to Step 5, if Not, Repair the open or shorted voltage supply circuit as required. 5. Using a ohmmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK replace the heated seat module with a known good unit and retest system, if Not OK, Repair the open or shorted ground circuit as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 50 Seat Heater Control Module: Service and Repair REMOVAL 1. Position the driver seat to the full rearward and inclined position. 2. Working under the driver front seat, remove the two heated seat module retaining screws. Due to the fact that the retaining screws are installed with the seat cushion pan removed, a small right angle screwdriver will be required to access and remove the screws. 3. Disconnect the seat wire harness connector from the connector receptacle on the back of the heated seat module. Depress the connector retaining tab and pull straight apart. 4. Remove the heated seat module from under the front seat. INSTALLATION 1. Position the heated seat module under the front seat. 2. Connect the seat wire harness connector on the connector receptacle on the back of the heated seat module. 3. Working under the driver front seat, install the heated seat module retaining screws. 4. Re-position the driver seat. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations EBC 125 (RWAL) EBC 325 (ABS) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 58 Electronic Brake Control Module: Diagrams Controller Antilock Brake C1 Controller Antilock Brake C2 (ABS) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 59 Electronic Brake Control Module: Description and Operation Fig.1 Hydraulic Control Unit CONTROLLER ANTILOCK BRAKE (CAB) The Controller Antilock Brake (CAB) is mounted to the Hydraulic Control Unit (HCU) and operates the ABS system. The CAB voltage source is through the ignition switch in the RUN position. 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 III 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 is being replaced with a new CAB is must be reprogrammed with the use of a DRB III. TRW EBC 125 CONTROLLER ANTILOCK BRAKE The CAB includes a microprocessor and two solenoids that control the valves that control brake pressure during RWAL braking and circuits that: Monitor the brake switch input to tell whether or not to prepare for possible antilock braking - Monitor the brake fluid level switch input to tell whether or not the state of the hydraulics has a problem - Monitor the wheel speed sensor input to determine when a rear wheel is tending to lock up - Operate the integral hydraulic control unit (HCU) during antilock braking based on comparing the speed sensor to information programmed in memory - Detect RWAL system related problems and take diagnostic action - Able to execute self-tests and output control commands TRW EBC 325 CONTROLLER ANTILOCK BRAKE The CAB 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 ABS braking - Monitor the brake fluid level switch input to tell whether or not the state of the hydraulics has a problem - Wheel speed sensors are monitored to determine when a wheel is tending to lock up. The CAB will operate the valves in the HCU to control braking pressure during ABS braking - Detect ABS system related problems and take diagnostic action - Able to execute self-tests and output control commands Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 60 Electronic Brake Control Module: Service and Repair REMOVAL 1. Remove the negative battery cable from the battery. 2. Pull up on the CAB harness connector release and remove connector. 3. Remove the CAB mounting bolts. 4. Remove the pump connector from the CAB. 5. Remove the CAB from the HCU. INSTALLATION NOTE: If the CAB is being replaced with a new CAB is must be reprogrammed with the use of a DRB III. 1. Install CAB to the HCU. 2. Install the pump connector to the CAB. 3. Install mounting bolts. Tighten to 2 Nm (16 in. lbs.). 4. Install the wiring harness connector to the CAB and push down on the release to secure the connector. 5. Install negative battery cable to the battery. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 68 Compressor Clutch Relay: Description and Operation A/C Compressor Clutch Micro-Relay The A/C compressor clutch relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The A/C compressor clutch relay is located in the integrated power module (IPM) in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the IPM cover for A/C compressor clutch relay identification and location. The black, molded plastic case is the most visible component of the A/C compressor clutch relay. Five male spade-type terminals extend from the bottom of the base to connect the relay to the vehicle electrical system, and the ISO designation for each terminal is molded into the base adjacent to each terminal. The ISO terminal designations are as follows: - 30 (Common Feed) - This terminal is connected to the movable contact point of the relay. - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The A/C compressor clutch relay is an electromechanical switch that uses a low current input from the powertrain control module (PCM) or engine control module (ECM) depending on engine application, to control the high current output to the compressor clutch electromagnetic coil. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. The resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The A/C compressor clutch relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the A/C compressor clutch relay include: - The common feed terminal (30) receives a battery current input from a fuse in the IPM through a fused B(+) circuit at all times. - The coil ground terminal (86) receives a ground input from the PCM/ECM through the A/C compressor clutch relay control circuit only when the PCM/ ECM electronically pulls the control circuit to ground. - The coil battery terminal (85) receives a battery current input from PTC 1 in the IPM through a fused ignition switch output (run) circuit only when the ignition switch is in the On position. - The normally open terminal (87) provides a battery current output to the compressor clutch coil through the A/C compressor clutch relay output circuit only when the A/C compressor clutch relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the A/C compressor clutch relay coil is de-energized. Refer to the appropriate wiring information for diagnosis and testing of the micro-relay and for complete HVAC wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 69 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. Integrated Power Module (IPM) 2. Remove the cover from the integrated power module (IPM). 3. Refer to the fuse and relay layout label on the IPM cover for compressor clutch relay identification and location. 4. Remove the A/C compressor clutch relay from the IPM. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the IPM cover for A/C compressor clutch relay location. 2. Position the A/C compressor clutch relay in the proper receptacle in the IPM. 3. Align the A/C compressor clutch relay terminals with the terminal cavities in the IPM receptacle. 4. Push down firmly on the A/C compressor clutch relay until the terminals are fully seated in the terminal cavities in the IPM receptacle. 5. Install the cover onto the IPM. 6. Reconnect the negative battery cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Description and Operation Brake Lamp Relay: Description and Operation DESCRIPTION The exterior lighting system for this model include the following components: ^ Backup Lamps ^ Brake Lamps ^ Daytime Running Lamps ^ Front Fog Lamps ^ Hazard Warning Lamps ^ Headlamps ^ Park Lamps ^ Turn Signal Lamps Other components of the exterior lighting system for this model include: ^ Backup Lamp Switch ^ Brake Lamp Switch ^ Front Control Module ^ Front Fog Lamp Relay See: Relays and Modules - Power and Ground Distribution/Relay Box ^ Hazard Switch ^ Multi-Function Switch ^ Park Lamp Relay See: Relays and Modules - Power and Ground Distribution/Relay Box ^ Trailer Tow Connectors Some of the interior and exterior lighting functions are governed by the front control module. The headlamp, dome, and door ajar switches provide signals to the instrument cluster. The instrument cluster sends a J1850 message to the front control module to enable the necessary components for illumination. Hard wired circuitry connects the exterior lighting system components to the electrical system of the vehicle. Refer to the appropriate wiring information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 80 Fog/Driving Lamp Relay: Description and Operation The front fog lamp relay is located in the Power Distribution Center (PDC)See: Relays and Modules - Power and Ground Distribution/Relay Box Applications and ID in the engine compartment of the vehicle. The front fog lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs by five integral male spade-type terminals that extend from the bottom of the relay base. The front fog lamp relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The front fog lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the front fog lamps. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The front fog lamp relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC). The inputs and outputs of the front fog lamp relay include: - Common Feed Terminal - The common feed terminal (30) receives battery voltage at all times from a fuse in the PDC through a fused B(+) circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a front fog lamp relay control circuit. The FCM controls front fog lamp operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery voltage at all times from a fuse in the PDC through a fused B(+) circuit. - Normally Open Terminal - The normally open terminal (87) is connected to the front fog lamps through a front fog lamp relay output circuit and provides battery voltage to the front fog lamps whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is not connected in this application. The front fog lamp relay can be diagnosed using conventional diagnostic tools and methods. Refer to the appropriate wiring information for diagnosis and testing of the front fog lamp micro-relay and for complete wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 81 Fog/Driving Lamp Relay: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. 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 cover for the Power Distribution Center (PDC). 3. Remove the front fog lamp relay by grasping it firmly and pulling it straight out from the receptacle in the PDC. INSTALLATION 1. Position the front fog lamp relay to the proper receptacle in the Power Distribution Center (PDC). 2. Align the front fog lamp relay terminals with the terminal cavities in the PDC. 3. Press firmly and evenly on the top of the front fog lamp relay until the terminals are fully seated in the PDC. 4. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 85 Parking Lamp Relay: Description and Operation The park lamp relay is located in the Power Distribution Center (PDC) of the vehicle. The park lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The park lamp relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The park lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the park lamps. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The park lamp relay terminals are connected to the vehicle electrical system through a connector in the Junction Block (JB). The inputs and outputs of the headlamp low beam relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the park lamps through the park lamp relay output circuit and provides ground to the park lamps when the relay is de-energized, and battery current to the park lamps whenever the relay is energized. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a park lamp relay control circuit. The FCM controls park lamp operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current at all times from a fuse in the PDC through a fused B(+) circuit. - Normally Open Terminal - The normally open terminal (87) receives battery current at all times from a fuse in the Power Distribution Center (PDC) through a fused B(+) circuit. - Normally Closed Terminal - The normally closed terminal (87A) is connected to ground at all times. The park lamp relay can be diagnosed using conventional diagnostic tools and methods. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 86 Parking Lamp Relay: Testing and Inspection The park lamp relay is located in the Power Distribution Center (PDC). Refer to the appropriate wiring information. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the park lamp relay from the PDC. 2. 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. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 8 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. 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, reinstall the relay and use a DRBIII(R) scan tool to perform further testing. Refer to the appropriate diagnostic information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 87 Parking Lamp Relay: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the Power Distribution Center (PDC) cover. 3. Remove the park lamp relay by grasping it firmly and pulling it straight out from the receptacle in the PDC. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the park lamp relay to the proper receptacle in the Power Distribution Center (PDC). 2. Align the park lamp relay terminals with the terminal cavities in the PDC. 3. Press firmly and evenly on the top of the park lamp relay until the terminals are fully seated in the PDC. 4. Install the PDC cover. 5. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations Power Distribution Module: Locations Left Front Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 92 Battery Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 93 Integrated Power Module And Fan Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 94 Power Distribution Module: Diagrams 8w-13-12 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 95 Module-Integrated Power C1 Module-Integrated Power C2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 96 Module-Integrated Power C3 Module-Integrated Power C4 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 97 Module-Integrated Power C5 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 98 Module-Integrated Power C6 Module-Integrated Power C7 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 101 Power Distribution Module: Description and Operation Front Control Module The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit. As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the FCM: - Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the FCM: - B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Data Bus Circuit Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 102 Power Distribution Module: Testing and Inspection FRONT CONTROL MODULE The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus network and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any FCM related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool. The most reliable, efficient, and accurate means to diagnose the FCM requires the use of an appropriate scan tool and the proper Diagnostic Procedures. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 105 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 106 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 107 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect and isolate the battery negative cable (3). 2. Partially remove the Integrated Power Module (IPM) (4) from the engine compartment. 3. Remove the Front Control Module (FCM) retaining screws. 4. Using both hands, separate the FCM from the IPM assembly disengaging the 49-way electrical connector and remove the FCM from the vehicle. INSTALLATION 1. Install the Front Control Module (FCM) onto the Integrated Power Module (IPM) (4) by pushing the 49-way electrical connector straight in. 2. Install the FCM retaining screws. Torque the screws to 7 in. lbs. 3. Install the IPM. 4. Connect the battery negative cable. 5. Verify normal vehicle operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Component Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Component Locations > Page 112 Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 113 Relay-Run-Accessory (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 114 Power Distribution Relay: Description and Operation RELAY-TRAILER TOW All vehicles are equipped with two trailer tow relays, one for the trailer right turn and brake lamps and the other for the trailer left turn and brake lamps. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. A trailer tow relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The trailer tow relays are electromechanical switches that use a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a right or left trailer tow turn relay control circuit. The FCM controls trailer brake and turn lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the trailer lamps through a right or left trailer tow turn relay output circuit and provides battery voltage to the right or left trailer brake and turn lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The trailer tow relays can be diagnosed using conventional diagnostic tools and methods. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 118 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 119 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 120 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 121 Module - Integrated Power (Rear View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 122 Relay Box: Application and ID Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 123 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 124 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 125 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 132 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 133 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 134 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 135 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 136 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 137 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 138 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 139 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 140 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 141 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 142 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 143 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 144 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 145 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 146 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 147 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 148 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 149 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 150 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 151 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 152 Body Control Module: Electrical Diagrams Airbag System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 153 Premium Audio System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 154 Base Audio System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 155 Remote Radio Controls Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 156 PCI Bus Communication Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 157 PCM Communication - JTEC PCM Communication - NGC Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 158 ECM Communication - Diesel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 159 Door Ajar System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 160 Heated Mirror System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 161 Rear Window Defogger Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 162 Exterior Lights Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 163 Heating A/C System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 164 Horn System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 165 Instrument Cluster Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 166 Overhead Console Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 167 Power Door Locks Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 168 Telecommunications - Hands Free System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 169 Vehicle Theft Security System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 170 Wipers Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information SERVICING SUB-ASSEMBLIES Some components of the body system are intended to be serviced as an assembly only. Attempting to remove or repair certain system subcomponents may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures should be serviced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 173 Body Control Module: Vehicle Damage Warnings ELECTRICAL TESTING PRECAUTIONS Before disconnecting any control module, make sure the ignition is "off". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description Body Control Module: Description and Operation System Description IDENTIFICATION OF SYSTEM The vehicle systems that are part of the "body" system are: - Airbag - Audio (with amplifier on premium systems) - Chime - Communication - Door Ajar System - Electrically heated system - Exterior lighting - Heating and A/C - Horn - Instrument Cluster - Interior Lighting - Memory Seat - Overhead Console - Power Door Lock/RKE - Power windows - Telecommunications (hands free phone) - Vehicle theft security system (VTSS) - Windshield Wiper and Washer SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 2004 DR consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI 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 information to perform its function. It will only respond to messages "addressed" to it through binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the communication section of this general information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 176 Body Control Module: Description and Operation Functional Operation Airbag System The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end or side collisions. The system is most effective when used in conjunction with the seat belt system. On some models the ACM supports Seat Belt Tensioners, Passenger Airbag Off Switch, and others Impact Sensor. It may be necessary to use the DRBIII(R) to reconfigure the ACM to the vehicle equipment. The airbag control module (ACM) is an electronic module that monitors the airbag system for proper operation, stores diagnostic trouble code (DTCs), controls the airbag warning lamp and contains the sensor and actuator that is responsible for driver, passenger, and curtain airbag deployment. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTCs) to the technician through the DRBIII(R) via the PCI bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Electro/Mechanical Instrument Cluster (EMIC) from the ACM via the PCI bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the "run" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6-8 seconds. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds, then goes off, there is usually an intermittent problem in the system. 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 OR DEATH. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. The DR will have two Airbag Control Modules. Each ACM is specifically calibrated for one body type, light duty or heavy duty. To determine the body types the ACM monitors the PCI Bus for a message containing the complete VIN. The ACM uses the 6th digit of the VIN to identify the heavy duty or light duty vehicle. The 6th digit of the VIN will be a number 1 for light-duty vehicle and a 2, 3 or 4 for heavy-duty vehicle. If the PCI Bus VIN message 6th character matches the ACM body type, the VIN will be stored within 5.6 seconds after ignition on. After the VIN is stored, the ACM verifies PCI Bus VIN message within 2.6 seconds after the ignition is turned on. If two valid matching PCI Bus VIN messages are not received within 5.6 seconds the ACM will set a Missing Original VIN DTC. If the ACM and PCM module types, 6th character of the VIN, light-duty or heavy-duty do not match the Calibration Mismatch DTC will be set. CAUTION: Therefore, the practice of exchanging (swapping) airbag control modules, instrument clusters, powertrain control modules and other electronic modules in this vehicle with those removed from another vehicle must always be avoided. DRIVER AIRBAG The airbag protective trim cover is the most visible part of the driver side airbag system. 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. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and hybrid inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. CLOCKSPRING The clockspring is mounted on the steering column behind the steering wheel. This assembly consist of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wiring and the driver airbag, the horn, and the vehicle speed control switches if equipped. The clockspring must be properly centered when it is reinstalled on the steering column following any service procedure, or it could be damaged. The clockspring cannot be repaired and it must be replaced. PASSENGER AIRBAG When supplied with the proper electrical signal the passenger airbag inflator or inflators discharge the gas directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 177 WARNING: THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE.BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. PASSENGER AIRBAG ON-OFF SWITCH The Passenger Airbag On-Off Switch allows the customer to turn the passenger airbag function ON or OFF. The OFF indicator will be illuminated whenever the switch is turned to the off position and for 2 seconds at ignition on for an indicator bulb test. The switch assembly is mounted in the center of instrument panel to make the OFF indicator visible to all front seat occupants. WARNING: TO AVOID PERSONAL INJURY OR DEATH, ALWAYS CHECK THE PASSENGER AIRBAG ON-OFF SWITCH POSITION BEFORE DRIVING THE VEHICLE. A SWITCH IN THE WRONG POSITION INCREASES THE RISK OF SERIOUS INJURY OR DEATH IN A COLLISION. To operate, insert the ignition key into the switch keyhole, push key in to release the internal plunger, and rotate to the desired switch position. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. The ignition key is the only key or object that should ever be inserted into the switch. NOTE: Do not turn the On-Off switch with the ignition on. The ACM continuously monitors the resistance of the Passenger Airbag On-Off Switch circuits to identify the switch position and provide circuit diagnostics. The on-off switch ON position resistance is 175 to 190 ohms and the OFF position resistance is 820 to 870 ohms. If the on-off switch circuits are open, shorted to ground or battery the ACM will set active and stored DTC. Upon receiving a switch diagnostic trouble code the airbag warning indicator, in the instrument cluster, will be turned on by the ACM. Whenever the airbag warning indicator is illuminated, the ACM should be the first module interrogated. SEAT BELT TENSIONER Front seat belt systems incorporate Tensioner Modules (SET). At the onset of an impact event each tensioner uses a pyrotechnic device, which is triggered simultaneously with the airbags, to rapidly retract the seat belts. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. The ACM module monitors the Seat Belt Tensioners circuit resistance and reports active and stored DTC's if any problem is found. SIDE IMPACT SENSORS The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration and when combined with the ACM Accelerometer provides verification of the direction and severity of a side impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Airbag Control Module. The ACM microprocessor continuously monitors all of the passive restraint system electrical circuits to determine the system readiness. If the ACM detects a system fault, it sets a Diagnostic Trouble Code and controls the airbag warning indicator operation accordingly. The side impact sensors receive battery current and ground through dedicated driver and passenger sensor signal and ground circuits from the ACM. The impact sensors and the ACM communicate by modulating the current in the sensor signal circuit. If the sensor is dropped it must be replaced. Disconnect the battery or remove both airbag fuses before servicing impact sensors. CAUTION: Do not remove or install the impact sensors while the sensor is attached to the vehicle wiring. CURTAIN AIRBAGS The Left and Right curtain airbags are located in the outboard edge of the roof under the headliner, just above the door openings. When supplied with the proper electrical signal the inflator can discharge the compress gas directly into the curtain airbag. Upon deployment, the curtain will tear open the headliner allowing the curtain airbag to fully deploy between the headliner and seat. The curtain airbag cannot be repaired and must be replaced if deployed or in any way damaged. WARNING: THE CURTAIN AIRBAG CONTAINS AN INERT GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 178 SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. SPECIAL TOOLS Some airbag diagnostic test use special tools, airbag load tools, 8310 and 8443 for testing squib circuits. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of an Driver or Passenger Airbag, curtain airbag, clockspring, or seat belt tensioner (use a jumper if needed). Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective component has been removed from the system and should be replaced. If the DTC is still active, continue this process until all component in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed the squib wiring can be tested for open and shorted conditions. AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRBIII(R). Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. ACTIVE CODES The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. STORED CODES Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned off. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. Maintain a safe distance from all airbags while performing the following inspection. If no obvious problems are found, erase stored codes, and with the ignition "on" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Audio System The factory installed radio receiver communicates on the Programmable Communication Interface (PCI) data bus network. The PCI Bus inputs into the Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 179 radio are used for VF dimming and remote steering wheel controls. All the radios are capable of displaying faults and allowing certain actuation tests through the use of the DRBIII(R). When attempting to perform PCI Bus diagnostics, the first step is to identify the radio in use in the vehicle. When trouble shooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term output refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio, or wiring could be at fault. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit, A faulty speaker could not cause this DTC. REMOTE RADIO CONTROLS These radios can be controlled via remote radio switches (optional). These switches are located on the back side of the steering wheel. They control mode, preset, seek up, seek down, volume up and volume down functions. These functions are inputs to the Instrument Cluster (MIC) and can be read with the DRBIII(R). The switches are a multiplexed signal to the MIC. The radio control MUX circuit is a 5 volt line that is pulled to ground through different value resistors built into the switches. This causes a voltage drop to be seen by the MIC and it sends a specific message to the radio on the PCI Bus circuit. The radio then responses to the message. This circuit is fairly simple to troubleshoot. The circuit must be complete from the switches in the steering wheel to the MIC. The ground must be complete so that the switches can cause the voltage drop for the MIC to see. The circuit passes through the clockspring so continuity through this devise must be verified. AMPLIFIER (PREMIUM SYSTEM) The Premium Audio Amplifier uses a microprocessor for audio digital signal processing (DSP) and system diagnostics. DSP provides a more accurate and consistent match of the audio system equalization to the vehicle interior. The DR Ram amplifier has six channels for superior sound quality. The amplifier reads the VIN from the PCI bus and sets itself to match the vehicle. The amplifier will send four beeps to the vehicle speakers at ignition on, if it does not read the VIN correctly. A replacement amplifier may beep at the first power up, but if these beeps are heard after the first ignition on, the DRBIII(R) should be used to verify the amplifier is connected to the PCI bus and that the VIN on the PCI bus is correct. The amplifier, wiring to the speakers and the speakers work independently from the radio. The amplifier's microprocessor supports several diagnostic functions. Tests can be run from the DRBIII(R) that will help in diagnosing audio system problems. The DRBIII(R) can display fault messages when an input or output problem to the amplifier is detected. The amplifier can detect wiring shorts and suggest which wires are likely to be shorted. The amplifier can send test signals that can be used to verify that the amplifier, speakers, and wiring to the speakers are operating properly. The amplifier can also be used to test if the radio is sending audio signals to it. The DRBIII(R) can be used to verify the amplifier equalization setting matches the vehicle, in case there is a sound quality complaint. Using the DRBIII(R) audio system diagnostics can determine the nature of the problem. Diagnostic tests the Amplifier can perform through the DRBIII(R): Continuous Tone Test - This test will send a continuous tone to each speaker and will verify the integrity of an individual channel. PCI Amplifier Test - This test will detect a PCI bus or checksum failure. Input Test - This test will detect the activity on the amplifiers input channels from the radio. Speaker Output Test - This test will detect the activity on the amplifiers output channels to the speakers NAVIGATION RADIO The optional navigation radio system receives GPS signals from up to eight satellites to display the position and direction of the vehicle. Map information is supplied through a DVD-ROM. An electronic gyrosensor and the vehicle's speed sensor enable the system to display the present vehicle position even in locations where GPS signals may be blocked. When a destination is selected, the navigation system uses information from the map to quickly calculate a route. As the vehicle is driven along the chosen route, the operator is guided with pictorial displays and voice prompts. For complete operating instructions, refer to the manual included with the vehicle. Communication The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25. Additional tracer colors may be added to the violet in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on this vehicle: - Front Control Module - Airbag Control Module - Controller Antilock Brake Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 180 - A/C Heater Control Module - Powertrain Control Module (gas only) - Engine Control Module (diesel only) - Radio - Amplifier (if equipped) - Hands Free Module - Transfer Case Control Module (if equipped) - Sentry Key Immobilizer Module - Compass Mini-Trip Computer (if equipped) - Electro/Mechanical Instrument Cluster Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRBIII(R) lab scope. The 12v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open PCI circuit at the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: - All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - Dashed lines in the overhead console ambient temperature display - No response received from any module on the PCI bus (except the ECM/PCM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRBIII(R). Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRBIII(R). If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRBIII(R) may display "BUS ± SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRBIII(R) and in noway indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 181 NOTE: The 2004 DR 3.7L, 4.7L, and 5.7L vehicles are equipped with the Powertrain Control Module and Transmission Control Module combined in a single control module. This module is the Next Generation Controller (NGC) for DaimlerChrysler and will be referred to as the Powertrain Control Module (PCM). The PCM has four color coded connectors C1/A through C4/D, (C1/A BLK, C2/B - ORANGE, C3/C - WHITE, C4/D -GREEN), with each connector containing 38 pins. The 5.9L Electronic Fuel Injection 24 valve Turbo Diesel has an Engine control module (ECM) CM845. New Diagnostic procedures and New DTC numbers are two of the changes you will see which reflect the new combined module technology. There are new Verification tests and module replacement procedures for the new PCM. Two tools are required to diagnose and repair the PCM terminals and harness connectors: 1. Miller #3638 Terminal Removal Pick must be used to release the connector terminals or harness and connector damage will occur. 2. Miller #8815 Pinout Box must be used to probe the PCM terminals or terminal damage will occur. Door Ajar System The door ajar state is used as an input for various control modules on the vehicle. The DRBIII(R) will display the state of the door ajar switches in Inputs/ Outputs. It's important to note, that when a door is closed, the switch state on the DRBIII(R) will show OPEN, and when the door is open, the switch state will show CLOSED. During diagnosis, if a door is closed and the DRBIII(R) displays the switch state as CLOSED, it indicates a shorted Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 182 door ajar circuit. If the door is open and the DRBIII(R) displays the switch state as OPEN, it indicates an open door ajar circuit. Compass Mini-Trip Computer (CMTC) When equipped, the Compass/Mini Trip Computer (CMTC) is located in the overhead console. The CMTC supplements the standard vehicle instrumentation. The CMTC uses a vacuum fluorescent (VF) display to supply the vehicle operator with a compass heading, outdoor temperature, average fuel economy, distance to empty, trip odometer, and elapsed ignition on time. If equipped, the CMTC is also available with an integrated Universal Garage Door Opener (UGDO) known as "HomeLink ■. The CMTC function buttons are labeled C/T, RESET, STEP, and US/M. The three UGDO buttons are labeled with dots to indicate the channel number. Most of the CMTC display information is received over the PCI bus. The CMTC sends and receives data over the PCI bus, communicating with the FCM (Diesel), PCM (3.7L, 4.7L, 5.7L), and the Instrument Cluster. VEHICLE INFORMATION DISPLAY The CMTC provides the following functions: - Compass direction - Outside temperature - Elapsed ignition on time - Distance to empty - Average fuel economy - Trip Odometer The CMTC will not display information for any of the screens for which it did not receive the proper PCI bus data. Refer to the symptom list in the Overhead Console section for problems related to the CMTC. The CMTC receives the following messages from the Instrument Cluster: - Verification of US/Metric status - VF display dimming brightness and exterior lamp status - Trip Odometer data The CMTC receives the following message from the PCM: - Vehicle Speed US/M BUTTON The US/M button is used to toggle the display between English and Metric measurement units. STEP BUTTON The STEP Button can be used in one of the following ways: 1. To sequentially select one of 4 displays or blank display in the following order: - Average Fuel Economy - Distance to Empty - Trip Odometer - Time Elapsed . Off (Blank) 2. To set the magnetic variance zone when VARIANCE = X (X = 1 - 15) is indicated in the VF display. RESET BUTTON The RESET Button has two different functions: 1. To clear the trip functions that may be reset 2. To enter and exit the diagnostic mode Pressing the RESET button once will clear the trip function that is currently being displayed and the CMTC will send a PCI bus beep request to the Instrument Cluster. If the RESET button is pressed again within 3 seconds, the CMTC will reset ALL of the trip functions and an additional beep request is sent to the Instrument Cluster. The trip functions that may be reset are: - Average Fuel Economy - Trip Odometer - Elapsed Time A reset will only occur if one of the trip functions that may be reset is currently being displayed. The CMTC module will send a beep request to the Instrument Cluster. Simultaneously pressing the RESET button and the C/T button while turning the ignition from Off to On will enter the CMTC into the self-diagnostic mode. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 183 COMPASS/TEMPERATURE (C/T) BUTTON Actuating the Compass/Temperature Button (C/T) will cause the CMTC to display the compass and temperature information. This function will operate from another traveler display. The CMTC simultaneously displays the compass reading and the outside temperature. Outside temperature information is received via the PCI bus from the FCM. The CMTC module internally senses and calculates the compass direction. TRAVELER DISPLAY FUNCTIONS Using the STEP button will change the CMTC between modes of operation and display the appropriate information according to data received from the PCI Bus. COMPASS OPERATION Upon ignition on, if the calibration information stored in the CMTC memory is within the normal range, the CMTC will perform in slow Auto-Cal mode. In slow Auto-Cal mode, the CMTC continuously compensates for the slowly changing magnetic field of the vehicle. The compass module detects changes in the vehicle magnetism and makes appropriate internal corrections to ensure proper displayed direction. However, if the calibration information stored in the CMTC memory is not within the normal range at ignition on, the CMTC will enter fast Auto-Cal. CAL is displayed along with the temperature. Auto activation of the fast Auto-Cal mode will also occur when the CMTC is subjected to high magnetic field strength levels, which cause all compass readings to be erroneous for a continuous period of five (5) minutes . During fast Auto-Cal, CAL will be displayed along with the temperature. Fast Auto-Cal can also be performed manually, by pressing and holding the RESET button for 10 seconds during the Compass/Temperature display mode. SETTING MAGNETIC ZONE VARIANCE Variance is the difference between magnetic North and geographic North. For proper compass function, the correct variance zone must be set. Refer to the Zone Variance map for the correct zone. Follow these steps to check or change the variance zone: - The ignition switch must be in the On position and the CMTC display must not be blank. - If the compass/temperature data is not currently being displayed, momentarily press and release the C/T button to display compass/temp information. - Press and hold the RESET button until VARIANCE = XX is displayed. The CMTC will display the variance zone stored in memory and the word VARIANCE. - Use the STEP button to select the proper variance zone number, 1 through 15. - After selecting the proper zone number, momentarily press and release the RESET button. The variance zone is then stored in the memory and the CMTC returns to normal operation. COMPASS CALIBRATION The compass module has 2 types of auto-calibration; slow-cal and fast-cal. Slow-cal ensures that during normal vehicle operation the compass performs auto-calibration functions to keep the compass sensors in their proper operating range. Whenever the ignition is On and the CMTC receives PC I bus data indicating that engine RPM is greater than zero, auto-calibration is performed continuously. If the calibration information stored in the compass module memory is not within the normal range after a power-up cycle, the compass will display CAL. The CMTC will enter into the fast-cal mode until calibration is complete. To enter the compass into Manual Calibration mode, perform the following steps: - Drive the vehicle to an area away from any large metal objects or overhead power lines. - Ensure that the proper variance zone is selected. See "Setting Magnetic Zone Variance." - The ignition switch must be in the On position and the CMTC display must not be blank. - Press the C/T button to view the Compass/ Temperature display. - Press and hold the RESET button until CAL is displayed, then release the button. - Drive slowly, less than 5 MPH (8KPH) in at least 1 complete 360-degree circle. - CAL will remain illuminated to alert the driver that the compass is in the calibration mode. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 184 - After calibration is complete, CAL will turn off. If the compass appears blank, unable to be calibrated, or the compass displays false indications, the vehicle must be demagnetized. Refer to Compass Demagnetizing Procedure. SELF-CHECK DIAGNOSTICS The CMTC is capable of performing a diagnostic self check on its internal functions. CMTC diagnostics may be performed using a DRBIII(R) or by using the following procedure: 1. With the ignition switch in the OFF position, depress and hold the RESET and the C/T buttons. 2. Turn the ignition switch to the ON position. 3. Continue to hold both buttons until the software versions are displayed, then release the buttons. 4. All of the VFD segments will illuminate for 2-4 seconds. Check for segments that do not illuminate or illuminate all the time. 5. When the self-check is complete the CMTC will display one of the following messages: - PASS - FAIL - NO BUS 6. To exit the self-check mode, depress the RESET button or cycle the ignition switch and the CMTC will return to normal operation. If a Communication fault is displayed, refer to the symptom list. If a FAILED SELF TEST is displayed, the CMTC must be replaced. AMBIENT TEMPERATURE SENSOR The ambient air temperature is monitored by the FCM or the PCM and displayed by the CMTC. For Diesel equipped vehicles, the FCM receives a hardwire input from the ambient temperature sensor (ATS). For 3.7L, 4.7L and 5.7L equipped vehicles, the PCM receives the hardwire input from the ATS. The ATS is a variable resistor that operates on a 5-volt reference signal circuit hardwired from the FCM or PCM. The resistance in the ATS changes as the outside temperature rises or falls. The FCM or PCM senses the change in reference voltage through the ATS resistor. Based on the resistance of the ATS, the FCM or PCM is programmed to correspond to a specific temperature. The FCM or PCM stores and niters the ambient temperature data and transmits this data to the CMTC via the PCI Bus. The ATS cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. AMBIENT TEMPERATURE SENSOR FAULT CODES The outside temperature function is supported by the ambient temperature sensor (ATS), a signal and ground circuit hardwired to the FCM or the PCM, and the CMTC display. If the CMTC display indicates 54° C (130° F) or the ATS sense circuit is open, the temp display will be 54° C (130° F) to indicate an OPEN circuit condition. If the CMTC display indicates -40° C (-40° F) or the ATS sense circuit is shorted to ground, the temp display will be -40° C (-40° F) to indicate a SHORT circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the CMTC VFD can be tested. The ATS is supported by the FCM or PCM. Ambient Temperature Sensor DTCs will be recorded in the FCM or PCM. The ATS can be diagnosed using the following Sensor Test. Test the ATS circuits using the diagnostics in the Body Diagnostic Procedures Manual. If the CMTC passes the self test, and the ATS, the circuits, and PCI bus communications are confirmed to be OK, but the CMTC temperature display is inoperative or incorrect, replace the FCM or PCM as required. AMBIENT TEMPERATURE SENSOR TEST 1. Turn the ignition OFF. 2. Disconnect the ATS harness connector. 3. Measure the resistance of the ATS using the following min/max values: - 0° C (32° F) Sensor Resistance = 29.33 - 35.99 Kiloohms - 10° C (50° F) Sensor Resistance = 17.99 - 21.81 Kiloohms - 20° C (68° F) Sensor Resistance = 11.37 - 13.61 Kiloohms - 25° C (77° F) Sensor Resistance = 9.12 - 10.86 Kiloohms 30° C (86° F) Sensor Resistance = 7.37 - 8.75 Kiloohms - 40° C (104° F) Sensor Resistance = 4.90 - 5.75 Kiloohms The sensor resistance should read between these min/max values. If the resistance values are not OK, replace the Sensor. HOMELINK(R) UNIVERSAL TRANSMITTER If equipped, the HomeLink(R) Universal Transmitter is integrated into the overhead console. For added security it will operate home security systems that use coded signals known generically as Rolling Codes. The overhead console display provides visual feedback to the driver, indicating which HomeLink(R) transmitter channel button is being pressed. The HomeLink(R) can learn and store up to three separate transmitter radio frequency codes to operate garage door openers, security gates, and security lighting. The HomeLink ■ buttons are marked with one, two, or three dots. For complete information, refer to Universal Transmitter. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 185 Electrically Heated Systems HEATED MIRROR RELAY A button located on the HVAC control head controls the Heated Mirror Relay, which is located in the IPM. The HVAC control will ground the Heated Mirror Relay Control circuit to energize this relay. The relay control circuit is continuously monitored for certain malfunctions that the HVAC will report as DTCs. Exterior Lighting System The Instrument Cluster monitors the Headlamp Switch and Multifunctions Switch on its MUX line. The Instrument Cluster sends a PCI bus message to the Front Control Module (FCM) to actuate the Headlamps ON when the ignition switch is ON and when an open or short failure occurs on the headlamps switch input circuit to the instrument cluster. If the exterior lamps are left ON and the ignition switch OFF for more than 5 minutes, the FCM will turn the exterior lamps off. This feature prevents the battery from being discharged when the Exterior Lamps have been left ON. Front Control Module The Front Control Module (FCM) is a microprocessor-based electrical control and interface center located in the engine compartment. When it is mated to the Power Distribution Center (PDC), it is referred to as the Integrated Power Module (IPM). The IPM, with its fuses and relays provides power and signal distribution throughout most of the vehicle. The FCM receives hardwired analog and resistor multiplexed inputs as well as digital electronic inputs from other electronic modules in the vehicle electrical system through its connection to the IPM and the Programmable Communications Interface (PCI) data bus network. Based on these inputs and programming, the FCM uses high side drivers to provide direct power feeds and low side drivers to provide relay control for some of the vehicle's most critical electrical systems. The FCM provides the following features: Controlled Feeds: - Brake lights - Headlamp power - Turn signals (front & rear) - Windshield washer pump motor Relay Controls - Adjustable pedals relay (when equipped) - Fog lamp relay (when equipped) - Horn relay - Park lamp relay - Trailer tow relays - Wiper on/off relay - Wiper high/low relay Electrical Inputs - Module battery supply - Power ground - Ignition switch RUN or START position status . PCI bus - Wiper park switch - Washer fluid level switch - Ambient Temperature sensor - Battery (+) connection detection CONTROLLED POWER FEEDS Headlamp Power The headlamp switch is a direct input to the instrument cluster which is sometimes known as the Cab Control Node (CCN). The instrument cluster sends a Programmable Communications Interface (PCI) bus message to the FCM informing it of a headlamp switch status change. The FCM then turns power on or off (depending on the bus message) to the headlamps through four "fuseless" circuits. These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied to each filament in a separate circuit. For vehicles equipped with Daytime Running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination levels. Washer Pump Motor The washer switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus message to the FCM informing it of a request to wash. The washer pump motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition, the FCM electronically protects the washer pump motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 186 If the FCM receives a prolonged request to wash lasting 30 seconds or more, it will treat the request as a stuck switch condition and deactivate the washer pump motor. The FCM will not reactivate the washer pump motor until there is at least a two second break in the request to wash from the instrument cluster. RELAY CONTROLS Adjustable Pedals Relay If equipped, the adjustable pedals relay, when not activated, supplies fused battery power to the adjustable pedals switch. If the FCM receives a bus message that the vehicle is in reverse or that the cruise control is engaged, it will apply a ground to the adjustable pedals relay control circuit. The ground will activate the relay which will open the power circuit to the adjustable pedals switch The relay control circuit is continuously monitored for malfunctions which the FCM will report as DTCs. Fog Lamp Relay If equipped, the fog lamp switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to turn on the fog lamp relay. The fog lamp relay is then actuated by the FCM through low side control. This circuit is electronically controlled and continuously monitored for malfunctions. Horn Relay The Horn Relay, which is internal to the IPM, is controlled by the FCM through PCI bus messages from the instrument cluster. These bus messages will be sent when either the horn switch is pressed which is hard wired to the instrument cluster, panic mode is requested from the RKE or for vehicle theft security reasons (if equipped). The relay control circuit is continuously monitored for malfunctions that the FCM will report as DTCs. The park lamp switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the park lamp relay. The park lamp relay is then actuated through the low side control circuit. This circuit is electronically controlled and continuously monitored for malfunctions. Wiper High/Low Relay The wiper switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the wiper high/ low relay. The relay switches power between the low speed and high speed of the wiper motor. The wiper high/low relay is then actuated through the low side control circuit. This circuit is electronically controlled and continuously monitored for malfunctions. Wiper On/Off Relay The wiper switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the wiper on/off relay. The wiper on/off relay is then actuated through the low side control circuit. This relay switches power to the wiper high/low relay. This circuit is electronically controlled and continuously monitored for malfunctions. ELECTRICAL INPUTS Module Battery Supply 12 Volt input for all FCM functions except headlamp operation. Power Ground Ground source for all FCM functions Ignition Switch RUN or START Position Status 12 volt input to inform the FCM of the ignition switch status for related FCM functions. PCI Bus Approximately 7.5 volt input to allow the FCM to communicate with other modules on the PCI bus. Wiper Park Switch Ground input used to determine the park placement of the wipers. The ground is also used as feedback to the FCM to determine wiper operating mode. Washer Fluid Level Switch Ground input from the washer fluid level switch which closes when washer fluid is low. Battery (+) Connection Detection 12 volt supply used to monitor battery connection to the IPM. The battery connection to the IPM uses an internal switch to check integrity of the connection and that the Connector Positive Assurance (CPA) is engaged. If the CPA is not properly engaged, a voltage is sent to the FCM to be interpreted as an unseated connector which will set a Diagnostic Trouble Code (DTC). Heating & A/C System SYSTEM AVAILABILITY - Depending on the model, either a Single-Zone or Dual-Zone HVAC system is available in these vehicles. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 187 SYSTEM CONTROLS The Heater Control Module: is fully addressable with the DRBIII(R). - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - controls heated mirror and EBL operation (if equipped). - controls electric door actuator operation. The A/C-Heater Control Module: is fully addressable with the DRBIII(R). - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - provides an A/C request to the Powertrain Control Module (PCM) over the PCI Bus when compressor operation is desired. - controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - controls heated mirror and EBL operation (if equipped). - controls electric door actuator operation. - A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C -Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. The Single-Zone HVAC system uses: one, two-wire electric blend door actuator. - two, two-wire electric mode door actuators. - one, two-wire electric recirculation door actuator. The Dual-Zone HVAC system uses: two, two-wire electric blend door actuators. - two, two-wire electric mode door actuators. - one, two-wire electric recirculation door actuator. SYSTEM REVISIONS The 2004 DR, HVAC system remains carryover from 2003. SYSTEM DIAGNOSTICS Fault detection is through active and stored Diagnostic Trouble Codes (DTCs) . DTCs are displayed by the DRBIII(R). Active DTCs are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTCs are those which occurred in the system since the A/C-Heater Control Module received the last "clear diagnostic info" message. The A/C Cooldown Test: is actuated with the DRBIII(R). - checks A/C system performance based on evaporator temperature sensor input. - will not run if ambient temperature is below 12.7° C (55° F). - will pass if the evaporator temperature drops 6.7° C (20° F) within two minutes of starting the test. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. - will cause the A/C mode switch status indicator to flash while the test is running. - If the test fails, the status indicator will continue to flash until either the test returns passed or the ignition key is cycled. It will also prevent the EBL mode switch status indicator from indicating EBL operating status. However, the EBL mode switch will continue to function in this state. The HVAC Door Recalibration function: is actuated with the DRBIII(R). - monitors for door span faults. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. - will cause the EBL mode switch status indicator to flash while the test is running. - If the test fails, the status indicator will continue to flash until either the test returns passed or the ignition key is cycled. It will also prevent the A/C mode switch status indicator from indicating A/C operating status. However, the A/C mode switch will continue to function in this state. The Actuator Circuit Test: is actuated with the DRBIII(R). - monitors for shorted actuator circuits. - allows service to easily diagnose and troubleshoot up to three simultaneous shorts. - supplements the continuous diagnostics on the actuator drive system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 188 - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. When Performing The Actuator Circuit Test CAUTION: To ensure a proper diagnosis, repair all Short Too Complex messages first, all common door driver circuit related messages second, and all other door driver circuit related messages last. - The DRBIII(R) can display up to three Actuator Circuit Test messages at a time. After repairing each Actuator Circuit Test message, cycle the ignition switch, then rerun the Actuator Circuit Test to ensure no new messages exist. - The Short Too Complex message: indicates that a specific determination of which lines are shorted could not be made. - is caused by more than three drivers being shorted in the same direction. For example, four drivers all shorted to ground, or two or more drivers shorted with at least one driver shorted to ignition/battery and one driver shorted to ground. - Messages displaying: XXX Driver/Circuit Shorted to Ignition/ Battery will set on a per-driver basis. - XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. - the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together. - When the test returns passed, then troubleshooting should proceed to clearing faults and running the HVAC Door Recalibration system test as a final check of system health. Instrument Cluster The DR Instrument Cluster is a new type of control module that includes the hardware and software necessary to function as the cluster and the body control module. The Instrument Cluster houses the Speedometer, Tachometer, Fuel gauge, Coolant Temperature gauge, Oil Pressure gauge, and the Voltage gauge. The cluster positions all of the gauges using PCI bus messages received from the PCM. The cluster contains certain warning indicators, depending on engine type and options. Some of the indicators are hardwire inputs and some indicators are controlled via PCI bus messages. The warning chime tone generator is contained within the cluster. The cluster includes a vacuum fluorescent (VF) display for the PRNDL, Total and Trip Odometers. The VF will also display warning messages such as door ajar, low washer fluid level, engine hours, and no bus communications. The cluster has the ability to set and store DTCs, communicate on the PCI bus, display engine information, and display certain inputs using the DRBIII(R). The following systems are controlled either completely by the Instrument Cluster or in conjunction with other inputs received by hardwire or via the PCI bus: - Audible Warnings - Brake Lamp Control - Brake Transmission Shift Interlock (BTSI) - Cargo Lamp Control - Central Locking - Door Lock Inhibit - Enhanced Accident Response - Exterior Lighting Control - Exterior Lighting Fail-Safe - Heated Seat Control - Horn Control - Interior Lamp Control - Interior Lamps - Enhanced Accident Response - Interior Lamps Load Shedding - Lamp Out Indicator Control - Panel Lamps Dimming Control - Parade Mode - Power Locks - Remote Keyless Entry (RKE) - Remote Radio Switch Interface - Rolling Door Locks - Turn Signal and Hazard Warning Lamp Control - Vacuum Fluorescent Display Synchronization - Vehicle Theft Security System (VTSS) CAUTION: Instrument clusters used in this model automatically configure themselves for compatibility with the features and optional equipment in the vehicle in which they are initially installed. The instrument cluster is programmed to do this by embedding the Vehicle Identification Number (VIN) and other information critical to proper cluster operation in electronic memory. This embedded information is learned through electronic messages received from other electronic modules in the vehicle over the Programmable Communications Interface (PCI) data bus, and through certain hard wired inputs received when the cluster is connected to the vehicle electrically. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 189 Once configured, the instrument cluster memory may be irreparably damaged and certain irreversible configuration errors may occur if the cluster is connected electrically to another vehicle; or, if an electronic module from another vehicle is connected that provides data to the instrument cluster (including odometer values) that conflicts with that which was previously learned and stored. Therefore, the practice of exchanging (swapping) instrument clusters and other electronic modules in this vehicle with those removed from another vehicle must always be avoided. Failure to observe this caution may result in instrument cluster damage, which is not reimbursable under the terms of the product warranty. Service replacement instrument clusters are provided with the correct VIN, and the certified odometer and engine hours values embedded in cluster memory, but will otherwise be automatically configured for compatibility with the features and optional equipment in the vehicle in which they are initially installed. DIAGNOSTIC SELF TEST The Instrument Cluster is capable of performing a Diagnostic Self Test. This self test can be initiated manually by depressing and holding the trip reset button while cycling the ignition from the Off to the On position. The self test can also be activated using the DRBIII(R). During the self test, all of the PCI bus indicators will be illuminated. The speedometer, tachometer, fuel gauge, oil pressure gauge, coolant temperature gauge, and voltage gauge will position at their calibration points. The VF display will illuminate all segments and also display the software version. The chime will sound. When the self test is complete, the cluster will return to normal operation. Turning the ignition to the Off position or the cluster detecting engine RPM greater than 0 (zero) will stop the self test. Interior Lighting The Instrument Cluster controls the Interior/ Courtesy Lamps. The Instrument Cluster activates the courtesy lamps when either a Dome Lamp switch is turned on or a door is opened. The Instrument Cluster also monitors the output of the Glove Box and Map lamps. The Cargo lamps are controlled by the Instrument Cluster, it receives an output message from the Headlamp switch to turn on the lamps. The Instrument Cluster provides battery protection by shutting down the interior lamps when a door or courtesy/map lamp is left on or open. Power Door Locks/Remote Keyless Entry The Instrument Cluster in response to the door lock switches or the RKE module directly controls the power door lock motors. The Instrument Cluster monitors the activation of the door lock motors and will set diagnostic trouble codes when there is an open or short condition. When there is a lock or unlock input from a switch or RKE command, the Instrument Cluster will activate the appropriate driver for 300 milliseconds. If a lock or unlock switch remains active, the request will be ignored until the switch transitions back to off. The lock switches are resistive multiplexed input devices hardwired to the Instrument Cluster. AUTOMATIC DOOR LOCKS The Instrument Cluster will automatically lock all the doors when the vehicle speed exceeds 15 MPH (24 KM/H), throttle position exceeds 10 percent and all the doors are closed. If a door is opened the Automatic Door Lock feature shall reset and the Instrument Cluster will lock the doors when the above conditions are met. This feature is programmable by the customer or the DRBIII(R). CENTRAL LOCKING/UNLOCKING The Instrument Cluster will lock all doors when the cylinder lock switch is activated in the "lock" position. When the Instrument Cluster receives an unlock command from the driver cylinder lock switch, it will unlock only that door. If the Instrument Cluster receives a second command within a 5-second period it will unlock all the remaining doors. The illuminated entry will activate during door unlock. DOOR LOCK INHIBIT When the key is in the ignition, in any position, and either front door is open, the door lock switches LOCK functions are disabled. The UNLOCK functions are still functional. This protects against locking the vehicle with the keys still in the ignition. The RKE transmitter will still lock the doors as usual. ENHANCED ACCIDENT RESPONSE Upon detection of an airbag deployment by way of the PCI bus, the Instrument Cluster shall: - Immediately disable the power door lock output - Unlock all doors by activating the door unlock output for approximately 300 milliseconds. - After actuating the door unlock output, allow the door lock motors to be activated if the door lock input has been inactive (not erratic) for 2 seconds since the reception of the airbag deployment message. Remote Keyless Entry The remote keyless entry (RKE) feature is used to control the power door locks and panic feature by using a remote transmitter (keyfob) and receiver located within the instrument cluster. The instrument cluster RKE feature controls the driver door unlock, all doors lock/unlock, horn chirp enabled/ disable, optical chirp enabled/disable, illuminated entry, the panic feature, initiate customer programming, and arming/disarming the Vehicle Theft Security System. When a valid lock message is received from the receiver, the instrument cluster will: - Arm the Vehicle Theft Security System (if equipped and all conditions are met). - Turn off the illuminated entry feature. - Activate the door lock motors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 190 - Transmit a PCI bus message to the FCM to perform horn chirp. When a valid unlock code is received from the receiver, the instrument cluster will: - Disarm the Vehicle Theft Security System (if equipped and previously set). - Activate the illuminated entry and cargo lamp. - Activate the driver door unlock motor (if customer programmed for driver door only unlock). - Transmit a PCI bus message to the FCM for optical chirp. Vehicle Theft Security System The Instrument Cluster controls the Vehicle Theft Security System (VTSS). When the VTSS is armed it will monitor the status of the ignition and door ajar switches. If the alarm is tripped it will sound the vehicles horn, flash the exterior lamps and the VTSS indicator located in the instrument cluster. The Instrument Cluster will enable the VTSS feature once it has received PCI bus messages from the Sentry Key Immobilizer Module and has also detected the driver cylinder lock switch being cycled to the lock/unlock position. Arming the system is accomplished following a normal exit sequence of removing the key from the ignition, opening the door pressing the power lock button to lock and closing the door, by using a cylinder lock switch or by pressing the RKE lock button. After all the doors are closed, the VTSS indicator will flash quickly for sixteen-seconds indicating the pre-arm process, after which it will flash at a slower rate indicating the system is armed. If during the pre-arm process a door is opened, the ignition is turned to the Run/Start position or if a RKE unlock button is pressed the system will exit the pre-arming process. Disarming can be accomplished with a RKE unlock, turning the ignition on with a valid Sentry key or unlocking the vehicle with a cylinder lock switch. The Alarming state will last for 18 minutes after which it will time out and return to the armed state. A tamper alert feature will alert the customer to the alarm being tripped while they were away upon returning to the vehicle by flashing the VTSS indicator for 30 seconds after the system has been disarmed. All of the switches for the VTSS system can be monitored using the DRBIII(R). The DRBIII(R) is also useful for a customer complaint of the alarm going off with no apparent reason by viewing the VTSS last alarm caused by display. Windshield Wipers/Washers The Instrument Cluster controls the wiper/ washer system. The instrument cluster receives a signal from the Multifunction Switch wipe position. The instrument cluster sends the message to the Front Control Module (FCM), sending the command to turn the wiper/washers on. Two relays, the High/Low relay and the On/Off relay also control the wipers. Both are located in the PDC or Integrated Power Module. Telecommunications HANDS FREE PHONE The vehicle telecommunications system consists of a Hands Free Module, Rear view Mirror, and a Blue-tooth Hands Free Profile enabled cell phone. The system allows vehicle occupants to use voice recognition technology to make, receive and screen phone calls without physically handling a cell phone. The system has a programmable phone book that can prevent the vehicle operator from becoming distracted searching for a specific number. Seven different wireless phones can be programmed to operate each individual system. Each of the seven phones is given a rank of priority when programmed. Incoming phone messages are transmitted to the vehicle occupants through the vehicles audio system when the ignition is on and the wireless phone is on. Upon receiving the signal from an incoming phone call, the vehicle audio system will fade out the current CD/DVD or radio output. The vehicle occupants are then directed to accept or reject the call. Outgoing audio messages are received through the microphone located in the rearview mirror then transmitted via hardwire to the Hands Free Module and finally transmitted through the wireless phone. Volume of the voice prompts and incoming conversation is controlled using the vehicles' radio audio controls and steering wheel controls if equipped. The rearview mirror contains a Phone Switch, Voice Recognition Switch and a microphone. The rear view mirror transmits these inputs via hardwired circuits to the Hands Free Module. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures Air Bag System Test 1 SYMPTOM AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES POSSIBLE CAUSES - Airbag warning indicator on without active trouble codes - Instrument cluster problems AM/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE this symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Amplifier Pretest Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 193 Test 1 SYMPTOM AMPLIFIER PRETEST POSSIBLE CAUSES - Amplifier pretest - No fault message displayed Any Station Preset Switch Inoperative Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Balance Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 194 Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure CD Eject Switch Inoperative Test 1 SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Equalizer Inoperative Test 1 SYMPTOM EQUALIZER INOPERATIVE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 195 TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure FF/RW Switch Inoperative Test 1 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure HOUR/MINUTE Switches Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 196 Test 1 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Pause/Play Switch Inoperative Test 1 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure PWR Switch Inoperative Test 1 SYMPTOM PWR SWITCH INOPERATIVE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 197 TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Scan Switch Inoperative Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Seek Switch Inoperative Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Set Switch Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 198 Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tape Eject Switch Inoperative Test 1 SYMPTOM TAPE EJECT INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 199 TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Chime Inoperative Test 1 SYMPTOM CHIME INOPERATIVE POSSIBLE CAUSES - Actuate chime with DRBIII(R) - Instrument cluster - chime inoperative Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 200 Test 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER DOOR OPEN KEY REMOVED POSSIBLE CAUSES - Key-in IGN SW status - Key-in ignition switch shorted - Key-in ignition SW sense short to ground - Instrument cluster Key In Ignition and Drivers Door Open Chime Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 201 Test 1 - 3 Test 4 - 5 SYMPTOM KEY IN IGNITION AND DRIVERS DOOR OPEN CHIME INOPERATIVE POSSIBLE CAUSES - Observe the key-in ignition switch status - Key-in ignition switch open - Key-in ignition switch ground circuit open - Key-in ignition switch sense circuit open - Instrument cluster - incorrect key-in ignition switch status Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 202 Vehicle Speed Warning Chime Problem Test 1 SYMPTOM VEHICLE SPEED WARNING CHIME PROBLEM POSSIBLE CAUSES - Incorrect country code programmed in instrument cluster - Instrument cluster Average Fuel Economy Inaccurate or Wrong Test 1 SYMPTOM AVERAGE FUEL ECONOMY INACCURATE OR WRONG POSSIBLE CAUSES - CMTC CMTC or EVIC Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 203 Test 1 - 3 SYMPTOM CMTC OR EVIC INOPERATIVE POSSIBLE CAUSES - Fused B(+) circuit open - Fused ignition switch output circuit open - Ground circuit open - Compass/mini-trip computer Compass Test Failure Test 1 SYMPTOM COMPASS TEST FAILURE POSSIBLE CAUSES - Compass/Mini-trip computer Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 204 Distance to Empty Inaccurate or Wrong Test 1 SYMPTOM DISTANCE TO EMPTY INACCURATE OR WRONG TEST NOTE This symptom is diagnosed using the test AVERAGE FUEL ECONOMY INACCURATE OR WRONG. POSSIBLE CAUSES - CMTC Elapsed Ignition on Time Inaccurate or Wrong Test 1 SYMPTOM ELAPSED IGNITION ON TIME INACCURATE OR WRONG TEST NOTE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 205 This symptom is diagnosed using the test AVERAGE FUEL ECONOMY INACCURATE OR WRONG. POSSIBLE CAUSES - CMTC Temperature Display Inaccurate or Inoperative Test 1 - 2 SYMPTOM TEMPERATURE DISPLAY INACCURATE OR INOPERATIVE POSSIBLE CAUSES - Ambient temperature sensor - Compass/Mini-trip computer Trip Odometer Inaccurate or Wrong Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 206 Test 1 SYMPTOM TRIP ODOMETER INACCURATE OR WRONG TEST NOTE This symptom is diagnosed using the test AVERAGE FUEL ECONOMY INACCURATE OR WRONG. POSSIBLE CAUSES - CMTC Driver Door Ajar Circuit Open Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 207 Test 1 - 4 SYMPTOM DRIVER DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Driver door ajar switch - Driver door ajar switch ground circuit open - Driver door ajar switch sense circuit open - Instrument cluster-driver door ajar open Driver Door Ajar Circuit Shorted to Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 208 Test 1 - 3 SYMPTOM DRIVER DOOR AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Driver door ajar switch shorted to ground - Driver door ajar switch sense circuit shorted to ground - Instrument cluster - driver door ajar shorted Left Rear Door Ajar Circuit Open Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 209 Test 1 - 4 SYMPTOM LEFT REAR DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Left rear door ajar switch - Left rear door ajar switch ground circuit open - Left rear door ajar switch sense circuit open - Instrument cluster - left rear door ajar open Left Rear Door Ajar Circuit Shorted to Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 210 Test 1 - 3 SYMPTOM LEFT REAR DOOR AJAR CIRCUIT SHORT TO GROUND POSSIBLE CAUSES - Left rear door ajar switch shorted to ground - Left rear door ajar switch sense circuit shorted to ground - Instrument cluster - driver door ajar shorted Passenger Door Ajar Circuit Shorted to Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 211 Test 1 - 3 SYMPTOM PASSENGER DOOR AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Passenger door ajar switch shorted to ground - Passenger door ajar switch sense circuit shorted to ground - Instrument cluster - passenger door ajar shorted Passenger Door Ajar CKT Open Test 1 - 4 SYMPTOM PASSENGER DOOR AJAR CKT OPEN POSSIBLE CAUSES - Passenger door ajar switch - Passenger door ajar switch ground circuit open - Passenger door ajar switch sense circuit open - Instrument cluster - passenger door ajar open Right Rear Door Ajar Circuit Open Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 212 Test 1 - 4 SYMPTOM RIGHT REAR DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Right rear door ajar switch - Right rear door ajar switch ground circuit open - Right rear door ajar switch sense circuit open - Instrument cluster - right rear door ajar open Right Rear Door Ajar Circuit Shorted to Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 213 Test 1 - 3 SYMPTOM RIGHT REAR DOOR AJAR CIRCUIT SHORT TO GROUND POSSIBLE CAUSES - Right rear door ajar switch shorted to ground - Right rear door ajar switch sense circuit shorted to ground - Instrument cluster - right rear door ajar shorted A/C Heater Control Illumination Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 214 Test 1 - 3 Test 4 SYMPTOM A/C - HEATER CONTROL ILLUMINATION INOPERATIVE POSSIBLE CAUSES - Check for instrument cluster (MIC) DTCs - Inoperative bulb(s) - A/C - heater control module - Panel lamps driver circuit open - Instrument cluster A/C Status Indicator Flashing Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 215 Test 1 - 2 Test 3 SYMPTOM A/C STATUS INDICATOR FLASHING POSSIBLE CAUSES - A/C cooldown test needs to be run - HVAC door recalibration needs to be run A/C Status Indicator Will Not Illuminate - A/C Heater Control Without EBL SW Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 216 Test 1 SYMPTOM A/C STATUS INDICATOR WILL NOT ILLUMINATE -- A/C - HEATER CONTROL WITHOUT EBL SW POSSIBLE CAUSES - HVAC door recalibration failed - A/C - Heater control module Blend/Mode/Recirc Door Operation Improper - Dual-Zone Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 217 Test 4 - 6 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 218 Test 7 - 8 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER - DUAL-ZONE POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTCs - Check for HVAC door recalibration fault messages - Mode door actuator(s)/linkage(s)/door(s) - Passenger blend door actuator/linkage/door - Driver blend door actuator/linkage/door - Recirculation door actuator/linkage/door Blend/Mode/Recirc Door Operation Improper - Single-Zone Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 219 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 220 Test 4 - 6 Test 7 SYMPTOM Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 221 BLEND/MODE/RECIRC DOOR OPERATION IMPROPER - SINGLE-ZONE POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTCs - Check for HVAC door recalibration fault messages - Mode door actuator(s)/linkage(s)/door(s) - Blend door actuator/linkage/door - Recirculation door actuator/linkage/door Blower Motor Inoperative Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 222 Test 4 - 8 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 223 Test 9 - 10 SYMPTOM BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - IPM fuse #4 - Blower motor feed circuit shorted to ground - Fused B(+) shorted to ground - Blower motor shorted to ground - Blower motor - Blower motor high driver circuit open - Ground circuit open - A/C - heater control module open - Blower motor feed circuit open - Fused B(+) circuit open - Ignition switch open Blower Motor Speeds Incorrect Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 224 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 225 Test 4 - 6 SYMPTOM BLOWER MOTOR SPEEDS INCORRECT POSSIBLE CAUSES - Blower motor driver circuit(s) shorted to ground - A/C - heater control module - Blower motor driver circuit(s) shorted to voltage - Blower motor driver circuits shorted together - A/C - heater control module - speeds incorrect - Blower motor driver circuit(s) open - Blower motor resistor block - open speed EBL Status Indicator Flashing Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 226 Test 1 - 2 Test 3 SYMPTOM EBL STATUS INDICATOR FLASHING TEST NOTE This symptom is diagnosed using the test A/C STATUS INDICATOR FLASHING. POSSIBLE CAUSES - A/C cooldown test needs to be run - HVAC door recalibration needs to be run HVAC System Test Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 227 Test 1 - 2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 228 Test 3 - 4 SYMPTOM HVAC SYSTEM TEST POSSIBLE CAUSES - Attempt to communicate with the PCM - Check for HVAC related DTCs in the PCM - Check for active HVAC DTCs and system test fault messages - Check for HVAC related DTCs in the PCM - Manual A/C system test Horn Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 229 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 230 Test 4 - 8 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 231 Test 9 - 11 SYMPTOM HORNS INOPERATIVE POSSIBLE CAUSES - Horn ground circuit open - Horn relay output circuit open - Horns - Instrument cluster - DTC present - Clockspring - Front control module - Fuse #45 - Horn switch - Horn switch ground - Horn switch sense open - Integrated power module All Gauges Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 232 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 233 Test 4 - 7 Test 8 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 234 SYMPTOM ALL GAUGES INOPERATIVE POSSIBLE CAUSES - No response - PCI BUS - PCI BUS - powertrain control module - PCI BUS - instrument cluster - Fused ignition switch output circuit (unlock/run) short to ground - Instrument cluster ground circuit open - Fused ignition switch output (run/start) circuit open - Fused ignition switch output (run/start) circuit short to ground - Fused ignition switch output (unlock/run) circuit open - Instrument cluster Any PCI Indicator Inoperative Test 1 - 4 SYMPTOM ANY PCI INDICATOR INOPERATIVE POSSIBLE CAUSES - Indicator message not received - No response - instrument cluster Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 235 - No response - PCI BUS - No response - PCI BUS - powertrain control module - Instrument cluster Brake Warning Indicator Always On Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 236 Test 4 - 5 SYMPTOM BRAKE WARNING INDICATOR ALWAYS ON POSSIBLE CAUSES - Brake fluid level switch - Brake fluid level switch sense circuit short to ground - Park brake switch - Park brake switch sense circuit short to ground - Control module - Instrument cluster Brake Warning Indicator Inoperative Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 237 Test 4 - 7 SYMPTOM BRAKE WARNING INDICATOR INOPERATIVE POSSIBLE CAUSES - Brake fluid level switch ground circuit open - Brake fluid level switch - Brake fluid level switch sense circuit open - Park brake switch - Park brake switch sense circuit open - Control module - Instrument cluster Fuel Gauge Inaccurate Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 238 Test 1 - 3 SYMPTOM FUEL GAUGE INACCURATE POSSIBLE CAUSES - DTC present - Instrument cluster - Fuel level sensor wiring - Fuel level sensor One Gauge Inoperative - Gas Engines Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 239 Test 1 - 2 SYMPTOM ONE GAUGE INOPERATIVE - GAS ENGINES POSSIBLE CAUSES - Powertrain control module DTCs - Intermittent condition - Instrument cluster PRNDL Not Displaying Correct Position (EATX Vehicles) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 240 Test 1 - 2 SYMPTOM PRNDL NOT DISPLAYING CORRECT POSITION (EATX VEHICLES) POSSIBLE CAUSES - DTC present - Instrument cluster - Intermittent condition Seat Belt Warning Indicator Always Off Test 1 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS OFF POSSIBLE CAUSES - Seat belt switch sense circuit short to ground - Instrument cluster Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 241 Seat Belt Warning Indicator Always Off - Standard Cab Test 1 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS OFF - STANDARD CAB POSSIBLE CAUSES - Seat belt switch sense circuit short to ground - Instrument cluster Seat Belt Warning Indicator Always on Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 242 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS ON POSSIBLE CAUSES - Seat belt switch - Seat belt switch ground circuit open - Seat belt switch sense circuit open - Instrument cluster Seat Belt Warning Indicator Always on - Standard Cab Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 243 Test 4 - 5 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS ON - STANDARD CAB POSSIBLE CAUSES - Fused ignition switch output (run-acc) circuit open - Seat belt tensioner reducer - Seat belt switch - Seat belt switch ground circuit open - Seat belt switch sense circuit open - Instrument cluster All Door Locks Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 244 Test 1 - 3 SYMPTOM ALL DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - DTC present - Fuse #22 open - Fuse B+ circuit open - Instrument cluster - open circuit Automatic (Rolling) Door Locks Inoperative Test 1 - 4 SYMPTOM AUTO (ROLLING) DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Check the door ajar switch status - With the DRB check for PCM DTC's - With the DRB enable auto door locks - Instrument cluster - auto door locks fail Cylinder Lock Switch Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 245 Test 1 - 3 Test 4 SYMPTOM CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Cylinder lock switch ground open - Cylinder lock switch MUX circuit open - Cylinder lock switch open - Instrument cluster - open Cylinder Lock Switch Will Not Arm and/or Disarm Alarm Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 246 Test 1 - 3 Test 4 SYMPTOM CYLINDER LOCK SWITCH WILL NOT ARM AND/OR DISARM ALARM TEST NOTE This symptom is diagnosed using the test CYLINDER LOCK SWITCH INOPERATIVE. POSSIBLE CAUSES - DTC present - Cylinder lock switch ground open - Cylinder lock switch MUX circuit open - Cylinder lock switch open - Instrument cluster - open Door Lock Inhibit Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 247 Test 1 SYMPTOM DOOR LOCK INHIBIT INOPERATIVE POSSIBLE CAUSES - Chime inoperative - Instrument cluster - door lock inhibit inoperative Left Doors Fail to Lock and Unlock - Quad Cab Test 1 - 4 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 248 Test 5 SYMPTOM LEFT DOORS FAIL TO LOCK AND UNLOCK - QUAD CAB POSSIBLE CAUSES - DTC present - Instrument cluster - door lock driver left doors open - Door unlock driver left doors wire open - Door lock driver left doors wire open - Door lock motor One Door Lock Motor Inoperative Test 1 SYMPTOM ONE DOOR LOCK MOTOR INOPERATIVE POSSIBLE CAUSES - Door lock motor open - Check door lock motor circuit Right Doors Fail to Lock and Unlock - Quad Cab Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 249 Test 1 - 4 Test 5 SYMPTOM RIGHT DOORS FAIL TO LOCK AND UNLOCK - QUAD CAB POSSIBLE CAUSES - DTC present - Instrument cluster - door lock driver right doors open - Door unlock driver right doors wire open - Door lock driver right doors wire open - Door lock motor RKE Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 250 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 251 Test 4 - 6 SYMPTOM RKE INOPERATIVE POSSIBLE CAUSES - Test transmitter with tester - RKE transmitter not programmed - DTC present - Transmitter not programmed - Substitute transmitter - Remote keyless entry module - RKE open - RKE module Alarm Trips On Its Own Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 252 Test 1 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSES - DRB display last VTSS cause - Intermittent condition Driver Door Does Not Trip VTSS Test 1 - 3 SYMPTOM DRIVER DOOR DOES NOT TRIP VTSS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 253 POSSIBLE CAUSES - Driver door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Headlamps Fail to Flash When Alarm Is Tripped Test 1 SYMPTOM HEADLAMPS FAIL TO FLASH WHEN ALARM IS TRIPPED POSSIBLE CAUSES - FCM DTCs or exterior lamp operation - Instrument cluster Horn Fails to Sound When Alarm Is Tripped Test 1 - 2 SYMPTOM HORN FAILS TO SOUND WHEN ALARM IS TRIPPED POSSIBLE CAUSES - DTC present - Horn circuit - Instrument cluster - VTSS Left Rear Door Does Not Trip VTSS (4 Door) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 254 Test 1 - 3 SYMPTOM LEFT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Passenger Door Does Not Trip VTSS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 255 Test 1 - 3 SYMPTOM PASSENGER DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Right Rear Door Does Not Trip VTSS (4 Door) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 256 Test 1 - 3 SYMPTOM RIGHT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSES - Passenger door ajar circuit malfunction - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster VTSS Will Not Arm Properly Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 257 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 258 Test 4 - 8 SYMPTOM VTSS WILL NOT ARM PROPERLY POSSIBLE CAUSES - VTSS not enabled - Check for DTCs and VTSS arming inhibitors - Check for SKIM no response - Cylinder lock switch ground open - Instrument cluster - Cylinder lock switch MUX circuit open - Cylinder lock switch open - Instrument cluster - cylinder lock switch MUX open Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 259 Body Control Module: Component Tests and General Diagnostics Six Step Troubleshooting Procedure Diagnosis of the body system 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 Road Testing Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. WARNING: REASSEMBLE ALL COMPONENTS BEFORE ROAD TESTING A VEHICLE. DO NOT TRY TO READ THE DRBIII(R) SCREEN OR OTHER TEST EQUIPMENT DURING A TEST DRIVE. DO NOT HANG THE DRBIII(R) OR OTHER TEST EQUIPMENT FROM THE REARVIEW MIRROR DURING A TEST DRIVE. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRBIII(R) OR OTHER TEST EQUIPMENT. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. Vehicle Preparation For Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Glossary of Terms ABS antilock brake system ACM airbag control module ACT actuator AECM airbag electronic control module (ACM) ASDM airbag system diagnostic module (ACM) BCM body control module BTSI brake transmission shift interlock CAB controller antilock brake CMTC compass/mini-trip computer CPA connector positive assurance DAB driver airbag DLC data link connector DTC diagnostic trouble code EBL electric back lite (rear window defogger) ECM engine control module EVIC electronic vehicle information center FCM front control module HFM hands free module HVAC heater ventilation, air conditioning IC instrument cluster (MIC) IPM integrated power module JB junction block MIC mechanical instrument cluster NGC next generation controller ODO odometer OR occupant restraint controller PAB passenger airbag PCI Programmable Communication Interface (vehicle communication bus) PCM powertrain control module PDC power distribution center PWM pulse width modulated RKE remote keyless entry RX receive SBS seat belt switch SBT seat belt tensioner SKIM sentry key immobilizer module SKIS sentry key immobilizer system SRS supplemental restraint system SUV sport utility vehicle Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 260 TCCM transfer case control module TCM transmission control module TX transmit UGDO universal garage door opener VFD vacuum fluorescent display VTSS vehicle theft security system Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 261 Body Control Module: Scan Tool Testing and Procedures Diagnostic Trouble Code DRB III Error Messages and Blank Screen Under normal operation, the DRBIII(R) will display one of only two error messages: - User-Requested WARM Boot or User Requested COLD Boot. If the DRBIII(R) should display any other error message, record the entire display and call the STAR Center. This is a sample of such an error message display. - User-Requested WARM Boot by pressing MORE and NO at the same time. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 262 ver: 2.29 date: 1 Oct 93 file: key_itf.cc date: Jan 12 1994 line: 544 err: 0x1 User-Requested WARM Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. or User-Requested COLD Boot by pressing MORE and YES at the same time. ver: 2.29 date: 1 Oct 99 file: keyhnd1.cc date: Mar 8 2000 line:1297 err: 0x1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRBIII(R) DOES NOT POWER UP If the LEDs do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRBIII(R). Check for proper ground connection at DLC cavities 4 and 5. If all connections are proper between the DRBIII(R) and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRBIII(R) may be the result of faulty cable or vehicle wiring. DRBIII(R) Scan Tool DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. DRB III Safety Information WARNING: EXCEEDING THE LIMITS OF THE DRBIII(R) MULTIMETER IS DANGEROUS. READ ALL DRBIII(R) INSTRUCTIONS BEFORE USING THE MULTIMETER. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. - Follow the vehicle manufacturer's service specifications at all times. - Do not use the DRBIII(R) if it has been damaged. - Do not use the test leads if the insulation is damaged or if metal is exposed. - To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. - Choose the proper range and functions for the measurement. Do not try voltage or current measurement that may exceed the rated capacity. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 263 - Do not exceed the limits shown in the table below: - Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. - Use caution when measuring voltage above 25v DC or 25v AC. - Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. - When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. - When measuring current, connect the meter in series with the load. - Disconnect the live test lead before disconnecting the common test lead. - When using the meter function, keep the DRBIII(R) away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Page 264 Body Control Module: Tools and Equipment DRBIII(R) (diagnostic read-out box) Jumper wires Ohmmeter Voltmeter Test Light 8310 Airbag System Load Tool 8443 SRS Airbag System Load Tool 8815 Diagnostic Pinout Box Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Customer Interest: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Powertrain Control Module: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 278 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 279 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 280 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Powertrain Control Module: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 290 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 291 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 292 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Locations > Component Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Locations > Component Locations > Page 295 Powertrain Control Module: Connector Locations Right Rear Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Locations > Component Locations > Page 296 Right Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Locations > Component Locations > Page 297 Right Rear Engine Wiring (SRT-10) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Connector Views Powertrain Control Module: Connector Views Module-Powertrain Control C1 (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Connector Views > Page 300 Module-Powertrain Control C2 (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Connector Views > Page 301 Module-Powertrain Control C3 (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM Powertrain Control Module: Description and Operation PCM The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - EATX module (if equipped) - Engine coolant temperature sensor - Fuel level (through J1850 circuitry) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 304 - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission converter clutch circuit. Driven through J1850 circuits. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 305 Powertrain Control Module: Description and Operation Modes of Operation As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (02S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (02S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the 02S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The 02S sensor heater element is energized via the ASD or 02S heater relay. The 02S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 306 This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. - When engine has reached operating temperature, the PCM will begin monitoring 02S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (02S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 307 ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 308 Powertrain Control Module: Description and Operation 5 Volt Supplies Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 309 Powertrain Control Module: Description and Operation Ignition Circuit Sense This circuit ties the ignition switch to the Powertrain Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 310 Powertrain Control Module: Description and Operation PCM The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - EATX module (if equipped) - Engine coolant temperature sensor Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 311 - Fuel level (through J1850 circuitry) - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission converter clutch circuit. Driven through J1850 circuits. Modes of Operation As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (02S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (02S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the 02S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 312 - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The 02S sensor heater element is energized via the ASD or 02S heater relay. The 02S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. - When engine has reached operating temperature, the PCM will begin monitoring 02S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 313 When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (02S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 314 Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 Volt Supplies Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). Ignition Circuit Sense This circuit ties the ignition switch to the Powertrain Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Power Grounds The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: - Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors Sensor Return The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > PCM/ECM/SKIM Programming Powertrain Control Module: Service and Repair PCM/ECM/SKIM Programming NOTE: Before replacing the Powertrain Control Module (PCM) or Engine Control Module (ECM), be certain to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM/ECM driver/control circuit failures are caused by internal component failures (i.e. relays and solenoids) and shorted circuits (i.e. pull-ups, drivers, and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has been set. When a Powertrain Control Module (PCM) for a gasoline engine, or a Engine Control Module for a diesel engine and the Sentry Key Immobilizer Module (SKIM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM/ECM. 2. Program the new SKIM. 3. Replace all ignition keys and program them into the new SKIM. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > PCM/ECM/SKIM Programming > Page 317 Powertrain Control Module: Service and Repair Programming the PCM/ECM/SKIM The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKIM is replaced, it is necessary to program the Secret Key into the new modules using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool menu for the module being replaced as appropriate. NOTE: - Be certain to enter the correct country code for the SKIM. If the incorrect country code is programmed into the SKIM, it cannot be changed and the SKIM must be replaced. - If the PCM/ECM and the SKIM are replaced at the same time, all vehicle ignition keys will need to be replaced and the new keys programmed into the new SKIM. - Programming the PCM/ECM or SKIM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > PCM/ECM/SKIM Programming > Page 318 Powertrain Control Module: Service and Repair Programming Ignition Keys to the SKIM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKIM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKIM. To program ignition keys into the SKIM, follow the programming steps outlined in the diagnostic scan tool for "Program Ignition Keys or Key FOBs" under the "SKIM" menu item. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM, that key has acquired the Secret Key for that SKIM and cannot be transferred to any other SKIM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - Programming Not Attempted - The scan tool attempts to read the programmed key status and there are no keys programmed into SKIM memory. - Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program an ignition key transponder due to one of the following: The ignition key transponder is faulty. - The ignition key transponder is or has been already programmed to another vehicle. - 8 Keys Already Learned, Programming Not Done - The SKIM transponder ID memory is full. - Learned Key In Ignition - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKIM memory. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > PCM/ECM/SKIM Programming > Page 319 Powertrain Control Module: Service and Repair Module - Powertrain Control CAUTION: - Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using the DRB scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. - Use the DRB scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. REMOVAL The PCM (1) is located in the engine compartment attached to the dash panel (3). To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > PCM/ECM/SKIM Programming > Page 320 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors (four 38-way connectors if equipped with NGC) from PCM (1). 4. Remove three PCM mounting bolts (3) and remove PCM from vehicle. INSTALLATION 1. Install PCM (3) and 3 mounting bolts (4) to vehicle. 2. Tighten bolts. Refer to torque specifications. 3. Check pin connectors in the PCM and the three 32-way connectors (four 38-way connectors if equipped with NGC) for corrosion or damage. Also, the pin heights in connectors should all be same. Repair as necessary before installing connectors. 4. Install three 32-way connectors (four 38-way connectors if equipped with NGC). 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install negative battery cable. 7. The 5.7L V-8 engine is equipped with a fully electronic accelerator pedal position sensor. If equipped with a 5.7L, also perform the following 3 steps: a. Connect negative battery cable to battery. b. Turn ignition switch ON, but do not crank engine. c. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn electrical parameters. d. The DRB III(R) Scan Tool may also be used to learn electrical parameters. Go to the Miscellaneous menu, and then select ETC Learn. 8. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set. 9. If necessary, use DRB III(R) Scan Tool to erase any Diagnostic Trouble Codes (DTC's) from PCM. Also use the DRB scan tool to reprogram new PCM with vehicles original Vehicle Identification Number (VIN) and original vehicle mileage. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 324 Main Relay (Computer/Fuel System): Description and Operation PCM OUTPUT The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. PCM OUTPUT The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 325 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 326 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Wiring Diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations Integrated Power Module Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 330 Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 331 Oxygen Sensor Relay: Description and Operation DESCRIPTION The Oxygen Sensors (02S) are attached to, and protrude into the vehicle exhaust system Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors Federal Emission Packages Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2) With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor The downstream sensor (1/2) is located just after the main catalytic convertor California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as ill and 2/1) and 2 downstream (referred to as 1/2 and 2/2) With this emission pack-age, the right upstream sensor (2/i) is located in the right exhaust downpipe just before the mini-catalytic convertor The left upstream sensor (1/i) is located in the left exhaust downpipe just before the mini-catalytic convertor The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 338 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 339 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 340 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 341 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 342 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 343 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 344 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 345 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 346 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 347 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 348 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 349 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 350 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 351 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 352 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 353 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 354 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 355 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 356 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 357 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 358 Fuel Pump Relay: Description and Operation The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shut-down the ground circuit to the fuel pump relay in approximately 1 - 3 seconds unless the engine is operating or the starter motor is engaged. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 359 Fuel Pump Relay: Service and Repair REMOVAL The fuel pump relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations Right Battery Tray Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 366 Main Relay (Computer/Fuel System): Description and Operation PCM OUTPUT The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. PCM OUTPUT The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 367 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 368 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Wiring Diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Diagrams Relay-Ignition Run-ACC (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Fig.37 Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 377 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 378 Air Bag Control Module: Diagrams Module-Occupant Restraint Controller C1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 379 Module-Occupant Restraint Controller C2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 380 Air Bag Control Module: Description and Operation The Airbag Control Module (ACM) (1) is also sometimes referred to as the Occupant Restraint Controller (ORC). The ACM is located below the instrument panel center stack in the passenger compartment of the vehicle, where it is secured by three screws to a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel just forward of the instrument panel center support bracket. Concealed within a hollow in the center of the die cast aluminum ACM housing is the electronic circuitry of the ACM which includes a microprocessor, an electronic impact sensor, an electronic sating sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ACM housing with four screws to enclose and protect the internal electronic circuitry and components. An arrow (2) printed on the label (3) on the top of the ACM housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ACM housing has integral mounting flanges on three corners. The mounting flange to the left of the connector receptacle has an integral locating pin on its lower surface. Both left side flanges have round mounting holes, while the flange on the right side has a slotted mounting hole. A molded plastic electrical connector (4) with two receptacles, one containing twenty-four terminal pins and the other containing thirty-two terminal pins, exits the rearward facing side of the ACM housing. These terminal pins connect the ACM to the vehicle electrical system through two dedicated take outs and connectors of the instrument panel wire harness. The impact sensor and sating sensor internal to the ACM are calibrated for the specific vehicle, and are only serviced as a unit with the ACM. In addition, there are unique versions of the ACM for light and heavy-duty models, and for vehicles with or without the optional side curtain airbags. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The microprocessor in the Airbag Control Module (ACM) contains the supplemental restraint system logic circuits and controls all of the supplemental restraint system components. The ACM uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Programmable Communications Interface (PCI) data bus network. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and for supplemental restraint system diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. The ACM microprocessor continuously monitors all of the supplemental restraint system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the PCI data bus to turn on the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ACM. For some DTCs, if a fault does not recur for a number of ignition cycles, the ACM will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. In standard cab models, the ACM also monitors a resistor multiplexed input from the passenger airbag on/off switch and provides a control output for the Off indicator in the switch through a passenger airbag indicator driver circuit. If the passenger airbag on/off switch is set to the Off position, the ACM turns on the passenger airbag on/off switch Off indicator and will internally disable the passenger airbag from being deployed. The ACM also turns on the on/off switch Off indicator for about seven seconds each time the ignition switch is turned to the On position as a bulb test. Following the bulb test, the ACM controls the status of the Off indicator based upon the resistance of the input from the on/off switch. The ACM will also set and/or store a DTC for faults it detects in the passenger airbag on/off switch circuits, and will turn on the airbag indicator in the EMIC if a fault has been detected. The ACM receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Integrated Power Module (IPM), and a fused ignition switch output (run-start) circuit through a second fuse in the IPM. The ACM receives ground through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector that is secured by a ground screw to the instrument panel structural support. These connections allow the ACM to be operational whenever the ignition switch is in the Start or On positions. The ACM also contains an energy-storage capacitor. When the ignition switch is in the Start or On positions, this capacitor is continually being charged with enough electrical energy to deploy the supplemental restraint components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup supplemental restraint system protection in case there is a loss of battery current supply to the ACM during an impact. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 381 Two sensors are contained within the ACM, an electronic impact sensor and a safing sensor. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provide verification of the direction and severity of an impact. On models equipped with optional side curtain airbags, the ACM also monitors inputs from two remote side impact sensors located within both the left and right B-pillars to control deployment of the side curtain airbag units. The safing sensor is an electronic accelerometer sensor within the ACM that provides an additional logic input to the ACM microprocessor. The safing sensor is used to verify the need for a supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. Vehicles equipped with optional side curtain airbags feature a second safing sensor within the ACM to provide confirmation to the ACM microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ACM microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require supplemental restraint system protection and, based upon the severity of the monitored impact and the status of the passenger airbag on/off switch input, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ACM sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and, if the vehicle is so equipped, either side curtain airbag unit. For vehicles equipped with the passenger airbag on/off switch, the passenger front airbag and seat belt tensioner will be deployed by the ACM only if enabled by the switch (passenger airbag on/off switch indicator Off) at the time of the impact. The hard wired inputs and outputs for the ACM may be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ACM, the PCI data bus network, or the electronic message inputs to and outputs from the ACM. The most reliable, efficient, and accurate means to diagnose the ACM, the PCI data bus, and the electronic message inputs to and outputs from the ACM requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Module Air Bag Control Module: Service and Repair Module WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE SUPPLEMENTAL RESTRAINTS. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. On models with a manual transmission, remove the floor console from the top of the floor panel transmission tunnel. 3. On models with an automatic transmission, remove the ACM cover from the instrument panel. 4. Reach through the rearward facing opening below the instrument panel center stack support bracket on the top of the floor panel transmission tunnel to access and disconnect the two wire harness connectors (3 & 4) for the Airbag Control Module (ACM) (1) from the ACM connector receptacles located on the rearward facing side of the module. To disconnect the wire harness connectors from the ACM, depress the release tab and lift the lever arm on each connector. 5. From the left side of the floor panel transmission tunnel, reach behind the module to access and loosen the screw (2) that secures the right side of the ACM to the bracket (5) on the floor panel transmission tunnel. Loosen the screw about 7 millimeters (0.25 inch). 6. From the left side of the floor panel transmission tunnel, remove the two screws that secure the left side of the ACM to the bracket on the floor panel transmission tunnel. 7. Still working from the left side of the floor panel transmission tunnel, lift the ACM upward far enough to disengage the locating pin on the bottom of the ACM mounting flange from the locating hole in the mounting bracket, then slide the ACM toward the left far enough to disengage the slotted hole in the right ACM mounting flange from under the head of the previously loosened right mounting screw. 8. Remove the ACM from the left side of the floor panel transmission tunnel. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Module > Page 384 1. Position the Airbag Control Module (ACM) (1) to the left side of the floor panel transmission tunnel near the ACM bracket (5). When the ACM is correctly positioned, the arrow on the ACM label will be pointed forward in the vehicle. 2. From the left side of the floor panel transmission tunnel, slide the ACM toward the right far enough to engage the slotted hole in the right ACM mounting flange under the head of the previously loosened right mounting screw (2), then engage the locating pin on the bottom of the left ACM mounting flange into the locating hole in the bracket. 3. Still working from the left side of the floor panel transmission tunnel, install and tighten the two screws that secure the left ACM mounting flanges to the bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 12 N.m (9 ft.lbs.). 4. From the left side of the floor panel transmission tunnel, reach behind the module to access and tighten the screw that secures the right side of the ACM to the bracket on the floor panel transmission tunnel. Tighten the screw to 12 N.m (9 ft.lbs.). 5. Reach through the rearward facing opening below the instrument panel center stack support bracket on the top of the floor panel transmission tunnel to access and reconnect the two wire harness connectors (3 & 4) for the ACM to the ACM connector receptacle located on the rearward facing side of the module. Be certain that the latches on the connectors are each fully engaged. 6. On models with an automatic transmission, reinstall the ACM cover onto the instrument panel. 7. On models with a manual transmission, reinstall the floor console onto the top of the floor panel transmission tunnel. 8. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Module > Page 385 Air Bag Control Module: Service and Repair Cover WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: The Airbag Control Module (ACM) cover is used only on models with an automatic transmission. Models with a manual transmission require that the floor console be removed to access the ACM for service. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry each side of the ACM cover (2) away from the instrument panel at each side of the center bracket on the floor panel transmission tunnel far enough to disengage the two snap clip retainers from the instrument panel receptacles (1). 3. Remove the ACM cover from the instrument panel. INSTALLATION 1. Position the ACM cover (2) to the instrument panel. 2. Align the snap clip retainer on each side of the ACM cover with the instrument panel receptacle (1) at each side of the center bracket on the floor panel transmission tunnel. 3. Using hand pressure, press firmly and evenly on the outside of the ACM cover over each snap clip retainer location until each retainer is fully engaged in its instrument panel receptacle. 4. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Component Locations Starter Relay: Component Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Component Locations > Page 391 Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 392 Starter Relay: Description and Operation The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted. If faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact. When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Starter Relay Starter Relay: Testing and Inspection Starter Relay Type 1 Relay The starter relay is located in Power Distribution Center (PDC). Refer to PDC cover for relay identification and location. For complete starter relay wiring circuit diagrams, refer to Wiring Diagrams. 1. Remove starter relay from PDC. 2. A relay in 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 faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace faulty relay. 4. Connect 12V 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, perform Relay Circuit Test that follows. If not OK, replace faulty relay. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 395 Starter Relay: Testing and Inspection Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair open circuit to fuse in PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to common feed terminal (30) in the energized position. This terminal supplies battery voltage to starter solenoid field coils. There should be continuity between cavity for relay terminal 87 and starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair open circuit to starter solenoid as required. 4. The coil battery terminal (86) is connected to electromagnet in relay. It is energized when ignition switch is held in Start position. On vehicles with manual transmission, clutch pedal must be fully depressed for this test. Check for battery voltage at cavity for relay terminal 86 with ignition switch in Start position, and no voltage when ignition switch is released to On position. If OK, go to Step 5. If not OK with automatic transmission, check for open or short circuit to ignition switch and repair, if required. If circuit to ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. If not OK with a manual transmission, check circuit between relay and clutch pedal position switch for open or a short. If circuit is OK, refer to Clutch Pedal Position Switch in 6 , Clutch. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gearshift selector lever is in Park or Neutral positions. Check for continuity to ground at cavity for relay terminal 85. If not OK with manual transmission, repair circuit to ground as required. If not OK with automatic transmission, check for pen or short circuit to park/neutral position switch and repair, if required. If circuit to park/neutral position switch is OK, refer to Park/Neutral Position Switch in 21, Transmission. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Page 396 Starter Relay: Service and Repair REMOVAL The starter relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Disconnect and isolate negative battery cable. 2. Remove cover from Power Distribution Center (PDC) for relay identification and location. 3. Remove starter relay from PDC. 4. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 5. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION 1. Push down firmly on starter relay until terminals are fully seated into PDC receptacle. 2. Install PDC cover. 3. Connect battery cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 403 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 404 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 405 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 406 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 407 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 408 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 409 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 410 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 411 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 412 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 413 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 414 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 415 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 416 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 417 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 418 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 419 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 420 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 421 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 422 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control Transmission Control System Relay: Description and Operation Relay-Transmission Control RELAY-TRANSMISSION CONTROL 45RFE/545RFE DESCRIPTION NOTE: The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control > Page 425 Transmission Control System Relay: Description and Operation 45RFE 4 Speed TRANSMISSION CONTROL RELAY - 45RFE/545RFE Automatic Transmission DESCRIPTION NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control > Page 426 Transmission Control System Relay: Description and Operation 48RE Automatic Transmission The Chrysler Corporation does not list a Transmission Control Relay for the 48RE Automatic Transmission. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 431 Heated Glass Element Relay: Description and Operation The rear window defogger relay is a International Standards Organization (ISO) micro-relay Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions The ISO micro-relay terminal functions are the same as a conventional ISO relay However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The rear window defogger relay is located in the power distribution center (PDC) in the engine compartment Refer to the PDC label for rear window defogger relay identification and location. The black, molded plastic case is the most visible component of the rear window defogger relay Five male spade-type terminals extend from the bottom of the base to connect the relay to the vehicle electrical system, and the ISO designation for each terminal is molded into the base adjacent to each terminal The ISO terminal designations are as follows - 30 (Common Feed) - This terminal is connected to the movable contact point of the relay. - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The rear window defogger relay cannot be adjusted or repaired If the relay is damaged or faulty, it must be replaced. The rear window defogger relay is an electromechanical switch that uses a low current input from the integrated power module (IPM) to control the high current output to the rear window defogger grid The movable common feed contact point is held against the fixed normally closed contact point by spring pressure When the relay coil is energized, an electromagnetic field is produced by the coil windings This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point The resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear window defogger relay terminals are connected to the vehicle electrical system through a receptacle in the IPM The inputs and outputs of the rear window defogger relay include: - The common feed terminal (30) receives a battery current input from fuse 27 (15 amp) in the IPM through a fused B(+) circuit at all times - The coil ground terminal (87) receives a ground input from the A/C-heater control when the A/Cheater control electronically pulls the control circuit to ground - The coil battery terminal (85) receives a battery current input from fuse 36 (10 amp) in the IPM through a fused B(+) circuit only when the ignition switch is in the Run position - The normally open terminal (86) provides a battery current output to the rear window defogger and heated power mirrors (when equipped) through the relay output circuit only when the rear window defogger relay coil is energized - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the rear window defogger relay coil is de-energized The rear window defogger relay cannot be repaired and, if faulty or damaged, it must be replaced Refer to the appropriate wiring information for diagnosis and testing of the micro-relay and for complete rear window defogger system wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 432 Heated Glass Element Relay: Service and Repair REMOVAL. 1. Disconnect and isolate the negative battery cable. 2. Remove the cover from the integrated power module (IPM). 3. Refer to the fuse and relay layout map on the inner surface of the IPM cover for rear window defogger relay identification and location. 4. Remove the rear window defogger relay from the IPM. INSTALLATION 1. Refer to the fuse and relay layout map on the inner surface of the integrated power module (IPM) for rear window defogger relay identification and location. 2. Position the rear window defogger relay into the proper receptacle in the IPM. 3. Align the rear window defogger relay terminals with the terminal cavities in the IPM receptacle. 4. Push down firmly on the rear window defogger relay until the terminals are fully seated in the terminal cavities in the IPM receptacle. 5. Install the cover onto the IPM. 6. Reconnect the negative battery cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Description and Operation Rear Defogger Relay: Description and Operation The rear window defogger relay is a International Standards Organization (ISO) micro-relay Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions The ISO micro-relay terminal functions are the same as a conventional ISO relay However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The rear window defogger relay is located in the power distribution center (PDC) in the engine compartment Refer to the PDC label for rear window defogger relay identification and location. The black, molded plastic case is the most visible component of the rear window defogger relay Five male spade-type terminals extend from the bottom of the base to connect the relay to the vehicle electrical system, and the ISO designation for each terminal is molded into the base adjacent to each terminal The ISO terminal designations are as follows - 30 (Common Feed) - This terminal is connected to the movable contact point of the relay. - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The rear window defogger relay cannot be adjusted or repaired If the relay is damaged or faulty, it must be replaced. The rear window defogger relay is an electromechanical switch that uses a low current input from the integrated power module (IPM) to control the high current output to the rear window defogger grid The movable common feed contact point is held against the fixed normally closed contact point by spring pressure When the relay coil is energized, an electromagnetic field is produced by the coil windings This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point The resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear window defogger relay terminals are connected to the vehicle electrical system through a receptacle in the IPM The inputs and outputs of the rear window defogger relay include: - The common feed terminal (30) receives a battery current input from fuse 27 (15 amp) in the IPM through a fused B(+) circuit at all times - The coil ground terminal (87) receives a ground input from the A/C-heater control when the A/Cheater control electronically pulls the control circuit to ground - The coil battery terminal (85) receives a battery current input from fuse 36 (10 amp) in the IPM through a fused B(+) circuit only when the ignition switch is in the Run position - The normally open terminal (86) provides a battery current output to the rear window defogger and heated power mirrors (when equipped) through the relay output circuit only when the rear window defogger relay coil is energized - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the rear window defogger relay coil is de-energized The rear window defogger relay cannot be repaired and, if faulty or damaged, it must be replaced Refer to the appropriate wiring information for diagnosis and testing of the micro-relay and for complete rear window defogger system wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Left Rear Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 440 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > Wiper High/Low Relay Wiper Relay: Description and Operation Wiper High/Low Relay The wiper high/low relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper high/low relay is located in the Power Distribution Center (PDC)/Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The wiper high/low relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The wiper high/low relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper high/low relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC)/Integrated Power Module (IPM). The inputs and outputs of the wiper high/low relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the output of the wiper on/off relay at all times through the wiper on/off relay output circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper high/low relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current when the ignition switch is in the On or Accessory positions from a fuse in the PDC/IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) is connected to the high speed brush of the wiper motor through a wiper high/low relay high speed output circuit, and is connected to the high speed brush whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to the low speed brush of the wiper motor through a wiper high/low relay low speed output circuit, and is connected to the low speed brush whenever the relay is de-energized. The wiper high/low relay can be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the ElectroMechanical Instrument Cluster (EMIC), the FCM, or the electronic message inputs to or outputs from the EMIC and the FCM that control the operation of the wiper high/low relay. The most reliable, efficient, and accurate means to diagnose the wiper high/low relay, the EMIC, the FCM, or the electronic message inputs and outputs related to the wiper high/low relay operation requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > Wiper High/Low Relay > Page 446 Wiper Relay: Description and Operation Wiper On/Off Relay The wiper on/off relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper on/off relay is located in the Power Distribution Center (PDC)/Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The wiper on/off relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The wiper on/off relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper on/off relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC)/Integrated Power Module (IPM). The inputs and outputs of the wiper on/off relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the common feed terminal of the wiper high/low relay at all times through the wiper on/off relay output circuit. Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper on/off relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current at all times from a fuse in the PDC/IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit, and provides battery current to the wiper on/off relay output circuit whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to ground at all times through a take out of the left headlamp and dash wire harness with an eyelet terminal connector that is secured by a screw to the front end sheet metal, and is connected to the wiper on/off relay output circuit whenever the relay is de-energized. The wiper on/off relay may be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the ElectroMechanical Instrument Cluster (EMIC), the FCM, or the electronic message inputs to or outputs from the EMIC and the FCM that control the operation of the wiper on/off relay. The most reliable, efficient, and accurate means to diagnose the wiper on/off relay, the EMIC, the FCM, or the electronic message inputs and outputs related to the wiper on/off relay operation requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams Switch-Cylinder Lock-Driver (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 455 Left Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 456 Starter-Adjustable Pedals (Except Base) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 457 Pedal Positioning Switch: Service and Repair BASE BRAKES SWITCH-ADJUSTABLE PEDALS REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations Steering Wheel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 461 Remote Switch: Diagrams Switch-Remote Radio-Left Switch-Remote Radio-Right Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 462 Remote Switch: Description and Operation Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). The six switches in the two remote radio switch units are normally open, resistor multiplexed momentary switches that are hard wired to the Integrated Power Module (IPM) through the clockspring. The IPM sends a five volt reference signal to both switch units on one circuit, and senses the status of all of the switches by reading the voltage drop on a second circuit. When the IPM senses an input (voltage drop) from any one of the remote radio switches, it sends the proper switch status messages on the Programmable Communication Interface (PCI) data bus network to the radio receiver. The electronic circuitry within the radio receiver is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the IPM or the PCI data bus, the use of a scan tool and the proper Diagnostic Procedures information is recommended. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 463 Remote Switch: Testing and Inspection Any diagnosis of the Audio system should begin with the use of scan tool. For information on the use of the scan tool. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switch Test Table 3. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 4. If not OK, replace the faulty switch. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Check for 5 volts at the radio control MUX circuit cavities of the steering wheel wire harness connectors for both remote radio switches. If OK, go to Step 5. If not OK, repair the open or shorted radio control MUX circuit to the Integrated Power Module (IPM) as required. 5. Disconnect and isolate the battery negative cable. Disconnect the 22-way instrument panel wire harness connector from the IPM. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted remote radio switch ground circuit to the IPM as required. 6. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and the 22-way instrument panel wire harness connector for the IPM. There should be continuity. If OK, refer to the proper Diagnostic Procedures to test the IPM and the PCI data bus. If not OK, repair the open remote radio switch ground circuit as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 464 Remote Switch: Service and Repair WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. 3. Remove the speed control switches (2). 4. Unplug the wire harness connector from the remote radio switch (1). 5. Depress the tabs on each side of each switch and push the switch through the rear steering wheel cover. INSTALLATION 1. Install remote radio switch (1) to the steering wheel. 2. Connect the wire harness to the remote radio switch. 3. Install the speed control switches (2). 4. Install the driver airbag. 5. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Locations > Page 469 Door Lock Cylinder Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Disconnect the door cylinder lock switch pigtail wire connector from the door wire harness connector. Door Cylinder Lock Switch Tests 3. Using an ohmmeter, perform the resistance tests between the two pins in the door cylinder lock switch pigtail wire connector. Actuate the switch by rotating the key in the door lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Door Cylinder Lock Switch Tests table. 4. If the switch fails any of the resistance tests, replace the faulty door cylinder lock switch as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Locations > Page 470 Door Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the exterior handle and lock cylinder (1) from the outside of the driver side front door as a unit. 3. Remove the bowed clip (3) that secures the lever arm (4) to the shaft on the back of the lock cylinder. 4. Remove the lever arm from the lock cylinder shaft. 5. Remove the door cylinder lock switch (2) from the back of the lock cylinder. INSTALLATION 1. Position the door cylinder lock switch (2) over the shaft on the back of the lock cylinder (1). 2. Position the lever arm (4) onto the shaft over the switch. 3. Install the bowed clip (3) that secures the lever arm to the shaft. 4. Reinstall the exterior handle and lock cylinder onto the outside of the driver side front door as a unit. 5. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Position Switch > Component Information > Locations Left Front Door Premium Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Position Switch > Component Information > Locations > Page 474 Door Position Switch: Description and Operation Vehicles that are equipped with the optional Vehicle Theft Security System (VTSS) have a door cylinder lock switch (1) secured to the back of the key lock cylinder inside the driver side front door. The door cylinder lock switch is a resistor multiplexed momentary switch that is hard wired in series between ground and the cylinder lock switch mux circuit input to the ElectroMechanical Instrument Cluster (EMIC) through a pigtail wire (2) connected to the left front door wire harness. The door cylinder lock switch is driven by the key lock cylinder and contains two internal resistors. One resistor value is used for the Lock position, and one for the Unlock position. The door cylinder lock switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The door cylinder lock switch is actuated by the key lock cylinder when the key is inserted in the lock cylinder and turned to the lock or unlock positions. The door cylinder lock switch closes a circuit between ground and the cylinder lock switch mux circuit through one of two internal resistors for the ElectroMechanical Instrument Cluster (EMIC) when the driver side front door key lock cylinder is in the Lock, or Unlock positions. The EMIC reads the switch status through an internal pull-up, then uses this information as an input for the Vehicle Theft Security System (VTSS) operation, as well as for control of a central locking feature for the power lock system. The door cylinder lock switch and circuit may be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC or its responses to the cylinder lock switch inputs. The most reliable, efficient, and accurate means to diagnose the door cylinder lock switch, the EMIC, and both the hard wired and electronic message inputs and outputs affected by the door cylinder lock switch inputs requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 478 Left Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 479 Starter-Adjustable Pedals (Except Base) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 480 Pedal Positioning Switch: Service and Repair BASE BRAKES SWITCH-ADJUSTABLE PEDALS REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations Left Front Door Premium Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 484 Right Front Door Premium Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 485 Power Door Lock Switch: Diagrams Switch-Door Lock-Passenger Switch-Window/Door Lock Driver C1 Switch-Window/Door Lock Driver C1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 486 Power Door Lock Switch: Description and Operation A window/lock switch is used on all models equipped with power locks, power windows, and power mirrors. The window/lock switch houses the following switches: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch selects the right or left power mirror for adjustment, or turns the power mirror system Off. Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, there are individual master switches for each passenger door power window. The window/lock switch also incorporates several green Light-Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility. The window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster input, which allows the instrument cluster to sense the switch position. Based upon the power lock switch input, the instrument cluster controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit. The switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window is labeled "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The power mirror switch circuitry is connected to battery current through a fuse in the IPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral Off position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the power mirror switch is connected to battery current through the power window circuit breaker in the IPM on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the On or Accessory positions. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Switch-Power Lock Power Door Lock Switch: Testing and Inspection Switch-Power Lock The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Integrated Power Module (IPM) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the window/lock switch. If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the On position. If OK, replace the faulty switch. 1. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel. Disconnect the door wire harness connector for the power lock switch from the switch connector receptacle. Power Lock Switch Test Table 2. Test the power lock switch resistance. See the Power Lock Switch Test chart to determine if the resistance is correct for the switch in each switch position. If not OK, replace the faulty power lock switch as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Switch-Power Lock > Page 489 Power Door Lock Switch: Testing and Inspection Window/Lock Switch The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Integrated Power Module (IPM). If all of the LEDs are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Switch-Power Lock > Page 490 Driver Door Module Switch Tests 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty DDM as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Switch-Power Lock Power Door Lock Switch: Service and Repair Switch-Power Lock REMOVAL The power lock switch on the driver side front door trim panel is integral to the window/lock switch. 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Switch-Power Lock > Page 493 Power Door Lock Switch: Service and Repair Switch-Window/Door Lock REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Install switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection Power Mirror Switch: Testing and Inspection The power mirror switch is included with the window/lock switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Page 497 Power Mirror Switch: Service and Repair The power mirror switch is included with the window/lock switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Power Seat Switch: Diagrams Switch-Seat Belt-Driver Switch-Seat Driver Switch-Seat-Passenger (Quad Cab) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 501 Switch-Seat Passenger (Standard Cab) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 502 Power Seat Switch: Description and Operation The power seats on this vehicle can be adjusted in eight different directions, up, down, front up, front down, rear up, rear down, rearward and forward. The power seat switch is located on the outboard side of the seat cushion on the seat cushion side shield. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or inoperative, the entire power seat switch assembly must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 503 Power Seat Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Power Seat Switch Test Table 3. Using an ohmmeter to test the continuity of the power seat switches in each position. Refer to the POWER SEAT SWITCH TEST TABLE. If not OK, replace the inoperative power seat switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 504 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. 3. Pull the switch bezel or side shield unit (1) out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module (2). 4. Remove the screws (3) that secure the power seat switch (2) to the side shield unit (1). INSTALLATION 1. Position the power seat switch (2) on the seat cushion side shield (1) and install the screws (3). 2. Connect the electrical connector. 3. Install the seat cushion side shield on the seat. 4. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Description and Operation Seat Heater Sensor: Description and Operation The heated seat temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. One temperature sensor is used for each seat. This temperature sensor is located in the seat cushion heating element on all models. The heated seat temperature sensor cannot be repaired or adjusted and must be replaced if defective. The heated seat cushion element must be replaced if the temperature sensor is defective. Refer to the procedure. When the temperature of the seat cushion cover rises, the resistance of the sensor decreases. The heated seat module supplies five-volts to one side of each sensor, and monitors the voltage drop through the sensor on a return circuit. The heated seat module uses this temperature sensor input to monitor the temperature of the seat, and regulates the current flow to the seat heating elements accordingly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Description and Operation > Page 508 Seat Heater Sensor: Testing and Inspection NOTE: Any resistance values (OHMS) given in the following text are supplied using the automatic range generated by a FLUKE(R) automotive meter. If another type of measuring device is used, the values generated may not be the same as the results shown here, or may have to be converted to the range used here. 1. Position the driver seat in the full rearward position. 2. Unclip the heated seat module from the bottom of the drivers seat cushion pan. 3. Back-probe the heated seat module wire harness connector, do not disconnect. Check cavity (#7 for passenger, #8 for driver seat) for a range in voltage from approx. 1.72 - 3.0 volts. It should be within this range, If OK check the heated seat element. If NOT OK, check for the proper 5 volt supply to the heated seat sensor, from the module. Refer to Wiring for specific information. If 5 volts is not being supplied to the sensor from the module, replace the heated seat module. 4. Test the seat wire harness between the heated seat module connector and the heated seat wire harness connector for shorted or open circuits. If OK, refer to Diagnosis and Testing the Heated Seat Module in Electronic Control Modules, for the proper heated seat module diagnosis and testing procedures. If not OK, repair the shorted or open heated seat wire harness as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Description and Operation > Page 509 Seat Heater Sensor: Service and Repair REMOVAL 1. For heated seat sensor replacement procedure. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations Seat Heater Switch: Locations Rear Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 513 Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 514 Center Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 515 Seat Heater Switch: Diagrams Switch-Heated Seat Driver Switch-Heated Seat-Passenger Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 516 Seat Heater Switch: Description and Operation The momentary, bidirectional rocker-type heated seat switch provides a resistor-multiplexed signal to the heated seat module via a mux circuit. Each switch has a center neutral position and momentary Low and High positions so that both the driver and the front seat passenger can select a preferred level of seat heating. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected mode (Low or High) of the seat heater. These indicator lamps also provide diagnostic feedback for the heated seat system. Each switch also has an incandescent bulb, which provides dimmer controlled back lighting of the switch when the headlamps or park lamps are on. The heated seat switches are both mounted in the instrument panel center bezel, located in the lower center of the instrument panel. The two switches are snapped into the mounting holes of the heated seat switch bezel, and the heated seat switch bezel is secured with screws to the instrument panel center bezel. The heated seat switches are differentiated by the keyway in the connector receptacle on the backs of the switches and keyway on the switch housing. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles on the switches so that the two heated seat switches can only be connected to the proper heated seat electrical. The two LED indicator lamps and the incandescent bulb in each heated seat switch cannot be repaired. If the indicator lamps or back lighting bulb are faulty or damaged, the individual heated seat switch must be replaced. The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hardwired resistance signal to the heated seat module. This signal tells the module to energize the heated seat element of the selected seat and maintain the requested temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new selection. If a heated seat switch is depressed a second time, the heated seat module interprets the second input as a request to turn the seat heater OFF. The High and Low LED indicator lamps in the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The ground side of each indicator lamp is controlled by the heated seat module. This control of the switch indicator lamps also allows the module to provide diagnostic feedback to the vehicle operator or technician to indicate heated seat system faults by flashing the indicator lamps on and off. One side of the incandescent back lighting bulb in each heated seat switch is connected to ground at all times. The other side of the incandescent bulb is connected to the fused panel lamps dimmer switch signal circuit. These bulbs are energized when the park lamps or headlamps are turned on, and their illumination intensity is controlled by the panel lamps dimmer switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 517 Seat Heater Switch: Testing and Inspection Refer to Wiring Diagrams for connector pin-outs and the location of complete heated seat system wiring diagrams. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. If the problem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps operate, go to Step 2. If the problem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps are also inoperative. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do not heat, proceed. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do heat, go to Step 6. If the problem being diagnosed involves a heated seat switch indicator lamp that remains illuminated after the heated seat has been turned Off. 2. Disconnect and isolate the battery negative cable. Remove the heated seat switch and bezel unit from the instrument panel. Disconnect the heated seat switch to be tested. Check for continuity between the ground circuit cavity of the heated seat switch and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open ground circuit to ground as required. 3. Reconnect the battery negative cable. Turn the park lamps on with the headlamp switch. Rotate the panel lamps dimmer thumb wheel on the headlamp switch upward to just before the interior lamps detent. Check for battery voltage at the fused panel lamps dimmer circuit cavity of the heated seat switch. If OK, go to Step 4. If not OK, repair the open fused panel lamps dimmer switch signal circuit to the fuse in the Integrated Power Module as required. 4. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the heated seat switch. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run) circuit as required. 5. Check the continuity and resistance values of the heated seat switch in the Neutral, Low and High positions as shown in the Heated Seat Switch Continuity chart. If OK, refer to Step 6. If not OK, replace the faulty heated seat switch. 6. Replace the inoperative heated seat switch with a known good unit and test the operation of the switch indicator lamps. If OK, discard the faulty heated seat switch. If not OK. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 518 Seat Heater Switch: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Wait two minutes for the system reserve capacitor to discharge before beginning any airbag or instrument panel service. 3. Remove the center bezel from the instrument panel. 4. Remove the screws that secure the heated seat switch bezel to the instrument panel center bezel. 5. Remove the heated seat switch bezel and both switches from the instrument panel as a unit. 6. From the back of the heated seat switch bezel, gently pry the switch free and push the heated seat switch out through the front of the bezel. INSTALLATION NOTE: When installing the heated seat switches, be certain they are installed in the proper mounting holes of the heated seat switch bezel. The heated seat switches are differentiated by the keyway in the connector receptacle on the backs of the switches and keyway on the switch housing. 1. From the back of the heated seat switch bezel, gently push the heated seat switch in through the front of the bezel. 2. Position the heated seat switch bezel to the instrument panel center bezel and install the retaining screws. 3. Install the center bezel on the instrument panel. 4. Connect the battery negative cable. 5. Verify vehicle and system operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Switch-Sunroof Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 522 Sunroof / Moonroof Switch: Description and Operation The power sunroof switch (3) is a combination push button and rocker switch module mounted in the overhead console. The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) The power sunroof switch is part of the overhead console assembly and cannot be replaced separately. If the switch is damaged or inoperative the overhead console must be replaced. The power sunroof switch is hard wired to the sunroof motor/module assembly. The switch receives battery current from the motor/module when the ignition switch is in the RUN and ACCESSORY positions or the vehicle Accessory Delay System is active. When one of the switch positions is pressed it sends battery current back to the motor/ module, signaling it to move the power sunroof to the appropriate position. The motor/module will perform one of the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 523 Sunroof / Moonroof Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. If completing the appropriate diagnostic information results in the sunroof switch being inoperative, perform the following test prior to switch replacement. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console. 3. Disconnect the power sunroof switch wire harness connector. Power Sunroof Switch Continuity Table 4. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage. Use a scan tool and the proper Diagnostic Procedures Information to complete diagnosis of the power sunroof system. If not OK, replace the overhead console. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 528 Brake Fluid Level Switch Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 529 Brake Fluid Level Sensor/Switch: Description and Operation BRAKE FLUID LEVEL SWITCH CIRCUIT The switch signals the CAB for a hydraulic fluid problem. The antilock system uses input from the brake fluid level switch when activated. A low brake fluid condition in the master cylinder will close the switch circuit and read 0 volts. When the brake fluid level is at specifications, the switch will open and circuit sense voltage will read 5 volts. This signal tells the CAB if there is enough brake fluid in the master cylinder to have an antilock operation. The brake fluid level switch is located in the master cylinder with 10k resistor. The switch is a Hall effect design and uses a float to determine level. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations Braking Sensor/Switch: Locations Fig.26 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 533 Fig.28 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 534 Fig.31 Left Side Engine Compartment and Hood Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Fig.26 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 538 Fig.27 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 539 Switch-Parking Brake Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 540 Parking Brake Warning Switch: Description and Operation The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the EMIC processing of the park brake switch sense input requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 541 Parking Brake Warning Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: If the brake indicator stays on with the ignition switch in the On position and the park brake released, or comes on while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or a faulty park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 542 Parking Brake Warning Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. INSTALLATION 1. Reach under the left end of the instrument panel to position park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 N.m (24 in.lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 543 5. Turn the ignition switch to the On position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Wheel Speed Sensors Front Sensor Bolt ................................................................................................................................................ 21 Nm (190 in. lbs.) Wheel Speed Sensors Bracket To Knuckle ............................................................................................................................................. 6.7 Nm (60 in. lbs.) Wheel Speed Sensors Rear Sensor Stud ............................................................................................................................................. 22.5 Nm (200 in. lbs.) Rear Wheel Speed Sensor Mounting Bolt .............................................................................................................................................. 24 Nm (200 in. lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 WHEEL SPEED SENSORS/TONE WHEELS Front Rear Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 549 Wheel Speed Sensor: Connector Locations Fig.25 Right Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 550 Fig.26 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 551 Fig.31 Left Side Engine Compartment and Hood Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 552 Fig.49 Rear Chassis Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 553 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor (ABS) Rear Wheel Speed Sensor (ABS) Right Front Wheel Speed Sensor (ABS) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 554 Wheel Speed Sensor: Description and Operation WHEEL SPEED SENSORS The EBC 125 (RWAL) system uses only one speed sensor mounted in the rear axle for the rear wheels. The EBC 325 (ABS) system uses one wheel speed sensor on each front wheel, and one 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 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 CAB takes control for antilock action through the HCU. Diagnostically, the coils of the wheel speed sensors have different amounts of resistance based upon the location. When measured across the connector two terminals, the resistance should be: Front sensor: 90 °C (194 °F) ..................................................................................................................................... ........................................... 2259 - 2761 Ohms 25 °C (77 °F) ............................................................. ..................................................................................................................... 1800 - 2200 Ohms -40 °C (-40 °F) ........................................................................................................................................... .................................... 1332 - 1628 Ohms Rear sensor: 90 °C (194 °F) ..................................................................................................................................... ........................................... 2900 - 3600 Ohms 25 °C (77 °F) ............................................................. ..................................................................................................................... 1600 - 2300 Ohms -40 °C (-40 °F) ........................................................................................................................................... ..................................... 1000 - 1400 Ohms NOTE:For all resistance ranges add 30% to the value for extreme heat, subtract 30% for extreme cold. On a EBC 325 (ABS) system each front wheel speed is monitored through the speed sensor mounted at the wheel end of the hub. On the EBC 125 (RWAL) and EBC 325 (ABS) systems the rear wheel speed is monitored through the speed sensor mounted in the rear axle assembly. The CAB will disable antilock control, illuminate the amber ABS warning indicator circuit via the PCI BUS, and store diagnostic 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 DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front hub/bearings. The third sensor is mounted on top of the rear axle differential housing. OPERATION The Wheel Speed Sensor consists of a magnet surrounded by windings from a single strand of wire. The sensor sends a small AC signal to the CAB. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) passes the stationary magnetic WSS. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 555 When the ring gear is rotated, the exciter ring passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings. This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated. Each AC signal (positive to negative signal or sinewave) is interpreted by the CAB. It then compares the frequency of the sinewave to a time value to calculate vehicle speed. The CAB continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: Magnetic field strength; the stronger the magnetic field, the stronger the signal - Number of windings in the sensor; more windings provide a stronger signal - Exciter ring speed; the faster the exciter ring/ tone wheel rotates, the stronger the signal will be - Distance between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be The rear WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 inch. The assembly plant performs a "Rolls Test" on every vehicle that leaves the assembly plant. One of the test performed is a test of the WSS. To properly test the sensor, the assembly plant connects test equipment to the Data Link Connector (DLC). This connector is located to the right of the steering column and attached to the lower portion of the instrument panel. The rolls test terminal is spliced to the WSS circuit. The vehicle is then Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 556 driven on a set of rollers and the WSS output is monitored for proper operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 557 Wheel Speed Sensor: Testing and Inspection DIAGNOSIS AND TESTING - REAR WHEEL SPEED SENSOR Diagnosis of base brake conditions, which are mechanical in nature, should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The Antilock brake system performs several self tests every time the ignition switch is turned on and the vehicle is driven. The CAB monitors the system inputs and outputs circuits to verify the system is operating properly. If the CAB senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: The MDS or ORB 111 scan tool is used to diagnose the Antilock Brake system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front REMOVAL 1. Remove the front rotor. 2. Remove the wheel speed sensor mounting bolt from the hub. 3. Remove the wheel speed sensor from the hub. 4. Remove the wiring from the clips and disconnect the electrical connector. INSTALLATION 1. Install the wiring to the clips and Reconnect the electrical connector. 2. Install the wheel speed sensor to the hub. 3. Install the wheel speed sensor mounting bolt to the hub. Tighten the bolt to 21 Nm (190 in. lbs.). 4. Install the front rotor and brake caliper assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 560 Wheel Speed Sensor: Service and Repair Rear REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the brake line mounting nut and remove the brake line from the sensor stud. 3. Remove the mounting stud from the sensor and shield. 4. Remove the sensor and shield from the differential housing. 5. Disconnect the sensor wire harness and remove the sensor. INSTALLATION 1. Connect the harness to the sensor. Be sure the seal is securely in place between the sensor and the wiring connector. 2. Install the O-ring on the sensor (if removed). 3. Insert the sensor in the differential housing. 4. Install the sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (200 in. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor / Switch HVAC > Component Information > Locations Left Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams Cruise Control Switch: Diagrams Switch-Speed Control-Left (ETC) Switch-Speed Control-Left (Except ETC) Switch-Speed Control-Right (ETC) Switch-Speed Control-Right (Except ETC) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 573 Cruise Control Switch: Description and Operation Two separate switch pods operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM (to the ECM for diesel) for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Depending on engine control computer (JTEC having a 3- plug connector or NGC having a 4- plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switch used with the NGC system has an attached pigtail lead. The switch used with the JTEC system does not have an attached pigtail lead. When speed control is selected by depressing the ON, OFF switch, the PCM (ECM for diesel) allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral (auto. trans.) - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal (manual trans.). - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM (ECM for diesel). NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's/ECM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM (ECM for diesel) is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's/ECM's RAM when the ACCEL switch is released. The PCM/ECM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM/ECM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's/ECM's ON, OFF input, and the battery voltage to the brake switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 574 Cruise Control Switch: Service and Repair REMOVAL Depending on engine control computer (JTEC having a 3-plug connector or 5.7L V-8 NGC having a 4-plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switches used with the NGC system have attached pigtail leads. The switch used with the JTEC system does not have an attached pigtail lead. 1. Remove switch mounting screw (2). 2. Pull switch (2) from steering wheel. 3. Unplug electrical connector from switch, or, switch pigtail wire harness from steering wheel wire harness (4) and remove switch. INSTALLATION 1. Plug electrical connector into switch, or connect pigtail wire harness to steering wheel wire harness. Be sure wires are not pinched. 2. Position switch to steering wheel. 3. Install switch mounting screw and tighten. Refer to torque specifications. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations Right Front Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 581 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 582 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 583 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 584 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 585 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 586 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 587 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 588 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 589 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 590 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 591 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 592 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 593 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 594 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 595 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 596 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 597 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 598 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 599 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 600 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 601 Sensor-Engine Oil Pressure (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations Right Front Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 605 Sensor-Engine Oil Temperature (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 606 Oil Temperature Sensor/Switch: Testing and Inspection 1. Disconnect the engine wire harness connector from the oil temperature sensor. 2. Using an ohmmeter and a test thermometer, test the resistance versus the oil temperature relationship of the sensor between the two terminals of the sensor as shown in the Oil Temperature Sensor Tests table. 3. If the sensor fails any of these tests, replace the faulty oil temperature sensor as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Left Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 611 Left Side Engine Compartment And Hood Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 612 Sensor-Ambient Air Temperature Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 613 Ambient Temperature Sensor / Switch HVAC: Description and Operation The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the left side of the radiator yoke, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent by the Front Control Module (FCM). The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the FCM. Based upon the resistance in the sensor, the FCM senses a specific voltage on the temperature sensor signal circuit. The FCM then translates the voltage into a temperature reading that it sent over the Programmable Communications Interface (PCI) data bus circuit to other modules utilizing temperature information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 614 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection The temperature function is supported by the ambient temperature sensor, a wiring circuit, and Front Control Module (FCM). If any portion of the ambient temperature sensor circuit fails or if Programmable Communications Interface (PCI) Data Bus information is missing, a (- -) will appear in the display in place of the temperature. When the sensor is exposed to temperatures above 55° C (130° F), or if the sensor circuit is shorted, 55° C (130° F) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below - 40° C (- 40° F) or if the sensor circuit is open, - 40° C (- 40° F) will appear in the display. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, test the compass mini-trip computer. SENSOR TEST 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is 336 kilohms. At 55° C (130° F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, refer to Sensor Circuit Test. If not OK, replace the inoperative ambient temperature sensor. SENSOR CIRCUIT TEST For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connectors from the ambient temperature sensor and the FCM. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the FCM harness connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Check for continuity between the ambient temperature sensor signal circuit cavity of the FCM harness connector and a good ground. There should be no continuity. If OK, test the compass mini-trip computer operation. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 615 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Open the hood. 2. Disconnect and isolate the battery negative cable. 3. Working on the underside of the hood, remove screw holding sensor to hood panel. 4. Disconnect the sensor electrical connector and remove sensor from vehicle. INSTALLATION 1. Connect the sensor electrical connector. 2. Working on the underside of the hood, install screw holding sensor to hood panel. 3. Connect the battery negative cable. 4. Close the hood. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation A/C-Heater Control - Single Zone Shown, Dual Zone Typical The blower motor is controlled by a rotary-type blower motor switch, mounted in the A/C-heater control. The switch allows the selection of one of four different blower motor speeds and includes an Off position. The blower motor switch provides a blower motor ground path through the A/C-heater mode control switch. The blower motor switch directs this ground path through or around the blower motor resistor wires, as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, the entire A/C-heater control must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation > Page 619 Blower Motor Switch: Testing and Inspection For circuit descriptions and diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check for battery voltage at the fuse in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the A/C-heater control from the instrument panel. Check for continuity between the ground circuit cavity of the A/C-heater control wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 3. With the A/C-heater control wire harness connector disconnected, place the A/C-heater mode control switch 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 A/C-heater control as you move the blower motor switch 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 A/C-heater control connector and the blower motor resistor as required. If not OK, replace the faulty A/C-heater control. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Coolant Temperature Sensor / Switch HVAC > Component Information > Locations Left Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 626 Sensor-Evaporator Temperature Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 627 Evaporator Temperature Sensor / Switch: Description and Operation The evaporator temperature sensor is a two-wire temperature sensing element located at the coldest point on the face of the evaporator. The sensor is attached to the evaporator coil fins. The evaporator temperature sensor prevents condensation on the evaporator coil from freezing and obstructing A/C system air flow. The evaporator temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The evaporator temperature sensor monitors the temperature of the evaporator. The sensor will change its internal resistance in response to the temperatures it monitors. The A/C-heater control module is connected to the sensor through a sensor ground circuit and a sensor signal circuit. As the evaporator temperature increases, the resistance of the sensor decreases and the voltage monitored by the module decreases. The module uses this monitored voltage reading to an indication of the evaporator temperature. The A/C-heater control module is programmed to respond to this input by cycling the air conditioning compressor clutch as necessary to optimize air conditioning system performance and to protect the system from evaporator freezing. The external location of the sensor allows the sensor to be removed or installed without disturbing the refrigerant in the system. The evaporator temperature sensor is diagnosed using a DRBIII(R) scan tool. Refer to Body Diagnostic Procedures. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 628 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the HVAC housing from the vehicle . Evaporator Temperature Sensor Wire Connector 3. Disconnect the HVAC wire harness connector from the evaporator temperature sensor. 4. Disassemble the HVAC housing to gain access to the evaporator coil. Evaporator Temperature Sensor Probe 5. Remove the evaporator temperature sensor probe from the evaporator coil. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 629 INSTALLATION 1. Install the evaporator probe into the evaporator coil. 2. Assemble the HVAC housing. 3. Connect the HVAC wire harness connector to the evaporator temperature sensor. 4. Install the HVAC housing . 5. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams Transducer-A/C Pressure (Diesel/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 633 Refrigerant Pressure Sensor / Switch: Description and Operation The A/C pressure transducer is a switch that is installed on a fitting located on the refrigerant discharge line between the compressor and the condenser in the front corner of the engine compartment. An internally threaded hex fitting on the transducer connects it to the externally threaded Schrader-type fitting on the discharge line. A rubber O-ring seals the connection between the transducer and the discharge line fitting. Three terminals within a molded plastic connector receptacle on the top of the transducer connect it to the vehicle electrical system through a wire lead and connector of the headlamp and dash wire harness. The A/C pressure transducer cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the discharge line. The transducer will change its internal resistance in response to the pressures it monitors. The Powertrain Control Module (PCM) or the Engine Control Module (ECM) depending on engine application, provides a five volt reference signal and a sensor ground to the transducer, then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure. The PCM/ ECM is programmed to respond to this and other sensor inputs by controlling the operation of the air conditioning compressor clutch and the radiator cooling fan to help optimize air conditioning system performance and to protect the system components from damage. The A/C pressure transducer input to the PCM/ECM will also prevent the air conditioning compressor clutch from engaging when ambient temperatures are below about 10° C (50° F) due to the pressure/temperature relationship of the refrigerant. The Schrader-type valve in the discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the system. The A/C pressure transducer is diagnosed using a DRBIII(R) scan tool. Refer to the appropriate diagnostic information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 634 Refrigerant Pressure Sensor / Switch: Testing and Inspection The A/C pressure transducer is tested using a DRBIII(R) scan tool. Refer to the appropriate diagnostic information. Before testing the A/C pressure transducer, be certain that the transducer wire harness connection is clean of corrosion and properly connected. For the air conditioning system to operate, an A/C pressure transducer voltage reading between 0.451 and 4.519 volts is required. Voltages outside this range indicate a low or high refrigerant system pressure condition to the Powertrain Control Module (PCM) or Engine Control Module (ECM) depending on engine application. The PCM/ECM is programmed to respond to a low or high refrigerant system pressure by suppressing operation of the compressor. Refer to the A/C Pressure Transducer Voltage chart for the possible conditions indicated by the transducer voltage reading. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 635 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the wire harness connector from the A/C pressure transducer. A/C Pressure Transducer - 3.7L Shown 3. Remove the A/C pressure transducer from the fitting on the discharge line. 4. Remove the O-ring seal from the A/C pressure transducer fitting and discard. INSTALLATION NOTE: Replace the O-ring seal before installing the A/C pressure transducer. 1. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the A/C pressure transducer fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 2. Install and tighten the A/C pressure transducer onto the discharge line fitting. The transducer should be hand-tightened securely onto the discharge line fitting. 3. Connect the wire harness connector to the A/C pressure transducer. 4. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams Dimmer Switch: Diagrams Lamp-Center Bezel Lamp CHMSL Aftermarket - 1 Way Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Description and Operation Door Switch: Description and Operation This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if faulty or damaged, the door latch unit must be replaced. The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the Electro-Mechanical Instrument Cluster (EMIC). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the PCI data bus, or the electronic messaging used to convey door ajar switch status to other modules in the vehicle. The most reliable, efficient, and accurate means to diagnose the EMIC, the PCI data bus, and both the hard wired and electronic message inputs and outputs affected by the door ajar switch inputs requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Sensor-Fuel Level Sending Unit Fuel Gauge Sender: Locations Sensor-Fuel Level Sending Unit The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Sensor-Fuel Level Sending Unit > Page 647 Fuel Gauge Sender: Locations Fuel Pump Module The fuel pump module assembly is located on the top of the fuel tank. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 650 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 651 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 652 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 653 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 654 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 655 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 656 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 657 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 658 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 659 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 660 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 661 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 662 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 663 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 664 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 665 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 666 Fuel Gauge Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 667 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 668 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 669 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 670 Fuel Gauge Sender: Description and Operation 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 variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit 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 diagnostic 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 671 Fuel Gauge Sender: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation. 2. Disconnect 4-wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. Refer to Special Tools in Wiring for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4-wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/ Installation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation KEY-IN IGNITION SWITCH DESCRIPTION The key-in ignition switch is integral to the ignition switch, which is mounted on the left side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition key cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition key cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Fig.26 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 678 Fig.27 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 679 Switch-Parking Brake Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 680 Parking Brake Warning Switch: Description and Operation The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the EMIC processing of the park brake switch sense input requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 681 Parking Brake Warning Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: If the brake indicator stays on with the ignition switch in the On position and the park brake released, or comes on while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or a faulty park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 682 Parking Brake Warning Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. INSTALLATION 1. Reach under the left end of the instrument panel to position park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 N.m (24 in.lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 683 5. Turn the ignition switch to the On position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Diagrams Sensor-Water In Fuel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 692 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 693 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 694 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 695 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 696 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 697 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 698 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 699 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 700 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 701 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 702 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 703 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 704 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 705 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 706 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 707 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 708 Backup Lamp Switch: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 709 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 710 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 711 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 712 Backup Lamp Switch: Connector Views Switch-Back Up Lamp (Gas) Switch-Back Up Lamp (SRT M/T) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 713 Backup Lamp Switch: Electrical Diagrams Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Page 714 Backup Lamp Switch: Description and Operation Vehicles equipped with a manual transmission have a normally open, spring-loaded plunger type back-up lamp switch. The backup lamp switch is located in a threaded hole on the side of the manual transmission housing. The backup lamp switch has a threaded body and a hex formation near the plunger end of the switch, and an integral connector at the opposite end of the switch. When installed, only the connector and the hex formation are visible on the outside of the transmission housing. Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. The TRS is described in further detail elsewhere in this service information. The backup lamp switch cannot be adjusted or repaired and, if faulty or damaged, the entire switch unit must be replaced. The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the automatic transmission. The backup lamp switch controls the flow of battery voltage to the backup lamp bulbs through an output on the back-up lamp feed circuit. The switch plunger is mechanically actuated by the gearshift mechanism within the transmission, which will depress the switch plunger and close the switch contacts whenever the reverse gear has been selected. The switch receives battery voltage through a fuse in the Integrated Power Module (IPM) on a fused ignition switch output (run) circuit whenever the ignition switch is in the On position. A take out of the engine wire harness connects the backup lamp switch to the vehicle electrical system. The backup lamp switch and circuits can be tested using conventional diagnostic tools and methods. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Page 715 Backup Lamp Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Raise and support the vehicle. 3. Locate and disconnect the engine wire harness connector for the backup lamp switch. 4. Check for continuity between the two terminal pins in the backup lamp switch connector. a. With the gear selector lever in the Reverse position, there should be continuity. b. With the gear selector lever in any position other than Reverse, there should be no continuity. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations Brake Light Switch: Component Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 720 Brake Light Switch: Connector Locations Fig.32 Steering Column Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 721 Fig.37 Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 722 Fig.39 Left Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 723 Brake Lamp Switch Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 724 Brake Light Switch: Description and Operation The plunger type brake lamp switch is mounted on a bracket attached to the base of the steering column, under the instrument panel. CAUTION: The switch can only be adjusted during initial installation. If the switch is not adjusted properly a new switch must be installed. The brake lamp switch is hard wired to the Center High Mount Stop Lamp (CHMSL) and also monitored by the Instrument Cluster for use by the brake lamp, speed control brake sensor circuits and electronic brake distribution (EBD). The brake lamp circuit is open until the plunger is depressed. The speed control and brake sensor circuits are closed until the plunger is depressed. When the brake lamp switch transitions, the CHMSL transitions and instrument cluster transmits a brake applied/released message on the bus. The Integrated Power Module (IPM) will then transition the brake lamps. When the brake light switch is activated, the Powertrain Control Module (PCM) receives an input indicating that the brakes are being applied. After receiving this input, the PCM maintains idle speed to a scheduled rpm through control of the Idle Air Control (IAC) motor. The brake switch input is also used to disable vent and vacuum solenoid output signals to the speed control servo. Vehicles equipped with the speed control option use a dual function brake lamp switch The PCM monitors the state of the dual function brake lamp switch. The brake switch is equipped with three sets of contacts, one normally open and the other two normally closed (brakes disengaged) The PCM sends a 12 volt signal to one of the normally closed contacts in the brake switch, which is returned to the PCM as a brake switch state signal With the contacts closed, the 12 volt signal is pulled to ground causing the signal to go low The low voltage signal, monitored by the PCM, indicates that the brakes are not applied When the brakes are applied, the contacts open, causing the PCM's output brake signal to go high, disengaging the speed control, cutting off PCM power to the speed control solenoids. The second set of normally closed contacts supplies 12 volts from the PCM any time speed control is turned on Through the brake switch, voltage is routed to the speed control servo solenoids The speed control solenoids (vacuum, vent and dump) are provided this voltage any time the speed control is ON and the brakes are disengaged. When the driver applies the brakes, the contacts open and voltage is interrupted to the solenoids The normally open contacts are fed battery voltage When the brakes are applied, battery voltage is supplied to the brake lamps. The brake lamp switch can only be adjusted once That is at the initial installation of the switch If the switch is not adjusted properly or has been removed, a new switch must be installed and adjusted. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 725 Brake Light Switch: Testing and Inspection BRAKE LAMP SWITCH The brake lamp switch can be tested with an ohm-meter The ohmmeter is used to check continuity between the pin terminals SWITCH CIRCUIT IDENTIFICATION - Terminals 1 and 2 brake lamp circuit - Terminals 3 and 4 RWAL/ABS module and Powertrain Control Module (PCM) circuit - Terminals 5 and 6 speed control circuit SWITCH CONTINUITY TEST NOTE: Disconnect switch harness before testing switch continuity With switch plunger extended, attach test leads to pins 1 and 2 Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 3 and 4 Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 5 and 6 Replace switch if meter indicates no continuity. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 726 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the switch harness 2. Press and hold the brake pedal in applied position 3. Rotate the switch counterclockwise about 30° to align the switch lock tab with the notch in bracket 4. Pull the switch rearward out of the mounting bracket and release the brake pedal INSTALLATION 1. Press and hold the brake pedal down. 2. Align the tab on the new switch with the notch in the switch bracket.Insert the switch in the bracket and turn it clockwise about 30° to lock it in place. 3. Connect the harness wires to the switch. 4. Release the brake pedal. 5. Move the release lever on the switch parallel with the connector to engage the switch plunger. The switch is now adjusted and can not be adjusted again. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Left Steering Column Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 730 Switch-Multifunction Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 731 Combination Switch: Description and Operation The multi-function switch is a resistive MUX switch that is monitored by the Instrument Cluster. The turn signals are actuated with the lever on Multi-Function Switch. The signals are automatically turned off by a canceling cam (two lobes molded to the back of the clock spring mechanism). The cam comes in contact with the cancel actuator on the turn signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. The Instrument Cluster monitors the multiplexed multifunction switch. In a turning event the Instrument Cluster senses a change in the turn signal lever and illuminates the appropriate turn signal indicator. At the same time, the Instrument Cluster will send a J1850 message on the PCI bus to the Front Control Module (FCM). The FCM will respond by activating the appropriate relay in the Power Distribution Center. A chime will sound after the turn is completed if vehicle has traveled a distance of approximately 1.0 mile and a speed of 15 mph, with the turn signal ON. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 732 Combination Switch: Testing and Inspection To test the turn signal, headlamp beam select and optical horn portion of the multi-function switch: 1. Remove the multi-function switch. 2. Using an ohmmeter check the resistance readings between multi-function switch pins. Refer to Wiring Diagrams for proper pin numbers and the MULTI-FUNCTION SWITCH TESTS table. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 733 Combination Switch: Service and Repair WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DISARMED. REFER TO THE ELECTRICAL RESTRAINT SYSTEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove the steering wheel and the upper and lower steering column shrouds. Refer to Steering, Column, Shroud, Removal. 3. Disconnect the wire connector from the back of the multi-function switch. 4. Remove the screws retaining the multi-function switch to the steering column adapter collar. 5. Remove the multi-function switch. 6. Remove the screws retaining the clock spring to the multifunction switch. INSTALLATION 1. Install the clock spring on the multifunction switch. 2. Position the switch on to the steering column. 3. Install the retaining screws. 4. Connect the wire harness connector. 5. Install the upper, lower steering column shrouds and the steering wheel. Refer to Steering, Column, Shroud, Installation. 6. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Description and Operation Door Switch: Description and Operation This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if faulty or damaged, the door latch unit must be replaced. The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the Electro-Mechanical Instrument Cluster (EMIC). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the PCI data bus, or the electronic messaging used to convey door ajar switch status to other modules in the vehicle. The most reliable, efficient, and accurate means to diagnose the EMIC, the PCI data bus, and both the hard wired and electronic message inputs and outputs affected by the door ajar switch inputs requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box from the instrument panel. 3. Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to access the instrument panel wire harness connector on the glove box lamp and switch. 4. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the glove box lamp and switch unit. 5. Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to depress the retaining tabs on the top and bottom of the glove box lamp and switch housing. 6. While holding the retaining tabs depressed, push the glove box lamp and switch unit out through the hole in the mounting bracket on the instrument panel glove box opening upper reinforcement. 7. Remove the glove box lamp and switch unit from the instrument panel. INSTALLATION 1. Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to feed the instrument panel wire harness connectors out through the hole in the glove box lamp and switch housing mounting bracket. 2. Position the glove box lamp and switch unit to the instrument panel. 3. Reconnect the instrument panel wire harness connector to the connector receptacle on the back of the glove box lamp and switch unit. 4. Push the glove box lamp and switch unit into the hole in the mounting bracket on the instrument panel glove box opening upper reinforcement. 5. Install the glove box onto the instrument panel. 6. Close the glove box. 7. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 The hazard switch is activated by a push button located in the multifunction switch on the top of the steering column between the steering wheel and instrument cluster. The hazard warning system allows the vehicle operator to provide other vehicle operators in the near proximity an optical indication that the vehicle is disabled or an obstacle to traffic flow. The hazard warning system has battery voltage at all times, regardless of ignition position. The instrument cluster monitors the multiplexed multifunction switch operation. When the hazard warning switch is activated, the instrument cluster will send a J1850 bus message to the Front Control Module (FCM), then activate the two turn signal indicators and audible click in the instrument cluster. The FCM will then activate the necessary relays in the Power Distribution Center (PDC) to begin flashing both the front and rear turn signal indicator lamps. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 746 Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 747 Left Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 748 Switch-Headlamp Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 749 Headlamp Switch: Description and Operation The multiplexed headlamp switch is located on the instrument panel. The headlamp switch controls the parking lamps, fog lamps and the headlamps. A separate switch in the module controls the interior lamps and instrument cluster illumination. This switch also contains a rheostat for controlling the illumination level of the cluster lamps. The multiplexed headlamp switch has an off, parking lamp, fog lamp and a headlamp on position. High beams are controlled by the multiplexed multifunction switch on the steering column. The fog lamps are illuminated by pulling back on the headlamp switch knob when in the parking lamp or headlamp ON position.The headlamp switch cannot be repaired. It must be replaced. The Instrument Cluster monitors the headlamp and multifunction switch operation. When the headlamp switch is rotated to the parking lamp or On position the Instrument Cluster sends a J1850 message to the Front Control Module, which is mated to the power distribution center to become the Integrated Control Module, to illuminate the appropriate bulbs. When the multifunction switch is activated to the optical horn or high beam position the Instrument Cluster illuminates the high beam indicator and sends a J1850 message to the Front Control Module to illuminate the appropriate bulbs. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 750 Headlamp Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Remove the left bezel and the headlamp switch from the instrument panel as a unit. 2. Disconnect the instrument panel wire harness connector from the back of the headlamp switch. Headlamp Switch Tests 3. Using an ohmmeter, test the resistance or continuity between the terminals of the switch as shown in the Headlamp Switch Tests table. 4. If the switch fails any of the tests, replace the faulty headlamp switch as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 751 Headlamp Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left instrument panel bezel. 3. Disconnect the harness connector. 4. Remove the screws that secure the headlamp switch to the instrument panel bezel. 5. Remove the headlamp switch from the instrument panel bezel. INSTALLATION 1. Position the headlamp switch to the left instrument panel bezel and secure with screws.Tighten the screws to 2.2 Nm (20 in. lbs.). 2. Reconnect the instrument panel wire harness connector for the headlamp switch. 3. Position the left instrument panel bezel on to the instrument panel. 4. Install the cluster bezel onto the instrument panel. 5. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams Switch-Horn Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 755 Horn Switch: Description and Operation The horn switch is molded into the driver airbag. The horn switch can not be serviced separately. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 756 Horn Switch: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the horn system requires the use of a scan tool and the proper Diagnostic Procedures information. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Left Front Facia And Battery Tray Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 766 Battery Temperature Sensor: Connector Locations Left Rear Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 767 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 768 Left Front Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 769 Integrated Power Module And Fan Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 770 Sensor-Battery Temperature Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 771 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 772 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. 1. Remove battery. Refer to Battery for procedures. Battery Temperature Sensor Location 2. Pry sensor straight up from battery tray mounting hole to gain access to electrical connector. 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. 1. Pull electrical connector up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Refer to Battery for procedures. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams Sensor-Camshaft Position (Gas) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 776 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor is located above the water pump and under the throttle body. The camshaft position sensor (1) provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses. The PCM determines crankshaft position from the camshaft position sensor and crankshaft position sensor inputs. The PCM uses the input to determine fuel injection synchronization and to determine which ignition coil to energize. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 777 The camshaft position sensor detects when a step down (1) in the camshaft sprocket passes beneath it. When the sensor detects the step down, the input voltage from the sensor to the PCM switches from low (0.3 volts) to high (5 volts). As the step up returns to the sensor, the input voltage switches back to low (0.3 volts). The paper spacer is not used on 8.3L motors. Don't use at all. It plugs up the oil pickup screen. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 778 Camshaft Position Sensor: Service and Repair REMOVAL 8.3L - REPLACING WITH NEW SENSOR The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. If a new replacement camshaft position sensor is to be installed, use this procedure. 1. Disconnect the sensor wiring harness connector from sensor. 2. Remove the sensor mounting bolt. 3. Carefully pry the sensor from the timing chain case/cover in a rocking action with two small screwdrivers. 4. Remove the sensor from vehicle. 8.3L - REPLACING OLD SENSOR WITH ORIGINAL The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. If the original camshaft position sensor is to be removed and installed, such as when servicing the timing chain, timing gears or timing chain cover, use this procedure. 1. Disconnect the sensor harness connector from the sensor. 2. Scribe the sensor for location depth. 3. Remove the sensor mounting bolt. 4. Carefully pry the sensor from the timing chain case/cover in a rocking action with two small screwdrivers. 5. Remove the sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 8.3L - INSTALLATION - WITH NEW SENSOR The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. 1. Apply a small amount of engine oil to the sensor O-ring. A low (step down) and high (step up) area are machined into the camshaft drive gear. The sensor is positioned in the timing gear cover so that a small air gap exists between the face of sensor and the high machined area of cam gear. Before the sensor is installed, the cam gear may have to be rotated. This is to allow the high machined area (step up) on the gear to be directly in front of the sensor mounting hole opening on the timing gear cover. Do not install sensor with gear positioned at low area. When the engine is started, the sensor will be broken. 2. Using a 1/2 in. wide metal ruler, measure the distance from the cam gear to the face of the sensor mounting hole opening on the timing gear cover. 3. If the dimension is approximately 1-15/32 inches or less, it is OK to install sensor. 4. If the dimension is approximately 1-5/8 inches or more, the cam gear will have to be rotated. 5. Attach a socket to the vibration damper mounting bolt and rotate engine until the 1-15/32 inch dimension is attained. 6. Install the sensor into the timing case/cover with a slight rocking action. Do not twist the sensor into position as damage to the O-ring may result. Push the sensor all the way into the cover until the rib material on the sensor contacts the camshaft gear. 7. Install the mounting bolt and tighten to 10.7 N.m (95 in.lbs.) torque. 8. Connect sensor wiring harness to engine harness. When the engine is started, the rib material will be sheared off the face of sensor. This will automatically set sensor air gap. 8.3L - REPLACING OLD SENSOR WITH ORIGINAL The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. When installing a used camshaft position sensor, the sensor depth must be adjusted to prevent contact with the camshaft gear (sprocket). 1. Apply a small amount of engine oil to the sensor O-ring. A low and high area are machined into the camshaft drive gear. The sensor is positioned in the timing gear cover so that a small air gap exists between the face of sensor and the high machined area of cam gear. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 779 Before the sensor is installed, the cam gear may have to be rotated. This is to allow the high machined area on the gear to be directly in front of the sensor mounting hole opening on the timing gear cover. Do not install sensor with gear positioned at low area. When the engine is started, the sensor will be broken. 2. Using a 1/2 in. wide metal ruler, measure the distance from the cam gear to the face of the sensor mounting hole opening on the timing gear cover. 3. If the dimension is approximately 1-15/32 inches or less, it is OK to install sensor. 4. If the dimension is approximately 1-5/8 inches or more, the cam gear will have to be rotated. 5. Attach a socket to the vibration damper mounting bolt and rotate engine until the 1-15/32 inch dimension is attained. 6. Install the sensor into the timing case/cover with a slight rocking action until the sensor is aligned to scribe line. The paper spacer can be used if reinstalling a used sensor. 7. Install sensor mounting bolt and tighten to 10.7 N.m (95 in.lbs.) torque. 8. Connect engine wiring harness to sensor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations Crankshaft Position Sensor: Locations The sensor is located at the rear lower passenger side of motor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 783 Sensor-Crankshaft Position (5.7L/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 784 Crankshaft Position Sensor: Service and Repair REMOVAL The sensor is located at the rear lower passenger side of motor. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting bolt. 3. Pull sensor out. A light tap to top of sensor may ease removal. INSTALLATION 1. Slide the sensor into the hole. 2. Install and tighten the mounting bolt to 11 Nm (95 in. lbs.) torque. 3. Connect the electrical connector to the sensor and lock. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Sensor-Fuel Level Sending Unit Fuel Level Sensor: Locations Sensor-Fuel Level Sending Unit The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Sensor-Fuel Level Sending Unit > Page 792 Fuel Level Sensor: Locations Fuel Pump Module The fuel pump module assembly is located on the top of the fuel tank. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 793 Fuel Level Sensor: Description and Operation 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 variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit 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 diagnostic 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 794 Fuel Level Sensor: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation. 2. Disconnect 4-wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. Refer to Special Tools in Wiring for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4-wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/ Installation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Left Front Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 798 Sensor-Intake Air Temperature (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 799 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL NOTE: Take care not to damage the thermistor pill when removing the sensor. 1. Remove the battery cover and disconnect the negative battery cable. 2. Disconnect the electrical connector from the inlet temperature sensor. 3. Remove sensor from inlet hose. INSTALLATION NOTE: Take care not to damage the open thermistor pill when installing the sensor. 1. Install sensor , use a little water to aid in insertion of sensor. 2. Make sure that the rib on the sensor matches up with the rib on the inlet hose. The thermistor pill should be in direct contact with the inlet air stream. 3. Connect the electrical connector. 4. Connect the negative battery cable and install battery cover. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 803 Knock Sensor: Diagrams Sensor-Knock No.1 (5.7L/SRT) Sensor-Knock No.2 (5.7L/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 804 Knock Sensor: Description and Operation The sensors are used only with 3.7L V-6, 4.7L V-8 and 5.7L V-8 engines. On 3.7L V-6 and 4.7L V-8 engines, the 2 knock sensors are bolted into the cylinder block under the intake manifold. On 5.7L V-8 engines, 2 knock sensors are also used. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. 3.7L V-6/4.7L V-8/5.7L V-8 Engines Only Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations Manifold Pressure/Vacuum Sensor: Component Locations The MAP sensor (2) mounts to the drivers side intake manifold plenum. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations > Page 809 Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 810 Sensor-Map (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 811 Manifold Pressure/Vacuum Sensor: Description and Operation The MAP sensor (2) mounts to the drivers side intake manifold plenum. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum. During key-on (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in. Hg. If a storm goes through, it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 812 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL The manifold absolute pressure sensor is mounted on the drivers side of the intake manifold. 1. Disconnect the electrical connector from the MAP sensor. 2. Remove MAP sensor mounting screws. INSTALLATION 1. Install the MAP sensor to the intake manifold. 2. Install MAP sensor mounting screws and tighten mounting screws to 4 Nm (35 in. lbs.). 3. Connect the electrical connector to the MAP sensor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Right Front Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 818 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 819 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 820 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 821 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 822 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 823 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 824 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 825 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 826 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 827 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 828 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 829 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 830 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 831 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 832 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 833 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 834 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 835 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 836 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 837 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 838 Sensor-Engine Oil Pressure (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations 4 Sensor Vehicle 2 Sensor Vehicle (1 = Downstream, 2 = Upstream) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 843 Oxygen Sensor: Connector Locations Left Transmission (RFE) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 844 Right Transmission (RFE) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 845 Manual Transmission (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 846 Transmission And Exhaust (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 847 Oxygen Sensor: Diagrams Sensor-Oxygen-Left Front (SRT) Sensor-Oxygen-Left Rear (SRT) Sensor-Oxygen-Right Front (SRT) Sensor-Oxygen-Right Rear (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 848 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 849 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the engine or emission package, the vehicle ] may use a total of either 2 or 4 sensors. Federal Emission Packages : Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 850 Oxygen Sensor: Service and Repair REMOVAL CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support vehicle. 2. Disconnect wire connector from O2S sensor. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in exhaust pipe using appropriate tap. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. 1. Install O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect O2S sensor wire connector. 3. Lower vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations The TPS (1) is mounted on the passenger side of the throttle body. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 854 Throttle Position Sensor: Description and Operation The TPS (1) is mounted on the passenger side of the throttle body. The sensor connects to the throttle blade shaft. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from .26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 855 Throttle Position Sensor: Service and Repair REMOVAL The TPS is attached to the throttle body. 1. Disconnect the TPS electrical connector. 2. Remove the TPS mounting screws. 3. Remove the TPS. INSTALLATION The TPS is attached to the throttle body. The throttle shaft end of the throttle body slides into a socket in the TPS. When indexed correctly, the TPS can rotate a few degrees to line up the mounting screw holes with the screw holes in the throttle body. If the sensor will not rotate into place, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS has slight tension when rotated to align the mounting holes. 1. Install TPS and mounting screws. 2. Attach electrical connector to the TPS. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Left Front Facia And Battery Tray Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations The TPS (1) is mounted on the passenger side of the throttle body. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 863 Throttle Position Sensor: Description and Operation The TPS (1) is mounted on the passenger side of the throttle body. The sensor connects to the throttle blade shaft. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from .26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 864 Throttle Position Sensor: Service and Repair REMOVAL The TPS is attached to the throttle body. 1. Disconnect the TPS electrical connector. 2. Remove the TPS mounting screws. 3. Remove the TPS. INSTALLATION The TPS is attached to the throttle body. The throttle shaft end of the throttle body slides into a socket in the TPS. When indexed correctly, the TPS can rotate a few degrees to line up the mounting screw holes with the screw holes in the throttle body. If the sensor will not rotate into place, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS has slight tension when rotated to align the mounting holes. 1. Install TPS and mounting screws. 2. Attach electrical connector to the TPS. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams Sensor-Camshaft Position (Gas) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 869 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor is located above the water pump and under the throttle body. The camshaft position sensor (1) provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses. The PCM determines crankshaft position from the camshaft position sensor and crankshaft position sensor inputs. The PCM uses the input to determine fuel injection synchronization and to determine which ignition coil to energize. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 870 The camshaft position sensor detects when a step down (1) in the camshaft sprocket passes beneath it. When the sensor detects the step down, the input voltage from the sensor to the PCM switches from low (0.3 volts) to high (5 volts). As the step up returns to the sensor, the input voltage switches back to low (0.3 volts). The paper spacer is not used on 8.3L motors. Don't use at all. It plugs up the oil pickup screen. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 871 Camshaft Position Sensor: Service and Repair REMOVAL 8.3L - REPLACING WITH NEW SENSOR The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. If a new replacement camshaft position sensor is to be installed, use this procedure. 1. Disconnect the sensor wiring harness connector from sensor. 2. Remove the sensor mounting bolt. 3. Carefully pry the sensor from the timing chain case/cover in a rocking action with two small screwdrivers. 4. Remove the sensor from vehicle. 8.3L - REPLACING OLD SENSOR WITH ORIGINAL The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. If the original camshaft position sensor is to be removed and installed, such as when servicing the timing chain, timing gears or timing chain cover, use this procedure. 1. Disconnect the sensor harness connector from the sensor. 2. Scribe the sensor for location depth. 3. Remove the sensor mounting bolt. 4. Carefully pry the sensor from the timing chain case/cover in a rocking action with two small screwdrivers. 5. Remove the sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 8.3L - INSTALLATION - WITH NEW SENSOR The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. 1. Apply a small amount of engine oil to the sensor O-ring. A low (step down) and high (step up) area are machined into the camshaft drive gear. The sensor is positioned in the timing gear cover so that a small air gap exists between the face of sensor and the high machined area of cam gear. Before the sensor is installed, the cam gear may have to be rotated. This is to allow the high machined area (step up) on the gear to be directly in front of the sensor mounting hole opening on the timing gear cover. Do not install sensor with gear positioned at low area. When the engine is started, the sensor will be broken. 2. Using a 1/2 in. wide metal ruler, measure the distance from the cam gear to the face of the sensor mounting hole opening on the timing gear cover. 3. If the dimension is approximately 1-15/32 inches or less, it is OK to install sensor. 4. If the dimension is approximately 1-5/8 inches or more, the cam gear will have to be rotated. 5. Attach a socket to the vibration damper mounting bolt and rotate engine until the 1-15/32 inch dimension is attained. 6. Install the sensor into the timing case/cover with a slight rocking action. Do not twist the sensor into position as damage to the O-ring may result. Push the sensor all the way into the cover until the rib material on the sensor contacts the camshaft gear. 7. Install the mounting bolt and tighten to 10.7 N.m (95 in.lbs.) torque. 8. Connect sensor wiring harness to engine harness. When the engine is started, the rib material will be sheared off the face of sensor. This will automatically set sensor air gap. 8.3L - REPLACING OLD SENSOR WITH ORIGINAL The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. When installing a used camshaft position sensor, the sensor depth must be adjusted to prevent contact with the camshaft gear (sprocket). 1. Apply a small amount of engine oil to the sensor O-ring. A low and high area are machined into the camshaft drive gear. The sensor is positioned in the timing gear cover so that a small air gap exists between the face of sensor and the high machined area of cam gear. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 872 Before the sensor is installed, the cam gear may have to be rotated. This is to allow the high machined area on the gear to be directly in front of the sensor mounting hole opening on the timing gear cover. Do not install sensor with gear positioned at low area. When the engine is started, the sensor will be broken. 2. Using a 1/2 in. wide metal ruler, measure the distance from the cam gear to the face of the sensor mounting hole opening on the timing gear cover. 3. If the dimension is approximately 1-15/32 inches or less, it is OK to install sensor. 4. If the dimension is approximately 1-5/8 inches or more, the cam gear will have to be rotated. 5. Attach a socket to the vibration damper mounting bolt and rotate engine until the 1-15/32 inch dimension is attained. 6. Install the sensor into the timing case/cover with a slight rocking action until the sensor is aligned to scribe line. The paper spacer can be used if reinstalling a used sensor. 7. Install sensor mounting bolt and tighten to 10.7 N.m (95 in.lbs.) torque. 8. Connect engine wiring harness to sensor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations Crankshaft Position Sensor: Locations The sensor is located at the rear lower passenger side of motor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 876 Sensor-Crankshaft Position (5.7L/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 877 Crankshaft Position Sensor: Service and Repair REMOVAL The sensor is located at the rear lower passenger side of motor. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting bolt. 3. Pull sensor out. A light tap to top of sensor may ease removal. INSTALLATION 1. Slide the sensor into the hole. 2. Install and tighten the mounting bolt to 11 Nm (95 in. lbs.) torque. 3. Connect the electrical connector to the sensor and lock. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 IGNITION SWITCH DESCRIPTION The ignition switch (5) is located on the steering column (4). It is used as the main on/off switching device for most electrical components. The mechanical key cylinder is used to engage/disengage the electrical ignition switch. OPERATION Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the shift cable. This interlock device is used to lock the transmission shifter in the PARK position when the key cylinder is in any position and the brake pedal is not depressed. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 882 Ignition Switch Lock Cylinder: Service and Repair KEY CYLINDER REMOVAL The ignition key (1) must be in the key cylinder (2) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at side of key cylinder assembly (2). a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. INSTALLATION The ignition key (1) must be in the key cylinder (2) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (2) with the ignition switch. 2. Push the key cylinder (2) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 886 Knock Sensor: Diagrams Sensor-Knock No.1 (5.7L/SRT) Sensor-Knock No.2 (5.7L/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 887 Knock Sensor: Description and Operation The sensors are used only with 3.7L V-6, 4.7L V-8 and 5.7L V-8 engines. On 3.7L V-6 and 4.7L V-8 engines, the 2 knock sensors are bolted into the cylinder block under the intake manifold. On 5.7L V-8 engines, 2 knock sensors are also used. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. 3.7L V-6/4.7L V-8/5.7L V-8 Engines Only Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations Air Bag Deactivation Switch: Locations Rear Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 892 Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 893 Left Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 894 Right Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 895 Switch-Passenger Airbag On/Off Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 896 Air Bag Deactivation Switch: Description and Operation The passenger airbag on/off switch (1) is standard equipment on all standard cab versions of this model when they are equipped with the dual front airbag system. This switch is a two-position, resistor multiplexed switch with a single integral red Light-Emitting Diode (LED), and a non-coded key cylinder-type actuator. The switch is located in the lower right corner of instrument panel center bezel, near the center of instrument panel to make the Off indicator (3) visible to all front seat occupants. When the switch is in its installed position, the only components visible through the dedicated opening of the cluster bezel are the switch face plate (2) and nomenclature, and the key cylinder actuator (4). The "Off" position of the switch is illuminated when this switch position is selected, while the "On" position of the switch is designated by text imprinted upon the face plate of the switch, but is not illuminated. The remainder of the switch is concealed behind the switch face plate and the instrument panel center bezel. The passenger airbag on/off switch housing is constructed of molded plastic and has three integral mounting tabs. These mounting tabs are used to secure the switch to the back of the molded plastic switch face plate with three small screws. The molded plastic face plate also has three integral mounting tabs that are used to secure the switch and face plate unit to the instrument panel center bezel with three additional screws. A molded plastic connector receptacle on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The molded plastic harness connector insulator is keyed and latched to ensure proper and secure switch electrical connections. The passenger airbag on/off switch cannot be adjusted or repaired and, if faulty or damaged, the switch must be replaced. The passenger airbag on/off switch allows the customer to turn the passenger airbag function On or Off to accommodate certain uses of the right front seating position where airbag protection may not be desired. See the vehicle glove box for specific recommendations on when to enable or disable the passenger airbag. The Off indicator of the switch will be illuminated whenever the switch is turned to the Off position and the ignition switch is in the On position. The ignition key is the only key or object that should ever be inserted into the key cylinder actuator of the switch. The on/off switch requires only a partial key insertion to fully depress a spring-loaded locking plunger. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. To actuate the passenger airbag on/off switch, insert the ignition key into the switch key actuator far enough to fully depress the plunger, then rotate the actuator to the desired switch position. When the switch key actuator is rotated to its clockwise stop (the key actuator slot will be aligned with the Off indicator), the Off indicator is illuminated and the passenger airbag is disabled. When the switch is rotated to its counterclockwise stop (the key actuator slot will be in a vertical position), the Off indicator will be extinguished and the passenger airbag is enabled. The passenger airbag on/off switch connects one of two internal resistors in series between the passenger airbag mux switch sense and passenger airbag mux switch return circuits of the Airbag Control Module (ACM). The ACM continually monitors the resistance in these circuits to determine the switch position that has been selected. When the switch is in the Off position, the ACM provides a ground input to the switch through the passenger airbag indicator driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the Off indicator of the switch. The ACM will also illuminate the Off indicator of the switch for about seven seconds each time the ignition switch is turned to the On position as a bulb test. The ACM will store a Diagnostic Trouble Code (DTC) for any fault it detects in the passenger airbag on/off switch or Off indicator circuits, and will illuminate the airbag indicator in the instrument cluster if a fault is detected. For proper diagnosis of the passenger airbag on/off switch or the ACM, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 897 Air Bag Deactivation Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the center bezel (1) from the instrument panel. 3. From the back of the center bezel, remove the three screws (2) that secure the passenger airbag on/off switch and face plate unit (3) to the back of the bezel. 4. Remove the passenger airbag on/off switch and face plate from the center bezel as a unit. INSTALLATION 1. Position the passenger airbag on/off switch and face plate unit (3) to the back of the center bezel (1). 2. Install and tighten the three screws (2) that secure the passenger airbag on/off switch face plate to the back of the center bezel. Tighten the screws to 2 N.m (17 in.lbs.). 3. Reinstall the center bezel onto the instrument panel. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 901 Impact Sensor: Diagrams Sensor-Side Impact-Left 1 Sensor-Side Impact-Right 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 902 Impact Sensor: Description and Operation Two side impact sensors (1) are used on this model when it is equipped with the optional side curtain air-bags, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the bi-directional safing sensor that is internal to the Air-bag Control Module (ACM). Each side impact sensor is secured with a nut within the right or left B-pillar just above the front seat belt retractors and behind the lower B-pillar trim within the passenger compartment. The sensor housing has an integral connector receptacle (2), an integral mounting stud (3), and an integral anti-rotation pin. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The side impact sensors cannot be repaired or adjusted and, if damaged or faulty, they must be replaced. The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Airbag Control Module (ACM). The ACM microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ACM. The impact sensors and the ACM communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the side impact sensors and the ACM may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ACM, the impact sensors, or the electronic message inputs to or outputs from the impact sensors. The most reliable, efficient, and accurate means to diagnose the impact sensors, the ACM, and the electronic message communication between the sensors and the ACM requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab Impact Sensor: Service and Repair Standard Cab WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE SIDE IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE SIDE IMPACT SENSOR ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. IF AN IMPACT SENSOR IS ACCIDENTALLY DROPPED DURING SERVICE, THE SENSOR MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Adjust the driver or passenger side front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the front outboard seat belt and retractor from the inside of the B-pillar. 4. Remove the nut (4) that secures the stud of the side impact sensor (1) to the inner B-pillar. 5. Reach through the retractor mounting hole (3) in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 6. Pull the side impact sensor out of the B-pillar far enough to access and disconnect the body wire harness connector (2) from the sensor connector receptacle. 7. Remove the sensor from the B-pillar. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab > Page 905 1. Position the side impact sensor (1) to the retractor mounting hole (3) in the inner B-pillar. 2. Reconnect the body wire harness connector (2) to the sensor connector receptacle. 3. Reach through the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (4) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in.lbs.). 5. Reinstall the front outboard seat belt and retractor to the inside of the B-pillar. 6. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab > Page 906 Impact Sensor: Service and Repair Quad Cab WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE SIDE IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE SIDE IMPACT SENSOR ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. IF AN IMPACT SENSOR IS ACCIDENTALLY DROPPED DURING SERVICE, THE SENSOR MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (2) to the inner B-pillar (1). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (4) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab > Page 907 1. Position the side impact sensor (2) to the large hole above the retractor mounting hole in the inner B-pillar (1). 2. Reconnect the body wire harness connector (4) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in.lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation Seat Belt Buckle Switch: Description and Operation The seat belt switch is a small, normally open, single pole, single throw, leaf contact, momentary switch. Only one seat belt switch is installed in the vehicle, and it is integral to the buckle of the driver side front seat belt buckle-half, located on the inboard side of the driver side front seat track (4). The seat belt switch is connected to the vehicle electrical system through a two-wire pigtail wire (3) and connector on the seat belt buckle-half (1), which is connected to a wire harness connector and take out of the seat wire harness routed beneath the driver side front seat cushion (2) in the passenger compartment. The seat belt switch cannot be adjusted or repaired and, if faulty or damaged, the entire driver side front seat belt buckle-half unit must be replaced. The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the ElectroMechanical Instrument Cluster (EMIC). When the driver side front seat belt tip-half is inserted into the seat belt buckle, the switch closes the path to ground; and, when the driver side front seat belt tip-half is removed from the seat belt buckle, the switch opens the ground path. The switch is actuated by the latch mechanism within the seat belt buckle. The seat belt switch is connected in series between ground and the seat belt switch sense input of the instrument cluster. The seat belt switch receives ground at all times through its pigtail wire connection to the seat wire harness from a take out of the body wire harness. An eyelet terminal connector on the body wire harness ground take out is secured beneath a ground screw on the left cowl side inner panel, beneath the instrument panel. The seat belt switch may de diagnosed using conventional diagnostic tools and methods. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Page 911 Seat Belt Buckle Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Disconnect and isolate the battery negative cable. Disconnect the seat belt switch pigtail wire connector from the seat wire harness connector for the seat belt switch on the inboard side of the driver side front seat forward of the seat belt buckle-half anchor. Check for continuity between the seat belt switch sense circuit and the ground circuit cavities of the seat belt switch pigtail wire connector. There should be continuity with the seat belt buckled, and no continuity with the seat belt unbuckled. If OK, go to Step 2. If not OK, replace the faulty front seat belt buckle-half assembly. 2. Check for continuity between the ground circuit cavity in the seat wire harness connector for the seat belt switch and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open ground circuit to ground (G301) as required. 3. Remove the instrument cluster from the instrument panel. Check for continuity between the seat belt switch sense circuit cavity of the seat wire harness connector for the seat belt switch and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. 4. Check for continuity between the seat belt switch sense circuit cavities of the seat wire harness connector for the seat belt switch and the instrument panel wire harness connector (Connector C2) for the instrument cluster. There should be continuity. If OK, test and replace the faulty instrument cluster as required. If not OK, repair the open seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 917 Battery Temperature Sensor: Connector Locations Left Rear Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 918 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 919 Left Front Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 920 Integrated Power Module And Fan Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 921 Sensor-Battery Temperature Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 922 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 923 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. 1. Remove battery. Refer to Battery for procedures. Battery Temperature Sensor Location 2. Pry sensor straight up from battery tray mounting hole to gain access to electrical connector. 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. 1. Pull electrical connector up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Refer to Battery for procedures. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection SWITCH CLUTCH PEDAL- SRT-10 1. Disconnect the connector on the clutch position switch (1) from the vehicle wiring harness. 2. Place a ohmmeter across the terminals of the switch connector. The switch should show no continuity with the clutch pedal in the released (clutch engaged) position. 3. Slowly push the clutch pedal to the floor (clutch disengaged). The ohmmeter should show continuity just before the pedal reaches the end of its travel. 4. If the clutch switch shows continuity with clutch pedal up or no continuity with clutch pedal down, the switch is defective. The switch has no serviceable parts and should be replaced as an assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection > Page 927 Clutch Switch: Service and Repair SWITCH CLUTCH PEDAL POSITION REMOVAL 1. Disconnect the clutch pedal position switch connector. 2. Disconnect the clutch actuation rod from the clutch pedal. 3. Remove the clutch master cylinder from the toe box. 4. Remove the white clutch pedal position switch retaining clip (1). 5. Push the switch up (1) the rod (2) slightly. Then pull the bottom of the switch outward. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection > Page 928 1. Install new switch (1) as shown. Be sure that the spring loaded plunger inside the switch is slightly compressed. The plunger inside the switch must go on the narrow section of the clutch master cylinder actuation rod. Place the top of the switch against the rod. Then push the switch up slightly. This will compress the plunger. Then push the bottom of the switch against the rod. Failure to install the switch as described or forcing the switch onto the rod will crack the switch. 2. Install new white plastic retaining clip. 3. Install the clutch master cylinder back into the vehicle. 4. Reconnect the clutch switch connector. 5. Check clutch position switch operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 IGNITION SWITCH DESCRIPTION The ignition switch (5) is located on the steering column (4). It is used as the main on/off switching device for most electrical components. The mechanical key cylinder is used to engage/disengage the electrical ignition switch. OPERATION Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the shift cable. This interlock device is used to lock the transmission shifter in the PARK position when the key cylinder is in any position and the brake pedal is not depressed. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 933 Ignition Switch Lock Cylinder: Service and Repair KEY CYLINDER REMOVAL The ignition key (1) must be in the key cylinder (2) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at side of key cylinder assembly (2). a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. INSTALLATION The ignition key (1) must be in the key cylinder (2) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (2) with the ignition switch. 2. Push the key cylinder (2) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation Heated Glass Element Switch: Description and Operation The rear window defogger switch is integrated into the A/C-heater control mounted in the center of the instrument panel. The rear window defogger switch and the rear window defogger LED indicator cannot be repaired and, if faulty or damaged, the A/C-heater control must be replaced. An LED indicator will illuminate when the rear window defogger switch is activated. The switch energizes the timing circuit integral to the A/C-heater control which then activates the rear window defogger relay. The rear window defogger relay controls the current to flow to the grids of the rear window defogger. The rear window defogger system will operate for approximately ten minutes or until the rear window defogger switch or ignition switch is turned off. The rear window defogger switch cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Left Front Door Premium Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 941 Right Front Door Premium Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 942 Left Rear Door (Right Side Similar) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 943 Power Window Switch: Diagrams Switch-Power Window-Left Rear Switch-Power Window-Passenger Switch-Power Window-Right Rear Switch-Window/Door Lock Driver C1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 944 Switch-Window/Door Lock Driver C1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 945 Power Window Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative, refer to testing. If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED(s) is faulty and must be replaced. For complete circuit diagrams, 1. Check the fuse in the Integrated Power Module (IPM) and the circuit breaker located near the park brake pedal. If OK, go to Step 2. If not OK, replace the faulty fuse or circuit breaker. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the Integrated Power Module (IPM). If OK, turn the ignition switch to the Off position and go to Step 3. If not OK, check circuit breaker and repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors). The drivers door switch is included with the window/lock switch. Unplug the wire harness connector from the switch unit. Power Window Switch Continuity Chart 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the Off, Up and Down switch positions. If OK, refer to testing. If not OK, replace the faulty switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 946 Power Window Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Left Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 951 Left Front Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 952 Integrated Power Module And Fan Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 953 Sensor-Washer Fluid Level Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 954 Washer Fluid Level Switch: Description and Operation The washer fluid level switch is a single pole, single throw reed-type switch mounted on the side of the washer reservoir (4) in the engine compartment. Only the molded plastic switch mounting flange (1) and the integral connector receptacle (8) are visible when the switch is installed in the reservoir. A short nipple formation (2) extends from the inner surface of the switch mounting flange, and a barb on the nipple is pressed through a rubber grommet seal (5) installed in the mounting hole of the reservoir. A small, molded plastic float (3) has two pivot pins (6) near its center that are snapped into two receptacles near the ends of two stanchions that extend toward the float from the nipple formation. A small magnet (7) is secured within the end of the float nearest the nipple, and a reed switch is concealed within the nipple. A diagnostic resistor is connected between the two switch terminals within the switch mounting flange. The washer fluid level switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. The washer fluid level switch uses a pivoting, oblong float to monitor the level of the washer fluid in the washer reservoir. The float contains a small magnet. When the float pivots, the proximity of this magnet to a stationary reed switch within the nipple formation of the switch changes. When the fluid level in the washer reservoir is at or above the float level, the float moves to a vertical position, the influence of the float magnetic field is removed from the reed switch, and the normally open reed switch contacts open. When the fluid level in the washer reservoir falls below the level of the pivoting float, the float moves to a horizontal position, the influence of the float magnetic field is applied to the reed switch, and the contacts of the normally open reed switch close. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the right (except SRT-10 and diesel engines) or left (SRT-10 and diesel engines only) headlamp and dash wire harness. The switch is connected in series between a clean ground output of the Front Control Module (FCM) on a sensor return circuit and the washer fluid switch sense input to the FCM. When the switch closes, the FCM senses the ground on the washer fluid switch sense circuit. The FCM is programmed to respond to this input by sending an electronic washer fluid indicator lamp-on message to the instrument cluster over the Programmable Communications Interface (PCI) data bus. The instrument cluster responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the instrument cluster, the FCM, or the electronic message inputs to or outputs from the instrument cluster and the FCM that control the operation of the washer fluid visual and/or audible indicators. The most reliable, efficient, and accurate means to diagnose the washer fluid level indicator, the instrument cluster, the FCM, or the electronic message inputs and outputs related to the washer fluid indicator requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 955 Washer Fluid Level Switch: Service and Repair REMOVAL NOTE: The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the washer hose (4) from the barbed outlet nipple of the washer pump/motor unit (3) and allow the washer fluid to drain into a clean container for reuse. 4. Disconnect the left headlamp and dash wire harness (1) connector for the washer fluid level switch (5) from the switch connector receptacle. NOTE: The pivoting float of the washer fluid level switch must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and in an upright position, the pivoting float will orient itself to the horizontal position when the switch connector receptacle is pointed straight upwards. 5. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the washer reservoir sump (2). Care must be taken not to damage the reservoir. 6. Remove the washer fluid level switch from the washer reservoir. 7. Remove the rubber grommet seal from the washer fluid level switch mounting hole in the washer reservoir and discard. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 956 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the washer reservoir (2). Always use a new rubber grommet seal on the reservoir. 2. Insert the float of the washer fluid level switch (5) through the rubber grommet seal and into the washer reservoir. The connector receptacle of the washer fluid level switch should be pointed upward. 3. Using hand pressure, press firmly and evenly on the washer fluid level switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Reconnect the left headlamp and dash wire harness (1) connector for the washer fluid level switch to the switch connector receptacle. 5. Reconnect the removed washer hose (4) to the barbed outlet nipple of the washer pump/motor unit (3). 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. 8. Close and latch the hood. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications Alignment: Specifications Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 961 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 962 Alignment: Description and Operation WHEEL ALIGNMENT DESCRIPTION NOTE: Suspension components with rubber/urethane bushings should be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur. Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. CAUTION: Never attempt to modify suspension or steering components by heating or bending. OPERATION - CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides less positive caster. Tilting the top of the knuckle rearward provides more positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns - CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire - TOE is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause's unstable steering, uneven tire wear and steering wheel off- center. The wheel toe position is the final front wheel alignment adjustment - THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 963 Alignment: Testing and Inspection PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart for additional information. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. 6. On 4x4 vehicles check suspension height (LD only). 7. Road test the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 964 Alignment: Service and Repair STANDARD PROCEDURE - CAMBER,CASTER AND TOE ADJUSTMENT NOTE: 4X4 (LD) SUSPENSION HEIGHT MEASUREMENT MUST BE PERFORMED BEFORE AN ALIGNMENT. Fig. 3 Camber and caster angle adjustments involve changing the position of the upper control arm with the slots in the frame brackets using special tool 8876 to move the upper control arm outwards for proper adjustment. NOTE: When the upper control arm pivot bolts are loosened the upper control arm will normally go inwards toward the frame automatically with the weight of the vehicle. CASTER Moving the front or rear position of the upper control arm in or out, will change the caster angle and camber angle significantly. To maintain the camber angle while adjusting caster, move one pivot bolt of the upper control arm in or out. Then move the other pivot bolt of the upper control arm in the opposite direction. Install special tool 8876 between the top of the upper control arm bracket and the upper control arm (on 1500 series 4X2 & 4X4). Install special tool 8876 between the bottom of the upper control arm bracket pressing the tool against the frame and the upper control arm (on 2500/3500 series 4X2) in order to move the upper control arm outwards for proper adjustment with the vehicle at normal ride height. To increase positive caster angle, move the rear position of the upper control arm inward (toward the engine). Move the front of the upper control arm outward (away from the engine) slightly until the original camber angle is obtained using special tool 8876 to move the upper control arm for proper adjustment. CAMBER Move both pivot bolts of the upper control arm together in or out. This will change the camber angle significantly and little effect on the caster angle using special tool 8876 to move the upper control arm for proper adjustment. After adjustment is made tighten the upper control arm nuts to proper torque specification. TOE ADJUSTMENT The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts. NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 965 Fig. 4 3. Adjust the wheel toe position by turning the inner tie rod as necessary. 4. Tighten the tie rod jam nut to 75 Nm (55 ft. lbs.). 5. Verify the specifications 6. Turn off engine. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 966 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel System Pressure ......................................................................................................................... ............................................ 400 ± 34 kPa (58 ± 2 psi) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 971 Fuel Pressure: Testing and Inspection Test 1 - 2 SYMPTOM FUEL PRESSURE LEAK DOWN POSSIBLE CAUSES - Faulty fuel pump module - Fuel injectors(s) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 975 Idle Speed: Description and Operation The idle air control motor is mounted at the front right of the intake manifold. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. 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. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. 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. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications 8.3L - FIRING ORDER 1-10-9-4-3-6-5-8-7-2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 984 Firing Order: Mechanical Specifications Firing Order ......................................................................................................................................... ................................................ 1-10-9-4-3-6-5-8-7-2 The cylinders are number from front to rear as follows: - on the left bank - 1-3-5-7-9 - on the right bank - 2-4-6-8-10 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 992 Ignition Cable: Description and Operation Spark plug cables are sometimes referred to as secondary ignition wires, or secondary ignition cables. Plug cables are used only on the 5.7L V-8 engine. The spark plug cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of non metallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Plug cables are used only on the 5.7L V-8 engine. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 993 Ignition Cable: Service and Repair REMOVAL Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. 1. Release the fuel pressure. 2. Disconnect the negative battery cable. 3. Remove the air cleaner assembly. 4. Remove the Intake Manifold, refer to the Engine/Manifolds/Intake Manifold for more information. 5. Use the following procedure when removing the high tension cable from the spark plug. Grasp the terminal as close as possible to the spark plug. Rotate the cover boot 1/2 turn slightly and pull straight up in a steady motion.Do not use pliers and do not pull the cable at an angle. Doing so will damage the insulation, cable terminal or the spark plug insulator. Wipe spark plug insulator clean before reinstalling cable. 6. Remove spark plug cable from coil first. 7. Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. INSTALLATION Install cables into the proper engine cylinder firing order sequence. Refer to Specifications. When replacing the spark plug and coil cables, route the cables correctly and secure them in the proper retainers. Failure to route the cables properly may cause the radio to reproduce ignition noise. It could also cause cross-ignition of the plugs, or, may 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. Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. The system uses two epoxy filled coil packs mounted on engine block post in the valley under the intake manifold. The rear coil pack, contains 3 separate coils and fires cylinders 1, 2, 3, 4, 6, and 7. The front coil pack, contains 2 individual coils and fires cylinders 5, 8, 9, and 10. NOTE: When replacing the spark plug and coil cables, route the cables correctly and secure them in the proper retainers. Failure to route the cables properly may cause the radio to reproduce ignition noise. It could also cause cross-ignition of the plugs, or, may short-circuit the cables to ground. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 994 1. Install wire separator clip on double ended stud on rear of engine block first. This is the wire separator clip closest to the ignition coil insulator boots. 2. Connector coil insulator boots over respective ignition coil side post. Take care to match cylinder number on ignition coil with cylinder number on ignition cables. Also, make sure to hear the audible click while making the connection to the coil post. 3. Sequentially install wires into separators clips mounted on double ended studs mounted on the outer side of valve cover and and. Start from the rear and work forward to the front of the engine. 4. After installing all wires into separator clips, install spark plug insulator boots over respective spark plugs sequentially from back of engine towards the front of engine. Make sure to hear the audible click during installation of spark plug boots. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 995 5. Install Intake Manifold. 6. Install Air Cleaner Assembly. 7. Connect the negative battery cable. 8. Use a diagnostic scan tool to pressurize the fuel system. Check for leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications > Page 1000 Spark Plug: Mechanical Specifications Gap Spark Plug Gap ................................................................................................................................... ....................................................... 0.033 to 0.038 in. Torque Spark Plug tightening torque ............................................................................................................... ...................................................... 27 Nm (20 ft.lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1001 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ................................................................. RC12ECC Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1002 Spark Plug: Description and Operation Resistor type spark plugs are used on all engines. Sixteen spark plugs (2 per cylinder) are used with 5.7L V-8 engines. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1003 Spark Plug: Testing and Inspection To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. Always use the recommended torque when tightening spark plugs. Incorrect torque can distort the spark plug and change plug gap. It can also pull the plug threads and do possible damage to both the spark plug and the cylinder head. 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. Replace spark plugs at the intervals recommended in the Lubrication and Maintenance section. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Spark plug resistance values range from 6,000 to 20,000 ohms (when checked with at least a 1000 volt spark plug tester). Do not use an ohmmeter to check the resistance values of the spark plugs. In accurate readings will result. NORMAL OPERATING 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 (.001 in) per 3200 km (2000 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 may be 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 CRASH ENCRUSTED Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1004 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 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 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1005 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 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1006 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 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 2000 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1007 Spark Plug: Adjustments CLEANING AND ADJUSTMENT The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. Adjust spark plug gap with a gap gauging tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications TORQUE-SPECIFICATIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1011 Drive Belt: Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1012 Drive Belt: Testing and Inspection BELT - DRIVE DIAGNOSIS AND TESTING ACCESSORY DRIVE BELT VISUAL DIAGNOSIS NOTE: 5.9L Diesel Engine - If a belt is broken or frayed, inspect engine speed sensor (located near the crankshaft damper) for damage. When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib, are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1013 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1014 ACCESSORY DRIVE BELT DIAGNOSIS CHART Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1015 Drive Belt: Service and Repair BELT - DRIVE REMOVAL 8.3L ENGINE 1. Remove the air intake tube between intake manifold and air filter assembly. 2. Release the belt tension by rotating the tensioner counterclockwise with a 15 mm wrench on the tensioner pulley bolt. Rotate belt tensioner until belt can be removed from pulleys. 3. Remove accessory drive belt. 4. Gently release tensioner. INSTALLATION NOTE: When installing accessory drive belt onto pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulleys. 1. Position the drive belt over all pulleys except for the water pump pulley. 2. Rotate tensioner counterclockwise and slip the belt over the water pump pulley. 3. Gently release tensioner. 4. Install the air intake tube between intake manifold and air filter assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations Cabin Air Filter: Locations Chrysler provides no information on a Cabin Air Filter for this vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: Customer Interest A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 1028 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: All Technical Service Bulletins A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 1034 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check Fluid Filter - A/T: Service and Repair Fluid Level and Condition Check STANDARD PROCEDURE - FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. The transmission fluid level can be checked two ways. PROCEDURE ONE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82°C (180°F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to NEUTRAL. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. 7. Remove dipstick (Fig. 89) and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough Mopar ATF +4, type 9602, to restore correct level. Do not overfill. PROCEDURE TWO 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up DRBIII scan tool and select engine. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1037 9. Adjust transmission fluid level shown on the dipstick according to the chart (Fig. 90). NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1038 Fluid Filter - A/T: Service and Repair Fluid and Filter Replacement STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission (Fig. 98). 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and gasket away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter to valve body (Fig. 99). 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal or fiber contamination. A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompanied by slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts or debris, refer to Testing and Inspection. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1039 Check the adjustment of the front and rear bands, adjust if necessary. CLEANING 1. Using a suitable solvent, clean pan and magnet. INSTALLATION 1. Position a new transmission oil filter onto the valve body 2. Install the screws to hold the filter to the valve body Tighten the screws to 4 Nm (35 inch lbs.). 3. Clean the gasket surfaces of the transmission oil pan and transmission pan rail. NOTE:The original transmission pan oil gasket is reusable, inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket onto the oil pan. 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. For OE type reusable pan gasket: tighten the bolts to 13.6 Nm (125 inch lbs.). For aftermarket pan gasket: tighten the bolts to 17 Nm (150 inch lbs.). 7. Lower vehicle and fill transmission. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1040 Fluid Filter - A/T: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar ATF +4, Automatic Transmission Fluid, to transmission: a. If only fluid and filter were changed, add 3 pints (1-1/2 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, or torque converter was replaced or drained, add 12 pints (6 quarts) of ATF +4 to transmission. 3. Apply parking brakes. 4. Start and run engine at normal curb idle speed. 5. Apply service brakes, shift transmission through all gear ranges then back to NEUTRAL, set parking brake, and leave engine running at curb idle speed. 6. Remove funnel, insert dipstick and check fluid level. If level is low, add fluid to bring level to MIN mark on dipstick. Check to see if the oil level is equal on both sides of the dipstick. If one side is noticeably higher than the other, the dipstick has picked up some oil from the dipstick tube. Allow the oil to drain down the dipstick tube and re-check. 7. Drive vehicle until transmission fluid is at normal operating temperature. 8. With the engine running at curb idle speed, the gear selector in NEUTRAL, and the parking brake applied, check the transmission fluid level. CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result. 9. Add fluid to bring level up to MAX arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. 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. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. 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. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Locations Fuel Pump Pickup Filter: Locations The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Locations > Page 1048 Fuel Pump Pickup Filter: Service and Repair REMOVAL The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (1). The fuel pump module is located inside of fuel tank. 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 (2) at bottom of module with 2 screwdrivers. Filter is snapped to module. 4. Clean bottom of pump module. INSTALLATION The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module. The fuel pump module is located inside of fuel tank. 1. Snap new filter to bottom of module. Be sure O-ring is in correct position. 2. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement Heater Hose: Service and Repair Heater Inlet Hose Replacement REMOVAL The heater inlet hose is constructed from rubber hoses and plastic hose connectors. The ends are secured to the heater core, engine and engine coolant reservoir (depending on engine application) by spring tension clamps. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Drain the engine cooling system. Heated Hoses - Typical 2. Remove the heater hose retaining brackets as required (depending on engine application). 3. Using spring tension clamp pliers, compress and slide the clamps off of each end of the hose being removed. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes/heater core, causing an engine coolant leak. 4. Disconnect each hose end by carefully twisting the hose back and forth on the tube, while gently pulling it away from the end of the tube. 5. If necessary, carefully cut the hose end and peel the hose off of the tube. NOTE: Replacement of the heater inlet hose will be required if the hose ends are cut for removal. 6. Remove the heater inlet hose from the engine compartment. 7. Separate the heater hoses from each other as required (depending on engine application). INSTALLATION 1. If separated, reconnect the heater hoses to each other as required (depending on engine application). 2. Position the heater inlet hose into the engine compartment. 3. Using spring tension clamp pliers, compress and slide each clamp away from the end of the hose being installed. 4. Install each hose by carefully twisting the hose back and forth while gently pushing it onto the tube end. 5. Using spring tension clamp pliers, compress and slide the clamps onto each end of the hose being installed. 6. Install the heater hose retaining brackets as required (depending on engine application). 7. Refill the engine cooling system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1054 Heater Hose: Service and Repair Heater Return Hose Replacement REMOVAL The heater return hose is constructed from rubber hoses and plastic hose connectors. The ends are secured to the heater core, engine and engine coolant reservoir (depending on engine application) by spring tension clamps. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Drain the engine cooling system. Heated Hoses - Typical 2. Remove the heater hose retaining brackets as required (depending on engine application). 3. Using spring tension clamp pliers, compress and slide the clamps off of each end of the hose being removed. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes/heater core, causing an engine coolant leak. 4. Disconnect each hose end by carefully twisting the hose back and forth on the tube, while gently pulling it away from the end of the tube. 5. If necessary, carefully cut the hose end and peel the hose off of the tube. NOTE: Replacement of the heater return hose will be required if the hose ends are cut for removal. 6. Remove the heater return hose from the engine compartment. 7. Separate the heater hoses from each other as required (depending on engine application). INSTALLATION 1. If separated, reconnect the heater hoses to each other as required (depending on engine application). 2. Position the heater return hose into the engine compartment. 3. Using spring tension clamp pliers, compress and slide each clamp away from the end of the hose being installed. 4. Install each hose by carefully twisting the hose back and forth while gently pushing it onto the tube end. 5. Using spring tension clamp pliers, compress and slide the clamps onto each end of the hose being installed. 6. Install the heater hose retaining brackets as required (depending on engine application). 7. Refill the engine cooling system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions Hose/Line HVAC: Service Precautions ENGINE COOLING SYSTEM WARNING: - THE ENGINE COOLING SYSTEM IS DESIGNED TO DEVELOP INTERNAL PRESSURES OF 97 TO 123 KILOPASCALS (14 TO 18 POUNDS PER SQUARE INCH). DO NOT REMOVE OR LOOSEN THE COOLANT PRESSURE CAP, CYLINDER BLOCK DRAIN PLUGS, RADIATOR DRAIN, RADIATOR HOSES, HEATER HOSES, OR HOSE CLAMPS WHILE THE ENGINE COOLING SYSTEM IS HOT AND UNDER PRESSURE. FAILURE TO OBSERVE THIS WARNING CAN RESULT IN SERIOUS BURNS FROM THE HEATED ENGINE COOLANT. ALLOW THE VEHICLE TO COOL FOR A MINIMUM OF 15 minutes BEFORE OPENING THE COOLING SYSTEM FOR SERVICE. A/C SYSTEM WARNING: - THE AIR CONDITIONING SYSTEM CONTAINS REFRIGERANT UNDER HIGH PRESSURE. SEVERE PERSONAL INJURY MAY RESULT FROM IMPROPER SERVICE PROCEDURES. REPAIRS SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL.AVOID BREATHING THE REFRIGERANT AND REFRIGERANT OIL VAPOR OR MIST. EXPOSURE MAY IRRITATE THE EYES, NOSE, AND/OR THROAT. WEAR EYE PROTECTION WHEN SERVICING THE AIR CONDITIONING REFRIGERANT SYSTEM. SERIOUS EYE INJURY CAN RESULT FROM DIRECT CONTACT WITH THE REFRIGERANT. IF EYE CONTACT OCCURS, SEEK MEDICAL ATTENTION IMMEDIATELY. - DO NOT EXPOSE THE REFRIGERANT TO OPEN FLAME. POISONOUS GAS IS CREATED WHEN REFRIGERANT IS BURNED. AN ELECTRONIC LEAK DETECTOR IS RECOMMENDED. - IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE THE WORK AREA BEFORE RESUMING SERVICE. LARGE AMOUNTS OF REFRIGERANT RELEASED IN A CLOSED WORK AREA WILL DISPLACE THE OXYGEN AND CAUSE SUFFOCATION. THE EVAPORATION RATE OF R-134a REFRIGERANT AT AVERAGE TEMPERATURE AND ALTITUDE IS EXTREMELY HIGH. AS A RESULT, ANYTHING THAT COMES IN CONTACT WITH THE REFRIGERANT WILL FREEZE. ALWAYS PROTECT THE SKIN OR DELICATE OBJECTS FROM DIRECT CONTACT WITH THE REFRIGERANT. - THE R-134a SERVICE EQUIPMENT OR THE VEHICLE REFRIGERANT SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. SOME MIXTURES OF AIR AND R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS, AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE. CAUTION: - Liquid refrigerant is corrosive to metal surfaces. Follow the operating instructions supplied with the service equipment being used. - Never add R-12 to a refrigerant system designed to use R-134a and do not use R-12 equipment or parts on the R-134a system. Damage to the system will result. - R-12 refrigerant oil must not be mixed with R-134a refrigerant oil. They are not compatible and damage to the system will result. - Do not overcharge the refrigerant system. Overcharging will cause excessive compressor head pressure and can cause noise and system failure. Recover the refrigerant before opening any fitting or connection. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. - If equipped, do not remove the secondary retention clip from any spring-lock coupler connection while the refrigerant system is under pressure. Recover the refrigerant before removing the secondary retention clip. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. - Do not open the refrigerant system or uncap a replacement component until you are ready to service the system. This will prevent contamination in the system. Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system. Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap or plug. - Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a container of refrigerant oil until you are ready to use it. Replace the cap on the oil container immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free container. - Keep service tools and the work area clean. Contamination of the refrigerant system must be avoided. - The use of A/C system sealers may result in damage to A/C refrigerant recovery/evacuation/recharging equipment and/or A/C systems. - Many federal, state/provincial and local regulations prohibit the recharge of A/C systems with known leaks. DaimlerChrysler recommends the detection of A/C system leaks through the use of approved leak detectors and fluorescent leak detection dyes. Vehicles found with A/C system sealers should be treated as contaminated and replacement of the entire A/C refrigerant system is recommended. A/C systems found to be contaminated with A/C system sealers, A/C stop-leak products or seal conditioners voids the warranty for the A/C system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line Hose/Line HVAC: Description and Operation A/C Discharge Hose/Line The A/C discharge line is the refrigerant line that goes from the A/C compressor to the A/C condenser. The A/C discharge line for the 5.9L Diesel engine is serviced as an assembly with the suction line. The A/C discharge line has no serviceable parts except the rubber O-ring seals. CAUTION: Use only O-ring seals specified for the vehicle. Failure to use correct O-ring seal will cause the refrigerant system connection to leak. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C discharge line is removed and installed. If the A/C discharge line is found to be leaking or is damaged, it must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 1060 Hose/Line HVAC: Description and Operation A/C Liquid Hose/Line The liquid line is the refrigerant line that carries refrigerant from the A/C condenser to the evaporator. The liquid line for this model consist of two separate lines that connect to each other. The liquid lines are made from light-weight aluminum or steel, and use braze-less fittings. The front half of the liquid line contains the fixed orifice tube. The liquid lines are only serviced as an assembly, except for the rubber O-ring seals used on the end fittings. The liquid lines cannot be adjusted or repaired and, if found to be leaking or damaged, they must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 1061 Hose/Line HVAC: Description and Operation A/C Suction Hose/Line The suction line is the refrigerant line that goes from the evaporator outlet tube to the compressor inlet port. The suction line for the 5.9L Diesel engine is only serviced as an assembly with the discharge line. The suction line has no serviceable parts except the rubber O-rings. If the suction line is found to be leaking or is damaged, it must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 1062 Hose/Line HVAC: Description and Operation Refrigerant Lines 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, which is sandwiched between rubber layers, is used for the R-134a air conditioning system on this vehicle. This nylon tube 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 or steel, and commonly use braze-less fittings. Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from an 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 are coupled with other components of the HVAC system with either O-rings or dual plane seals. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Page 1063 Hose/Line HVAC: Testing and Inspection REFRIGERANT SYSTEM LEAKS WARNING: R-134a SERVICE EQUIPMENT OR VEHICLE A/C SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. MIXTURE OF AIR and R-134a CAN BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE. AVOID BREATHING A/C REFRIGERANT AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY IRRITATE EYES, NOSE AND THROAT. USE ONLY APPROVED SERVICE EQUIPMENT MEETING SAE REQUIREMENTS TO DISCHARGE R-134a SYSTEM. IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE WORK AREA BEFORE RESUMING SERVICE. NOTE: The refrigerant system does come from the factory with a yellow tracer dye already installed to aid in detection of leaks. If the A/C system is not cooling properly, determine if the refrigerant system is fully charged with R-134a. This is accomplished by performing a system Charge Level-Check or Fill. If while performing this test A/C liquid line pressure is less than 345 kPa (50 psi) proceed to System Empty procedure. If liquid line pressure is greater than 345 kPa (50 psi) proceed to System Low procedure. If the refrigerant system is empty or low in refrigerant charge, a leak at any line fitting or component seal is likely. A review of the fittings, lines and components for oily residue is an indication of the leak location. To detect a leak in the refrigerant system, perform one of the following procedures as indicated by the symptoms. SYSTEM EMPTY 1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approx. 28 in Hg.). Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level, proceed with this procedure. 2. Prepare a 0.284 Kg. (10 oz.) refrigerant charge to be injected into the system. 3. Connect and dispense 0.284 Kg. (10 oz.) of refrigerant into the evacuated refrigerant system. 4. Proceed to Step 2 of System Low procedure. SYSTEM LOW 1. Determine if there is any (R-134a) refrigerant in the system. 2. Position the vehicle in a wind free work area. This will aid in detecting small leaks. 3. Bring the refrigerant system up to operating temperature and pressure. This is done by allowing the engine to run for five minutes with the system set to the following: Transmission in Park or Neutral with parking brake set - Engine idling at 700 rpm - A/C controls set in 100 percent outside air - Blower switch in the high A/C position - A/C in the ON position - Open all windows CAUTION: A leak detector designed for R-12 refrigerant (only) will not detect leaks in a R-134a refrigerant system. 4. Shut off the vehicle and wait 2 to 7 minutes. Then use an Electronic Leak Detector that is designed to detect R-134a type refrigerant and search for leaks. Fittings, lines, or components that appear to be oily usually indicates a refrigerant leak. To inspect the evaporator core for leaks, insert the leak detector probe into the drain tube opening or a heat duct. A R-134a dye is available to aid in leak detection, use only DaimlerChrysler approved refrigerant dye. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Liquid Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement REMOVAL WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Disconnect and isolate the battery negative cable. 2. If equipped with the diesel engine, remove the passenger side battery. 3. If equipped with the diesel engine, remove the passenger side battery tray. 4. Recover the refrigerant from the refrigerant system. 5. Remove the plastic cover from the condenser outlet stud. A/C Liquid Line - Typical 6. Remove the nut that secures the liquid line fitting to the condenser outlet. 7. Disconnect the liquid line from the condenser. 8. Remove the seal from the liquid line fitting and discard. 9. Install plugs in, or tape over the liquid line fitting and condenser outlet port. 10. Disengage the liquid lines from the body retaining clips. 11. Remove the secondary retaining clip from the spring-lock coupler that secures the front section of the liquid line to the rear section of the liquid line. 12. Using the proper A/C line disconnect tool, disconnect the front section of the liquid line from the rear section of the liquid line. 13. Remove the O-ring seal from the liquid line fitting and discard. 14. Install plugs in, or tape over the opened front liquid line fitting and rear liquid line tube. 15. Remove the secondary retaining clip from the spring-lock coupler that secures the liquid line to the evaporator inlet tube. 16. Using the proper A/C line disconnect tool, disconnect the liquid line from the evaporator inlet tube. 17. Remove the O-ring seal from the liquid line fitting and discard. 18. Install plugs in, or tape over the opened liquid line fitting and evaporator inlet tube. 19. Remove both sections of the liquid line from the engine compartment. INSTALLATION 1. Position both sections of the liquid line into the engine compartment. 2. Remove the tape or plugs from the rear liquid line fitting and the evaporator inlet tube. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Liquid Hose/Line Replacement > Page 1066 3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the rear liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the liquid line fitting to the evaporator inlet tube. 5. Install the secondary retaining clip onto the spring-lock coupler that secures the liquid line fitting to the evaporator inlet tube. 6. Remove the tape or plugs from the front liquid line fitting and the rear liquid line tube. 7. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the front liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the front liquid line fitting to the rear liquid line tube. 9. Install the secondary retaining clip onto the spring-lock coupler that secures the front liquid line fitting to the rear liquid line tube. 10. Engage the liquid lines to the body retaining clips. 11. Remove the tape or plugs from the liquid line fitting and condenser outlet port. 12. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 13. Connect the liquid line to the condenser outlet port. 14. Install and tighten the nut that secures the liquid line fitting to the condenser. Tighten the nut to 20 Nm (180 in. lbs.). 15. Install the plastic cover onto the condenser outlet stud. 16. If equipped with the diesel engine, install the passenger side battery tray. 17. If equipped with the diesel engine, install the passenger side battery. 18. Reconnect the battery negative cables. 19. Evacuate the refrigerant system. 20. Charge the refrigerant system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Liquid Hose/Line Replacement > Page 1067 Hose/Line HVAC: Service and Repair Diode Replacement 1. Disconnect and isolate the battery negative cable. If the vehicle has dual batteries, remove the negative cable from both batteries. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness. Note the direction of current flow. 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. If necessary refer to the appropriate wiring diagram for current flow. 6. Solder the connections together using rosin core type solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 8. Reconnect the battery negative cable(s) and test the affected systems. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Liquid Hose/Line Replacement > Page 1068 Hose/Line HVAC: Service and Repair Handling Tubing and Fittings CAUTION: The system must be completely empty before opening any fitting or connection in the refrigeration system. Open fittings with caution even after the system has been emptied. If any pressure is noticed as a fitting is loosened, retighten fitting and evacuate the system again. A good rule for the flexible hose lines is to keep the radius of all bends at least 10 times the diameter of the hose. Sharper bends will reduce the flow of refrigerant. The flexible hose lines should be routed so they are at least 3 inches (80 mm) from the exhaust manifold. Inspect all flexible hose lines to make sure they are in good condition and properly routed. The use of correct wrenches when making connections is very important. Improper wrenches or improper use of wrenches can damage the fittings. The internal parts of the A/C system will remain stable as long as moisture-free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system. When opening a refrigeration system, have everything you will need to repair the system ready. This will minimize the amount of time the system must be opened. Cap or plug all lines and fittings as soon as they are opened. This will help prevent the entrance of dirt and moisture. All new lines and components should be capped or sealed until they are ready to be used. Before connecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system. All tools, including the refrigerant dispensing manifold, the manifold gauge set, and test hoses should be kept clean and dry. Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and moisture can enter the system when it is opened for repair or replacement of lines or components. The refrigerant oil will absorb moisture readily out of the air. This moisture will convert into acids within a closed system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting Power Steering Line/Hose: Service and Repair Fluid Cooler Line Quick Connect Fitting STANDARD PROCEDURE - FLUID COOLER LINE QUICK CONNECT FITTING DISASSEMBLY 1. Remove dust cap (2) by pulling it straight back off of quick connect fitting (1). 2. Place disconnect tool (Special Tool 8875) (4) onto fluid cooler line with the fingers of the tool facing the quick connect fitting (1). 3. Slide disconnect tool down the line (3) and engage the fingers of the tool into the retaining clip. When properly engaged in the clip, the tool will fit flush against the quick connect fitting (1). 4. Rotate the disconnect tool 60° to expand the retaining clip. 5. While holding the disconnect tool (4) against the quick connect fitting (1), pull back on the oil cooler line to remove. ASSEMBLY Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 1073 1. Align fluid cooler line (3) with quick connect fitting (1) while pushing straight into the fitting. 2. Push in on oil cooler line until a "click" is heard or felt. 3. Slide dust cap (4) down the oil cooler line and snap it over the quick connect fitting until it is fully seated and rotates freely. Dust cap (4) will only snap over quick connect fitting when the cooler line is properly installed. NOTE: If dust cap will not snap into place, repeat assembly step #2. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 1074 Power Steering Line/Hose: Service and Repair Fluid Cooler Tube FLUID COOLER TUBE REMOVAL 1. Drain and siphon the power steering fluid. 2. Remove the underneath splash shield. 3. Disconnect the quick connect power steering fluid cooler tubes (3) from the fluid cooler (1) using special tool 8875 (2). 4. Disconnect the quick connect (1) return and supply tubes connected to the power steering fluid cooler using special tool 8875. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 1075 5. Remove the tube retaining bracket (4) and then the fluid cooler tubes (2). INSTALLATION 1. Reconnect the quick connect fitting (2) to the return and supply tubes (3) to the power steering fluid cooler (1). 2. Reconnect the quick connect fitting (2) to the return and supply tubes to the power steering fluid hoses. 3. Install the Tube retaining bracket (4). 4. Install the lower front air deflector. 5. Refill the power steering fluid. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 1076 Power Steering Line/Hose: Service and Repair Pressure Hose - Pump to Fan PRESSURE HOSE - PUMP TO FAN REMOVAL NOTE: Review all Warnings and Cautions. CAUTION: Cap all open ends of power steering hoses, power steering pump fittings and steering gear ports when disconnected. This will prevent the entry of foreign material into the components during servicing. 1. Siphon power steering fluid from fluid reservoir. 2. Unthread power steering pressure hose quick-connect (10) from power steering pump pressure fitting. Drain excess power steering fluid from line. 3. Unthread power steering pressure hose quick-connect (8) from hydraulic fan (6). Drain excess power steering fluid from line. 4. Remove power steering pressure hose (7) from routing clip on cooling module (5) . Remove hose. INSTALLATION NOTE: Before installing power steering hose, replace used o-rings as necessary. Clean hose ends and open ports with a lint-free cloth. Lubricate o-rings with clean power steering fluid. 1. If pressure hose is separate from quick-connect fittings: a. Thread quick-connect fitting (8) into cooling fan port. Tighten fitting to 28 Nm (21 ft. lbs.) torque. b. Slide fan end of pressure hose tube into quick-connect fitting until it locks into place. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 1077 2. If pressure hose has quick-connect fittings installed on ends, thread fan end quick-connect fitting into fan port. Tighten hose fitting to 28 Nm (21 ft. lbs.) torque. 3. Install power steering pressure hose into routing clip (7) on cooling module (5). 4. If pressure hose is separate from quick-connect fittings: a. Thread quick-connect fitting into power steering pump pressure fitting (10). Tighten hose fitting to 28 Nm (21 ft. lbs.) torque. b. Slide pump end of pressure hose tube into quick-connect fitting until it locks into place. 5. If pressure hose has quick-connect fittings installed on ends, thread pump end quick-connect fitting into power steering pump pressure fitting. Tighten fitting to 28 Nm (21 ft. lbs.) torque. 6. Fill power steering pump reservoir to correct fluid level. 7. Perform Power Steering Pump Initial Operation procedure. 8. Check for leaks at all hose connections. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 1078 Power Steering Line/Hose: Service and Repair Pressure Hose - Fan to Gear PRESSURE HOSE - FAN TO GEAR REMOVAL NOTE: Review all Warnings and Cautions. CAUTION: Cap all open ends of power steering hoses, power steering pump fittings and steering gear ports when disconnected. This will prevent the entry of foreign material into the components during servicing. 1. Siphon power steering fluid from fluid reservoir. 2. Unthread power steering pressure hose quick-connect (6) from hydraulic fan (1). Drain excess power steering fluid from line. 3. Unthread power steering pressure hose tube nut from power steering gear port. Drain excess power steering fluid from line. 4. Remove power steering pressure hose. INSTALLATION NOTE: Before installing power steering hose, replace used o-rings as necessary. Clean hose ends and open ports with a lint-free cloth. Lubricate o-rings with clean power steering fluid. 1. Thread power steering pressure hose tube nut on end of hose into power steering gear port. Tighten tube nut to 28 Nm (21 ft. lbs.) torque. 2. If fan end of pressure hose is separate from quickconnect fitting: a. Thread quick-connect fitting (6) into cooling fan port (1). Tighten fitting to 28 Nm (21 ft. lbs.) torque. b. Slide fan end of pressure hose tube into quickconnect fitting until it locks into place. 3. If fan end of pressure hose has quick-connect fitting installed, thread fan end quick-connect fitting into fan port. Tighten fitting to 28 Nm (21 ft. lbs.) torque. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 1079 4. Fill power steering pump reservoir to correct fluid level. 5. Perform Power Steering Pump Initial Operation procedure. 6. Check for leaks at all hose connections. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 1080 Power Steering Line/Hose: Service and Repair Fluid Cooler Line Quick Connect Fitting STANDARD PROCEDURE - FLUID COOLER LINE QUICK CONNECT FITTING DISASSEMBLY 1. Remove dust cap (2) by pulling it straight back off of quick connect fitting (1). 2. Place disconnect tool (Special Tool 8875) (4) onto fluid cooler line with the fingers of the tool facing the quick connect fitting (1). 3. Slide disconnect tool down the line (3) and engage the fingers of the tool into the retaining clip. When properly engaged in the clip, the tool will fit flush against the quick connect fitting (1). 4. Rotate the disconnect tool 60° to expand the retaining clip. 5. While holding the disconnect tool (4) against the quick connect fitting (1), pull back on the oil cooler line to remove. ASSEMBLY Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 1081 1. Align fluid cooler line (3) with quick connect fitting (1) while pushing straight into the fitting. 2. Push in on oil cooler line until a "click" is heard or felt. 3. Slide dust cap (4) down the oil cooler line and snap it over the quick connect fitting until it is fully seated and rotates freely. Dust cap (4) will only snap over quick connect fitting when the cooler line is properly installed. NOTE: If dust cap will not snap into place, repeat assembly step #2. Fluid Cooler Tube FLUID COOLER TUBE REMOVAL 1. Drain and siphon the power steering fluid. 2. Remove the underneath splash shield. 3. Disconnect the quick connect power steering fluid cooler tubes (3) from the fluid cooler (1) using special tool 8875 (2). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 1082 4. Disconnect the quick connect (1) return and supply tubes connected to the power steering fluid cooler using special tool 8875. 5. Remove the tube retaining bracket (4) and then the fluid cooler tubes (2). INSTALLATION 1. Reconnect the quick connect fitting (2) to the return and supply tubes (3) to the power steering fluid cooler (1). 2. Reconnect the quick connect fitting (2) to the return and supply tubes to the power steering fluid hoses. 3. Install the Tube retaining bracket (4). 4. Install the lower front air deflector. 5. Refill the power steering fluid. Pressure Hose - Pump to Fan Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 1083 PRESSURE HOSE - PUMP TO FAN REMOVAL NOTE: Review all Warnings and Cautions. CAUTION: Cap all open ends of power steering hoses, power steering pump fittings and steering gear ports when disconnected. This will prevent the entry of foreign material into the components during servicing. 1. Siphon power steering fluid from fluid reservoir. 2. Unthread power steering pressure hose quick-connect (10) from power steering pump pressure fitting. Drain excess power steering fluid from line. 3. Unthread power steering pressure hose quick-connect (8) from hydraulic fan (6). Drain excess power steering fluid from line. 4. Remove power steering pressure hose (7) from routing clip on cooling module (5) . Remove hose. INSTALLATION NOTE: Before installing power steering hose, replace used o-rings as necessary. Clean hose ends and open ports with a lint-free cloth. Lubricate o-rings with clean power steering fluid. 1. If pressure hose is separate from quick-connect fittings: a. Thread quick-connect fitting (8) into cooling fan port. Tighten fitting to 28 Nm (21 ft. lbs.) torque. b. Slide fan end of pressure hose tube into quick-connect fitting until it locks into place. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 1084 2. If pressure hose has quick-connect fittings installed on ends, thread fan end quick-connect fitting into fan port. Tighten hose fitting to 28 Nm (21 ft. lbs.) torque. 3. Install power steering pressure hose into routing clip (7) on cooling module (5). 4. If pressure hose is separate from quick-connect fittings: a. Thread quick-connect fitting into power steering pump pressure fitting (10). Tighten hose fitting to 28 Nm (21 ft. lbs.) torque. b. Slide pump end of pressure hose tube into quick-connect fitting until it locks into place. 5. If pressure hose has quick-connect fittings installed on ends, thread pump end quick-connect fitting into power steering pump pressure fitting. Tighten fitting to 28 Nm (21 ft. lbs.) torque. 6. Fill power steering pump reservoir to correct fluid level. 7. Perform Power Steering Pump Initial Operation procedure. 8. Check for leaks at all hose connections. Pressure Hose - Fan to Gear PRESSURE HOSE - FAN TO GEAR REMOVAL NOTE: Review all Warnings and Cautions. CAUTION: Cap all open ends of power steering hoses, power steering pump fittings and steering gear ports when disconnected. This will prevent the entry of foreign material into the components during servicing. 1. Siphon power steering fluid from fluid reservoir. 2. Unthread power steering pressure hose quick-connect (6) from hydraulic fan (1). Drain excess power steering fluid from line. 3. Unthread power steering pressure hose tube nut from power steering gear port. Drain excess power steering fluid from line. 4. Remove power steering pressure hose. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 1085 INSTALLATION NOTE: Before installing power steering hose, replace used o-rings as necessary. Clean hose ends and open ports with a lint-free cloth. Lubricate o-rings with clean power steering fluid. 1. Thread power steering pressure hose tube nut on end of hose into power steering gear port. Tighten tube nut to 28 Nm (21 ft. lbs.) torque. 2. If fan end of pressure hose is separate from quickconnect fitting: a. Thread quick-connect fitting (6) into cooling fan port (1). Tighten fitting to 28 Nm (21 ft. lbs.) torque. b. Slide fan end of pressure hose tube into quickconnect fitting until it locks into place. 3. If fan end of pressure hose has quick-connect fitting installed, thread fan end quick-connect fitting into fan port. Tighten fitting to 28 Nm (21 ft. lbs.) torque. 4. Fill power steering pump reservoir to correct fluid level. 5. Perform Power Steering Pump Initial Operation procedure. 6. Check for leaks at all hose connections. Return Hose - Fan to Pump RETURN HOSE - FAN TO PUMP REMOVAL NOTE: Review all Warnings and Cautions. CAUTION: Cap all open ends of power steering hoses, power steering pump fittings and steering gear ports when disconnected. This will prevent the entry of foreign material into the components during servicing. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 1086 1. Siphon power steering fluid from fluid reservoir. 2. Remove clamp, then return hose at reservoir (9). 3. Remove clamp, then return hose at fan (9). 4. Remove hose. INSTALLATION NOTE: Before installing power steering hose, clean open power steering hose ends and fittings with a lint-free towel. 1. Slide hose clamps onto ends of return hose far enough to clear molded fitting on pump reservoir and fan fitting once hose is installed. 2. Slide fan end of return hose (9) onto fan fluid fitting. Expand hose clamp and slide it into position on hose past bead formed into fitting. 3. Install power steering pressure hose into routing clip (7) on cooling module (5). 4. Slide pump end of return hose (9) onto molded fitting on pump reservoir (3). Expand hose clamp and slide it into position on hose past bead formed into reservoir fitting. 5. Fill power steering pump reservoir to correct fluid level. 6. Perform Power Steering Pump Initial Operation procedure. 7. Check for leaks at all hose connections. Return Hose - Gear to Cooler RETURN HOSE - GEAR TO COOLER REMOVAL NOTE: Review all Warnings and Cautions. CAUTION: Cap all open ends of power steering hoses, power steering pump fittings and steering gear ports when disconnected. This will prevent the entry of foreign material into the components during servicing. 1. Siphon power steering fluid from fluid reservoir. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 1087 2. Unthread power steering return hose tube nut from power steering gear port (1). Pull tube out of gear port and drain excess power steering fluid from line. 3. Raise vehicle. 4. Remove front splash shield 5. Disconnect the quick connect fittings (1) on the cooler hose going to the cooler using special tool 8875. INSTALLATION NOTE: Before installing power steering hose, replace used o-rings as necessary. Clean hose ends, fittings and open ports with a lint-free cloth. Lubricate o-rings with clean power steering fluid. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 1088 1. Install return hose into engine compartment using reverse of how it was removed. 2. Install hose at fluid cooler to the quick connect (1). 3. Install front air deflector. 4. Lower vehicle. 5. Thread return hose tube nut on gear end of hose into power steering gear port. Tighten tube nut to 28 Nm (21 ft. lbs.) torque. 6. Fill power steering pump reservoir to correct fluid level. 7. Perform Power Steering Pump Initial Operation procedure. 8. Check for leaks at all hose connections. Return Hose - Cooler to Pump RETURN HOSE - COOLER TO PUMP REMOVAL NOTE: Review all Warnings and Cautions. CAUTION: Cap all open ends of power steering hoses, power steering pump fittings and steering gear ports when disconnected. This will prevent the entry of foreign material into the components during servicing. 1. Siphon power steering fluid from fluid reservoir. 2. Remove clamp, then return hose at reservoir. 3. Raise vehicle. 4. Remove front air deflector. 5. Disconnect the quick connect filling (6) at the return hose from the metal line at the cooler using special tool 8875. INSTALLATION NOTE: Before installing power steering hose, replace used o-rings as necessary. Clean hose ends, fittings and open ports with a lint-free cloth. Lubricate o-rings with clean power steering fluid. 1. Install hose into engine compartment using reverse of how it was removed. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 1089 2. Reconnect the quick connect fitting (6) of the hose at fluid cooler (5). 3. Install front air deflector. 4. Lower vehicle. 5. Slide pump end of return hose onto molded fitting of pump reservoir. Expand hose clamp and slide it into position on hose past bead formed into reservoir fitting. 6. Fill power steering pump reservoir to correct fluid level. 7. Perform Power Steering Pump Initial Operation procedure. 8. Check for leaks at all hose connections. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Brake Fluid ............................................................................................................................................... Mopar DOT 3 and SAE J1703 should be used If DOT 3 brake fluid is not available, then DOT 4 or DOT 4+ is acceptable. Use only recommended brake fluids. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1094 Brake Fluid: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1095 Brake Fluid: Service and Repair STANDARD PROCEDURE - BRAKE FLUID LEVEL Always clean the master cylinder reservoir and caps before checking fluid level. If not cleaned, dirt could enter the fluid. The fluid fill level is indicated on the side of the master cylinder reservoir. The correct fluid level is to the MAX indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications Clutch Master/Slave Cylinder ............................................................................................................................................ DOT 4 compatible Brake Fluid Clutch Linkage ................................................................................................................................................ Multipurpose Grease, NLGI Grade 2 E.P. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity ................................................................................................................................. ............................................................. 20 qts. (19 L) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1103 Coolant: Fluid Type Specifications Mopar Antifreeze/Coolant 5 Year/102,000 Mile Formula HOAT (Hybrid Organic Additive Technology) P/N 05066386AA or equivalent. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Engine Coolant Coolant: Description and Operation Engine Coolant COOLANT DESCRIPTION ENGINE COOLANT WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. ETHYLENE-GLYCOL MIXTURES CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 year/100,000 Mile Formula (ethylene-glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37°C (-35°F). The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% 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. 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°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 percent ethylene-glycol freezes at 22°C (8°F). PROPYLENE-GLYCOL MIXTURES 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°C 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 or freeze-up on a cooling system 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 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. OPERATION Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Engine Coolant > Page 1106 Coolant: Description and Operation Hoat Coolant HOAT COOLANT WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE-GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/ fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/10O,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water - Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to --67.7°C (--90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. COOLANT SELECTION AND ADDITIVES The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. OPERATION Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page 1107 Coolant: Testing and Inspection DIAGNOSIS AND TESTING COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C (-34°F) to -46°C (-50°F). The use of a hydrometer or a refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A refractometer Tool 8286 will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended. CAUTION: Do not mix types of coolant - corrosion protection will be severely reduced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1112 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1113 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1114 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1115 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1116 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Service Fill 48RE ................................................................................................................................. ....................................................................... 3.8 Liters (4.0 qts.) Overhaul Fill 48RE .............................................................................................................................. ................................................................. 14-16 Liters (29-33 pts.) Note: Dry fill capacity Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these figures may vary. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1119 Fluid - A/T: Fluid Type Specifications Automatic Transmission Fluid Type .............................................................................................................. Mopar ATF+4 Automatic Transmission Fluid Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check Fluid - A/T: Service and Repair Fluid Level and Condition Check STANDARD PROCEDURE - FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. The transmission fluid level can be checked two ways. PROCEDURE ONE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82°C (180°F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to NEUTRAL. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. 7. Remove dipstick (Fig. 89) and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough Mopar ATF +4, type 9602, to restore correct level. Do not overfill. PROCEDURE TWO 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up DRBIII scan tool and select engine. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1122 9. Adjust transmission fluid level shown on the dipstick according to the chart (Fig. 90). NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1123 Fluid - A/T: Service and Repair Fluid and Filter Replacement STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission (Fig. 98). 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and gasket away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter to valve body (Fig. 99). 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal or fiber contamination. A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompanied by slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts or debris, refer to Testing and Inspection. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1124 Check the adjustment of the front and rear bands, adjust if necessary. CLEANING 1. Using a suitable solvent, clean pan and magnet. INSTALLATION 1. Position a new transmission oil filter onto the valve body 2. Install the screws to hold the filter to the valve body Tighten the screws to 4 Nm (35 inch lbs.). 3. Clean the gasket surfaces of the transmission oil pan and transmission pan rail. NOTE:The original transmission pan oil gasket is reusable, inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket onto the oil pan. 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. For OE type reusable pan gasket: tighten the bolts to 13.6 Nm (125 inch lbs.). For aftermarket pan gasket: tighten the bolts to 17 Nm (150 inch lbs.). 7. Lower vehicle and fill transmission. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1125 Fluid - A/T: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar ATF +4, Automatic Transmission Fluid, to transmission: a. If only fluid and filter were changed, add 3 pints (1-1/2 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, or torque converter was replaced or drained, add 12 pints (6 quarts) of ATF +4 to transmission. 3. Apply parking brakes. 4. Start and run engine at normal curb idle speed. 5. Apply service brakes, shift transmission through all gear ranges then back to NEUTRAL, set parking brake, and leave engine running at curb idle speed. 6. Remove funnel, insert dipstick and check fluid level. If level is low, add fluid to bring level to MIN mark on dipstick. Check to see if the oil level is equal on both sides of the dipstick. If one side is noticeably higher than the other, the dipstick has picked up some oil from the dipstick tube. Allow the oil to drain down the dipstick tube and re-check. 7. Drive vehicle until transmission fluid is at normal operating temperature. 8. With the engine running at curb idle speed, the gear selector in NEUTRAL, and the parking brake applied, check the transmission fluid level. CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result. 9. Add fluid to bring level up to MAX arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Tremec T56 Manual Transmission ........................................................................................................................................................ 2.27 Liters (4.8 pts.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1130 Fluid - M/T: Fluid Type Specifications Tremec T56 ................................................................................ Mopar Synthetic Manual Transmission Lubricant 75W/85 (Castrol Syntorq LT 75W/85) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 1131 Fluid - M/T: Service and Repair T56 TRANSMISSION DRAIN AND FILL 1. Raise and support vehicle. 2. Remove drain plug (1) on transmission tail housing and drain fluid. 3. Install drain plug. 4. Remove transmission fill plug on left side of the transmission case. 5. Fill transmission with Mopar(R) Synthetic Manual Trans Lubricant 75W-85. The transmission is full when the fluid level is even with the bottom of the fill hole. 6. Install transmission fill plug. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Differential - Fluid Level Inspection Procedure Fluid - Differential: Technical Service Bulletins Differential - Fluid Level Inspection Procedure NUMBER: 03-003-06 GROUP: Axle DATE: October 20, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 03-001-04 REV. A, DATED MAY 11, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS. SUBJECT: Axle Fluid Level MODELS: 2004 (AN) Dakota **2004 - 2007** (DR/DH/D1/DC) Ram Truck **2004 - 2007** (HB/HG) Durango / Aspen **2005 - 2007** (ND) Dakota DISCUSSION: The axle fill holes on some Dodge Truck vehicle axles may be located considerably higher than the actual fluid level. Filling the axle until the fluid comes out of the fill hole will over fill the axle, which may cause fluid foaming. When checking fluid level or filling a rear axle with fluid, you must measure the distance from the bottom of the fill hole to the top of the actual fluid level. This can easily be accomplished using a pipe cleaner or piece of wire. Make a 90 degree bend in the wire 2 inches from the end. The wire can then be inserted into the axle fill hole to use as a dipstick. Measure the distance from the bend to the oil level. The fluid levels for the axles are shown in the table below. CORRECT FLUID LEVELS FOR DURANGO / ASPEN: NOTE: Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Differential - Fluid Level Inspection Procedure > Page 1136 The Trac-Lok feature is not available on Durango rear axles. Traction control is provided electronically through the ABS system. Trac-Lok additives or friction modifiers are not required. CORRECT FLUID LEVELS FOR RAM TRUCK 1500: CORRECT FLUID LEVELS FOR RAM TRUCK 2500 -3500: CORRECT FLUID LEVELS FOR DAKOTA: NOTE: The Trac-Lok feature is available on Dakota rear axles. Trac-Lok additives are required on axles equipped with Trac Lok. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Dana M60 HD/248 ............................................................................................................................... .................................................... 2.8Liters (5.9 pts.) Limited-Slip Rear Axles require the addition of 147 ml (5 oz.) Mopar limited slip additive. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1139 Fluid - Differential: Fluid Type Specifications Limited Slip Rear Axle ......................................................................................................................... ...................................................... Mopar SAE 90W Limited-Slip Rear Axles require the addition of 147 ml (5 oz.) Mopar limited slip additive. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Capacity (with filter) ........................................................................................................... ..................................................... 8.0Liters (8.5 Qt) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1144 Engine Oil: Fluid Type Specifications Engine Oil Viscosity Above 0°F (-18°C) ............................................................................................................................... ................................................. 10W-30 (Preferred) Below 32°F (0°C) ................................................................................................................................. ..................................................................... 5W-30 Chrysler only recommends synthetic engine oils, such as Mobil 1, that are API Certified and meet the requirements of Material Standard MS-10725. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Power Steering - Additive Prohibition Power Steering Fluid: Technical Service Bulletins Power Steering - Additive Prohibition NUMBER: 19-010-04 GROUP: Steering DATE: November 29, 2004 SUBJECT: Power Steering Fluid Contamination MODELS: 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR/DH) Ram Truck 2004 - 2005 (HB) Durango 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004 - 2005 (KJ) Liberty 2004 - 2005 (LX) 300/Magnum 2004 - 2005 (PL) Neon/SRT4 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2004 - 2005 (ST) Sebring Coupe/Stratus Coupe 2004 - 2005 (TJ) Wrangler 2004 - 2005 (ZB) Viper DISCUSSION: Do not use fluids or supplements that contain Teflon as they will cause a restriction at the filter in the power steering fluid reservoir, causing severe damage to the steering system. The power steering fluid used in Chrysler Group vehicles is an engineered product, the addition of ANY unapproved fluids or supplements can interfere with the proper function of the fluid and cause damage to the steering system. To ensure the performance and durability of Chrysler Group steering systems, use only Mopar Power Steering Fluid +4, ATF+4 Automatic Transmission Fluid, or equivalent (MS-9602), in the power steering system. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Power Steering - Additive Prohibition > Page 1149 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Power Steering - Additive Prohibition > Page 1150 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Power Steering - Additive Prohibition > Page 1151 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Power Steering - Additive Prohibition > Page 1152 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Power steering fluid capacities are dependent on engine/chassis options as well as steering gear/cooler options. Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these capacities may vary. Chrysler does not provide a capacity specification for this vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 1155 Power Steering Fluid: Fluid Type Specifications Power Steering Fluid Type ....................................................................................................................... Mopar ATF+4 Automatic Transmission Fluid Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page 1156 Power Steering Fluid: Description and Operation FLUID NOTE: It is normal that some pressure will build up inside the reservoir, especially, with a warm vehicle. A slight popping noise upon removal of the cap is normal. The fluid level should read between the ADD and the FULL COLD marks. When the fluid is hot it should read between ADD and FULL HOT marks. Only add fluid when the vehicle is cold. The recommended fluid for the power steering system is Mopar(R) ATF +4. Mopar(R) ATF+4, when new is red in color. The ATF+4 is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition, As the vehicle is driven, the ATF+4 will begin to look darker in color and may eventually become brown. THIS IS NORMAL. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page 1157 Power Steering Fluid: Testing and Inspection POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION: MOPAR(R) ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. The power steering fluid level can be viewed on the dipstick attached to the filler cap. There are two ranges listed on the dipstick, COLD and HOT. Before opening power steering system, wipe the reservoir filler cap free of dirt and debris. Remove the cap and check the fluid level on its dipstick. When the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the fluid level should read between the minimum and maximum area of the cold range. When the fluid is hot, fluid level is allowed to read up to the highest end of the HOT range. Only add fluid when the vehicle is cold. Use only Mopar(R) ATF+4 Do not overfill the power steering system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications REFRIGERANT CAPACITY Refer to the A/C Underhood Specification Label located in the engine compartment. 2004 Ram Gas ...................................................................................................................................................... .................................. 0.728kg (1.604 lbs.) 2004 Ram Diesel ............................................................. ....................................................................................................................... 0.850kg (1.873 lbs.) 2005 Ram Gas .................................................................................................................................... .................................................... 0.728kg (1.604 lbs.) 2005 Ram Diesel ........................................... ......................................................................................................................................... 0.850kg (1.873 lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1162 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ...................................................................... R-134a Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1163 Refrigerant: Description and 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery Refrigerant: Service and Repair Refrigerant System - Recovery WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT BEFORE PERFORMING THE FOLLOWING OPERATION. A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to recover the refrigerant from an R-134a refrigerant system. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 1166 Refrigerant: Service and Repair Refrigerant System - Evacuate NOTE: - Special effort must be used to prevent moisture from entering the A/C system oil. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. - If a compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended period of time. It is recommended that the refrigerant oil be drained and replaced with new oil or a new compressor be used. This will eliminate the possibility of contaminating the refrigerant system. - If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be filled. Moisture and air mixed with the refrigerant will raise the compressor head pressure above acceptable operating levels. This will reduce the performance of the air conditioner and damage the compressor. Moisture will boil at near room temperature when exposed to vacuum. To evacuate the refrigerant system: - When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection. 1. Recover the refrigerant system. 2. Connect a suitable charging station, refrigerant recovery machine or a manifold gauge set with vacuum pump and refrigerant recovery equipment. 3. Open the suction and discharge valves and start the vacuum pump. The vacuum pump should run a minimum of 45 minutes prior to charge to eliminate all moisture in system. When the suction gauge reads -88 kPa (- 26 in. Hg) vacuum or greater for 30 minutes, close all valves and turn off vacuum pump. If the system fails to reach specified vacuum, the refrigerant system likely has a leak that must be corrected. If the refrigerant system maintains specified vacuum for at least 30 minutes, start the vacuum pump, open the suction and discharge valves. Then allow the system to evacuate an additional 10 minutes. 4. Close all valves. Turn off and disconnect the vacuum pump. 5. Charge the refrigerant system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 1167 Refrigerant: Service and Repair Refrigerant System - Charge WARNING: - REVIEW SAFETY PRECAUTIONS AND WARNINGS BEFORE CHARGING THE REFRIGERANT SYSTEM. - AVOID BREATHING A/C REFRIGERANT AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY IRRITATE EYES, NOSE AND THROAT. USE ONLY APPROVED SERVICE EQUIPMENT MEETING SAE REQUIREMENTS TO DISCHARGE R-134a SYSTEM. IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE WORK AREA BEFORE RESUMING SERVICE. - R-134a SERVICE EQUIPMENT OR VEHICLE A/C SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. MIXTURE OF AIR and R-134a CAN BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE. CAUTION: - Do not overcharge refrigerant system, as excessive compressor head pressure can cause noise and system failure. - A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process. Refer the equipment manufacturer instructions for more information. The procedure below should be used to fill the refrigerant charge in the air conditioning system. This A/C system does not have or use a sight glass to check or charge the system. After the system has been tested for leaks and evacuated, a refrigerant (R-134a) charge can be injected into the system. NOTE: When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection. 1. If using a separate vacuum pump close all valves before disconnecting pump. Connect manifold gauge set to the A/C service ports. NOTE: Always refer to the underhood HVAC Specification label for the refrigerant fill level of the vehicle being serviced. 2. Measure refrigerant. Refer to the instructions provided with the equipment being used. 3. Verify engine is shut off. Open the suction and discharge valves. Open the charge valve to allow the refrigerant to flow into the system. When the transfer of refrigerant has stopped, close the suction and discharge valve. 4. If all of the charge did not transfer from the dispensing device, put vehicle controls into the following mode: - Automatic transmission in park or manual transmission in neutral - Engine at idle - A/C mode control set to outside air - A/C mode control set to panel mode - A/C temperature control set to full cool - Blower motor control set on highest speed - Vehicle windows closed If the A/C compressor does not engage, test the compressor clutch control circuit and correct any failure. 5. Open the suction valve to allow the remaining refrigerant to transfer to the system. WARNING: TAKE CARE NOT TO OPEN THE DISCHARGE (HIGH-PRESSURE) VALVE AT THIS TIME. 6. Close all valves and test the A/C system performance. 7. Disconnect the charging station or manifold gauge set. Install the service port caps. REFRIGERANT CHARGE CAPACITY 2004 Ram Gas .................................................................................................................................... .................................................... 0.728kg (1.604 lbs.) 2004 Ram Diesel ........................................... ......................................................................................................................................... 0.850kg (1.873 lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Total System Fill .................................................................................................................................. ............................................................ 6 oz (180 ml) Accumulator ......................................................................................................................................... ............................................................... 2 oz (60 ml) Condenser ........................................................................................................................................... ................................................................. 1 oz (30 ml) Evaporator ........................................................................................................................................... ................................................................ 2 oz (60 ml) Compressor ..................................................................................................................................... Drain and measure the oil from the old compressor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1172 Refrigerant Oil: Fluid Type Specifications Denso 10S17 Compressor .................................................................................................................. ........................................................... ND-8 PAG Oil Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1173 Refrigerant Oil: Description and Operation The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, PolyAlkylene Glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to an R-134a refrigerant system. There are different PAG oils available, and each contains a different additive package. Two different type of A/C compressors are used in this vehicle depending on engine application. Both compressors are designed to use a PAG refrigerant oil. However, the PAG oil type differs between the two compressor designs. Use only refrigerant oil of the same type as recommended to service the refrigerant system (always refer to the specification tag included with the replacement A/C compressor or the under-hood A/C system specification tag). After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause compressor damage, and too much can reduce air conditioning system performance. PAG refrigerant oil is much more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Refrigerant Oil Level Refrigerant Oil: Service and Repair Refrigerant Oil Level STANDARD PROCEDURE - REFRIGERANT OIL LEVEL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. CAUTION: The refrigerant oil in the R-134a A/C system is unique depending on the A/C compressor used. Use only PAG oils that are designed to work with R-134a refrigerant and the A/C compressor in the vehicle. Always refer to the underhood A/C System Specification Label for the correct oil designation. It is important to have the correct amount of lubricant in the A/C refrigerant system to ensure proper lubrication of the A/C compressor. Too little lubricant will result in damage to the compressor. Too much lubricant will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. The lubricant used in the compressor is polyalkalene glycol PAG lubricant. Only the refrigerant lubricant approved for use with this vehicle should be used to service the system. Do not use any other lubricant. The lubricant container should be kept tightly capped until it is ready for use. Refrigerant lubricant will quickly absorb any moisture it comes in contact with. It will not be necessary to check the oil level in the A/C compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to component replacement, or a rupture or leak from a refrigerant line, connector fitting, component or component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of the recommended 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. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Refrigerant Oil Level > Page 1176 Refrigerant Oil: Service and Repair Component Refrigerant Oil Level Check A/C Component Referigerant Oil Capacities When an air conditioning system is first assembled at the factory, all components (except the A/C compressor) are refrigerant oil free. After the refrigerant system has been charged with (R-134a) refrigerant and operated, the oil in the A/C compressor is dispersed through the lines and components. The A/C evaporator, A/C condenser, and accumulator will retain a significant amount of oil. Refer to the A/C Component Refrigerant Oil Capacities table. When a component is replaced, the specified amount of refrigerant oil must be added. When a new A/C compressor is being installed, drain the lubricant from the used compressor, measure the amount drained and discard the used lubricant. Drain the lubricant from the new A/C compressor into a clean container. Return the amount of lubricant measured from the used compressor, plus the amount reclaimed from the system back into the new A/C compressor. When a line or component has ruptured and oil has escaped, the accumulator must be replaced along with the ruptured component. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Refrigerant Oil Level > Page 1177 Refrigerant Oil: Service and Repair Compressor Refrigerant Oil Level Check NOTE: Most reclaim/recycling equipment will measure the lubricant being removed during recovery. This amount of lubricant should be added back into the system. Refer to the reclaim/recycling equipment manufacturers instructions. 1. Recover the refrigerant from the system. 2. Disconnect the refrigerant lines from the A/C compressor. Cap open lines to prevent moisture from entering the system. 3. Remove the A/C compressor from the vehicle. 4. From the suction and discharge ports on the A/C compressor, drain the lubricant from the old A/C compressor into a clean container. 5. From the suction and discharge ports on the A/C compressor, drain the lubricant from the new A/C compressor into a clean container. 6. Install new lubricant back into the new A/C compressor in the amount measured from the used compressor, plus adding any amount of lubricant lost when the refrigerant system was reclaimed. 7. Install the A/C compressor and connect the refrigerant lines. Then evacuate and charge refrigerant system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding Brake Bleeding: Service and Repair Hydraulic Brake Booster Bleeding STANDARD PROCEDURE - BLEEDING The hydraulic booster is generally self-bleeding, this procedure will normally bleed the air from the booster. Normal driving and operation of the unit will remove any remaining trapped air. 1. Fill power steering pump reservoir. 2. Disconnect fuel shutdown relay and crank the engine for several seconds. 3. Check fluid level and add if necessary. 4. Connect fuel shutdown relay and start the engine. 5. Turn the steering wheel slowly from lock to lock twice. 6. Stop the engine and discharge the accumulator by depressing the brake pedal 5 times. 7. Start the engine and turn the steering wheel slowly from lock to lock twice. 8. Turn off the engine and check fluid level and add if necessary. NOTE: If fluid foaming occurs, wait for foam to dissipate and repeat steps 7 and 8. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding > Page 1182 Brake Bleeding: Service and Repair Master Cylinder Bleeding STANDARD PROCEDURE - MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports. Then position each tube end into 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding > Page 1183 Brake Bleeding: Service and Repair Base Brake System STANDARD PROCEDURE - MANUAL BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J 1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 1. Remove reservoir filler caps and fill reservoir. 2. If calipers, 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. 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. STANDARD PROCEDURE - PRESSURE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J 1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15 - 20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding > Page 1184 Brake Bleeding: Service and Repair Antilock Brake System STANDARD PROCEDURE - ABS BRAKE BLEEDING 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 ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING 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 disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations Positive Temperature Coefficients (PTC) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations Fuse: Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1195 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1196 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1197 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Connector Views Fuse Holder (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Page 1200 Fuse: Application and ID Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Page 1201 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Page 1202 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Page 1203 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations Fuse Block: Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 1207 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 1208 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 1209 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views Module - Integrated Power (Rear View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1212 Fuse Block: Application and ID Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1213 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1214 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1215 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations Relay Box: Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1219 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1220 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1221 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1222 Module - Integrated Power (Rear View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1223 Relay Box: Application and ID Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1224 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1225 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1226 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation Chrysler provides no information regarding a Maintenance Required Lamp/Indicator. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. This indicator is located on the left side of the instrument cluster, to the left of the voltage gauge. The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for "Engine" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or the Engine Control Module (ECM) on vehicles with a diesel engine has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM or ECM over the Programmable Communications Interface (PCI) data bus. The MIL Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the MIL for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the indicator is illuminated for about two seconds as a bulb test. The entire bulb test is a function of the PCM or ECM. - MIL Lamp-On Message - Each time the cluster receives a MIL lamp-on message from the PCM or ECM, the indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the PCM or ECM message. For some DTC's, if a problem does not recur, the PCM or ECM will send a lamp-off message automatically. Other DTC's may require that a fault be repaired and the PCM or ECM be reset before a lamp-off message will be sent. - Communication Error - If the cluster receives no messages from the PCM or ECM for about ten seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the PCM or ECM. - Actuator Test - Each time the cluster is put through the actuator test, the MIL indicator will be turned on during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. On vehicles with a diesel engine, the ECM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM or ECM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For further diagnosis of the MIL or the instrument cluster circuitry that controls the LED, refer to testing. If the instrument cluster turns on the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the MIL, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > System Information > Description and Operation Tire Monitoring System: Description and Operation Chrysler provides no information on a Tire Pressure Monitoring System for this vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation DESCRIPTION SPARE / TEMPORARY TIRE The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 50 M.P.H. when using the temporary spare tire. Refer to Owner's Manual for complete details. FULL SIZE, SPARE WHEEL WITH MATCHING TIRE The spare is a full usage wheel with a matching tire. It can be used within the (posted legal) speed limits or distance limitations as of the rest of the vehicles four tires. Refer to Owner's Manual for complete details. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels Wheels: Technical Service Bulletins Wheels - Caring for Chrome Wheels NUMBER: 22-001-05 GROUP: Wheels and Tires DATE: December 1, 2005 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-004-03, DATED SEPTEMBER 26, 2003 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS AND CLEANER SUGGESTIONS. SUBJECT: Chrome Wheel Care MODELS: 2000 - 2003 (AB) Ram Van/Wagon 2002 - 2004 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2004 - **2006** (CS) Pacifica 2002 - 2003 (DN) Durango 2002 - **2006 (DR/DH) Ram Truck** 2004 - **2006** (HB) Durango 2001 - **2006** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 - **2006** (KJ) Liberty 1998 - 2004 (LH) Concorde/Intrepid/LHS/300M 2005 - **2006 (LX/LE) 300/Charger/Magnum** **2005 - 2006 (ND) Dakota** 1998 - 2000 (NS) Town & Country 2002 - **2005** (PL) Neon 1999 - 2002 (PR) Prowler 2001 - **2006** (PT) PT Cruiser 2001 - **2006** (RS) Town & Country/Caravan 2001 - **2005** (ST) Sebring/Stratus Coupe 2002 - **2006** (TJ) Wrangler **2002 - 2006 (VA) Sprinter** 2001 - 2004 (WJ) Grand Cherokee **2005 - 2006 (WK/WH) Grand Cherokee** **2006 (XK) Commander** 2003 - **2006 (ZB) Viper/Viper Coupe** Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels > Page 1246 2004 - **2006 (ZH) Crossfire/Crossfire Convertible/SRT6** DISCUSSION: Chrome wheels should be cleaned regularly with **good quality car wash such as MOPAR Car Wash Concentrate p/n 04796236AB,** and water to maintain their luster and prevent corrosion. Wash them with the same soap solution as the body of the vehicle. Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to wheels. MOPAR Tire and Wheel Cleaner, p/n 05066247AB - 22 oz. or 05066248AB - 5 gal. **or MOPAR Wheel Cleaner, p/n 04796239AB,** is recommended to remove normal brake dust, dirt, grease and grime. NOTE: To clean extremely dirty wheels, MOPAR Chrome Cleaner, pin 04318013, is recommended. Any of the "DO NOT USE" items listed below can damage or stain wheels and wheel trim. DO NOT USE: ^ Wheel cleaners that contain hydroflouric acid, biflouride compounds, sulfuric acid, or phosphoric acid. ^ Any abrasive type cleaner ^ Any abrasive cleaning pad (such as steel wool) or abrasive brush ^ Any oven cleaner. ^ A car wash that has carbide tipped wheel-cleaning brushes. CAUTION: Many commercial wheel cleaners contain acids that may harm the wheel surface. Avoid all "wheel acid" type cleaners. CAUTION: Any facility found using acid based wheel cleaners will void all wheel warranties, and all damage to customer wheels will be the facility's responsibility. Refer to Global Warranty Bulletin D-01-22 for further information. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1247 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1248 Wheels: Description and Operation WHEELS DESCRIPTION Original equipment wheels are designed for the specified Maximum Vehicle Capacity. All models use steel or aluminum drop center wheels. Aluminum wheels require special balance weights and alignment equipment. 1. On vehicles equipped with dual rear wheels, The rim is an eight stud hole pattern wheel. The wheels have a flat mounting surface (1). 2. The slots (1) in the wheel must be aligned to provide access to the valve stem. WHEEL DESIGN The rim size is on the vehicle safety certification label located on the drivers door shut face. The size of the rim is determined by the drivetrain package. Original equipment wheels/rims are designed for operation up to the specified maximum vehicle capacity. All models use stamped steel, cast aluminum or forged aluminum wheels. Every wheel has raised sections between the rim flanges (1) and rim drop well (3) called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1249 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1250 Wheels: Testing and Inspection WHEEL INSPECTION Inspect wheels for: Excessive run out - Dents or cracks - Damaged wheel lug nut holes - Air Leaks from any area or surface of the rim NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged an original equipment replacement wheel should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: FAILURE TO USE EQUIVALENT REPLACEMENT WHEELS MAY ADVERSELY AFFECT THE SAFETY AND HANDLING OF THE VEHICLE. USED WHEELS ARE NOT RECOMMENDED. THE SERVICE HISTORY OF THE WHEEL MAY HAVE INCLUDED SEVERE TREATMENT OR VERY HIGH MILEAGE. THE RIM COULD FAIL WITHOUT WARNING. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel Bearing Grease ...................................................................................................... Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1254 Wheel Bearing: Service and Repair HUB/BEARING - 4X2 REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped (4). 5. Remove the three hub/bearing mounting bolts (5) from the steering knuckle (3). 6. Slide the hub/bearing (1) out of the steering knuckle (3). NOTE: The next step excludes SAT-10. (SAT-10 does not have a dust shield) 7. Remove the brake dust shield (2). INSTALLATION 1. Install the brake dust shield (2). SRT-10 Excluded in this step. 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts (5) to 163 Nm (120 ft. lbs.) 4X2 LD. Or tighten the bolts (5) to 176 Nm (130 ft. lbs.) 4X2 HD.. 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped (4). 5. Install the wheel and tire assembly. 6. Remove the support and lower vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair Wheel Cover: Service and Repair WHEEL COVER REMOVAL NOTE: The hub caps must be removed before raising the vehicle off the ground. NOTE: You must use the flat end of the hub/cap remover/installer combination tool to pry off the wheel skins. Insert the flat tip completely and using a back and forth motion, loosen the wheel skin. repeat this procedure around the tire until the wheel skin pops off. 1. On 2500/3500 single rear wheel (SRW) models, insert a hub/cap remover/installer combination tool using the blade on the end of the tool to pry the cap off in a back and forth motion. 2. On 3500 models with Dual Rear Wheels (DRW), you must first remove the hub caps. The hub/cap remover/installer combination tool must be inserted in the pry off notch of the rear hub caps. 3. Position the hub/cap remover/installer combination tool and pull out on the tool firmly. The cap should come off. 4. The wheel skins can now be removed from the wheel. 5. On 3500 models front hub caps use the hub/cap remover/installer combination tool to pry off the cap in a back and forth motion. The wheel skins can now be removed. INSTALLATION REAR 1. Install one 1 1/2 inch valve stem extension on each rear inner wheel. NOTE: A 3/8 inch drive 10mm deep wheel socket with a 10 inch or greater extension can be used to remove the existing valve stem cap and install the extension. 2. Install one 1 inch valve stem extension on each outer wheel. 3. Align the cooling windows of the wheel skin with the cooling windows of the wheel. Seat one side of the wheel skin's retainer onto the wheel. Using a rubber mallet, strike the wheel skin on the outer circumference. Strike at several locations around the circumference until the skin is fully seated. NOTE: The wheel skin and the hub cap are fully seated when there is a consistent gap between the skin/cap and the wheel. 4. Tug on the hub/cap wheel skin to ensure that they are properly installed. FRONT 1. Align the valve stem with the notch in the wheel skin. 2. Seat on side of the wheel skin's wire retainer on to the wheel. 3. Using a rubber mallet, strike the opposite side of the wheel skin until the skin is properly seated. NOTE: The wheel skin and the hub cap are fully seated when there is a consistent gap between the skin/cap and the wheel. 4. Tug on the hub cap/wheel skin to ensure that they are properly installed. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Independent front suspension Halfshaft nut ........................................................................................ ................................................................................................. 251 Nm (185 ft. lbs.) Link/coil suspension Axle nut step 1 .................................................................................................... ................................................................................................ 179 Nm (132 ft. lbs.) step 2 ................ .............................................................................................................................................................. ...................... 356 Nm (263 ft. lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1265 Wheel Fastener: Service and Repair STUDS REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, caliper adapter and rotor. 4. Remove the wheel speed sensor from the hub. 5. Press the stud from the hub using special tool C-4150A (1). 6. Remove the stud (2) from the hub (1) through the backing plate access hole (3). INSTALLATION 1. Install the new stud (2) into the hub flange (1). 2. Install three proper sized washers onto the stud, then install lug nut with the flat side of the nut against the washers. 3. Tighten the lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. 4. Remove the lug nut and washers. 5. Install the brake rotor, caliper adapter, and caliper. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1266 6. Install the wheel speed sensor. 7. Install the wheel and tire assembly, use new lug nut on the stud or studs that were replaced. 8. Remove the support and lower the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque Technical Service Bulletin # D19 Date: 040401 Campaign - Engine Camshaft Sprocket Bolt Torque April 2004 Customer Satisfaction Notification No. D19 Camshaft Sprocket Bolt Torque Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Service Action # 04-006 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2004 (ZB) Dodge Viper (DR) Dodge Ram SRT-10 NOTE: This notification applies only to the above vehicles equipped with an 8.3L V-10 engine ("Z" in the 8th VIN position) built through January 31, 2004 (MDH 013100). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The camshaft sprocket retaining bolts on about 1,200 of the above vehicles may not have been properly tightened. A loose cam sprocket bolt can back out and cause significant engine damage. Repair The camshaft sprocket retaining bolts must be tightened to the proper specification. Parts Information IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers. Parts may be ordered as needed to support scheduled repairs. The parts are required for each vehicle shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1278 Use the labor operation number and time allowance shown. Add the cost of the parts plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not Applicable. Dealer Notification All dealers will receive a copy of this dealer notification letter by DMAIL and by mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this notification 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 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 should 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 mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. 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 Ram SRT-10 Truck Repair Procedure NOTE: Refer to Viper repair procedure. 1. Disconnect the negative battery cable and isolate it. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1279 2. Remove the air cleaner cover and air inlet tube. 3. Raise the vehicle on an appropriate hoist. 4. Remove the front belly pan 5. Drain the engine coolant via the petcock and the lower radiator hose. Filter and save the coolant for later reuse. 6. Disconnect the power steering lines from the bottom of the radiator fan module and drain the power steering fluid. 7. Detach the power steering line retaining clip from the radiator fan module. 8. Remove the accessory drive belt. 9. Drain the engine oil and remove the oil filter. Discard the filter. 10. Remove the lower radiator hose. 11. Disconnect the oil cooler line from the timing chain cover using special tool # 9005 (Figure 1). 12. Remove the A/C compressor and mounting bracket assembly and then set it aside. Do not disconnect the refrigerant lines or discharge the A/C system. 13. Remove the steering gear assembly retaining bolts and lower the assembly (Figure 2). 14. Remove the sway bar-to-frame attaching bolts and lower the sway bar (Figure 2). 15. Loosen the right and left engine mount through bolts. 16. Lower the vehicle. 17. Remove the upper radiator hose. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1280 18. Disconnect the cooling fan module electrical connector and hydraulic lines (Figure 3). 19. Remove the coolant recovery bottle. 20. Remove the cooling fan module (Figure 4). 21. Remove the crankshaft pulley. 22. Remove the crankshaft vibration damper using special tool # 1023 (puller) and special tool # 6827-A (insert). 23. Inspect the mating surfaces of the crankshaft and vibration damper. If there is evidence of the damper slipping on the crankshaft, polish the crankshaft with emery or crocus cloth and discard the vibration damper. 24. Remove the pressure hose from the power steering pump. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1281 25. Remove the power steering pump assembly and set it aside in the driver side frame rail area (Figure 5). 26. Remove the accessory drive belt idler pulley (Figure 5). 27 Remove the generator (Figure 5). 28. Disconnect the heater hoses from the timing chain cover. 29. Disconnect the ground cable from the thermostat housing. 30. Install engine lift fixture special tool # 8534-B and # 9363 and raise engine/transmission assembly. Raise the vehicle. 32. Remove the flywheel inspection cover. 33. Remove the oil pan bolts. 34. Carefully separate the oil pan from the oil pan-to-engine block gasket. Lower the oil pan leaving the gasket attached to the block. Do not remove the oil pan gasket. It can be reused, unless it is damaged. 35. Disconnect oil pick up tube and lower it into the oil pan (Figure 6). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1282 36. Remove the accessory drive belt tensioner. 37. Carefully cut the RTV between the timing chain cover and the oil pan gasket. 38. Lower the vehicle. 39. Remove the timing chain cover bolts (Figure 7). 40. Remove the timing chain cover (Figure 7). 41. Remove the front crankshaft seal from the timing chain cover and discard the seal. Use care to not damage the machined surfaces. 42. Inspect the three (3) camshaft sprocket bolts (Figure 8). 43. If any camshaft sprocket bolt is broken or missing, contact the STAR Center for further information. 44. If any camshaft sprocket bolts are loose but not broken, inspect the camshaft position sensor in the timing chain cover for damage. Remove and discard the sensor if it is damaged. 45. Rotate crankshaft to position the camshaft sprocket so that the raised front edge is at the upper (12 O'clock) position. 46. Snug the three (3) camshaft sprocket bolts to 50 in-lbs (6 N.m) to ensure hard contact of the joint faces. 47. Tighten each camshaft sprocket bolt to 250 in-lbs (29 N.m) starting with the bolt opposite the dowel pin. Tighten the bolts in a clockwise pattern. 48. Install the timing chain cover onto the location dowels without the front crankshaft seal installed (Figure 7). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1283 49. Install all timing chain cover bolts and tighten to 100 in-lbs (11 N.m) using the sequence found in Figure 9, then using the same sequence, tighten the bolts to 200 in-lbs (22 N.m). 50. Using crank seal installation tool MD998306, install the front crankshaft seal to the proper depth (Figure 10). 51. If the camshaft position sensor was removed due to damage, slide a new sensor (P/N 05245084) into the timing chain cover sensor hole until it makes light contact with raised edge on the camshaft sprocket. Tighten the sensor retention bolt to 100 in-lbs (11 N.m). 52. Raise the vehicle. 53. Install the accessory drive belt tensioner and nut to the appropriate position and tighten to 30 ft-lbs (41 N.m). 54. Clean any coolant and oil from the oil pan using MOPAR brake cleaner (P/N 04897150AB). 55. Inspect the oil pickup tube 0-ring (Figure 6). Install a new 0-ring (P/N 06032920) if it is damaged. 56. Install the oil pickup tube into the timing chain cover, seating the 0-ring (Figure 6). 57. Install oil pickup tube flange onto the timing chain cover (Figure 6). Tighten the bolt to 100 in-lbs (11 N.m). 58. Install the oil pickup tube main bearing stud nuts to secure the oil pickup tube straps (Figure 6). Tighten the nuts to 200 in-lbs (22 N.m). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1284 59. Clean and inspect the oil pan gasket. Install a new oil pan gasket (P/N 05037163AC) if the original gasket was damaged. 60. Apply a 1/8" bead of Mopar RTV (P/N 04883971) to the timing chain cover-to-block-to-oil pan joint area (two locations) and to the rear main seal-to-block-to-oil pan joint area (two locations). 61. Place the oil pan gasket onto the oil pan and place the oil pan into position on the engine. 62. Install all of the oil pan bolts. Tighten the small bolts to 100 in-lbs (11 N.m) and the large bolts to 200 in-lbs (22 N.m). 63. Install the oil pan drain plug. Tighten the drain plug to 25 ft-lbs (34 N.m). 64. Install the flywheel inspection cover. 65. Lower the vehicle. 66. Lower the engine/transmission assembly. 67. Remove the engine lift fixture. 68. Install the ground cable onto the thermostat housing. 69. Connect the heater hoses to the timing chain cover. 70. Install the generator (Figure 5). 71 Install the accessory drive belt idler pulley (Figure 5). Tighten the bolt to 30 ft-lbs (41 N.m). 72. Install the power steering pump assembly (Figure 5). Tighten the bolts to 200 in-lbs (22 N.m). 73. Install the crankshaft vibration damper using special tools # 8512-A, # 8698-1 and # 9055-1. If the original damper was damaged, install a new vibration damper (P/N 05159003AA). 74. Place the transmission in gear. 75. Install the vibration damper bolt and tighten it to 130 ft-lbs (176 N.m). 76. Install the crankshaft pulley. Tighten the crankshaft pulley bolts to 200 in-lbs (22 N.m). 77. Install the cooling fan module (Figure 4). 78. Install the coolant recovery bottle. 79. Connect the cooling fan module electrical connector and hydraulic lines (Figure 3). 80. Install the upper radiator hose. 81. Raise the vehicle. 82. Tighten the engine mount through bolts to 75 ft-lbs (102 N.m). 83. Install the sway bar-to-frame mounting bolts (Figure 2). Tighten the bolts to 45 ft-lbs (61 N.m). 84. Install the steering gear assembly (Figure 2). Tighten the mounting bolts to 235 ft-lbs (319 N.m). 85. Install the A/C compressor and bracket assembly. Tighten the fasteners to 200 in-lbs (22 N.m). 86. Install the oil cooler line to the timing chain cover (Figure 1). 87. Install the lower radiator hose. 88. Install a new oil filter (P/N 05281090). 89. Install the accessory drive belt by positioning the belt over all pulleys except the water pump pulley, then rotate tensioner counterclockwise and slip the belt over water pump pulley and gently release the tensioner. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1285 90. Install the cooling fan module power steering line retainer. 91 Install the power steering and cooling fan hydraulic lines (Figure 3). Tighten the return line to 52 ft-lbs (71 Nm), the pump-to-fan line to 275 in-lbs (32 N.m) and the pump-to-steering gear line to 325 in-lbs (37 N.m). 92. Install the front belly pan. Tighten the fasteners to 50 in-lbs (6 N.m). 93. Lower the vehicle. 94. Open the coolant bleeder valve. 95. Fill the engine with the original coolant until coolant bleeder valve has steady flow of coolant. Close the bleeder valve and install the radiator cap. 96. Fill the engine with 9 quarts of Mobil 1 10W30 Synthetic motor oil (P/N P5007324). 97. Install the air cleaner cover and air inlet tube. 98. Connect the negative battery cable. 99. Fill the power steering pump reservoir with Power Steering Fluid (ATF+4) (P/N 05013457AA). 100. Start the engine and ruin for 1 minute. 101. Turn the engine off. 102. Check all fluid levels after 5 minutes and top off as required. 103. Start the engine. 104. Remove air from steering system by using the DRBIII(R) (Scan Tool) to actuate cooling fan at 50% duty while slowly rotating the steering wheel lock to lock. 105. Turn the engine off and check all fluid levels after 5 minutes and top off as required. 106. Check for fluid leaks. Viper Repair Procedure 1. Place the vehicle on an appropriate hoist. 2. Open the trunk and pull back the carpet. 3. Remove the battery cover, disconnect the negative battery cable and isolate it. 4. Open the hood. 5. Remove the air cleaner assembly. 6. Drain the engine coolant via the radiator petcock. Filter and save the coolant for later reuse. 7. Remove the upper radiator hose. 8. Remove front strut tower to tower brace. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1286 9. Remove the accessory drive belt (Figure 11). 10. Remove the power steering pump (Figure 11). 11. Remove the generator (Figure 11). 12. Remove the heater hoses from the timing chain cover. 13. Raise the vehicle. 14. Drain the engine oil and remove the oil filter. Discard the filter. 15. Remove the flywheel inspection cover. 16. Remove the A/C compressor and mounting bracket assembly and then set it aside. Do not disconnect the refrigerant lines or discharge the A/C system. 17. Remove coolant hose from the thermostat housing. 18. Remove the A/C line retaining bolt at the oil pan. 19. Remove the four (4) bell housing-to-oil pan bolts. 20. Remove the oil pan bolts. 21. Carefully separate the oil pan from the oil pan-to-engine block gasket. Remove the oil pan leaving the gasket attached to the block. Do not remove the oil pan gasket. It can be reused, unless it is damaged. 22. Carefully cut the RTV between timing chain cover and the oil pan gasket. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1287 23. Remove the oil pick up tube (Figure 12). 24. Remove the left and right motor mount retaining nuts. 25 Temporarily install the oil pan for lifting engine. 26. Lower the vehicle. 27. Raise the engine with a floor jack (place wood between the jack and the oil pan). 28. Remove the crankshaft pulley. 29. Remove the crankshaft vibration damper using special tool # 1023 (puller) and special tool # 6827-A (insert). 30. Inspect the mating surfaces of the crankshaft and vibration damper. If there is evidence of the damper slipping on the crankshaft, polish the crankshaft with emery or crocus cloth and discard the vibration damper. 31. Remove the oil cooler line from the timing chain cover using special tool #9005 (Figure 13). 32. Remove the lower radiator hose from the front cover. 33. Remove the accessory drive belt tensioner. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1288 34. Remove the timing chain cover (Figure 14). 35. Remove the front crankshaft seal from the timing chain cover and discard the seal~ Use care to not damage the machined surfaces. 36. Inspect the three (3) camshaft sprocket bolts (Figure 15). 37. If any camshaft sprocket bolt is broken or missing, contact the STAR Center for further information. 38. If any camshaft sprocket bolts are loose but not broken, inspect the camshaft position sensor in the timing chain cover for damage. Remove and discard the sensor if it is damaged. 39. Rotate crankshaft to position the camshaft sprocket so that the raised front edge is at the upper (12 O'clock) position. 40. Snug the three (3) camshaft sprocket bolts (Figure 15) to 50 in-lbs (6 Nm) to ensure hard contact of the joint faces. 41. Tighten each camshaft sprocket bolt to 250 in-lbs (29 N.m) starting with the bolt opposite the dowel pin. Tighten the bolts in a clockwise pattern. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1289 42. In stall the timing chain cover onto the location dowels without the front crank seal installed (Figure 14). 43. In stall all timing chain cover bolts and tighten to 100 in-lbs (11 N.m) using the sequence shown in Figure 16, then using the same sequence, tighten the bolts to 200 in-lbs (22 N.m). 44. Using crank seal installation tool MD998306, install the front crankshaft seal to the proper depth (Figure 17). 45. If the camshaft position sensor was removed due to damage, slide a new sensor (P/N 05245084) into the timing chain cover sensor hole until it makes light contact with raised edge on the camshaft sprocket. Tighten the sensor retention bolt to 100 in-lbs (11 N.m). 46. Install the accessory drive belt tensioner and nut to the appropriate position and tighten to 30 ft-lbs (41 N.m). 47. Install the lower radiator hose onto the timing chain cover. 48. Install the oil cooler line onto the timing chain cover (Figure 13). 49. Install the crankshaft vibration damper using special tools # 8512-A, # 8698-1 and # 9055-1. If the original damper was damaged, install a new vibration damper (P/N 05159003AA). 50. Place the transmission in gear. 51. Install the vibration damper bolt and tighten it to 130 ft-lbs (176 N.m). 52. Install the crankshaft pulley. Tighten the crankshaft pulley bolts to 200 in-lbs (22 N.m). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1290 53. Lower the engine. 54. Raise the vehicle. 55. Install the left and right motor mount retaining bolts. 56. Clean any coolant and oil from the oil pan using MOPAR brake cleaner (P/N 04897150AB). 57. Inspect the oil pickup tube 0-ring (Figure 12). Install a new 0-ring (P/N 06032920) if it is damaged. 58. Install the oil pickup tube into the timing chain cover, seating the 0-ring (Figure 12). 59. Install oil pickup tube flange onto the timing chain cover (Figure 12). Tighten the bolt to 100 in-lbs (11 N.m). 60. Install the oil pickup tube main bearing stud nuts to secure the oil pickup tube strap (Figure 12). Tighten the nuts to 200 in-lbs (22 N.m). 61. Clean and inspect the oil pan gasket. Install a new oil pan gasket (P/N 05037163AC) if the original gasket was damaged. 62. Apply a 1/8" bead of Mopar RTV (P/N 04883971) to the timing chain cover-to-block-to-oil pan joint area (two locations) and to the rear main seal-to-block-to-oil pan joint area (two locations). 63. Place the oil pan gasket onto the oil pan and place the oil pan into position on the engine. 64. Install all of the oil pan bolts~ Tighten the small bolts to 100 in-lbs (11 N.m) and the large bolts to 200 in-lbs (22 N.m). 65. Install the oil pan drain plug. Tighten the drain plug to 25 ft-lbs (34 N.m). 66. Install the flywheel inspection cover. 67 Install the A/C line retaining bolt at the oil pan. 68. Install the coolant hose at thermostat housing. 69. Install the A/C compressor/bracket to the engine, tighten the fasteners to 200 in-lbs (22 N.m). 70. Lower the vehicle. 71. Install the heater hoses onto the timing chain cover. 72. Install the generator (Figure 11). 73. Install power steering pump (Figure 11) Tighten the fasteners to 200 in-lbs (22 N.m). 74. Install accessory drive belt (Figure 11) by positioning the belt over all pulleys except water pump pulley, then rotate tensioner counterclockwise and slip belt over water pump pulley and gently release tensioner. 75. Install the front strut tower to tower brace. 76. Install the upper radiator hose. 77. Install the air cleaner assembly. 78. Install and secure all electrical sensor connections. 79. Open the coolant bleeder valve. 80. Fill the engine with the original coolant until coolant bleeder valve has steady flow of coolant. Close the bleeder valve and install the radiator cap. 81. Fill the engine with 10 quarts of Mobil 1 10W30 Synthetic motor oil (P/N P5007324). 82. Connect the battery cable and install the battery cover. Place the trunk carpeting back into its proper position. 83. Verify the fluid level in the power steering pump. 84. Start the engine and run for 1 minute. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1291 85. Turn the engine off. 86. Check all fluid levels after 5 minutes and top off as required. 87. Check for fluid leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque Technical Service Bulletin # D19 Date: 040401 Campaign - Engine Camshaft Sprocket Bolt Torque April 2004 Customer Satisfaction Notification No. D19 Camshaft Sprocket Bolt Torque Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Service Action # 04-006 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2004 (ZB) Dodge Viper (DR) Dodge Ram SRT-10 NOTE: This notification applies only to the above vehicles equipped with an 8.3L V-10 engine ("Z" in the 8th VIN position) built through January 31, 2004 (MDH 013100). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The camshaft sprocket retaining bolts on about 1,200 of the above vehicles may not have been properly tightened. A loose cam sprocket bolt can back out and cause significant engine damage. Repair The camshaft sprocket retaining bolts must be tightened to the proper specification. Parts Information IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers. Parts may be ordered as needed to support scheduled repairs. The parts are required for each vehicle shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1297 Use the labor operation number and time allowance shown. Add the cost of the parts plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not Applicable. Dealer Notification All dealers will receive a copy of this dealer notification letter by DMAIL and by mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this notification 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 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 should 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 mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. 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 Ram SRT-10 Truck Repair Procedure NOTE: Refer to Viper repair procedure. 1. Disconnect the negative battery cable and isolate it. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1298 2. Remove the air cleaner cover and air inlet tube. 3. Raise the vehicle on an appropriate hoist. 4. Remove the front belly pan 5. Drain the engine coolant via the petcock and the lower radiator hose. Filter and save the coolant for later reuse. 6. Disconnect the power steering lines from the bottom of the radiator fan module and drain the power steering fluid. 7. Detach the power steering line retaining clip from the radiator fan module. 8. Remove the accessory drive belt. 9. Drain the engine oil and remove the oil filter. Discard the filter. 10. Remove the lower radiator hose. 11. Disconnect the oil cooler line from the timing chain cover using special tool # 9005 (Figure 1). 12. Remove the A/C compressor and mounting bracket assembly and then set it aside. Do not disconnect the refrigerant lines or discharge the A/C system. 13. Remove the steering gear assembly retaining bolts and lower the assembly (Figure 2). 14. Remove the sway bar-to-frame attaching bolts and lower the sway bar (Figure 2). 15. Loosen the right and left engine mount through bolts. 16. Lower the vehicle. 17. Remove the upper radiator hose. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1299 18. Disconnect the cooling fan module electrical connector and hydraulic lines (Figure 3). 19. Remove the coolant recovery bottle. 20. Remove the cooling fan module (Figure 4). 21. Remove the crankshaft pulley. 22. Remove the crankshaft vibration damper using special tool # 1023 (puller) and special tool # 6827-A (insert). 23. Inspect the mating surfaces of the crankshaft and vibration damper. If there is evidence of the damper slipping on the crankshaft, polish the crankshaft with emery or crocus cloth and discard the vibration damper. 24. Remove the pressure hose from the power steering pump. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1300 25. Remove the power steering pump assembly and set it aside in the driver side frame rail area (Figure 5). 26. Remove the accessory drive belt idler pulley (Figure 5). 27 Remove the generator (Figure 5). 28. Disconnect the heater hoses from the timing chain cover. 29. Disconnect the ground cable from the thermostat housing. 30. Install engine lift fixture special tool # 8534-B and # 9363 and raise engine/transmission assembly. Raise the vehicle. 32. Remove the flywheel inspection cover. 33. Remove the oil pan bolts. 34. Carefully separate the oil pan from the oil pan-to-engine block gasket. Lower the oil pan leaving the gasket attached to the block. Do not remove the oil pan gasket. It can be reused, unless it is damaged. 35. Disconnect oil pick up tube and lower it into the oil pan (Figure 6). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1301 36. Remove the accessory drive belt tensioner. 37. Carefully cut the RTV between the timing chain cover and the oil pan gasket. 38. Lower the vehicle. 39. Remove the timing chain cover bolts (Figure 7). 40. Remove the timing chain cover (Figure 7). 41. Remove the front crankshaft seal from the timing chain cover and discard the seal. Use care to not damage the machined surfaces. 42. Inspect the three (3) camshaft sprocket bolts (Figure 8). 43. If any camshaft sprocket bolt is broken or missing, contact the STAR Center for further information. 44. If any camshaft sprocket bolts are loose but not broken, inspect the camshaft position sensor in the timing chain cover for damage. Remove and discard the sensor if it is damaged. 45. Rotate crankshaft to position the camshaft sprocket so that the raised front edge is at the upper (12 O'clock) position. 46. Snug the three (3) camshaft sprocket bolts to 50 in-lbs (6 N.m) to ensure hard contact of the joint faces. 47. Tighten each camshaft sprocket bolt to 250 in-lbs (29 N.m) starting with the bolt opposite the dowel pin. Tighten the bolts in a clockwise pattern. 48. Install the timing chain cover onto the location dowels without the front crankshaft seal installed (Figure 7). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1302 49. Install all timing chain cover bolts and tighten to 100 in-lbs (11 N.m) using the sequence found in Figure 9, then using the same sequence, tighten the bolts to 200 in-lbs (22 N.m). 50. Using crank seal installation tool MD998306, install the front crankshaft seal to the proper depth (Figure 10). 51. If the camshaft position sensor was removed due to damage, slide a new sensor (P/N 05245084) into the timing chain cover sensor hole until it makes light contact with raised edge on the camshaft sprocket. Tighten the sensor retention bolt to 100 in-lbs (11 N.m). 52. Raise the vehicle. 53. Install the accessory drive belt tensioner and nut to the appropriate position and tighten to 30 ft-lbs (41 N.m). 54. Clean any coolant and oil from the oil pan using MOPAR brake cleaner (P/N 04897150AB). 55. Inspect the oil pickup tube 0-ring (Figure 6). Install a new 0-ring (P/N 06032920) if it is damaged. 56. Install the oil pickup tube into the timing chain cover, seating the 0-ring (Figure 6). 57. Install oil pickup tube flange onto the timing chain cover (Figure 6). Tighten the bolt to 100 in-lbs (11 N.m). 58. Install the oil pickup tube main bearing stud nuts to secure the oil pickup tube straps (Figure 6). Tighten the nuts to 200 in-lbs (22 N.m). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1303 59. Clean and inspect the oil pan gasket. Install a new oil pan gasket (P/N 05037163AC) if the original gasket was damaged. 60. Apply a 1/8" bead of Mopar RTV (P/N 04883971) to the timing chain cover-to-block-to-oil pan joint area (two locations) and to the rear main seal-to-block-to-oil pan joint area (two locations). 61. Place the oil pan gasket onto the oil pan and place the oil pan into position on the engine. 62. Install all of the oil pan bolts. Tighten the small bolts to 100 in-lbs (11 N.m) and the large bolts to 200 in-lbs (22 N.m). 63. Install the oil pan drain plug. Tighten the drain plug to 25 ft-lbs (34 N.m). 64. Install the flywheel inspection cover. 65. Lower the vehicle. 66. Lower the engine/transmission assembly. 67. Remove the engine lift fixture. 68. Install the ground cable onto the thermostat housing. 69. Connect the heater hoses to the timing chain cover. 70. Install the generator (Figure 5). 71 Install the accessory drive belt idler pulley (Figure 5). Tighten the bolt to 30 ft-lbs (41 N.m). 72. Install the power steering pump assembly (Figure 5). Tighten the bolts to 200 in-lbs (22 N.m). 73. Install the crankshaft vibration damper using special tools # 8512-A, # 8698-1 and # 9055-1. If the original damper was damaged, install a new vibration damper (P/N 05159003AA). 74. Place the transmission in gear. 75. Install the vibration damper bolt and tighten it to 130 ft-lbs (176 N.m). 76. Install the crankshaft pulley. Tighten the crankshaft pulley bolts to 200 in-lbs (22 N.m). 77. Install the cooling fan module (Figure 4). 78. Install the coolant recovery bottle. 79. Connect the cooling fan module electrical connector and hydraulic lines (Figure 3). 80. Install the upper radiator hose. 81. Raise the vehicle. 82. Tighten the engine mount through bolts to 75 ft-lbs (102 N.m). 83. Install the sway bar-to-frame mounting bolts (Figure 2). Tighten the bolts to 45 ft-lbs (61 N.m). 84. Install the steering gear assembly (Figure 2). Tighten the mounting bolts to 235 ft-lbs (319 N.m). 85. Install the A/C compressor and bracket assembly. Tighten the fasteners to 200 in-lbs (22 N.m). 86. Install the oil cooler line to the timing chain cover (Figure 1). 87. Install the lower radiator hose. 88. Install a new oil filter (P/N 05281090). 89. Install the accessory drive belt by positioning the belt over all pulleys except the water pump pulley, then rotate tensioner counterclockwise and slip the belt over water pump pulley and gently release the tensioner. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1304 90. Install the cooling fan module power steering line retainer. 91 Install the power steering and cooling fan hydraulic lines (Figure 3). Tighten the return line to 52 ft-lbs (71 Nm), the pump-to-fan line to 275 in-lbs (32 N.m) and the pump-to-steering gear line to 325 in-lbs (37 N.m). 92. Install the front belly pan. Tighten the fasteners to 50 in-lbs (6 N.m). 93. Lower the vehicle. 94. Open the coolant bleeder valve. 95. Fill the engine with the original coolant until coolant bleeder valve has steady flow of coolant. Close the bleeder valve and install the radiator cap. 96. Fill the engine with 9 quarts of Mobil 1 10W30 Synthetic motor oil (P/N P5007324). 97. Install the air cleaner cover and air inlet tube. 98. Connect the negative battery cable. 99. Fill the power steering pump reservoir with Power Steering Fluid (ATF+4) (P/N 05013457AA). 100. Start the engine and ruin for 1 minute. 101. Turn the engine off. 102. Check all fluid levels after 5 minutes and top off as required. 103. Start the engine. 104. Remove air from steering system by using the DRBIII(R) (Scan Tool) to actuate cooling fan at 50% duty while slowly rotating the steering wheel lock to lock. 105. Turn the engine off and check all fluid levels after 5 minutes and top off as required. 106. Check for fluid leaks. Viper Repair Procedure 1. Place the vehicle on an appropriate hoist. 2. Open the trunk and pull back the carpet. 3. Remove the battery cover, disconnect the negative battery cable and isolate it. 4. Open the hood. 5. Remove the air cleaner assembly. 6. Drain the engine coolant via the radiator petcock. Filter and save the coolant for later reuse. 7. Remove the upper radiator hose. 8. Remove front strut tower to tower brace. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1305 9. Remove the accessory drive belt (Figure 11). 10. Remove the power steering pump (Figure 11). 11. Remove the generator (Figure 11). 12. Remove the heater hoses from the timing chain cover. 13. Raise the vehicle. 14. Drain the engine oil and remove the oil filter. Discard the filter. 15. Remove the flywheel inspection cover. 16. Remove the A/C compressor and mounting bracket assembly and then set it aside. Do not disconnect the refrigerant lines or discharge the A/C system. 17. Remove coolant hose from the thermostat housing. 18. Remove the A/C line retaining bolt at the oil pan. 19. Remove the four (4) bell housing-to-oil pan bolts. 20. Remove the oil pan bolts. 21. Carefully separate the oil pan from the oil pan-to-engine block gasket. Remove the oil pan leaving the gasket attached to the block. Do not remove the oil pan gasket. It can be reused, unless it is damaged. 22. Carefully cut the RTV between timing chain cover and the oil pan gasket. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1306 23. Remove the oil pick up tube (Figure 12). 24. Remove the left and right motor mount retaining nuts. 25 Temporarily install the oil pan for lifting engine. 26. Lower the vehicle. 27. Raise the engine with a floor jack (place wood between the jack and the oil pan). 28. Remove the crankshaft pulley. 29. Remove the crankshaft vibration damper using special tool # 1023 (puller) and special tool # 6827-A (insert). 30. Inspect the mating surfaces of the crankshaft and vibration damper. If there is evidence of the damper slipping on the crankshaft, polish the crankshaft with emery or crocus cloth and discard the vibration damper. 31. Remove the oil cooler line from the timing chain cover using special tool #9005 (Figure 13). 32. Remove the lower radiator hose from the front cover. 33. Remove the accessory drive belt tensioner. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1307 34. Remove the timing chain cover (Figure 14). 35. Remove the front crankshaft seal from the timing chain cover and discard the seal~ Use care to not damage the machined surfaces. 36. Inspect the three (3) camshaft sprocket bolts (Figure 15). 37. If any camshaft sprocket bolt is broken or missing, contact the STAR Center for further information. 38. If any camshaft sprocket bolts are loose but not broken, inspect the camshaft position sensor in the timing chain cover for damage. Remove and discard the sensor if it is damaged. 39. Rotate crankshaft to position the camshaft sprocket so that the raised front edge is at the upper (12 O'clock) position. 40. Snug the three (3) camshaft sprocket bolts (Figure 15) to 50 in-lbs (6 Nm) to ensure hard contact of the joint faces. 41. Tighten each camshaft sprocket bolt to 250 in-lbs (29 N.m) starting with the bolt opposite the dowel pin. Tighten the bolts in a clockwise pattern. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1308 42. In stall the timing chain cover onto the location dowels without the front crank seal installed (Figure 14). 43. In stall all timing chain cover bolts and tighten to 100 in-lbs (11 N.m) using the sequence shown in Figure 16, then using the same sequence, tighten the bolts to 200 in-lbs (22 N.m). 44. Using crank seal installation tool MD998306, install the front crankshaft seal to the proper depth (Figure 17). 45. If the camshaft position sensor was removed due to damage, slide a new sensor (P/N 05245084) into the timing chain cover sensor hole until it makes light contact with raised edge on the camshaft sprocket. Tighten the sensor retention bolt to 100 in-lbs (11 N.m). 46. Install the accessory drive belt tensioner and nut to the appropriate position and tighten to 30 ft-lbs (41 N.m). 47. Install the lower radiator hose onto the timing chain cover. 48. Install the oil cooler line onto the timing chain cover (Figure 13). 49. Install the crankshaft vibration damper using special tools # 8512-A, # 8698-1 and # 9055-1. If the original damper was damaged, install a new vibration damper (P/N 05159003AA). 50. Place the transmission in gear. 51. Install the vibration damper bolt and tighten it to 130 ft-lbs (176 N.m). 52. Install the crankshaft pulley. Tighten the crankshaft pulley bolts to 200 in-lbs (22 N.m). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1309 53. Lower the engine. 54. Raise the vehicle. 55. Install the left and right motor mount retaining bolts. 56. Clean any coolant and oil from the oil pan using MOPAR brake cleaner (P/N 04897150AB). 57. Inspect the oil pickup tube 0-ring (Figure 12). Install a new 0-ring (P/N 06032920) if it is damaged. 58. Install the oil pickup tube into the timing chain cover, seating the 0-ring (Figure 12). 59. Install oil pickup tube flange onto the timing chain cover (Figure 12). Tighten the bolt to 100 in-lbs (11 N.m). 60. Install the oil pickup tube main bearing stud nuts to secure the oil pickup tube strap (Figure 12). Tighten the nuts to 200 in-lbs (22 N.m). 61. Clean and inspect the oil pan gasket. Install a new oil pan gasket (P/N 05037163AC) if the original gasket was damaged. 62. Apply a 1/8" bead of Mopar RTV (P/N 04883971) to the timing chain cover-to-block-to-oil pan joint area (two locations) and to the rear main seal-to-block-to-oil pan joint area (two locations). 63. Place the oil pan gasket onto the oil pan and place the oil pan into position on the engine. 64. Install all of the oil pan bolts~ Tighten the small bolts to 100 in-lbs (11 N.m) and the large bolts to 200 in-lbs (22 N.m). 65. Install the oil pan drain plug. Tighten the drain plug to 25 ft-lbs (34 N.m). 66. Install the flywheel inspection cover. 67 Install the A/C line retaining bolt at the oil pan. 68. Install the coolant hose at thermostat housing. 69. Install the A/C compressor/bracket to the engine, tighten the fasteners to 200 in-lbs (22 N.m). 70. Lower the vehicle. 71. Install the heater hoses onto the timing chain cover. 72. Install the generator (Figure 11). 73. Install power steering pump (Figure 11) Tighten the fasteners to 200 in-lbs (22 N.m). 74. Install accessory drive belt (Figure 11) by positioning the belt over all pulleys except water pump pulley, then rotate tensioner counterclockwise and slip belt over water pump pulley and gently release tensioner. 75. Install the front strut tower to tower brace. 76. Install the upper radiator hose. 77. Install the air cleaner assembly. 78. Install and secure all electrical sensor connections. 79. Open the coolant bleeder valve. 80. Fill the engine with the original coolant until coolant bleeder valve has steady flow of coolant. Close the bleeder valve and install the radiator cap. 81. Fill the engine with 10 quarts of Mobil 1 10W30 Synthetic motor oil (P/N P5007324). 82. Connect the battery cable and install the battery cover. Place the trunk carpeting back into its proper position. 83. Verify the fluid level in the power steering pump. 84. Start the engine and run for 1 minute. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1310 85. Turn the engine off. 86. Check all fluid levels after 5 minutes and top off as required. 87. Check for fluid leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 HEATER - ENGINE BLOCK DESCRIPTION WARNING: DO NOT OPERATE ENGINE UNLESS BLOCK HEATER CORD HAS BEEN DISCONNECTED FROM POWER SOURCE AND SECURED IN PLACE. THE POWER CORD MUST BE SECURED IN ITS RETAINING CLIPS AND ROUTED AWAY FROM EXHAUST MANIFOLDS AND MOVING PARTS. An optional engine block heater is available with all models. The heater is equipped with a power cord. The cord is attached to an engine compartment component with tie-straps. The heater warms the engine providing easier engine starting and faster warm-up in low temperatures. The heater is mounted in a core hole of the engine cylinder block in place of a freeze plug with the heating element immersed in engine coolant. The 3.7L/4.7L gas powered engines have the block heater located to the rear on the right side of the engine. The 5.9L diesel engine has the block heater located on the right side of the engine below the exhaust manifold next to the oil cooler (1). OPERATION The heater warms the engine coolant providing easier engine starting and faster warm-up in low temperatures. Connecting the power cord to a grounded 110-120 volt AC electrical outlet with a grounded three wire extension cord provides the electricity needed to heat the element. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1315 Engine Block Heater: Testing and Inspection DIAGNOSIS AND TESTING - ENGINE BLOCK HEATER If the unit does not operate, possible causes can be either the power cord or the heater element. Test the power cord for continuity with a 110-volt voltmeter or 110-volt test light. Test heater element continuity with an ohmmeter or a 12-volt test light. CAUTION: To prevent damage, the power cord must be secured in it's retainer clips and away from any components that may cause abrasion or damage, such as linkages, exhaust components, etc. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1316 Engine Block Heater: Service and Repair ENGINE BLOCK HEATER REMOVAL GAS ENGINES 1. Disconnect the battery negative cable. 2. Drain the coolant. 3. Remove the power cord from the heater by unplugging. 4. Loosen (but do not completely remove) the screw at center of block heater. 5. Remove the block heater by carefully prying from side-to-side. Note the direction of the heating element coil (up or down). The element coil must be installed correctly to prevent damage. INSTALLATION 1. Clean and inspect the block heater hole. 2. Install the new O-ring seal(s) to heater. 3. Insert the block heater into cylinder block and position the element properly. 4. With the heater fully seated, tighten center screw to 2 Nm (17 inch lbs.). 5. Fill the cooling system with the recommended coolant. 6. Start and warm the engine. 7. Check the block heater for leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. 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. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. 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. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications TORQUE-SPECIFICATIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1325 Drive Belt: Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1326 Drive Belt: Testing and Inspection BELT - DRIVE DIAGNOSIS AND TESTING ACCESSORY DRIVE BELT VISUAL DIAGNOSIS NOTE: 5.9L Diesel Engine - If a belt is broken or frayed, inspect engine speed sensor (located near the crankshaft damper) for damage. When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib, are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1327 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1328 ACCESSORY DRIVE BELT DIAGNOSIS CHART Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1329 Drive Belt: Service and Repair BELT - DRIVE REMOVAL 8.3L ENGINE 1. Remove the air intake tube between intake manifold and air filter assembly. 2. Release the belt tension by rotating the tensioner counterclockwise with a 15 mm wrench on the tensioner pulley bolt. Rotate belt tensioner until belt can be removed from pulleys. 3. Remove accessory drive belt. 4. Gently release tensioner. INSTALLATION NOTE: When installing accessory drive belt onto pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulleys. 1. Position the drive belt over all pulleys except for the water pump pulley. 2. Rotate tensioner counterclockwise and slip the belt over the water pump pulley. 3. Gently release tensioner. 4. Install the air intake tube between intake manifold and air filter assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Bolt - Automatic Belt Tensioner to Block ................................................................................................................................................ 41 Nm (30 ft. lbs.) Bolt - Automatic Belt Tensioner Pulley .................................................................................................................................................... 61 Nm (45 ft. lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 1333 Drive Belt Tensioner: Description and Operation TENSIONER-BELT DESCRIPTION Correct drive belt tension is required to ensure optimum performance of the belt driven engine accessories. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power steering assist, loss of air conditioning capacity, reduced generator output rate, and greatly reduced belt life. It is not necessary to adjust belt tension. All engines are equipped with an automatic belt tensioner. The tensioner maintains correct belt tension at all times. CAUTION: Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner. OPERATION The automatic belt tensioner maintains belt tension by using internal spring pressure, a pivoting arm and pulley to press against the drive belt. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 1334 Drive Belt Tensioner: Service and Repair TENSIONER-BELT 8.3L ENGINE REMOVAL 1. Remove the air intake tube between intake manifold and air filter assembly. 2. Release the belt tension by rotating the tensioner counterclockwise with a 15 mm wrench on the tensioner pulley bolt. Rotate belt tensioner until belt can be removed from pulleys. 3. Remove accessory drive belt. 4. Gently release tensioner. 5. Remove tensioner mounting nut. INSTALLATION NOTE: When installing accessory drive belt onto pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulleys. 1. Install tensioner and mounting nut. Torque mounting nut to 41 Nm (30 ft. lbs.). 2. Install accessory drive belt. 3. Install the air intake tube between intake manifold and air filter assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications Idler Pulley: Specifications Bolt - Idler Pulley ................................................................................................................................. .................................................... 54 Nm (40 ft. lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Capacity (with filter) ........................................................................................................... ..................................................... 8.0Liters (8.5 Qt) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1343 Engine Oil: Fluid Type Specifications Engine Oil Viscosity Above 0°F (-18°C) ............................................................................................................................... ................................................. 10W-30 (Preferred) Below 32°F (0°C) ................................................................................................................................. ..................................................................... 5W-30 Chrysler only recommends synthetic engine oils, such as Mobil 1, that are API Certified and meet the requirements of Material Standard MS-10725. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Tools and Equipment Oil Cooler: Tools and Equipment 1/2" Oil Cooler Line Rem. AST tool# 8016 Used for removing both of the oil cooler lines from the fittings on automatic transmission and oil coolers. - Used for R and R of Oil and Transmission Cooler Lines - Green-Anodized Aluminum Construction - See Application Chart - Included in the 8100, 8107 and #8110 Line Disconnect Sets. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Tool is also available in the following kits: Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Tools and Equipment > Page 1347 8107 - 7-Piece Line Disconnect Set 8110 - 10-Pc. Line Disconnect Set Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair Oil Pan: Service and Repair PAN-OIL REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect engine oil indicator tube fastener from the right cylinder head cover. 3. Install engine lifting fixture TOOL 9363 and support TOOL. 4. Raise vehicle on hoist. 5. Remove the lower engine shield. 6. Drain engine oil. 7. Remove the front cross member. 8. Remove flywheel inspection cover. 9. Loosen engine mount through bolts. 10. Wiggle and separate the oil level indicator tube from the oil pan. NOTE: Careful positioning of the jack stand is necessary to prevent damage to other components Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Page 1351 11. Using lifting fixture TOOL 9363 and support TOOL, raise the front of the engine 12. Remove transmission to oil pan fasteners. 13. Remove oil pan bolts and remove oil pan. NOTE: Clean and inspect oil pan gasket. The pan gasket can be used again if in good condition. INSTALLATION 1. Clean gasket surfaces. Inspect oil pan gasket. Replace as necessary 2. Apply an 1/8 in. bead of Mopar Engine RTV at the two joints between the cylinder block to timing chain case cover and the two joints between the rear main seal retainer and engine block. 3. Position oil pan and gasket to engine block, seat the oil level indicator tube in the oil pan and hand start all fasteners. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Page 1352 4. Tighten the transmission to oil pan bolts in finger tight. 5. Torque 5/16-18 oil pan bolts to 23 Nm (200 inch lbs.). Torque 1/4-20 oil pan bolts to 11 Nm (95 inch lbs.). 6. Torque transmission to oil pan bolts to 23 Nm (200 inch lbs.). 7. Lower the engine. 8. Install and tighten engine mount through bolts to 102 Nm (75 ft. lbs.). 9. Install flywheel inspection cover. 10. Install frame front cross member. 11. Lower vehicle. 12. Install the oil level indicator tube fastener. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Page 1353 13. Fill the crankcase with the correct oil to proper level. 14. Start the engine and inspect for leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation An oil pressure gauge is standard equipment on all instrument clusters. The oil pressure gauge is located in the upper right quadrant of the instrument cluster, above the coolant temperature gauge. The oil pressure gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "L" (or Low) to "H" (or High) for gasoline engines except SRT-10. On SRT-10 models, the scale reads from "0" kPa to "700" kPa in markets where a metric instrument cluster is specified, or from "0" psi to "100" psi in all other markets. On vehicles with a diesel engine the scale reads from "0" kPa to "760" kPa in markets where a metric instrument cluster is specified, or from "0" psi to "110" psi in all other markets. An International Control and Display Symbol icon for "Engine Oil" is located on the cluster overlay, directly below the left end of the gauge scale. On all models except SRT-10 the oil pressure gauge graphics are black against a white field except for two red graduations at the low end of the gauge scale. On SRT-10 the gauge graphics are black against a silver field except for a single red zone at the low end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. For all models except SRT-10, each time the cluster receives a message from the PCM or ECM indicating the engine oil pressure is above about 41 kPa (6 psi) the cluster holds the gauge needle at a point near the middle increment within the normal range on the gauge scale. For SRT-10 models, each time the cluster receives a message from the PCM indicating the engine oil pressure is above about 41 kPa (6 psi) the cluster moves the gauge needle in a linear fashion to the proper relative pressure position of the gauge scale. - Engine Oil Pressure Low Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine oil pressure is below about 41 kPa (6 psi), the gauge needle is moved to the red graduations (except SRT-10) or to the red zone (SRT-10) at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the left end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine oil pressure is above about 41 kPa (6 psi), or until the ignition switch is turned to the Off position, whichever occurs first. The cluster will only turn the check gauges indicator on in response to an engine oil pressure low message if the engine speed message is greater than zero. - Communication Error - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the oil pressure gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure. On vehicles with a diesel engine, the ECM continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM or ECM then sends the proper engine oil pressure messages to the instrument cluster. If the instrument cluster turns on the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the oil pressure gauge, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations Right Front Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1362 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1363 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1364 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1365 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1366 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1367 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1368 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1369 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1370 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1371 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1372 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1373 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1374 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1375 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1376 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1377 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1378 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1379 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1380 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1381 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1382 Sensor-Engine Oil Pressure (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Gauge > Component Information > Diagrams Gauge - Engine Oil Temperature (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Gauge > Component Information > Diagrams > Page 1386 Oil Temperature Gauge: Description and Operation An oil temperature gauge (1) is standard equipment on all SRT-10 models. This electronic, analog gauge is located in the lower end of the left A-pillar trim molding below the grab handle (2), in clear view of the vehicle operator. The gauge dial face is visible through a clear plastic lens, which is secured to the gauge housing with a silver anodized trim ring. The remainder of the gauge, including the mounting provisions and the electrical connections, are concealed behind the left A-pillar trim molding. The molded plastic housing at the rear of the gauge protects the electronic circuitry of the gauge and has two mounting studs, which are secured by nuts to a molded plastic mounting bracket screwed to the back of the A-pillar trim molding. A short pigtail wire with a connector extends from the back of the gauge housing and connects the gauge to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The oil temperature gauge consists of a movable gauge needle or pointer with a 270 degree sweep that is controlled by the electronic gauge circuitry. The gauge overlay reads left-to-right from "60" to "150" with "° C" indicated directly below the low (left) end of the scale in markets where a metric instrument cluster is specified, or from "140" to "300" with "° F" indicated directly below the left end of the scale for all other markets. The text "OIL TEMP" is imprinted on the center of the gauge overlay below the hub of the gauge needle, while the text "SRT" is imprinted above the hub of the gauge needle. The gauge graphics are black against a silver field except for a single red zone at the high (right) end of the gauge scale and are clearly visible in daylight. General illumination lighting for the gauge is provided by a Light Emitting Diode (LED) that is soldered onto the gauge circuit board. The gauge overlay is a laminated plastic unit. The dark, visible, outer surface of the overlay is marked with the gauge dial face and graduations, but this layer is also translucent. The underlying layer of the overlay is opaque and allows light from the LED on the circuit board behind it to be visible through the outer layer of the overlay only through predetermined stencil-like cutouts. When illuminated from behind by the panel lamps dimmer controlled gauge lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Gauge > Component Information > Diagrams > Page 1387 The oil temperature gauge cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The gauge illumination LED unit is not available for service replacement and, if damaged or faulty, the entire gauge must be replaced. The oil temperature gauge gives an indication to the vehicle operator of the engine oil temperature. This gauge is controlled by its own internal electronic circuit board based upon a hard wired input received by the gauge from an oil temperature sensor (4) installed in a tapped hole that penetrates an oil passage on the right side of the engine block (2) just behind the oil pressure sensor (3). The oil temperature sensor is a Negative Temperature Coefficient (NTC) thermistor that changes its internal resistance with changes in temperature. The sensor has two terminals. One terminal receives a hard wired ground path through a take out and connector of the engine wire harness (1), and the second terminal provides a variable output to the gauge through the same take out and connector. As the oil temperature increases the resistance of the sensor decreases, and as the oil temperature decreases the resistance of the sensor increases. The oil temperature gauge is an air core magnetic unit. The gauge pigtail wire and connector provides the gauge electronic circuit board with a hard wired ground path, battery current through a fused ignition switch output (run-start) circuit, a Pulse Width Modulated (PWM) panel lamps dimmer input from the instrument cluster for general illumination, and the input from the oil temperature sensor. This gauge is only operational when the ignition switch is in the On or Start positions. The gauge electronic circuit board reads the input from the oil temperature sensor, then provides linear positioning of the gauge needle on the gauge scale based upon that input. The gauge electronics will move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The oil temperature gauge and the oil temperature sensor may be diagnosed using conventional diagnostic tools and methods. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Gauge > Component Information > Diagrams > Page 1388 Oil Temperature Gauge: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. The hard wired oil temperature gauge and gauge lighting circuits may be diagnosed and tested using conventional diagnostic tools and procedures. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. NOTE: When testing the oil temperature gauge by alternately opening and shorting the oil temperature sensor signal circuit, the gauge pointer may rotate in either direction (clockwise or counterclockwise) to reach the objective point on the gauge scale. This is a normal condition as the gauge electronics are programmed to move the pointer from its current position to the objective position in the direction that provides the shortest pointer travel distance. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Gauge > Component Information > Diagrams > Page 1389 Oil Temperature Gauge: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim molding (5) from the inside of the left A-pillar. 3. Remove the two nuts (2) that secure the oil temperature gauge (4) mounting studs to the mounting bracket (1) on the back of the A-pillar trim. 4. Remove the four screws (3) that secure the mounting bracket to the back of the A-pillar trim. 5. Remove the mounting bracket from the back of the A-pillar trim. 6. Push the gauge and the gauge pigtail wire (6) and connector out through the mounting hole on the face of the A-pillar trim. INSTALLATION 1. Position the oil temperature gauge (4) into the mounting hole on the face of the A-pillar trim (5). 2. Position the mounting bracket (1) to the back of the A-pillar trim with the gauge pigtail wire (6) and connector routed between the two lower mounting bracket screw bosses on the back of the A-pillar trim. 3. Install and tighten the four screws (3) that secure the mounting bracket to the back of the A-pillar trim. Tighten the screws to 1 N.m (9 in.lbs.). 4. Align and insert the two mounting studs on the back of the gauge housing through the appropriate holes in the mounting bracket. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Gauge > Component Information > Diagrams > Page 1390 5. Install and tighten the two nuts that secure the gauge mounting studs to the mounting bracket. Tighten the nuts to 0.5 N.m (5 in.lbs.). 6. Reinstall the trim molding onto the inside of the left A-pillar. 7. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Locations Right Front Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 1394 Sensor-Engine Oil Temperature (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 1395 Oil Temperature Sensor/Switch: Testing and Inspection 1. Disconnect the engine wire harness connector from the oil temperature sensor. 2. Using an ohmmeter and a test thermometer, test the resistance versus the oil temperature relationship of the sensor between the two terminals of the sensor as shown in the Oil Temperature Sensor Tests table. 3. If the sensor fails any of these tests, replace the faulty oil temperature sensor as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 An oil pressure gauge is standard equipment on all instrument clusters. The oil pressure gauge is located in the upper right quadrant of the instrument cluster, above the coolant temperature gauge. The oil pressure gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "L" (or Low) to "H" (or High) for gasoline engines except SRT-10. On SRT-10 models, the scale reads from "0" kPa to "700" kPa in markets where a metric instrument cluster is specified, or from "0" psi to "100" psi in all other markets. On vehicles with a diesel engine the scale reads from "0" kPa to "760" kPa in markets where a metric instrument cluster is specified, or from "0" psi to "110" psi in all other markets. An International Control and Display Symbol icon for "Engine Oil" is located on the cluster overlay, directly below the left end of the gauge scale. On all models except SRT-10 the oil pressure gauge graphics are black against a white field except for two red graduations at the low end of the gauge scale. On SRT-10 the gauge graphics are black against a silver field except for a single red zone at the low end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. For all models except SRT-10, each time the cluster receives a message from the PCM or ECM indicating the engine oil pressure is above about 41 kPa (6 psi) the cluster holds the gauge needle at a point near the middle increment within the normal range on the gauge scale. For SRT-10 models, each time the cluster receives a message from the PCM indicating the engine oil pressure is above about 41 kPa (6 psi) the cluster moves the gauge needle in a linear fashion to the proper relative pressure position of the gauge scale. - Engine Oil Pressure Low Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine oil pressure is below about 41 kPa (6 psi), the gauge needle is moved to the red graduations (except SRT-10) or to the red zone (SRT-10) at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the left end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine oil pressure is above about 41 kPa (6 psi), or until the ignition switch is turned to the Off position, whichever occurs first. The cluster will only turn the check gauges indicator on in response to an engine oil pressure low message if the engine speed message is greater than zero. - Communication Error - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the oil pressure gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure. On vehicles with a diesel engine, the ECM continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM or ECM then sends the proper engine oil pressure messages to the instrument cluster. If the instrument cluster turns on the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the oil pressure gauge, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Temperature Gauge > Component Information > Diagrams Gauge - Engine Oil Temperature (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Temperature Gauge > Component Information > Diagrams > Page 1403 Oil Temperature Gauge: Description and Operation An oil temperature gauge (1) is standard equipment on all SRT-10 models. This electronic, analog gauge is located in the lower end of the left A-pillar trim molding below the grab handle (2), in clear view of the vehicle operator. The gauge dial face is visible through a clear plastic lens, which is secured to the gauge housing with a silver anodized trim ring. The remainder of the gauge, including the mounting provisions and the electrical connections, are concealed behind the left A-pillar trim molding. The molded plastic housing at the rear of the gauge protects the electronic circuitry of the gauge and has two mounting studs, which are secured by nuts to a molded plastic mounting bracket screwed to the back of the A-pillar trim molding. A short pigtail wire with a connector extends from the back of the gauge housing and connects the gauge to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The oil temperature gauge consists of a movable gauge needle or pointer with a 270 degree sweep that is controlled by the electronic gauge circuitry. The gauge overlay reads left-to-right from "60" to "150" with "° C" indicated directly below the low (left) end of the scale in markets where a metric instrument cluster is specified, or from "140" to "300" with "° F" indicated directly below the left end of the scale for all other markets. The text "OIL TEMP" is imprinted on the center of the gauge overlay below the hub of the gauge needle, while the text "SRT" is imprinted above the hub of the gauge needle. The gauge graphics are black against a silver field except for a single red zone at the high (right) end of the gauge scale and are clearly visible in daylight. General illumination lighting for the gauge is provided by a Light Emitting Diode (LED) that is soldered onto the gauge circuit board. The gauge overlay is a laminated plastic unit. The dark, visible, outer surface of the overlay is marked with the gauge dial face and graduations, but this layer is also translucent. The underlying layer of the overlay is opaque and allows light from the LED on the circuit board behind it to be visible through the outer layer of the overlay only through predetermined stencil-like cutouts. When illuminated from behind by the panel lamps dimmer controlled gauge lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Temperature Gauge > Component Information > Diagrams > Page 1404 The oil temperature gauge cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The gauge illumination LED unit is not available for service replacement and, if damaged or faulty, the entire gauge must be replaced. The oil temperature gauge gives an indication to the vehicle operator of the engine oil temperature. This gauge is controlled by its own internal electronic circuit board based upon a hard wired input received by the gauge from an oil temperature sensor (4) installed in a tapped hole that penetrates an oil passage on the right side of the engine block (2) just behind the oil pressure sensor (3). The oil temperature sensor is a Negative Temperature Coefficient (NTC) thermistor that changes its internal resistance with changes in temperature. The sensor has two terminals. One terminal receives a hard wired ground path through a take out and connector of the engine wire harness (1), and the second terminal provides a variable output to the gauge through the same take out and connector. As the oil temperature increases the resistance of the sensor decreases, and as the oil temperature decreases the resistance of the sensor increases. The oil temperature gauge is an air core magnetic unit. The gauge pigtail wire and connector provides the gauge electronic circuit board with a hard wired ground path, battery current through a fused ignition switch output (run-start) circuit, a Pulse Width Modulated (PWM) panel lamps dimmer input from the instrument cluster for general illumination, and the input from the oil temperature sensor. This gauge is only operational when the ignition switch is in the On or Start positions. The gauge electronic circuit board reads the input from the oil temperature sensor, then provides linear positioning of the gauge needle on the gauge scale based upon that input. The gauge electronics will move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The oil temperature gauge and the oil temperature sensor may be diagnosed using conventional diagnostic tools and methods. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Temperature Gauge > Component Information > Diagrams > Page 1405 Oil Temperature Gauge: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. The hard wired oil temperature gauge and gauge lighting circuits may be diagnosed and tested using conventional diagnostic tools and procedures. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. NOTE: When testing the oil temperature gauge by alternately opening and shorting the oil temperature sensor signal circuit, the gauge pointer may rotate in either direction (clockwise or counterclockwise) to reach the objective point on the gauge scale. This is a normal condition as the gauge electronics are programmed to move the pointer from its current position to the objective position in the direction that provides the shortest pointer travel distance. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Temperature Gauge > Component Information > Diagrams > Page 1406 Oil Temperature Gauge: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim molding (5) from the inside of the left A-pillar. 3. Remove the two nuts (2) that secure the oil temperature gauge (4) mounting studs to the mounting bracket (1) on the back of the A-pillar trim. 4. Remove the four screws (3) that secure the mounting bracket to the back of the A-pillar trim. 5. Remove the mounting bracket from the back of the A-pillar trim. 6. Push the gauge and the gauge pigtail wire (6) and connector out through the mounting hole on the face of the A-pillar trim. INSTALLATION 1. Position the oil temperature gauge (4) into the mounting hole on the face of the A-pillar trim (5). 2. Position the mounting bracket (1) to the back of the A-pillar trim with the gauge pigtail wire (6) and connector routed between the two lower mounting bracket screw bosses on the back of the A-pillar trim. 3. Install and tighten the four screws (3) that secure the mounting bracket to the back of the A-pillar trim. Tighten the screws to 1 N.m (9 in.lbs.). 4. Align and insert the two mounting studs on the back of the gauge housing through the appropriate holes in the mounting bracket. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Temperature Gauge > Component Information > Diagrams > Page 1407 5. Install and tighten the two nuts that secure the gauge mounting studs to the mounting bracket. Tighten the nuts to 0.5 N.m (5 in.lbs.). 6. Reinstall the trim molding onto the inside of the left A-pillar. 7. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations Right Front Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1414 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1415 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1416 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1417 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1418 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1419 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1420 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1421 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1422 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1423 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1424 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1425 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1426 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1427 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1428 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1429 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1430 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1431 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1432 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1433 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1434 Sensor-Engine Oil Pressure (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations Right Front Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 1438 Sensor-Engine Oil Temperature (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 1439 Oil Temperature Sensor/Switch: Testing and Inspection 1. Disconnect the engine wire harness connector from the oil temperature sensor. 2. Using an ohmmeter and a test thermometer, test the resistance versus the oil temperature relationship of the sensor between the two terminals of the sensor as shown in the Oil Temperature Sensor Tests table. 3. If the sensor fails any of these tests, replace the faulty oil temperature sensor as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque Technical Service Bulletin # D19 Date: 040401 Campaign - Engine Camshaft Sprocket Bolt Torque April 2004 Customer Satisfaction Notification No. D19 Camshaft Sprocket Bolt Torque Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Service Action # 04-006 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2004 (ZB) Dodge Viper (DR) Dodge Ram SRT-10 NOTE: This notification applies only to the above vehicles equipped with an 8.3L V-10 engine ("Z" in the 8th VIN position) built through January 31, 2004 (MDH 013100). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The camshaft sprocket retaining bolts on about 1,200 of the above vehicles may not have been properly tightened. A loose cam sprocket bolt can back out and cause significant engine damage. Repair The camshaft sprocket retaining bolts must be tightened to the proper specification. Parts Information IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers. Parts may be ordered as needed to support scheduled repairs. The parts are required for each vehicle shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1449 Use the labor operation number and time allowance shown. Add the cost of the parts plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not Applicable. Dealer Notification All dealers will receive a copy of this dealer notification letter by DMAIL and by mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this notification 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 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 should 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 mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. 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 Ram SRT-10 Truck Repair Procedure NOTE: Refer to Viper repair procedure. 1. Disconnect the negative battery cable and isolate it. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1450 2. Remove the air cleaner cover and air inlet tube. 3. Raise the vehicle on an appropriate hoist. 4. Remove the front belly pan 5. Drain the engine coolant via the petcock and the lower radiator hose. Filter and save the coolant for later reuse. 6. Disconnect the power steering lines from the bottom of the radiator fan module and drain the power steering fluid. 7. Detach the power steering line retaining clip from the radiator fan module. 8. Remove the accessory drive belt. 9. Drain the engine oil and remove the oil filter. Discard the filter. 10. Remove the lower radiator hose. 11. Disconnect the oil cooler line from the timing chain cover using special tool # 9005 (Figure 1). 12. Remove the A/C compressor and mounting bracket assembly and then set it aside. Do not disconnect the refrigerant lines or discharge the A/C system. 13. Remove the steering gear assembly retaining bolts and lower the assembly (Figure 2). 14. Remove the sway bar-to-frame attaching bolts and lower the sway bar (Figure 2). 15. Loosen the right and left engine mount through bolts. 16. Lower the vehicle. 17. Remove the upper radiator hose. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1451 18. Disconnect the cooling fan module electrical connector and hydraulic lines (Figure 3). 19. Remove the coolant recovery bottle. 20. Remove the cooling fan module (Figure 4). 21. Remove the crankshaft pulley. 22. Remove the crankshaft vibration damper using special tool # 1023 (puller) and special tool # 6827-A (insert). 23. Inspect the mating surfaces of the crankshaft and vibration damper. If there is evidence of the damper slipping on the crankshaft, polish the crankshaft with emery or crocus cloth and discard the vibration damper. 24. Remove the pressure hose from the power steering pump. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1452 25. Remove the power steering pump assembly and set it aside in the driver side frame rail area (Figure 5). 26. Remove the accessory drive belt idler pulley (Figure 5). 27 Remove the generator (Figure 5). 28. Disconnect the heater hoses from the timing chain cover. 29. Disconnect the ground cable from the thermostat housing. 30. Install engine lift fixture special tool # 8534-B and # 9363 and raise engine/transmission assembly. Raise the vehicle. 32. Remove the flywheel inspection cover. 33. Remove the oil pan bolts. 34. Carefully separate the oil pan from the oil pan-to-engine block gasket. Lower the oil pan leaving the gasket attached to the block. Do not remove the oil pan gasket. It can be reused, unless it is damaged. 35. Disconnect oil pick up tube and lower it into the oil pan (Figure 6). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1453 36. Remove the accessory drive belt tensioner. 37. Carefully cut the RTV between the timing chain cover and the oil pan gasket. 38. Lower the vehicle. 39. Remove the timing chain cover bolts (Figure 7). 40. Remove the timing chain cover (Figure 7). 41. Remove the front crankshaft seal from the timing chain cover and discard the seal. Use care to not damage the machined surfaces. 42. Inspect the three (3) camshaft sprocket bolts (Figure 8). 43. If any camshaft sprocket bolt is broken or missing, contact the STAR Center for further information. 44. If any camshaft sprocket bolts are loose but not broken, inspect the camshaft position sensor in the timing chain cover for damage. Remove and discard the sensor if it is damaged. 45. Rotate crankshaft to position the camshaft sprocket so that the raised front edge is at the upper (12 O'clock) position. 46. Snug the three (3) camshaft sprocket bolts to 50 in-lbs (6 N.m) to ensure hard contact of the joint faces. 47. Tighten each camshaft sprocket bolt to 250 in-lbs (29 N.m) starting with the bolt opposite the dowel pin. Tighten the bolts in a clockwise pattern. 48. Install the timing chain cover onto the location dowels without the front crankshaft seal installed (Figure 7). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1454 49. Install all timing chain cover bolts and tighten to 100 in-lbs (11 N.m) using the sequence found in Figure 9, then using the same sequence, tighten the bolts to 200 in-lbs (22 N.m). 50. Using crank seal installation tool MD998306, install the front crankshaft seal to the proper depth (Figure 10). 51. If the camshaft position sensor was removed due to damage, slide a new sensor (P/N 05245084) into the timing chain cover sensor hole until it makes light contact with raised edge on the camshaft sprocket. Tighten the sensor retention bolt to 100 in-lbs (11 N.m). 52. Raise the vehicle. 53. Install the accessory drive belt tensioner and nut to the appropriate position and tighten to 30 ft-lbs (41 N.m). 54. Clean any coolant and oil from the oil pan using MOPAR brake cleaner (P/N 04897150AB). 55. Inspect the oil pickup tube 0-ring (Figure 6). Install a new 0-ring (P/N 06032920) if it is damaged. 56. Install the oil pickup tube into the timing chain cover, seating the 0-ring (Figure 6). 57. Install oil pickup tube flange onto the timing chain cover (Figure 6). Tighten the bolt to 100 in-lbs (11 N.m). 58. Install the oil pickup tube main bearing stud nuts to secure the oil pickup tube straps (Figure 6). Tighten the nuts to 200 in-lbs (22 N.m). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1455 59. Clean and inspect the oil pan gasket. Install a new oil pan gasket (P/N 05037163AC) if the original gasket was damaged. 60. Apply a 1/8" bead of Mopar RTV (P/N 04883971) to the timing chain cover-to-block-to-oil pan joint area (two locations) and to the rear main seal-to-block-to-oil pan joint area (two locations). 61. Place the oil pan gasket onto the oil pan and place the oil pan into position on the engine. 62. Install all of the oil pan bolts. Tighten the small bolts to 100 in-lbs (11 N.m) and the large bolts to 200 in-lbs (22 N.m). 63. Install the oil pan drain plug. Tighten the drain plug to 25 ft-lbs (34 N.m). 64. Install the flywheel inspection cover. 65. Lower the vehicle. 66. Lower the engine/transmission assembly. 67. Remove the engine lift fixture. 68. Install the ground cable onto the thermostat housing. 69. Connect the heater hoses to the timing chain cover. 70. Install the generator (Figure 5). 71 Install the accessory drive belt idler pulley (Figure 5). Tighten the bolt to 30 ft-lbs (41 N.m). 72. Install the power steering pump assembly (Figure 5). Tighten the bolts to 200 in-lbs (22 N.m). 73. Install the crankshaft vibration damper using special tools # 8512-A, # 8698-1 and # 9055-1. If the original damper was damaged, install a new vibration damper (P/N 05159003AA). 74. Place the transmission in gear. 75. Install the vibration damper bolt and tighten it to 130 ft-lbs (176 N.m). 76. Install the crankshaft pulley. Tighten the crankshaft pulley bolts to 200 in-lbs (22 N.m). 77. Install the cooling fan module (Figure 4). 78. Install the coolant recovery bottle. 79. Connect the cooling fan module electrical connector and hydraulic lines (Figure 3). 80. Install the upper radiator hose. 81. Raise the vehicle. 82. Tighten the engine mount through bolts to 75 ft-lbs (102 N.m). 83. Install the sway bar-to-frame mounting bolts (Figure 2). Tighten the bolts to 45 ft-lbs (61 N.m). 84. Install the steering gear assembly (Figure 2). Tighten the mounting bolts to 235 ft-lbs (319 N.m). 85. Install the A/C compressor and bracket assembly. Tighten the fasteners to 200 in-lbs (22 N.m). 86. Install the oil cooler line to the timing chain cover (Figure 1). 87. Install the lower radiator hose. 88. Install a new oil filter (P/N 05281090). 89. Install the accessory drive belt by positioning the belt over all pulleys except the water pump pulley, then rotate tensioner counterclockwise and slip the belt over water pump pulley and gently release the tensioner. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1456 90. Install the cooling fan module power steering line retainer. 91 Install the power steering and cooling fan hydraulic lines (Figure 3). Tighten the return line to 52 ft-lbs (71 Nm), the pump-to-fan line to 275 in-lbs (32 N.m) and the pump-to-steering gear line to 325 in-lbs (37 N.m). 92. Install the front belly pan. Tighten the fasteners to 50 in-lbs (6 N.m). 93. Lower the vehicle. 94. Open the coolant bleeder valve. 95. Fill the engine with the original coolant until coolant bleeder valve has steady flow of coolant. Close the bleeder valve and install the radiator cap. 96. Fill the engine with 9 quarts of Mobil 1 10W30 Synthetic motor oil (P/N P5007324). 97. Install the air cleaner cover and air inlet tube. 98. Connect the negative battery cable. 99. Fill the power steering pump reservoir with Power Steering Fluid (ATF+4) (P/N 05013457AA). 100. Start the engine and ruin for 1 minute. 101. Turn the engine off. 102. Check all fluid levels after 5 minutes and top off as required. 103. Start the engine. 104. Remove air from steering system by using the DRBIII(R) (Scan Tool) to actuate cooling fan at 50% duty while slowly rotating the steering wheel lock to lock. 105. Turn the engine off and check all fluid levels after 5 minutes and top off as required. 106. Check for fluid leaks. Viper Repair Procedure 1. Place the vehicle on an appropriate hoist. 2. Open the trunk and pull back the carpet. 3. Remove the battery cover, disconnect the negative battery cable and isolate it. 4. Open the hood. 5. Remove the air cleaner assembly. 6. Drain the engine coolant via the radiator petcock. Filter and save the coolant for later reuse. 7. Remove the upper radiator hose. 8. Remove front strut tower to tower brace. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1457 9. Remove the accessory drive belt (Figure 11). 10. Remove the power steering pump (Figure 11). 11. Remove the generator (Figure 11). 12. Remove the heater hoses from the timing chain cover. 13. Raise the vehicle. 14. Drain the engine oil and remove the oil filter. Discard the filter. 15. Remove the flywheel inspection cover. 16. Remove the A/C compressor and mounting bracket assembly and then set it aside. Do not disconnect the refrigerant lines or discharge the A/C system. 17. Remove coolant hose from the thermostat housing. 18. Remove the A/C line retaining bolt at the oil pan. 19. Remove the four (4) bell housing-to-oil pan bolts. 20. Remove the oil pan bolts. 21. Carefully separate the oil pan from the oil pan-to-engine block gasket. Remove the oil pan leaving the gasket attached to the block. Do not remove the oil pan gasket. It can be reused, unless it is damaged. 22. Carefully cut the RTV between timing chain cover and the oil pan gasket. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1458 23. Remove the oil pick up tube (Figure 12). 24. Remove the left and right motor mount retaining nuts. 25 Temporarily install the oil pan for lifting engine. 26. Lower the vehicle. 27. Raise the engine with a floor jack (place wood between the jack and the oil pan). 28. Remove the crankshaft pulley. 29. Remove the crankshaft vibration damper using special tool # 1023 (puller) and special tool # 6827-A (insert). 30. Inspect the mating surfaces of the crankshaft and vibration damper. If there is evidence of the damper slipping on the crankshaft, polish the crankshaft with emery or crocus cloth and discard the vibration damper. 31. Remove the oil cooler line from the timing chain cover using special tool #9005 (Figure 13). 32. Remove the lower radiator hose from the front cover. 33. Remove the accessory drive belt tensioner. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1459 34. Remove the timing chain cover (Figure 14). 35. Remove the front crankshaft seal from the timing chain cover and discard the seal~ Use care to not damage the machined surfaces. 36. Inspect the three (3) camshaft sprocket bolts (Figure 15). 37. If any camshaft sprocket bolt is broken or missing, contact the STAR Center for further information. 38. If any camshaft sprocket bolts are loose but not broken, inspect the camshaft position sensor in the timing chain cover for damage. Remove and discard the sensor if it is damaged. 39. Rotate crankshaft to position the camshaft sprocket so that the raised front edge is at the upper (12 O'clock) position. 40. Snug the three (3) camshaft sprocket bolts (Figure 15) to 50 in-lbs (6 Nm) to ensure hard contact of the joint faces. 41. Tighten each camshaft sprocket bolt to 250 in-lbs (29 N.m) starting with the bolt opposite the dowel pin. Tighten the bolts in a clockwise pattern. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1460 42. In stall the timing chain cover onto the location dowels without the front crank seal installed (Figure 14). 43. In stall all timing chain cover bolts and tighten to 100 in-lbs (11 N.m) using the sequence shown in Figure 16, then using the same sequence, tighten the bolts to 200 in-lbs (22 N.m). 44. Using crank seal installation tool MD998306, install the front crankshaft seal to the proper depth (Figure 17). 45. If the camshaft position sensor was removed due to damage, slide a new sensor (P/N 05245084) into the timing chain cover sensor hole until it makes light contact with raised edge on the camshaft sprocket. Tighten the sensor retention bolt to 100 in-lbs (11 N.m). 46. Install the accessory drive belt tensioner and nut to the appropriate position and tighten to 30 ft-lbs (41 N.m). 47. Install the lower radiator hose onto the timing chain cover. 48. Install the oil cooler line onto the timing chain cover (Figure 13). 49. Install the crankshaft vibration damper using special tools # 8512-A, # 8698-1 and # 9055-1. If the original damper was damaged, install a new vibration damper (P/N 05159003AA). 50. Place the transmission in gear. 51. Install the vibration damper bolt and tighten it to 130 ft-lbs (176 N.m). 52. Install the crankshaft pulley. Tighten the crankshaft pulley bolts to 200 in-lbs (22 N.m). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1461 53. Lower the engine. 54. Raise the vehicle. 55. Install the left and right motor mount retaining bolts. 56. Clean any coolant and oil from the oil pan using MOPAR brake cleaner (P/N 04897150AB). 57. Inspect the oil pickup tube 0-ring (Figure 12). Install a new 0-ring (P/N 06032920) if it is damaged. 58. Install the oil pickup tube into the timing chain cover, seating the 0-ring (Figure 12). 59. Install oil pickup tube flange onto the timing chain cover (Figure 12). Tighten the bolt to 100 in-lbs (11 N.m). 60. Install the oil pickup tube main bearing stud nuts to secure the oil pickup tube strap (Figure 12). Tighten the nuts to 200 in-lbs (22 N.m). 61. Clean and inspect the oil pan gasket. Install a new oil pan gasket (P/N 05037163AC) if the original gasket was damaged. 62. Apply a 1/8" bead of Mopar RTV (P/N 04883971) to the timing chain cover-to-block-to-oil pan joint area (two locations) and to the rear main seal-to-block-to-oil pan joint area (two locations). 63. Place the oil pan gasket onto the oil pan and place the oil pan into position on the engine. 64. Install all of the oil pan bolts~ Tighten the small bolts to 100 in-lbs (11 N.m) and the large bolts to 200 in-lbs (22 N.m). 65. Install the oil pan drain plug. Tighten the drain plug to 25 ft-lbs (34 N.m). 66. Install the flywheel inspection cover. 67 Install the A/C line retaining bolt at the oil pan. 68. Install the coolant hose at thermostat housing. 69. Install the A/C compressor/bracket to the engine, tighten the fasteners to 200 in-lbs (22 N.m). 70. Lower the vehicle. 71. Install the heater hoses onto the timing chain cover. 72. Install the generator (Figure 11). 73. Install power steering pump (Figure 11) Tighten the fasteners to 200 in-lbs (22 N.m). 74. Install accessory drive belt (Figure 11) by positioning the belt over all pulleys except water pump pulley, then rotate tensioner counterclockwise and slip belt over water pump pulley and gently release tensioner. 75. Install the front strut tower to tower brace. 76. Install the upper radiator hose. 77. Install the air cleaner assembly. 78. Install and secure all electrical sensor connections. 79. Open the coolant bleeder valve. 80. Fill the engine with the original coolant until coolant bleeder valve has steady flow of coolant. Close the bleeder valve and install the radiator cap. 81. Fill the engine with 10 quarts of Mobil 1 10W30 Synthetic motor oil (P/N P5007324). 82. Connect the battery cable and install the battery cover. Place the trunk carpeting back into its proper position. 83. Verify the fluid level in the power steering pump. 84. Start the engine and run for 1 minute. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > Recalls for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1462 85. Turn the engine off. 86. Check all fluid levels after 5 minutes and top off as required. 87. Check for fluid leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque Technical Service Bulletin # D19 Date: 040401 Campaign - Engine Camshaft Sprocket Bolt Torque April 2004 Customer Satisfaction Notification No. D19 Camshaft Sprocket Bolt Torque Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Service Action # 04-006 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2004 (ZB) Dodge Viper (DR) Dodge Ram SRT-10 NOTE: This notification applies only to the above vehicles equipped with an 8.3L V-10 engine ("Z" in the 8th VIN position) built through January 31, 2004 (MDH 013100). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The camshaft sprocket retaining bolts on about 1,200 of the above vehicles may not have been properly tightened. A loose cam sprocket bolt can back out and cause significant engine damage. Repair The camshaft sprocket retaining bolts must be tightened to the proper specification. Parts Information IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers. Parts may be ordered as needed to support scheduled repairs. The parts are required for each vehicle shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1468 Use the labor operation number and time allowance shown. Add the cost of the parts plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Parts Return Not Applicable. Dealer Notification All dealers will receive a copy of this dealer notification letter by DMAIL and by mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this notification 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 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 should 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 mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. 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 Ram SRT-10 Truck Repair Procedure NOTE: Refer to Viper repair procedure. 1. Disconnect the negative battery cable and isolate it. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1469 2. Remove the air cleaner cover and air inlet tube. 3. Raise the vehicle on an appropriate hoist. 4. Remove the front belly pan 5. Drain the engine coolant via the petcock and the lower radiator hose. Filter and save the coolant for later reuse. 6. Disconnect the power steering lines from the bottom of the radiator fan module and drain the power steering fluid. 7. Detach the power steering line retaining clip from the radiator fan module. 8. Remove the accessory drive belt. 9. Drain the engine oil and remove the oil filter. Discard the filter. 10. Remove the lower radiator hose. 11. Disconnect the oil cooler line from the timing chain cover using special tool # 9005 (Figure 1). 12. Remove the A/C compressor and mounting bracket assembly and then set it aside. Do not disconnect the refrigerant lines or discharge the A/C system. 13. Remove the steering gear assembly retaining bolts and lower the assembly (Figure 2). 14. Remove the sway bar-to-frame attaching bolts and lower the sway bar (Figure 2). 15. Loosen the right and left engine mount through bolts. 16. Lower the vehicle. 17. Remove the upper radiator hose. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1470 18. Disconnect the cooling fan module electrical connector and hydraulic lines (Figure 3). 19. Remove the coolant recovery bottle. 20. Remove the cooling fan module (Figure 4). 21. Remove the crankshaft pulley. 22. Remove the crankshaft vibration damper using special tool # 1023 (puller) and special tool # 6827-A (insert). 23. Inspect the mating surfaces of the crankshaft and vibration damper. If there is evidence of the damper slipping on the crankshaft, polish the crankshaft with emery or crocus cloth and discard the vibration damper. 24. Remove the pressure hose from the power steering pump. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1471 25. Remove the power steering pump assembly and set it aside in the driver side frame rail area (Figure 5). 26. Remove the accessory drive belt idler pulley (Figure 5). 27 Remove the generator (Figure 5). 28. Disconnect the heater hoses from the timing chain cover. 29. Disconnect the ground cable from the thermostat housing. 30. Install engine lift fixture special tool # 8534-B and # 9363 and raise engine/transmission assembly. Raise the vehicle. 32. Remove the flywheel inspection cover. 33. Remove the oil pan bolts. 34. Carefully separate the oil pan from the oil pan-to-engine block gasket. Lower the oil pan leaving the gasket attached to the block. Do not remove the oil pan gasket. It can be reused, unless it is damaged. 35. Disconnect oil pick up tube and lower it into the oil pan (Figure 6). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1472 36. Remove the accessory drive belt tensioner. 37. Carefully cut the RTV between the timing chain cover and the oil pan gasket. 38. Lower the vehicle. 39. Remove the timing chain cover bolts (Figure 7). 40. Remove the timing chain cover (Figure 7). 41. Remove the front crankshaft seal from the timing chain cover and discard the seal. Use care to not damage the machined surfaces. 42. Inspect the three (3) camshaft sprocket bolts (Figure 8). 43. If any camshaft sprocket bolt is broken or missing, contact the STAR Center for further information. 44. If any camshaft sprocket bolts are loose but not broken, inspect the camshaft position sensor in the timing chain cover for damage. Remove and discard the sensor if it is damaged. 45. Rotate crankshaft to position the camshaft sprocket so that the raised front edge is at the upper (12 O'clock) position. 46. Snug the three (3) camshaft sprocket bolts to 50 in-lbs (6 N.m) to ensure hard contact of the joint faces. 47. Tighten each camshaft sprocket bolt to 250 in-lbs (29 N.m) starting with the bolt opposite the dowel pin. Tighten the bolts in a clockwise pattern. 48. Install the timing chain cover onto the location dowels without the front crankshaft seal installed (Figure 7). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1473 49. Install all timing chain cover bolts and tighten to 100 in-lbs (11 N.m) using the sequence found in Figure 9, then using the same sequence, tighten the bolts to 200 in-lbs (22 N.m). 50. Using crank seal installation tool MD998306, install the front crankshaft seal to the proper depth (Figure 10). 51. If the camshaft position sensor was removed due to damage, slide a new sensor (P/N 05245084) into the timing chain cover sensor hole until it makes light contact with raised edge on the camshaft sprocket. Tighten the sensor retention bolt to 100 in-lbs (11 N.m). 52. Raise the vehicle. 53. Install the accessory drive belt tensioner and nut to the appropriate position and tighten to 30 ft-lbs (41 N.m). 54. Clean any coolant and oil from the oil pan using MOPAR brake cleaner (P/N 04897150AB). 55. Inspect the oil pickup tube 0-ring (Figure 6). Install a new 0-ring (P/N 06032920) if it is damaged. 56. Install the oil pickup tube into the timing chain cover, seating the 0-ring (Figure 6). 57. Install oil pickup tube flange onto the timing chain cover (Figure 6). Tighten the bolt to 100 in-lbs (11 N.m). 58. Install the oil pickup tube main bearing stud nuts to secure the oil pickup tube straps (Figure 6). Tighten the nuts to 200 in-lbs (22 N.m). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1474 59. Clean and inspect the oil pan gasket. Install a new oil pan gasket (P/N 05037163AC) if the original gasket was damaged. 60. Apply a 1/8" bead of Mopar RTV (P/N 04883971) to the timing chain cover-to-block-to-oil pan joint area (two locations) and to the rear main seal-to-block-to-oil pan joint area (two locations). 61. Place the oil pan gasket onto the oil pan and place the oil pan into position on the engine. 62. Install all of the oil pan bolts. Tighten the small bolts to 100 in-lbs (11 N.m) and the large bolts to 200 in-lbs (22 N.m). 63. Install the oil pan drain plug. Tighten the drain plug to 25 ft-lbs (34 N.m). 64. Install the flywheel inspection cover. 65. Lower the vehicle. 66. Lower the engine/transmission assembly. 67. Remove the engine lift fixture. 68. Install the ground cable onto the thermostat housing. 69. Connect the heater hoses to the timing chain cover. 70. Install the generator (Figure 5). 71 Install the accessory drive belt idler pulley (Figure 5). Tighten the bolt to 30 ft-lbs (41 N.m). 72. Install the power steering pump assembly (Figure 5). Tighten the bolts to 200 in-lbs (22 N.m). 73. Install the crankshaft vibration damper using special tools # 8512-A, # 8698-1 and # 9055-1. If the original damper was damaged, install a new vibration damper (P/N 05159003AA). 74. Place the transmission in gear. 75. Install the vibration damper bolt and tighten it to 130 ft-lbs (176 N.m). 76. Install the crankshaft pulley. Tighten the crankshaft pulley bolts to 200 in-lbs (22 N.m). 77. Install the cooling fan module (Figure 4). 78. Install the coolant recovery bottle. 79. Connect the cooling fan module electrical connector and hydraulic lines (Figure 3). 80. Install the upper radiator hose. 81. Raise the vehicle. 82. Tighten the engine mount through bolts to 75 ft-lbs (102 N.m). 83. Install the sway bar-to-frame mounting bolts (Figure 2). Tighten the bolts to 45 ft-lbs (61 N.m). 84. Install the steering gear assembly (Figure 2). Tighten the mounting bolts to 235 ft-lbs (319 N.m). 85. Install the A/C compressor and bracket assembly. Tighten the fasteners to 200 in-lbs (22 N.m). 86. Install the oil cooler line to the timing chain cover (Figure 1). 87. Install the lower radiator hose. 88. Install a new oil filter (P/N 05281090). 89. Install the accessory drive belt by positioning the belt over all pulleys except the water pump pulley, then rotate tensioner counterclockwise and slip the belt over water pump pulley and gently release the tensioner. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1475 90. Install the cooling fan module power steering line retainer. 91 Install the power steering and cooling fan hydraulic lines (Figure 3). Tighten the return line to 52 ft-lbs (71 Nm), the pump-to-fan line to 275 in-lbs (32 N.m) and the pump-to-steering gear line to 325 in-lbs (37 N.m). 92. Install the front belly pan. Tighten the fasteners to 50 in-lbs (6 N.m). 93. Lower the vehicle. 94. Open the coolant bleeder valve. 95. Fill the engine with the original coolant until coolant bleeder valve has steady flow of coolant. Close the bleeder valve and install the radiator cap. 96. Fill the engine with 9 quarts of Mobil 1 10W30 Synthetic motor oil (P/N P5007324). 97. Install the air cleaner cover and air inlet tube. 98. Connect the negative battery cable. 99. Fill the power steering pump reservoir with Power Steering Fluid (ATF+4) (P/N 05013457AA). 100. Start the engine and ruin for 1 minute. 101. Turn the engine off. 102. Check all fluid levels after 5 minutes and top off as required. 103. Start the engine. 104. Remove air from steering system by using the DRBIII(R) (Scan Tool) to actuate cooling fan at 50% duty while slowly rotating the steering wheel lock to lock. 105. Turn the engine off and check all fluid levels after 5 minutes and top off as required. 106. Check for fluid leaks. Viper Repair Procedure 1. Place the vehicle on an appropriate hoist. 2. Open the trunk and pull back the carpet. 3. Remove the battery cover, disconnect the negative battery cable and isolate it. 4. Open the hood. 5. Remove the air cleaner assembly. 6. Drain the engine coolant via the radiator petcock. Filter and save the coolant for later reuse. 7. Remove the upper radiator hose. 8. Remove front strut tower to tower brace. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1476 9. Remove the accessory drive belt (Figure 11). 10. Remove the power steering pump (Figure 11). 11. Remove the generator (Figure 11). 12. Remove the heater hoses from the timing chain cover. 13. Raise the vehicle. 14. Drain the engine oil and remove the oil filter. Discard the filter. 15. Remove the flywheel inspection cover. 16. Remove the A/C compressor and mounting bracket assembly and then set it aside. Do not disconnect the refrigerant lines or discharge the A/C system. 17. Remove coolant hose from the thermostat housing. 18. Remove the A/C line retaining bolt at the oil pan. 19. Remove the four (4) bell housing-to-oil pan bolts. 20. Remove the oil pan bolts. 21. Carefully separate the oil pan from the oil pan-to-engine block gasket. Remove the oil pan leaving the gasket attached to the block. Do not remove the oil pan gasket. It can be reused, unless it is damaged. 22. Carefully cut the RTV between timing chain cover and the oil pan gasket. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1477 23. Remove the oil pick up tube (Figure 12). 24. Remove the left and right motor mount retaining nuts. 25 Temporarily install the oil pan for lifting engine. 26. Lower the vehicle. 27. Raise the engine with a floor jack (place wood between the jack and the oil pan). 28. Remove the crankshaft pulley. 29. Remove the crankshaft vibration damper using special tool # 1023 (puller) and special tool # 6827-A (insert). 30. Inspect the mating surfaces of the crankshaft and vibration damper. If there is evidence of the damper slipping on the crankshaft, polish the crankshaft with emery or crocus cloth and discard the vibration damper. 31. Remove the oil cooler line from the timing chain cover using special tool #9005 (Figure 13). 32. Remove the lower radiator hose from the front cover. 33. Remove the accessory drive belt tensioner. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1478 34. Remove the timing chain cover (Figure 14). 35. Remove the front crankshaft seal from the timing chain cover and discard the seal~ Use care to not damage the machined surfaces. 36. Inspect the three (3) camshaft sprocket bolts (Figure 15). 37. If any camshaft sprocket bolt is broken or missing, contact the STAR Center for further information. 38. If any camshaft sprocket bolts are loose but not broken, inspect the camshaft position sensor in the timing chain cover for damage. Remove and discard the sensor if it is damaged. 39. Rotate crankshaft to position the camshaft sprocket so that the raised front edge is at the upper (12 O'clock) position. 40. Snug the three (3) camshaft sprocket bolts (Figure 15) to 50 in-lbs (6 Nm) to ensure hard contact of the joint faces. 41. Tighten each camshaft sprocket bolt to 250 in-lbs (29 N.m) starting with the bolt opposite the dowel pin. Tighten the bolts in a clockwise pattern. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1479 42. In stall the timing chain cover onto the location dowels without the front crank seal installed (Figure 14). 43. In stall all timing chain cover bolts and tighten to 100 in-lbs (11 N.m) using the sequence shown in Figure 16, then using the same sequence, tighten the bolts to 200 in-lbs (22 N.m). 44. Using crank seal installation tool MD998306, install the front crankshaft seal to the proper depth (Figure 17). 45. If the camshaft position sensor was removed due to damage, slide a new sensor (P/N 05245084) into the timing chain cover sensor hole until it makes light contact with raised edge on the camshaft sprocket. Tighten the sensor retention bolt to 100 in-lbs (11 N.m). 46. Install the accessory drive belt tensioner and nut to the appropriate position and tighten to 30 ft-lbs (41 N.m). 47. Install the lower radiator hose onto the timing chain cover. 48. Install the oil cooler line onto the timing chain cover (Figure 13). 49. Install the crankshaft vibration damper using special tools # 8512-A, # 8698-1 and # 9055-1. If the original damper was damaged, install a new vibration damper (P/N 05159003AA). 50. Place the transmission in gear. 51. Install the vibration damper bolt and tighten it to 130 ft-lbs (176 N.m). 52. Install the crankshaft pulley. Tighten the crankshaft pulley bolts to 200 in-lbs (22 N.m). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1480 53. Lower the engine. 54. Raise the vehicle. 55. Install the left and right motor mount retaining bolts. 56. Clean any coolant and oil from the oil pan using MOPAR brake cleaner (P/N 04897150AB). 57. Inspect the oil pickup tube 0-ring (Figure 12). Install a new 0-ring (P/N 06032920) if it is damaged. 58. Install the oil pickup tube into the timing chain cover, seating the 0-ring (Figure 12). 59. Install oil pickup tube flange onto the timing chain cover (Figure 12). Tighten the bolt to 100 in-lbs (11 N.m). 60. Install the oil pickup tube main bearing stud nuts to secure the oil pickup tube strap (Figure 12). Tighten the nuts to 200 in-lbs (22 N.m). 61. Clean and inspect the oil pan gasket. Install a new oil pan gasket (P/N 05037163AC) if the original gasket was damaged. 62. Apply a 1/8" bead of Mopar RTV (P/N 04883971) to the timing chain cover-to-block-to-oil pan joint area (two locations) and to the rear main seal-to-block-to-oil pan joint area (two locations). 63. Place the oil pan gasket onto the oil pan and place the oil pan into position on the engine. 64. Install all of the oil pan bolts~ Tighten the small bolts to 100 in-lbs (11 N.m) and the large bolts to 200 in-lbs (22 N.m). 65. Install the oil pan drain plug. Tighten the drain plug to 25 ft-lbs (34 N.m). 66. Install the flywheel inspection cover. 67 Install the A/C line retaining bolt at the oil pan. 68. Install the coolant hose at thermostat housing. 69. Install the A/C compressor/bracket to the engine, tighten the fasteners to 200 in-lbs (22 N.m). 70. Lower the vehicle. 71. Install the heater hoses onto the timing chain cover. 72. Install the generator (Figure 11). 73. Install power steering pump (Figure 11) Tighten the fasteners to 200 in-lbs (22 N.m). 74. Install accessory drive belt (Figure 11) by positioning the belt over all pulleys except water pump pulley, then rotate tensioner counterclockwise and slip belt over water pump pulley and gently release tensioner. 75. Install the front strut tower to tower brace. 76. Install the upper radiator hose. 77. Install the air cleaner assembly. 78. Install and secure all electrical sensor connections. 79. Open the coolant bleeder valve. 80. Fill the engine with the original coolant until coolant bleeder valve has steady flow of coolant. Close the bleeder valve and install the radiator cap. 81. Fill the engine with 10 quarts of Mobil 1 10W30 Synthetic motor oil (P/N P5007324). 82. Connect the battery cable and install the battery cover. Place the trunk carpeting back into its proper position. 83. Verify the fluid level in the power steering pump. 84. Start the engine and run for 1 minute. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Gear/Sprocket: > D19 > Apr > 04 > Campaign - Engine Camshaft Sprocket Bolt Torque > Page 1481 85. Turn the engine off. 86. Check all fluid levels after 5 minutes and top off as required. 87. Check for fluid leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel System Pressure ......................................................................................................................... ............................................ 400 ± 34 kPa (58 ± 2 psi) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1486 Fuel Pressure: Testing and Inspection Test 1 - 2 SYMPTOM FUEL PRESSURE LEAK DOWN POSSIBLE CAUSES - Faulty fuel pump module - Fuel injectors(s) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1490 Idle Speed: Description and Operation The idle air control motor is mounted at the front right of the intake manifold. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. 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. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. 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. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications 8.3L - FIRING ORDER 1-10-9-4-3-6-5-8-7-2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1499 Firing Order: Mechanical Specifications Firing Order ......................................................................................................................................... ................................................ 1-10-9-4-3-6-5-8-7-2 The cylinders are number from front to rear as follows: - on the left bank - 1-3-5-7-9 - on the right bank - 2-4-6-8-10 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1507 Ignition Cable: Description and Operation Spark plug cables are sometimes referred to as secondary ignition wires, or secondary ignition cables. Plug cables are used only on the 5.7L V-8 engine. The spark plug cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of non metallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Plug cables are used only on the 5.7L V-8 engine. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1508 Ignition Cable: Service and Repair REMOVAL Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. 1. Release the fuel pressure. 2. Disconnect the negative battery cable. 3. Remove the air cleaner assembly. 4. Remove the Intake Manifold, refer to the Engine/Manifolds/Intake Manifold for more information. 5. Use the following procedure when removing the high tension cable from the spark plug. Grasp the terminal as close as possible to the spark plug. Rotate the cover boot 1/2 turn slightly and pull straight up in a steady motion.Do not use pliers and do not pull the cable at an angle. Doing so will damage the insulation, cable terminal or the spark plug insulator. Wipe spark plug insulator clean before reinstalling cable. 6. Remove spark plug cable from coil first. 7. Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. INSTALLATION Install cables into the proper engine cylinder firing order sequence. Refer to Specifications. When replacing the spark plug and coil cables, route the cables correctly and secure them in the proper retainers. Failure to route the cables properly may cause the radio to reproduce ignition noise. It could also cause cross-ignition of the plugs, or, may 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. Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. The system uses two epoxy filled coil packs mounted on engine block post in the valley under the intake manifold. The rear coil pack, contains 3 separate coils and fires cylinders 1, 2, 3, 4, 6, and 7. The front coil pack, contains 2 individual coils and fires cylinders 5, 8, 9, and 10. NOTE: When replacing the spark plug and coil cables, route the cables correctly and secure them in the proper retainers. Failure to route the cables properly may cause the radio to reproduce ignition noise. It could also cause cross-ignition of the plugs, or, may short-circuit the cables to ground. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1509 1. Install wire separator clip on double ended stud on rear of engine block first. This is the wire separator clip closest to the ignition coil insulator boots. 2. Connector coil insulator boots over respective ignition coil side post. Take care to match cylinder number on ignition coil with cylinder number on ignition cables. Also, make sure to hear the audible click while making the connection to the coil post. 3. Sequentially install wires into separators clips mounted on double ended studs mounted on the outer side of valve cover and and. Start from the rear and work forward to the front of the engine. 4. After installing all wires into separator clips, install spark plug insulator boots over respective spark plugs sequentially from back of engine towards the front of engine. Make sure to hear the audible click during installation of spark plug boots. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1510 5. Install Intake Manifold. 6. Install Air Cleaner Assembly. 7. Connect the negative battery cable. 8. Use a diagnostic scan tool to pressurize the fuel system. Check for leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications > Page 1515 Spark Plug: Mechanical Specifications Gap Spark Plug Gap ................................................................................................................................... ....................................................... 0.033 to 0.038 in. Torque Spark Plug tightening torque ............................................................................................................... ...................................................... 27 Nm (20 ft.lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1516 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ................................................................. RC12ECC Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1517 Spark Plug: Description and Operation Resistor type spark plugs are used on all engines. Sixteen spark plugs (2 per cylinder) are used with 5.7L V-8 engines. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1518 Spark Plug: Testing and Inspection To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. Always use the recommended torque when tightening spark plugs. Incorrect torque can distort the spark plug and change plug gap. It can also pull the plug threads and do possible damage to both the spark plug and the cylinder head. 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. Replace spark plugs at the intervals recommended in the Lubrication and Maintenance section. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Spark plug resistance values range from 6,000 to 20,000 ohms (when checked with at least a 1000 volt spark plug tester). Do not use an ohmmeter to check the resistance values of the spark plugs. In accurate readings will result. NORMAL OPERATING 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 (.001 in) per 3200 km (2000 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 may be 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 CRASH ENCRUSTED Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1519 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 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 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1520 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 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1521 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 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 2000 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1522 Spark Plug: Adjustments CLEANING AND ADJUSTMENT The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. Adjust spark plug gap with a gap gauging tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Tighten water pump mounting bolts to ........................................................................................................................................ 40 Nm (30 ft. lbs.) torque. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1526 Water Pump: Description and Operation PUMP-WATER DESCRIPTION A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a single serpentine drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The housing has two small holes to allow seepage to escape. The water pump seals are lubricated by the antifreeze in the coolant mixture. No additional lubrication is necessary. OPERATION A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core, this coolant absorbs the heat generated when the engine is running. The pump is driven by the engine crankshaft via a drive belt. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1527 Water Pump: Testing and Inspection DIAGNOSIS AND TESTING - WATER PUMP A quick test to determine if pump is working is to check if heater warms properly. A defective water pump will not be able to circulate heated coolant through the long heater hose to the heater core. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1528 Water Pump: Service and Repair WATER PUMP REMOVAL 8.3L ENGINE NOTE: The water pump on all models can be removed without discharging the air conditioning system (if equipped). The water pump on all gas powered engines is bolted directly to the engine timing chain case/ cover. On the 8.0L V-10 engine, a rubber O-ring (instead of 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 conditions of the thermal viscous fan drive. 1. Disconnect negative battery cable from battery. 2. Drain cooling system. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. 3. Remove windshield washer reservoir tank from radiator fan shroud. 4. Remove the four fan shroud mounting bolts at the radiator. Do not attempt to remove shroud from vehicle at this time. 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. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with a matching number or letter. 5. Remove radiator upper hose at radiator. 6. Remove accessory drive belt. 7. Remove the radiator lower hose at water pump. 8. Remove heater hose at water pump fitting. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1529 9. Remove the seven water pump mounting bolts. 10. Loosen the clamp at the water pump end of bypass hose. Slip the bypass hose from the water pump while removing pump from vehicle. Do not remove the clamp from the bypass hose. 11. Discard the water pump-to-timing chain/case cover O-ring seal. 12. Remove the heater hose fitting from water pump if pump replacement is necessary. Note position (direction) of fitting before removal. Fitting must be re-installed to same position. CAUTION: Do not pry the water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks. CLEANING Clean the gasket mating surface. Use caution not to damage the gasket sealing surface. INSPECTION Inspect the water pump assembly for cracks in the housing, water leaks from shaft seal, worn bearing or impeller rubbing either the pump body or timing chain case/cover. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1530 1. If water pump is being replaced, install the heater hose fitting to the pump. Tighten fitting to 16 Nm (144 inch lbs.) torque. After fitting has been torqued, position fitting as shown in. When positioning fitting, do not back off (rotate counterclockwise). Use a sealant on the fitting such as Mopar(R) Thread Sealant With Teflon. Refer to the directions on the package. CAUTION: This heater hose fitting must be installed to pump before pump is installed to engine. 2. Clean the O-ring mating surfaces at rear of water pump and front of timing chain/case cover. 3. Apply a small amount of petroleum jelly to O-ring. This will help retain O-ring to water pump. 4. Install water pump to engine as follows: Guide water pump fitting into bypass hose as pump is being installed. Install water pump bolts. Tighten water pump mounting bolts to 40 Nm (30 ft. lbs.) torque. 5. Position bypass hose clamp to bypass hose. 6. Spin water pump to be sure that pump impeller does not rub against timing chain case/cover. 7. Connect radiator lower hose to water pump. 8. Connect heater hose and hose clamp to heater hose fitting. 9. Install drive belt. 10. Position fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit. 11. Install fan shroud to radiator. Tighten bolts to 6 Nm (50 inch lbs.) torque. 12. Install fan blade/viscous fan drive assembly to water pump shaft. 13. Fill cooling system. 14. Connect negative battery cable. 15. Start and warm the engine. Check for leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Actuators and Solenoids - Cooling System > Hydraulic Cooling Fan Solenoid Valve > Component Information > Diagrams Solenoid-Radiator Fan (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity ................................................................................................................................. ............................................................. 20 qts. (19 L) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1540 Coolant: Fluid Type Specifications Mopar Antifreeze/Coolant 5 Year/102,000 Mile Formula HOAT (Hybrid Organic Additive Technology) P/N 05066386AA or equivalent. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Engine Coolant Coolant: Description and Operation Engine Coolant COOLANT DESCRIPTION ENGINE COOLANT WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. ETHYLENE-GLYCOL MIXTURES CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 year/100,000 Mile Formula (ethylene-glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37°C (-35°F). The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% 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. 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°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 percent ethylene-glycol freezes at 22°C (8°F). PROPYLENE-GLYCOL MIXTURES 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°C 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 or freeze-up on a cooling system 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 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. OPERATION Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Engine Coolant > Page 1543 Coolant: Description and Operation Hoat Coolant HOAT COOLANT WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE-GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/ fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/10O,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water - Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to --67.7°C (--90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. COOLANT SELECTION AND ADDITIVES The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. OPERATION Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Page 1544 Coolant: Testing and Inspection DIAGNOSIS AND TESTING COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C (-34°F) to -46°C (-50°F). The use of a hydrometer or a refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A refractometer Tool 8286 will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended. CAUTION: Do not mix types of coolant - corrosion protection will be severely reduced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation Coolant Reservoir: Description and Operation CONTAINER-COOLANT RECOVERY-GAS ENGINES DESCRIPTION The coolant reserve/overflow tank is mounted on top of the fan shroud, and is made of high temperature plastic. OPERATION The coolant reserve/overflow system works in conjunction with the radiator pressure cap. It utilizes thermal expansion and contraction of coolant to keep coolant free of trapped air. It provides a volume for expansion and contraction of coolant. It also provides a convenient and safe method for checking coolant level and adjusting level at atmospheric pressure. This is done without removing the radiator pressure cap. The system also provides some reserve coolant to the radiator to cover minor leaks and evaporation or boiling losses. As the engine cools, a vacuum is formed in the cooling system of both the radiator and engine. Coolant will then be drawn from the coolant tank and returned to a proper level in the radiator. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Page 1548 Coolant Reservoir: Service and Repair CONTAINER-COOLANT RECOVERY REMOVAL 8.3L ENGINE 1. Remove coolant recovery tube from radiator filler neck. 2. Remove coolant recovery container mounting bolt. 3. Remove coolant recover container. INSTALLATION 1. Position coolant recover bottle. 2. Install mounting bolt. Tighten bolt to 10 Nm (89 inch lbs.). 3. Route and connect coolant recovery tube to radiator filler neck. 4. Check coolant level. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1554 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1555 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1556 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1557 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1558 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1559 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1560 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1561 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1562 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1563 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1564 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1565 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1566 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1567 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1568 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1569 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1570 Radiator Cooling Fan Motor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1571 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1572 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1573 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1574 Radiator Cooling Fan Motor: Testing and Inspection ELECTRONICALLY CONTROLLED VISCOUS FAN DRIVE NOISE NOTE: It is normal for fan noise to be louder (roaring) when: Fan duty cycle high. This may occur when ambient (outside air temperature) is very high. - Engine loads and temperatures are high such as when towing a trailer. - Operating conditions where transmission temperatures may be high - 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation Fan Clutch: Description and Operation FAN DRIVE VISCOUS DESCRIPTION GAS ENGINES 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. OPERATION A thermostatic bimetallic 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. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Hydraulic Cooling Fan Solenoid Valve > Component Information > Diagrams Solenoid-Radiator Fan (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor / Switch HVAC > Component Information > Locations Left Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation Heater Core: Description and Operation The heater core is located in the HVAC housing, behind the instrument panel. It is a heat exchanger made of rows of tubes and fins. Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows through the heater core, heat is removed from the engine and is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The blend door allows control of the heater output air temperature by regulating the amount of air flowing through the heater core within the HVAC housing. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Page 1591 Heater Core: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Disassembly of the HVAC housing is not required to remove heater core. 1. Remove the HVAC housing. Refer to Housing Assembly HVAC/ Service and Repair/ Procedures. 2. Remove the foam seal from the heater core tubes. Heated Core - Dual Zone Shown, Single Zone Typical 3. If equipped with the Dual Zone system, remove the linkage rod from the actuator levers to gain access to the heater core. 4. Remove the two screws that secure the heater core tube bracket to the HVAC housing. 5. Remove the heater core tube bracket. 6. Pull the heater core out of the HVAC housing. 7. Inspect all foam seals and repair or replace them as required. INSTALLATION 1. Install the heater core into the HVAC housing. 2. Position the heater core tube bracket onto the HVAC housing. 3. Install the two screws that secure the heater core bracket to the HVAC housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 4. If equipped with the Dual Zone system, install the linkage rod onto the actuator levers. 5. Install the foam seal onto the heater core tubes. 6. Install the HVAC housing. Refer to Housing Assembly HVAC/ Service and Repair/ Procedures. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement Heater Hose: Service and Repair Heater Inlet Hose Replacement REMOVAL The heater inlet hose is constructed from rubber hoses and plastic hose connectors. The ends are secured to the heater core, engine and engine coolant reservoir (depending on engine application) by spring tension clamps. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Drain the engine cooling system. Heated Hoses - Typical 2. Remove the heater hose retaining brackets as required (depending on engine application). 3. Using spring tension clamp pliers, compress and slide the clamps off of each end of the hose being removed. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes/heater core, causing an engine coolant leak. 4. Disconnect each hose end by carefully twisting the hose back and forth on the tube, while gently pulling it away from the end of the tube. 5. If necessary, carefully cut the hose end and peel the hose off of the tube. NOTE: Replacement of the heater inlet hose will be required if the hose ends are cut for removal. 6. Remove the heater inlet hose from the engine compartment. 7. Separate the heater hoses from each other as required (depending on engine application). INSTALLATION 1. If separated, reconnect the heater hoses to each other as required (depending on engine application). 2. Position the heater inlet hose into the engine compartment. 3. Using spring tension clamp pliers, compress and slide each clamp away from the end of the hose being installed. 4. Install each hose by carefully twisting the hose back and forth while gently pushing it onto the tube end. 5. Using spring tension clamp pliers, compress and slide the clamps onto each end of the hose being installed. 6. Install the heater hose retaining brackets as required (depending on engine application). 7. Refill the engine cooling system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 1596 Heater Hose: Service and Repair Heater Return Hose Replacement REMOVAL The heater return hose is constructed from rubber hoses and plastic hose connectors. The ends are secured to the heater core, engine and engine coolant reservoir (depending on engine application) by spring tension clamps. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Drain the engine cooling system. Heated Hoses - Typical 2. Remove the heater hose retaining brackets as required (depending on engine application). 3. Using spring tension clamp pliers, compress and slide the clamps off of each end of the hose being removed. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes/heater core, causing an engine coolant leak. 4. Disconnect each hose end by carefully twisting the hose back and forth on the tube, while gently pulling it away from the end of the tube. 5. If necessary, carefully cut the hose end and peel the hose off of the tube. NOTE: Replacement of the heater return hose will be required if the hose ends are cut for removal. 6. Remove the heater return hose from the engine compartment. 7. Separate the heater hoses from each other as required (depending on engine application). INSTALLATION 1. If separated, reconnect the heater hoses to each other as required (depending on engine application). 2. Position the heater return hose into the engine compartment. 3. Using spring tension clamp pliers, compress and slide each clamp away from the end of the hose being installed. 4. Install each hose by carefully twisting the hose back and forth while gently pushing it onto the tube end. 5. Using spring tension clamp pliers, compress and slide the clamps onto each end of the hose being installed. 6. Install the heater hose retaining brackets as required (depending on engine application). 7. Refill the engine cooling system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower right quadrant of the instrument cluster, below the oil pressure gauge. The engine coolant temperature gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "C" (or Cold) to "H" (or Hot) for gasoline engines except SRT-10. On SRT-10 models, the scale reads from "60"° C to "120"° C in markets where a metric instrument cluster is specified, or from "140"° F to "260"° F in all other markets. On vehicles with a diesel engine, the scale reads from "60"° C to "120"° C in markets where a metric instrument cluster is specified, or from "140"° F to "245"° F in all other markets. An International Control and Display Symbol icon for "Engine Coolant Temperature" is located on the cluster overlay directly below the left end of the gauge scale. On all models except SRT-10 the engine coolant temperature gauge graphics are black against a white field except for two red graduations at the high end of the gauge scale. On SRT-10 the gauge graphics are black against a silver field except for a single red zone at the high end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black gauge graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives a message from the PCM or ECM indicating the engine coolant temperature is between the low end of normal [about 54° C (130° F) for gasoline engines except SRT-10, or about 60° C (140° F) for SRT-10 and diesel engines] and the high end of normal [about 122° C (252° F) for gasoline engines, about or about 116° C (240° F) for diesel engines], the gauge needle is moved to the actual relative temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives a message from the PCM or ECM indicating the engine coolant temperature is below the low end of normal [about 54° C (130° F) for gasoline engines except SRT-10, or about 60° C (140° F) for SRT-10 and diesel engines], the gauge needle is held at the graduation on the far left end of the gauge scale. The gauge needle remains at the left end of the gauge scale until the cluster receives a message from the PCM or ECM indicating that the engine temperature is above about 54° C (130° F) for gasoline engines except SRT-10, or about 60° C (140° F) for SRT-10 and diesel engines, or until the ignition switch is turned to the Off position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine coolant temperature is above about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, the gauge needle is moved into the red zone at the far right end of gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The gauge needle remains in the red zone and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine temperature is below about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled off and then on again by the appropriate engine temperature messages from the PCM or ECM. - Communication Error - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the engine coolant temperature gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. On vehicles with a diesel engine, the ECM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM or ECM then sends the proper engine coolant temperature messages to the instrument cluster. If the instrument cluster turns on the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the engine coolant temperature gauge, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation Radiator: Description and Operation RADIATOR DESCRIPTION The radiator is a aluminum cross-flow design with horizontal tubes through the radiator core and vertical plastic side tanks. This radiator does not contain an internal transmission oil cooler. OPERATION The radiator supplies sufficient heat transfer using the cooling fins interlaced between the horizontal tubes in the radiator core to cool the engine. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Page 1604 Radiator: Testing and Inspection DIAGNOSIS AND TESTING RADIATOR COOLANT FLOW Use the following procedure to determine if coolant is flowing through the cooling system. 1. Idle engine until operating temperature is reached. If the upper radiator hose is warm to the touch, the thermostat is opening and coolant is flowing to the radiator. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. USING A RAG TO COVER THE RADIATOR PRESSURE CAP, OPEN RADIATOR CAP SLOWLY TO THE FIRST STOP. THIS WILL ALLOW ANY BUILT-UP PRESSURE TO VENT TO THE RESERVE/OVERFLOW TANK. AFTER PRESSURE BUILD-UP HAS BEEN RELEASED, REMOVE CAP FROM FILLER NECK. 2. Drain a small amount of coolant from the radiator until the ends of the radiator tubes are visible through the filler neck. Idle the engine at normal operating temperature. If coolant is flowing past the exposed tubes, the coolant is circulating. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Page 1605 Radiator: Service and Repair RADIATOR REMOVAL 8.3L ENGINE 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. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. 1. Disconnect both battery negative cables. 2. Drain the cooling system. 3. Remove radiator fan. 4. Remove the power steering cooler mounting bolts (1) and pushpins (5). Position the power steering cooler out of the way. 5. Lower vehicle. 6. Remove the two radiator upper mounting bolts. 7. Lift radiator straight up and out of engine compartment. The bottom of the radiator is equipped with two alignment dowels that fit into holes in the lower radiator support panel. Rubber biscuits (insulators) are installed to these dowels. Take care not to damage cooling fins or tubes on the radiator and air conditioning condenser when removing. CLEANING Clean radiator fins are necessary for good heat transfer. The radiator and oil cooler fins should be cleaned when an accumulation of debris has occurred. With the engine cold, apply cold water and compressed air to the back (engine side) of the radiator to flush the radiator and/or oil coolers of debris. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Page 1606 INSPECTION Inspect the radiator side tanks for cracks, and broken or missing fittings. Inspect the joint where the tanks seam up to the radiator core for signs of leakage and/or deteriorating seals. Inspect radiator core for corroded, bent or missing cooling fins. Inspect the core for bent or damaged cooling tubes. INSTALLATION 1. Install rubber insulators to alignment dowels at lower part of radiator. 2. Lower the radiator into position while guiding the two alignment dowels into lower radiator support. Different alignment holes are provided in the lower radiator support for each engine application. 3. Install two upper radiator mounting bolts. Tighten bolts to 11.8 Nm (105 inch lbs.) torque. 4. Install radiator fan and shroud assembly. 5. Install the coolant recovery container. 6. Install upper radiator hose. 7. Raise vehicle. 8. Install pressure line to radiator fan motor. Tighten fitting to 47 Nm (35 ft. lbs.). 9. Install return line to radiator fan motor. Tighten fitting to 29 Nm (21 ft. lbs.). 10. Install lower radiator hoses. 11. Position power steering cooler on the radiator and tighten nuts to 10 Nm (90 inch lbs.). 12. Install cushion clamp (4) and pushpin (5). 13. Lower vehicle. 14. Install air box and inlet hose. Tighten clamps to 4 Nm (35 inch lbs.). 15. Fill cooling system. 16. Connect negative battery cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Page 1607 17. Fill power steering system. 18. Operate engine until it reaches normal temperature. Check cooling system and automatic transmission (if equipped) fluid levels. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation Radiator Cap: Description and Operation CAP - RADIATOR PRESSURE DESCRIPTION All cooling systems are equipped with a pressure cap. For 5.9L engines, the pressure cap is located on top of the radiator outlet tank. For all engines, the pressure cap is located on top of the coolant degas container. The cap releases pressure at some point within a range of 97-to-124 kPa (14-to-18 psi). The pressure relief point (in pounds) is engraved on top of the cap The cooling system will operate at pressures slightly above atmospheric pressure. This results in a higher coolant boiling point allowing increased radiator cooling capacity. The cap contains a spring-loaded pressure relief valve. This valve opens when system pressure reaches the release range of 97-to-124 kPa (14-to-18 psi). A rubber gasket seals the radiator filler neck. This is done to maintain vacuum during coolant cool-down and to prevent leakage when system is under pressure. OPERATION A vent valve in the center of the cap will remain shut as long as the cooling system is pressurized. As the coolant cools, it contracts and creates a vacuum in the cooling system. This causes the vacuum valve to open and coolant in the reserve/overflow container to be drawn through the recovery hose connecting the filler neck and reserve/ overflow container. If the vacuum valve is stuck shut, or the recovery hose is kinked, radiator hoses will collapse on cool down. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Cooling System Pressure Relief Testing Radiator Cap: Testing and Inspection Cooling System Pressure Relief Testing DIAGNOSIS AND TESTING RADIATOR CAP-TO-FILLER NECK SEAL The pressure cap upper gasket (seal) pressure relief can be tested by removing overflow hose from the radiator filler neck tube. Attach the hose of the pressure tester tool 7700 (or equivalent) to the tube. It will be necessary to disconnect hose from its adapter for the filler neck. Pump air into radiator. The pressure cap upper gasket should relieve at 69 to 124kPa (10 to 18 psi) and hold pressure at a minimum of 55 kPa (8 psi). WARNING: THE WARNING WORDS, "DO NOT OPEN HOT", ON RADIATOR PRESSURE CAP, ARE A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PREVENT SCALDING OR INJURY, RADIATOR CAP SHOULD NOT BE REMOVED WHILE SYSTEM IS HOT AND/OR UNDER PRESSURE. Do not remove the radiator cap at any time except for the following purposes: Check and adjust antifreeze freeze point. - Refill the system with new antifreeze. - Conducting service procedures. - Checking for vacuum leaks. WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT AT LEAST 15 MINUTES BEFORE REMOVING RADIATOR CAP. WITH A RAG, SQUEEZE RADIATOR UPPER HOSE TO CHECK IF SYSTEM IS UNDER PRESSURE. PLACE A RAG OVER CAP AND WITHOUT PUSHING CAP DOWN, ROTATE IT COUNTER-CLOCKWISE TO FIRST STOP. ALLOW FLUID TO ESCAPE THROUGH THE COOLANT RESERVE/OVERFLOW HOSE INTO RESERVE/OVERFLOW TANK. SQUEEZE RADIATOR UPPER HOSE TO DETERMINE WHEN PRESSURE HAS BEEN RELEASED. WHEN COOLANT AND STEAM STOP BEING PUSHED INTO TANK AND SYSTEM PRESSURE DROPS, REMOVE RADIATOR CAP COMPLETELY. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Cooling System Pressure Relief Testing > Page 1613 Radiator Cap: Testing and Inspection Radiator Cap Testing INSPECTION Hold cap at eye level, right side up. The vent valve at bottom of cap should closed. A slight downward pull on the vent valve should open it. If the rubber gasket has swollen and prevents vent valve from opening, replace cap. Hold cap at eye level, upside down. If any light can be seen between vent valve and rubber gasket, replace cap. A replacement cap must be the type designed for a coolant reserve/overflow system with a completely sealed diaphragm spring and a rubber gasket. This gasket is used to seal to radiator filler neck top surface. Use of proper cap will allow coolant return to red radiator. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Page 1614 Radiator Cap: Service and Repair RADIATOR CAP Remove the cap from the radiator. Be sure that the sealing surfaces are clean. Moisten the rubber gasket with water and install the cap on the pressure tester 7700 or an equivalent. Operate the tester pump to bring the pressure to 104 kPa (15 psi) on the gauge. If the pressure cap fails to hold pressure of at least 97 kPa (14 psi) replace the cap. Refer to the following CAUTION. The pressure cap may test properly while positioned on tool 7700 (or equivalent). It may not hold pressure or vacuum when installed on the radiator. If so, inspect the radiator filler neck and radiator cap's top gasket for damage. Also inspect for dirt or distortion that may prevent the cap from sealing properly. CAUTION: Radiator pressure testing tools are very sensitive to small air leaks which will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to tool. Turn tool upside down and recheck pressure cap to confirm that cap needs replacement. CLEANING Use only a mild soap and water to clean the radiator cap. Using any type of solvent may cause damage to the seal in the radiator cap. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor / Switch HVAC > Component Information > Locations Left Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower right quadrant of the instrument cluster, below the oil pressure gauge. The engine coolant temperature gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "C" (or Cold) to "H" (or Hot) for gasoline engines except SRT-10. On SRT-10 models, the scale reads from "60"° C to "120"° C in markets where a metric instrument cluster is specified, or from "140"° F to "260"° F in all other markets. On vehicles with a diesel engine, the scale reads from "60"° C to "120"° C in markets where a metric instrument cluster is specified, or from "140"° F to "245"° F in all other markets. An International Control and Display Symbol icon for "Engine Coolant Temperature" is located on the cluster overlay directly below the left end of the gauge scale. On all models except SRT-10 the engine coolant temperature gauge graphics are black against a white field except for two red graduations at the high end of the gauge scale. On SRT-10 the gauge graphics are black against a silver field except for a single red zone at the high end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black gauge graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives a message from the PCM or ECM indicating the engine coolant temperature is between the low end of normal [about 54° C (130° F) for gasoline engines except SRT-10, or about 60° C (140° F) for SRT-10 and diesel engines] and the high end of normal [about 122° C (252° F) for gasoline engines, about or about 116° C (240° F) for diesel engines], the gauge needle is moved to the actual relative temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives a message from the PCM or ECM indicating the engine coolant temperature is below the low end of normal [about 54° C (130° F) for gasoline engines except SRT-10, or about 60° C (140° F) for SRT-10 and diesel engines], the gauge needle is held at the graduation on the far left end of the gauge scale. The gauge needle remains at the left end of the gauge scale until the cluster receives a message from the PCM or ECM indicating that the engine temperature is above about 54° C (130° F) for gasoline engines except SRT-10, or about 60° C (140° F) for SRT-10 and diesel engines, or until the ignition switch is turned to the Off position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine coolant temperature is above about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, the gauge needle is moved into the red zone at the far right end of gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The gauge needle remains in the red zone and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine temperature is below about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled off and then on again by the appropriate engine temperature messages from the PCM or ECM. - Communication Error - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the engine coolant temperature gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. On vehicles with a diesel engine, the ECM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM or ECM then sends the proper engine coolant temperature messages to the instrument cluster. If the instrument cluster turns on the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the engine coolant temperature gauge, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications On all engines the thermostat is closed below ............................................................................................................................................... 195°F (90°C). Above this temperature, coolant is allowed to flow to the radiator. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1629 Thermostat: Description and Operation THERMOSTAT - ENGINE COOLANT DESCRIPTION 8.3L ENGINE The thermostat's primary purpose is to maintain engine temperature in a range that will provide satisfactory engine performance and emission levels under all expected driving conditions. OPERATION The thermostat is unique because the center does not open and close like a conventional thermostat; it works like a sliding sleeve. The outside sleeve moves, directing coolant flow through the engine block or through the bypass passages back to the water pump. During warm-up below 85°C (185°F), the thermostat is seated in the retracted position. This will allow the coolant to flow into the bypass passage, and back to the water pump. At 85°C (185°F) the thermostat begins to open, allowing coolant to flow through both the bypass and the radiator. At 97°C (207°F) the thermostat will fully open, blocking the path to the bypass, allowing all coolant to flow through the radiator. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1630 Thermostat: Testing and Inspection DIAGNOSIS AND TESTING THERMOSTAT ON-BOARD DIAGNOSTICS - GAS ENGINES All gasoline powered models are equipped with On-Board Diagnostics for certain cooling system components. Refer to On-Board Diagnostics (OBD) for additional information. See: Testing and Inspection/Symptom Related Diagnostic Procedures/Description of On-Board Diagnostics If the Powertrain Control Module (PCM) detects low engine coolant temperature, it will record a Diagnostic Trouble Code (DTC) in the PCM memory. Do not change a thermostat for lack of heat as indicated by the instrument panel gauge or by poor heater performance unless a DTC is present. The DTC can also be accessed through the DRBIII (R) scan tool. Refer to the appropriate Powertrain Diagnostic Procedures information for diagnostic information and operation of the DRBIII (R) scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1631 Thermostat: Service and Repair THERMOSTAT REMOVAL 8.3L ENGINE 1. Partially drain the cooling system below the thermostat level. 2. Disconnect throttle body air inlet hose, remove air cleaner housing assembly. 3. Disconnect upper radiator hose from thermostat housing. 4. Remove thermostat housing attaching bolts in the reverse order of the torque sequence. 5. Remove thermostat housing. 6. Remove thermostat from housing and discard thermostat housing gasket. INSTALLATION CAUTION: Do not use a metal scraper to clean aluminum sealing surfaces, as damage to surfaces may occur. Use only a plastic scraper and Mopar Brake Parts Cleaner or the equivalent. 1. Clean both sealing surfaces using a plastic scraper and Mopar(R) Brake Parts Cleaner or the equivalent. Take care not to scratch or gouge sealing surfaces. 2. Install new thermostat into thermostat housing. 3. Install new thermostat housing gasket. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1632 4. Install thermostat housing to chain case cover. 5. Tighten thermostat housing bolts in the sequence shown in to 11 Nm (95 inch lbs.). 6. Connect upper radiator hose to thermostat housing. 7. Install air cleaner housing assembly, connect throttle body air inlet hose. 8. Refill cooling system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Bolts - Thermostat Housing - All Except 5.9L Diesel ......................................................................................................................... 13 Nm (112 inch lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Tighten water pump mounting bolts to ........................................................................................................................................ 40 Nm (30 ft. lbs.) torque. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1639 Water Pump: Description and Operation PUMP-WATER DESCRIPTION A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a single serpentine drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The housing has two small holes to allow seepage to escape. The water pump seals are lubricated by the antifreeze in the coolant mixture. No additional lubrication is necessary. OPERATION A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core, this coolant absorbs the heat generated when the engine is running. The pump is driven by the engine crankshaft via a drive belt. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1640 Water Pump: Testing and Inspection DIAGNOSIS AND TESTING - WATER PUMP A quick test to determine if pump is working is to check if heater warms properly. A defective water pump will not be able to circulate heated coolant through the long heater hose to the heater core. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1641 Water Pump: Service and Repair WATER PUMP REMOVAL 8.3L ENGINE NOTE: The water pump on all models can be removed without discharging the air conditioning system (if equipped). The water pump on all gas powered engines is bolted directly to the engine timing chain case/ cover. On the 8.0L V-10 engine, a rubber O-ring (instead of 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 conditions of the thermal viscous fan drive. 1. Disconnect negative battery cable from battery. 2. Drain cooling system. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. 3. Remove windshield washer reservoir tank from radiator fan shroud. 4. Remove the four fan shroud mounting bolts at the radiator. Do not attempt to remove shroud from vehicle at this time. 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. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with a matching number or letter. 5. Remove radiator upper hose at radiator. 6. Remove accessory drive belt. 7. Remove the radiator lower hose at water pump. 8. Remove heater hose at water pump fitting. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1642 9. Remove the seven water pump mounting bolts. 10. Loosen the clamp at the water pump end of bypass hose. Slip the bypass hose from the water pump while removing pump from vehicle. Do not remove the clamp from the bypass hose. 11. Discard the water pump-to-timing chain/case cover O-ring seal. 12. Remove the heater hose fitting from water pump if pump replacement is necessary. Note position (direction) of fitting before removal. Fitting must be re-installed to same position. CAUTION: Do not pry the water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks. CLEANING Clean the gasket mating surface. Use caution not to damage the gasket sealing surface. INSPECTION Inspect the water pump assembly for cracks in the housing, water leaks from shaft seal, worn bearing or impeller rubbing either the pump body or timing chain case/cover. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1643 1. If water pump is being replaced, install the heater hose fitting to the pump. Tighten fitting to 16 Nm (144 inch lbs.) torque. After fitting has been torqued, position fitting as shown in. When positioning fitting, do not back off (rotate counterclockwise). Use a sealant on the fitting such as Mopar(R) Thread Sealant With Teflon. Refer to the directions on the package. CAUTION: This heater hose fitting must be installed to pump before pump is installed to engine. 2. Clean the O-ring mating surfaces at rear of water pump and front of timing chain/case cover. 3. Apply a small amount of petroleum jelly to O-ring. This will help retain O-ring to water pump. 4. Install water pump to engine as follows: Guide water pump fitting into bypass hose as pump is being installed. Install water pump bolts. Tighten water pump mounting bolts to 40 Nm (30 ft. lbs.) torque. 5. Position bypass hose clamp to bypass hose. 6. Spin water pump to be sure that pump impeller does not rub against timing chain case/cover. 7. Connect radiator lower hose to water pump. 8. Connect heater hose and hose clamp to heater hose fitting. 9. Install drive belt. 10. Position fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit. 11. Install fan shroud to radiator. Tighten bolts to 6 Nm (50 inch lbs.) torque. 12. Install fan blade/viscous fan drive assembly to water pump shaft. 13. Fill cooling system. 14. Connect negative battery cable. 15. Start and warm the engine. Check for leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation CONVERTER - CATALYTIC DESCRIPTION WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. CAUTION: 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. The stainless steel catalytic converter body is designed to last the life of the vehicle. 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. Unleaded gasoline must be used to avoid contaminating the catalyst core. 50 State emission vehicles incorporate two mini catalytic converters located after the exhaust manifolds and before the inline catalytic converter. OPERATION The catalytic converter captures and burns any unburned fuel mixture exiting the combustion chambers during the exhaust stroke of the engine. This process aids in reducing emissions output. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 1648 Catalytic Converter: Service and Repair CONVERTER - CATALYTIC 8.3L ENGINE 1. Raise and support vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Disconnect oxygen sensor electrical connectors. 4. Remove LH exhaust pipe to manifold bolts (2), retainers and nuts (1). 5. Remove LH catalytic converter to muffler clamp nuts (4). 6. Rotate LH catalytic converters (6) from the muffler (5). 7. Remove RH exhaust pipe to manifold bolts (2), retainers and nuts (1). 8. Remove RH catalytic converter to muffler clamp nuts (4). 9. Rotate RH catalytic converter (3) from the muffler (5). 10. Remove clamps and nuts (4). 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. If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber mallet may indicate a damaged core. INSTALLATION 1. Make sure catalytic converters (3, 6) and mufflers (5) are free of burrs. 2. Insert RH catalytic converter (3) into muffler (5). 3. Make sure the alignment tang on the catalytic converter (3) seats in the alignment slot on the muffler (5). 4. Position the catalytic converter (3) to the exhaust manifold. Install and hand tighten bolts (2), retainers and nuts (1). 5. Insert LH catalytic converter (6) into muffler (5). 6. Make sure the alignment tang on the catalytic converter (6) seats in the alignment slot on the muffler (5). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 1649 7. Position the catalytic converter (6) to the exhaust manifold. Install and hand tighten bolts (2), retainers and nuts (1) 8. Check the exhaust system for contact with the body panels. A minimum of 25.4 mm (1.0 inch) is required between the exhaust system components and body/frame parts. Clearance between catalytic converter and frame is 15 mm (0.59 inch). Make the necessary adjustments, if needed. 9. Tighten catalytic converter to exhaust manifold bolts (2) to 20.3 Nm (15 ft. lbs.) torque. 10. Tighten the clamp nuts to 54.2 Nm (40 ft. lbs.) torque. 11. Lower the vehicle. 12. Start the engine and inspect for exhaust leaks. and exhaust system. Repair exhaust leaks as necessary. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Bolts-Exhaust Manifold to Cylinder Head-(8.3L) ............................................................................................................................... 22 Nm (195 inch lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe Exhaust Pipe: Service and Repair Exhaust Pipe PIPE EXHAUST 8.3L ENGINE 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Remove clamp nuts. 4. Remove exhaust pipe isolators. 5. Rotate the exhaust pipes to remove from the muffle. INSPECTION Discard rusted clamps, broken or worn supports and attaching parts. Replace a component with original equipment parts, or equivalent. This will assure proper alignment with other parts in the system and provide acceptable exhaust noise levels. INSTALLATION 1. Make sure exhaust pipe is free of any burrs. 2. Insert exhaust pipes into muffler. 3. Make sure alignment tang on exhaust pipes seat into alignment slot on muffler. 4. Install exhaust pipe insulators. 5. Position the exhaust pipe for proper clearance with the frame and underbody parts. A minimum clearance of 25.4 mm (1.0 inch) is required. 6. Tighten the clamp nuts to 54.2 Nm (40 ft. lbs.) torque. 7. Lower the vehicle. 8. Start the engine and inspect for exhaust leaks and inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe > Page 1657 Exhaust Pipe: Service and Repair Tailpipe TAILPIPE REMOVAL 8.3L ENGINE 1. Raise and support the vehicle. 2. Saturate the clamp nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Disconnect the exhaust tailpipe support insulators (3 and 5). 4. Remove clamps (4) and nuts. 5. Remove the exhaust tailpipes (6). INSPECTION Discard rusted clamps, broken or worn supports and attaching parts. Replace a component with original equipment parts, or equivalent. This will assure proper alignment with other parts in the system and provide acceptable exhaust noise levels. INSTALLATION 1. Position tailpipes (6) into muffler (2). 2. Make sure alignment tang on tailpipes (6) fully seat into alignment slots on muffler (2). 3. Install insulators (5). 4. Check the exhaust system for contact with the body panels. A minimum of 25.4 mm (1.0 inch) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 5. Tighten all clamp (4) nuts to 54.2 Nm (40 ft. lbs.) torque. 6. Lower the vehicle. 7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation Heat Shield: Description and Operation HEAT SHIELDS DESCRIPTION There are two types of heat shields used. One is stamped steel the other is molded foil sheets. The shields attach to the vehicle around the exhaust system to prevent heat from the exhaust system from entering the passenger area and other areas where the heat can cause damage to other components. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation > Page 1661 Heat Shield: Service and Repair HEAT SHIELDS REMOVAL 1. Raise and support the vehicle. 2. Remove the nuts or bolts holding the exhaust heat shield to the floor pan, crossmember or bracket. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation > Page 1662 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. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation > Page 1663 2. Tighten the nuts and bolts 11 Nm (100 inch lbs.). 3. Lower the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair MUFFLER REMOVAL 8.3L ENGINE 1. Raise and support the vehicle. 2. Saturate the clamp nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Remove exhaust pipes. 4. Saturate the clamp nuts with heat valve lubricant. Allow 5 minutes for penetration. 5. Disconnect the muffler hangers. 6. Remove muffler-to-catalytic converter clamp nuts. 7. Remove the muffler. INSTALLATION 1. Make sure catalytic converters are free of burrs. 2. Assemble muffler and clamps loosely to permit proper alignment of all parts. 3. Make sure alignment tangs on catalytic converters seat into alignment slots on mufflers. 4. Connect the muffler hangers. 5. Install exhaust pipes. 6. Check the exhaust system for contact with the body panels. A minimum of 25.4 mm (1.0 inch) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed.. 7. Tighten the clamp nuts to 54.2 Nm (40 ft. lbs.) torque. 8. Lower the vehicle. 9. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1674 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1675 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1676 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1677 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1678 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1679 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1680 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1681 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1682 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1683 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1684 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1685 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1686 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1687 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1688 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1689 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1690 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1691 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1692 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1693 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1694 Body Control Module: Electrical Diagrams Airbag System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1695 Premium Audio System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1696 Base Audio System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1697 Remote Radio Controls Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1698 PCI Bus Communication Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1699 PCM Communication - JTEC PCM Communication - NGC Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1700 ECM Communication - Diesel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1701 Door Ajar System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1702 Heated Mirror System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1703 Rear Window Defogger Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1704 Exterior Lights Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1705 Heating A/C System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1706 Horn System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1707 Instrument Cluster Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1708 Overhead Console Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1709 Power Door Locks Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1710 Telecommunications - Hands Free System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1711 Vehicle Theft Security System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1712 Wipers Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information SERVICING SUB-ASSEMBLIES Some components of the body system are intended to be serviced as an assembly only. Attempting to remove or repair certain system subcomponents may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures should be serviced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 1715 Body Control Module: Vehicle Damage Warnings ELECTRICAL TESTING PRECAUTIONS Before disconnecting any control module, make sure the ignition is "off". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description Body Control Module: Description and Operation System Description IDENTIFICATION OF SYSTEM The vehicle systems that are part of the "body" system are: - Airbag - Audio (with amplifier on premium systems) - Chime - Communication - Door Ajar System - Electrically heated system - Exterior lighting - Heating and A/C - Horn - Instrument Cluster - Interior Lighting - Memory Seat - Overhead Console - Power Door Lock/RKE - Power windows - Telecommunications (hands free phone) - Vehicle theft security system (VTSS) - Windshield Wiper and Washer SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 2004 DR consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI 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 information to perform its function. It will only respond to messages "addressed" to it through binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the communication section of this general information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 1718 Body Control Module: Description and Operation Functional Operation Airbag System The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end or side collisions. The system is most effective when used in conjunction with the seat belt system. On some models the ACM supports Seat Belt Tensioners, Passenger Airbag Off Switch, and others Impact Sensor. It may be necessary to use the DRBIII(R) to reconfigure the ACM to the vehicle equipment. The airbag control module (ACM) is an electronic module that monitors the airbag system for proper operation, stores diagnostic trouble code (DTCs), controls the airbag warning lamp and contains the sensor and actuator that is responsible for driver, passenger, and curtain airbag deployment. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTCs) to the technician through the DRBIII(R) via the PCI bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Electro/Mechanical Instrument Cluster (EMIC) from the ACM via the PCI bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the "run" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6-8 seconds. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds, then goes off, there is usually an intermittent problem in the system. 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 OR DEATH. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. The DR will have two Airbag Control Modules. Each ACM is specifically calibrated for one body type, light duty or heavy duty. To determine the body types the ACM monitors the PCI Bus for a message containing the complete VIN. The ACM uses the 6th digit of the VIN to identify the heavy duty or light duty vehicle. The 6th digit of the VIN will be a number 1 for light-duty vehicle and a 2, 3 or 4 for heavy-duty vehicle. If the PCI Bus VIN message 6th character matches the ACM body type, the VIN will be stored within 5.6 seconds after ignition on. After the VIN is stored, the ACM verifies PCI Bus VIN message within 2.6 seconds after the ignition is turned on. If two valid matching PCI Bus VIN messages are not received within 5.6 seconds the ACM will set a Missing Original VIN DTC. If the ACM and PCM module types, 6th character of the VIN, light-duty or heavy-duty do not match the Calibration Mismatch DTC will be set. CAUTION: Therefore, the practice of exchanging (swapping) airbag control modules, instrument clusters, powertrain control modules and other electronic modules in this vehicle with those removed from another vehicle must always be avoided. DRIVER AIRBAG The airbag protective trim cover is the most visible part of the driver side airbag system. 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. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and hybrid inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. CLOCKSPRING The clockspring is mounted on the steering column behind the steering wheel. This assembly consist of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wiring and the driver airbag, the horn, and the vehicle speed control switches if equipped. The clockspring must be properly centered when it is reinstalled on the steering column following any service procedure, or it could be damaged. The clockspring cannot be repaired and it must be replaced. PASSENGER AIRBAG When supplied with the proper electrical signal the passenger airbag inflator or inflators discharge the gas directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 1719 WARNING: THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE.BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. PASSENGER AIRBAG ON-OFF SWITCH The Passenger Airbag On-Off Switch allows the customer to turn the passenger airbag function ON or OFF. The OFF indicator will be illuminated whenever the switch is turned to the off position and for 2 seconds at ignition on for an indicator bulb test. The switch assembly is mounted in the center of instrument panel to make the OFF indicator visible to all front seat occupants. WARNING: TO AVOID PERSONAL INJURY OR DEATH, ALWAYS CHECK THE PASSENGER AIRBAG ON-OFF SWITCH POSITION BEFORE DRIVING THE VEHICLE. A SWITCH IN THE WRONG POSITION INCREASES THE RISK OF SERIOUS INJURY OR DEATH IN A COLLISION. To operate, insert the ignition key into the switch keyhole, push key in to release the internal plunger, and rotate to the desired switch position. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. The ignition key is the only key or object that should ever be inserted into the switch. NOTE: Do not turn the On-Off switch with the ignition on. The ACM continuously monitors the resistance of the Passenger Airbag On-Off Switch circuits to identify the switch position and provide circuit diagnostics. The on-off switch ON position resistance is 175 to 190 ohms and the OFF position resistance is 820 to 870 ohms. If the on-off switch circuits are open, shorted to ground or battery the ACM will set active and stored DTC. Upon receiving a switch diagnostic trouble code the airbag warning indicator, in the instrument cluster, will be turned on by the ACM. Whenever the airbag warning indicator is illuminated, the ACM should be the first module interrogated. SEAT BELT TENSIONER Front seat belt systems incorporate Tensioner Modules (SET). At the onset of an impact event each tensioner uses a pyrotechnic device, which is triggered simultaneously with the airbags, to rapidly retract the seat belts. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. The ACM module monitors the Seat Belt Tensioners circuit resistance and reports active and stored DTC's if any problem is found. SIDE IMPACT SENSORS The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration and when combined with the ACM Accelerometer provides verification of the direction and severity of a side impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Airbag Control Module. The ACM microprocessor continuously monitors all of the passive restraint system electrical circuits to determine the system readiness. If the ACM detects a system fault, it sets a Diagnostic Trouble Code and controls the airbag warning indicator operation accordingly. The side impact sensors receive battery current and ground through dedicated driver and passenger sensor signal and ground circuits from the ACM. The impact sensors and the ACM communicate by modulating the current in the sensor signal circuit. If the sensor is dropped it must be replaced. Disconnect the battery or remove both airbag fuses before servicing impact sensors. CAUTION: Do not remove or install the impact sensors while the sensor is attached to the vehicle wiring. CURTAIN AIRBAGS The Left and Right curtain airbags are located in the outboard edge of the roof under the headliner, just above the door openings. When supplied with the proper electrical signal the inflator can discharge the compress gas directly into the curtain airbag. Upon deployment, the curtain will tear open the headliner allowing the curtain airbag to fully deploy between the headliner and seat. The curtain airbag cannot be repaired and must be replaced if deployed or in any way damaged. WARNING: THE CURTAIN AIRBAG CONTAINS AN INERT GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 1720 SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. SPECIAL TOOLS Some airbag diagnostic test use special tools, airbag load tools, 8310 and 8443 for testing squib circuits. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of an Driver or Passenger Airbag, curtain airbag, clockspring, or seat belt tensioner (use a jumper if needed). Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective component has been removed from the system and should be replaced. If the DTC is still active, continue this process until all component in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed the squib wiring can be tested for open and shorted conditions. AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRBIII(R). Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. ACTIVE CODES The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. STORED CODES Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned off. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. Maintain a safe distance from all airbags while performing the following inspection. If no obvious problems are found, erase stored codes, and with the ignition "on" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Audio System The factory installed radio receiver communicates on the Programmable Communication Interface (PCI) data bus network. The PCI Bus inputs into the Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 1721 radio are used for VF dimming and remote steering wheel controls. All the radios are capable of displaying faults and allowing certain actuation tests through the use of the DRBIII(R). When attempting to perform PCI Bus diagnostics, the first step is to identify the radio in use in the vehicle. When trouble shooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term output refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio, or wiring could be at fault. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit, A faulty speaker could not cause this DTC. REMOTE RADIO CONTROLS These radios can be controlled via remote radio switches (optional). These switches are located on the back side of the steering wheel. They control mode, preset, seek up, seek down, volume up and volume down functions. These functions are inputs to the Instrument Cluster (MIC) and can be read with the DRBIII(R). The switches are a multiplexed signal to the MIC. The radio control MUX circuit is a 5 volt line that is pulled to ground through different value resistors built into the switches. This causes a voltage drop to be seen by the MIC and it sends a specific message to the radio on the PCI Bus circuit. The radio then responses to the message. This circuit is fairly simple to troubleshoot. The circuit must be complete from the switches in the steering wheel to the MIC. The ground must be complete so that the switches can cause the voltage drop for the MIC to see. The circuit passes through the clockspring so continuity through this devise must be verified. AMPLIFIER (PREMIUM SYSTEM) The Premium Audio Amplifier uses a microprocessor for audio digital signal processing (DSP) and system diagnostics. DSP provides a more accurate and consistent match of the audio system equalization to the vehicle interior. The DR Ram amplifier has six channels for superior sound quality. The amplifier reads the VIN from the PCI bus and sets itself to match the vehicle. The amplifier will send four beeps to the vehicle speakers at ignition on, if it does not read the VIN correctly. A replacement amplifier may beep at the first power up, but if these beeps are heard after the first ignition on, the DRBIII(R) should be used to verify the amplifier is connected to the PCI bus and that the VIN on the PCI bus is correct. The amplifier, wiring to the speakers and the speakers work independently from the radio. The amplifier's microprocessor supports several diagnostic functions. Tests can be run from the DRBIII(R) that will help in diagnosing audio system problems. The DRBIII(R) can display fault messages when an input or output problem to the amplifier is detected. The amplifier can detect wiring shorts and suggest which wires are likely to be shorted. The amplifier can send test signals that can be used to verify that the amplifier, speakers, and wiring to the speakers are operating properly. The amplifier can also be used to test if the radio is sending audio signals to it. The DRBIII(R) can be used to verify the amplifier equalization setting matches the vehicle, in case there is a sound quality complaint. Using the DRBIII(R) audio system diagnostics can determine the nature of the problem. Diagnostic tests the Amplifier can perform through the DRBIII(R): Continuous Tone Test - This test will send a continuous tone to each speaker and will verify the integrity of an individual channel. PCI Amplifier Test - This test will detect a PCI bus or checksum failure. Input Test - This test will detect the activity on the amplifiers input channels from the radio. Speaker Output Test - This test will detect the activity on the amplifiers output channels to the speakers NAVIGATION RADIO The optional navigation radio system receives GPS signals from up to eight satellites to display the position and direction of the vehicle. Map information is supplied through a DVD-ROM. An electronic gyrosensor and the vehicle's speed sensor enable the system to display the present vehicle position even in locations where GPS signals may be blocked. When a destination is selected, the navigation system uses information from the map to quickly calculate a route. As the vehicle is driven along the chosen route, the operator is guided with pictorial displays and voice prompts. For complete operating instructions, refer to the manual included with the vehicle. Communication The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25. Additional tracer colors may be added to the violet in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on this vehicle: - Front Control Module - Airbag Control Module - Controller Antilock Brake Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 1722 - A/C Heater Control Module - Powertrain Control Module (gas only) - Engine Control Module (diesel only) - Radio - Amplifier (if equipped) - Hands Free Module - Transfer Case Control Module (if equipped) - Sentry Key Immobilizer Module - Compass Mini-Trip Computer (if equipped) - Electro/Mechanical Instrument Cluster Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRBIII(R) lab scope. The 12v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open PCI circuit at the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: - All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - Dashed lines in the overhead console ambient temperature display - No response received from any module on the PCI bus (except the ECM/PCM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRBIII(R). Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRBIII(R). If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRBIII(R) may display "BUS ± SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRBIII(R) and in noway indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 1723 NOTE: The 2004 DR 3.7L, 4.7L, and 5.7L vehicles are equipped with the Powertrain Control Module and Transmission Control Module combined in a single control module. This module is the Next Generation Controller (NGC) for DaimlerChrysler and will be referred to as the Powertrain Control Module (PCM). The PCM has four color coded connectors C1/A through C4/D, (C1/A BLK, C2/B - ORANGE, C3/C - WHITE, C4/D -GREEN), with each connector containing 38 pins. The 5.9L Electronic Fuel Injection 24 valve Turbo Diesel has an Engine control module (ECM) CM845. New Diagnostic procedures and New DTC numbers are two of the changes you will see which reflect the new combined module technology. There are new Verification tests and module replacement procedures for the new PCM. Two tools are required to diagnose and repair the PCM terminals and harness connectors: 1. Miller #3638 Terminal Removal Pick must be used to release the connector terminals or harness and connector damage will occur. 2. Miller #8815 Pinout Box must be used to probe the PCM terminals or terminal damage will occur. Door Ajar System The door ajar state is used as an input for various control modules on the vehicle. The DRBIII(R) will display the state of the door ajar switches in Inputs/ Outputs. It's important to note, that when a door is closed, the switch state on the DRBIII(R) will show OPEN, and when the door is open, the switch state will show CLOSED. During diagnosis, if a door is closed and the DRBIII(R) displays the switch state as CLOSED, it indicates a shorted Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 1724 door ajar circuit. If the door is open and the DRBIII(R) displays the switch state as OPEN, it indicates an open door ajar circuit. Compass Mini-Trip Computer (CMTC) When equipped, the Compass/Mini Trip Computer (CMTC) is located in the overhead console. The CMTC supplements the standard vehicle instrumentation. The CMTC uses a vacuum fluorescent (VF) display to supply the vehicle operator with a compass heading, outdoor temperature, average fuel economy, distance to empty, trip odometer, and elapsed ignition on time. If equipped, the CMTC is also available with an integrated Universal Garage Door Opener (UGDO) known as "HomeLink ■. The CMTC function buttons are labeled C/T, RESET, STEP, and US/M. The three UGDO buttons are labeled with dots to indicate the channel number. Most of the CMTC display information is received over the PCI bus. The CMTC sends and receives data over the PCI bus, communicating with the FCM (Diesel), PCM (3.7L, 4.7L, 5.7L), and the Instrument Cluster. VEHICLE INFORMATION DISPLAY The CMTC provides the following functions: - Compass direction - Outside temperature - Elapsed ignition on time - Distance to empty - Average fuel economy - Trip Odometer The CMTC will not display information for any of the screens for which it did not receive the proper PCI bus data. Refer to the symptom list in the Overhead Console section for problems related to the CMTC. The CMTC receives the following messages from the Instrument Cluster: - Verification of US/Metric status - VF display dimming brightness and exterior lamp status - Trip Odometer data The CMTC receives the following message from the PCM: - Vehicle Speed US/M BUTTON The US/M button is used to toggle the display between English and Metric measurement units. STEP BUTTON The STEP Button can be used in one of the following ways: 1. To sequentially select one of 4 displays or blank display in the following order: - Average Fuel Economy - Distance to Empty - Trip Odometer - Time Elapsed . Off (Blank) 2. To set the magnetic variance zone when VARIANCE = X (X = 1 - 15) is indicated in the VF display. RESET BUTTON The RESET Button has two different functions: 1. To clear the trip functions that may be reset 2. To enter and exit the diagnostic mode Pressing the RESET button once will clear the trip function that is currently being displayed and the CMTC will send a PCI bus beep request to the Instrument Cluster. If the RESET button is pressed again within 3 seconds, the CMTC will reset ALL of the trip functions and an additional beep request is sent to the Instrument Cluster. The trip functions that may be reset are: - Average Fuel Economy - Trip Odometer - Elapsed Time A reset will only occur if one of the trip functions that may be reset is currently being displayed. The CMTC module will send a beep request to the Instrument Cluster. Simultaneously pressing the RESET button and the C/T button while turning the ignition from Off to On will enter the CMTC into the self-diagnostic mode. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 1725 COMPASS/TEMPERATURE (C/T) BUTTON Actuating the Compass/Temperature Button (C/T) will cause the CMTC to display the compass and temperature information. This function will operate from another traveler display. The CMTC simultaneously displays the compass reading and the outside temperature. Outside temperature information is received via the PCI bus from the FCM. The CMTC module internally senses and calculates the compass direction. TRAVELER DISPLAY FUNCTIONS Using the STEP button will change the CMTC between modes of operation and display the appropriate information according to data received from the PCI Bus. COMPASS OPERATION Upon ignition on, if the calibration information stored in the CMTC memory is within the normal range, the CMTC will perform in slow Auto-Cal mode. In slow Auto-Cal mode, the CMTC continuously compensates for the slowly changing magnetic field of the vehicle. The compass module detects changes in the vehicle magnetism and makes appropriate internal corrections to ensure proper displayed direction. However, if the calibration information stored in the CMTC memory is not within the normal range at ignition on, the CMTC will enter fast Auto-Cal. CAL is displayed along with the temperature. Auto activation of the fast Auto-Cal mode will also occur when the CMTC is subjected to high magnetic field strength levels, which cause all compass readings to be erroneous for a continuous period of five (5) minutes . During fast Auto-Cal, CAL will be displayed along with the temperature. Fast Auto-Cal can also be performed manually, by pressing and holding the RESET button for 10 seconds during the Compass/Temperature display mode. SETTING MAGNETIC ZONE VARIANCE Variance is the difference between magnetic North and geographic North. For proper compass function, the correct variance zone must be set. Refer to the Zone Variance map for the correct zone. Follow these steps to check or change the variance zone: - The ignition switch must be in the On position and the CMTC display must not be blank. - If the compass/temperature data is not currently being displayed, momentarily press and release the C/T button to display compass/temp information. - Press and hold the RESET button until VARIANCE = XX is displayed. The CMTC will display the variance zone stored in memory and the word VARIANCE. - Use the STEP button to select the proper variance zone number, 1 through 15. - After selecting the proper zone number, momentarily press and release the RESET button. The variance zone is then stored in the memory and the CMTC returns to normal operation. COMPASS CALIBRATION The compass module has 2 types of auto-calibration; slow-cal and fast-cal. Slow-cal ensures that during normal vehicle operation the compass performs auto-calibration functions to keep the compass sensors in their proper operating range. Whenever the ignition is On and the CMTC receives PC I bus data indicating that engine RPM is greater than zero, auto-calibration is performed continuously. If the calibration information stored in the compass module memory is not within the normal range after a power-up cycle, the compass will display CAL. The CMTC will enter into the fast-cal mode until calibration is complete. To enter the compass into Manual Calibration mode, perform the following steps: - Drive the vehicle to an area away from any large metal objects or overhead power lines. - Ensure that the proper variance zone is selected. See "Setting Magnetic Zone Variance." - The ignition switch must be in the On position and the CMTC display must not be blank. - Press the C/T button to view the Compass/ Temperature display. - Press and hold the RESET button until CAL is displayed, then release the button. - Drive slowly, less than 5 MPH (8KPH) in at least 1 complete 360-degree circle. - CAL will remain illuminated to alert the driver that the compass is in the calibration mode. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 1726 - After calibration is complete, CAL will turn off. If the compass appears blank, unable to be calibrated, or the compass displays false indications, the vehicle must be demagnetized. Refer to Compass Demagnetizing Procedure. SELF-CHECK DIAGNOSTICS The CMTC is capable of performing a diagnostic self check on its internal functions. CMTC diagnostics may be performed using a DRBIII(R) or by using the following procedure: 1. With the ignition switch in the OFF position, depress and hold the RESET and the C/T buttons. 2. Turn the ignition switch to the ON position. 3. Continue to hold both buttons until the software versions are displayed, then release the buttons. 4. All of the VFD segments will illuminate for 2-4 seconds. Check for segments that do not illuminate or illuminate all the time. 5. When the self-check is complete the CMTC will display one of the following messages: - PASS - FAIL - NO BUS 6. To exit the self-check mode, depress the RESET button or cycle the ignition switch and the CMTC will return to normal operation. If a Communication fault is displayed, refer to the symptom list. If a FAILED SELF TEST is displayed, the CMTC must be replaced. AMBIENT TEMPERATURE SENSOR The ambient air temperature is monitored by the FCM or the PCM and displayed by the CMTC. For Diesel equipped vehicles, the FCM receives a hardwire input from the ambient temperature sensor (ATS). For 3.7L, 4.7L and 5.7L equipped vehicles, the PCM receives the hardwire input from the ATS. The ATS is a variable resistor that operates on a 5-volt reference signal circuit hardwired from the FCM or PCM. The resistance in the ATS changes as the outside temperature rises or falls. The FCM or PCM senses the change in reference voltage through the ATS resistor. Based on the resistance of the ATS, the FCM or PCM is programmed to correspond to a specific temperature. The FCM or PCM stores and niters the ambient temperature data and transmits this data to the CMTC via the PCI Bus. The ATS cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. AMBIENT TEMPERATURE SENSOR FAULT CODES The outside temperature function is supported by the ambient temperature sensor (ATS), a signal and ground circuit hardwired to the FCM or the PCM, and the CMTC display. If the CMTC display indicates 54° C (130° F) or the ATS sense circuit is open, the temp display will be 54° C (130° F) to indicate an OPEN circuit condition. If the CMTC display indicates -40° C (-40° F) or the ATS sense circuit is shorted to ground, the temp display will be -40° C (-40° F) to indicate a SHORT circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the CMTC VFD can be tested. The ATS is supported by the FCM or PCM. Ambient Temperature Sensor DTCs will be recorded in the FCM or PCM. The ATS can be diagnosed using the following Sensor Test. Test the ATS circuits using the diagnostics in the Body Diagnostic Procedures Manual. If the CMTC passes the self test, and the ATS, the circuits, and PCI bus communications are confirmed to be OK, but the CMTC temperature display is inoperative or incorrect, replace the FCM or PCM as required. AMBIENT TEMPERATURE SENSOR TEST 1. Turn the ignition OFF. 2. Disconnect the ATS harness connector. 3. Measure the resistance of the ATS using the following min/max values: - 0° C (32° F) Sensor Resistance = 29.33 - 35.99 Kiloohms - 10° C (50° F) Sensor Resistance = 17.99 - 21.81 Kiloohms - 20° C (68° F) Sensor Resistance = 11.37 - 13.61 Kiloohms - 25° C (77° F) Sensor Resistance = 9.12 - 10.86 Kiloohms 30° C (86° F) Sensor Resistance = 7.37 - 8.75 Kiloohms - 40° C (104° F) Sensor Resistance = 4.90 - 5.75 Kiloohms The sensor resistance should read between these min/max values. If the resistance values are not OK, replace the Sensor. HOMELINK(R) UNIVERSAL TRANSMITTER If equipped, the HomeLink(R) Universal Transmitter is integrated into the overhead console. For added security it will operate home security systems that use coded signals known generically as Rolling Codes. The overhead console display provides visual feedback to the driver, indicating which HomeLink(R) transmitter channel button is being pressed. The HomeLink(R) can learn and store up to three separate transmitter radio frequency codes to operate garage door openers, security gates, and security lighting. The HomeLink ■ buttons are marked with one, two, or three dots. For complete information, refer to Universal Transmitter. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 1727 Electrically Heated Systems HEATED MIRROR RELAY A button located on the HVAC control head controls the Heated Mirror Relay, which is located in the IPM. The HVAC control will ground the Heated Mirror Relay Control circuit to energize this relay. The relay control circuit is continuously monitored for certain malfunctions that the HVAC will report as DTCs. Exterior Lighting System The Instrument Cluster monitors the Headlamp Switch and Multifunctions Switch on its MUX line. The Instrument Cluster sends a PCI bus message to the Front Control Module (FCM) to actuate the Headlamps ON when the ignition switch is ON and when an open or short failure occurs on the headlamps switch input circuit to the instrument cluster. If the exterior lamps are left ON and the ignition switch OFF for more than 5 minutes, the FCM will turn the exterior lamps off. This feature prevents the battery from being discharged when the Exterior Lamps have been left ON. Front Control Module The Front Control Module (FCM) is a microprocessor-based electrical control and interface center located in the engine compartment. When it is mated to the Power Distribution Center (PDC), it is referred to as the Integrated Power Module (IPM). The IPM, with its fuses and relays provides power and signal distribution throughout most of the vehicle. The FCM receives hardwired analog and resistor multiplexed inputs as well as digital electronic inputs from other electronic modules in the vehicle electrical system through its connection to the IPM and the Programmable Communications Interface (PCI) data bus network. Based on these inputs and programming, the FCM uses high side drivers to provide direct power feeds and low side drivers to provide relay control for some of the vehicle's most critical electrical systems. The FCM provides the following features: Controlled Feeds: - Brake lights - Headlamp power - Turn signals (front & rear) - Windshield washer pump motor Relay Controls - Adjustable pedals relay (when equipped) - Fog lamp relay (when equipped) - Horn relay - Park lamp relay - Trailer tow relays - Wiper on/off relay - Wiper high/low relay Electrical Inputs - Module battery supply - Power ground - Ignition switch RUN or START position status . PCI bus - Wiper park switch - Washer fluid level switch - Ambient Temperature sensor - Battery (+) connection detection CONTROLLED POWER FEEDS Headlamp Power The headlamp switch is a direct input to the instrument cluster which is sometimes known as the Cab Control Node (CCN). The instrument cluster sends a Programmable Communications Interface (PCI) bus message to the FCM informing it of a headlamp switch status change. The FCM then turns power on or off (depending on the bus message) to the headlamps through four "fuseless" circuits. These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied to each filament in a separate circuit. For vehicles equipped with Daytime Running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination levels. Washer Pump Motor The washer switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus message to the FCM informing it of a request to wash. The washer pump motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition, the FCM electronically protects the washer pump motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 1728 If the FCM receives a prolonged request to wash lasting 30 seconds or more, it will treat the request as a stuck switch condition and deactivate the washer pump motor. The FCM will not reactivate the washer pump motor until there is at least a two second break in the request to wash from the instrument cluster. RELAY CONTROLS Adjustable Pedals Relay If equipped, the adjustable pedals relay, when not activated, supplies fused battery power to the adjustable pedals switch. If the FCM receives a bus message that the vehicle is in reverse or that the cruise control is engaged, it will apply a ground to the adjustable pedals relay control circuit. The ground will activate the relay which will open the power circuit to the adjustable pedals switch The relay control circuit is continuously monitored for malfunctions which the FCM will report as DTCs. Fog Lamp Relay If equipped, the fog lamp switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to turn on the fog lamp relay. The fog lamp relay is then actuated by the FCM through low side control. This circuit is electronically controlled and continuously monitored for malfunctions. Horn Relay The Horn Relay, which is internal to the IPM, is controlled by the FCM through PCI bus messages from the instrument cluster. These bus messages will be sent when either the horn switch is pressed which is hard wired to the instrument cluster, panic mode is requested from the RKE or for vehicle theft security reasons (if equipped). The relay control circuit is continuously monitored for malfunctions that the FCM will report as DTCs. The park lamp switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the park lamp relay. The park lamp relay is then actuated through the low side control circuit. This circuit is electronically controlled and continuously monitored for malfunctions. Wiper High/Low Relay The wiper switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the wiper high/ low relay. The relay switches power between the low speed and high speed of the wiper motor. The wiper high/low relay is then actuated through the low side control circuit. This circuit is electronically controlled and continuously monitored for malfunctions. Wiper On/Off Relay The wiper switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the wiper on/off relay. The wiper on/off relay is then actuated through the low side control circuit. This relay switches power to the wiper high/low relay. This circuit is electronically controlled and continuously monitored for malfunctions. ELECTRICAL INPUTS Module Battery Supply 12 Volt input for all FCM functions except headlamp operation. Power Ground Ground source for all FCM functions Ignition Switch RUN or START Position Status 12 volt input to inform the FCM of the ignition switch status for related FCM functions. PCI Bus Approximately 7.5 volt input to allow the FCM to communicate with other modules on the PCI bus. Wiper Park Switch Ground input used to determine the park placement of the wipers. The ground is also used as feedback to the FCM to determine wiper operating mode. Washer Fluid Level Switch Ground input from the washer fluid level switch which closes when washer fluid is low. Battery (+) Connection Detection 12 volt supply used to monitor battery connection to the IPM. The battery connection to the IPM uses an internal switch to check integrity of the connection and that the Connector Positive Assurance (CPA) is engaged. If the CPA is not properly engaged, a voltage is sent to the FCM to be interpreted as an unseated connector which will set a Diagnostic Trouble Code (DTC). Heating & A/C System SYSTEM AVAILABILITY - Depending on the model, either a Single-Zone or Dual-Zone HVAC system is available in these vehicles. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 1729 SYSTEM CONTROLS The Heater Control Module: is fully addressable with the DRBIII(R). - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - controls heated mirror and EBL operation (if equipped). - controls electric door actuator operation. The A/C-Heater Control Module: is fully addressable with the DRBIII(R). - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - provides an A/C request to the Powertrain Control Module (PCM) over the PCI Bus when compressor operation is desired. - controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - controls heated mirror and EBL operation (if equipped). - controls electric door actuator operation. - A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C -Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. The Single-Zone HVAC system uses: one, two-wire electric blend door actuator. - two, two-wire electric mode door actuators. - one, two-wire electric recirculation door actuator. The Dual-Zone HVAC system uses: two, two-wire electric blend door actuators. - two, two-wire electric mode door actuators. - one, two-wire electric recirculation door actuator. SYSTEM REVISIONS The 2004 DR, HVAC system remains carryover from 2003. SYSTEM DIAGNOSTICS Fault detection is through active and stored Diagnostic Trouble Codes (DTCs) . DTCs are displayed by the DRBIII(R). Active DTCs are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTCs are those which occurred in the system since the A/C-Heater Control Module received the last "clear diagnostic info" message. The A/C Cooldown Test: is actuated with the DRBIII(R). - checks A/C system performance based on evaporator temperature sensor input. - will not run if ambient temperature is below 12.7° C (55° F). - will pass if the evaporator temperature drops 6.7° C (20° F) within two minutes of starting the test. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. - will cause the A/C mode switch status indicator to flash while the test is running. - If the test fails, the status indicator will continue to flash until either the test returns passed or the ignition key is cycled. It will also prevent the EBL mode switch status indicator from indicating EBL operating status. However, the EBL mode switch will continue to function in this state. The HVAC Door Recalibration function: is actuated with the DRBIII(R). - monitors for door span faults. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. - will cause the EBL mode switch status indicator to flash while the test is running. - If the test fails, the status indicator will continue to flash until either the test returns passed or the ignition key is cycled. It will also prevent the A/C mode switch status indicator from indicating A/C operating status. However, the A/C mode switch will continue to function in this state. The Actuator Circuit Test: is actuated with the DRBIII(R). - monitors for shorted actuator circuits. - allows service to easily diagnose and troubleshoot up to three simultaneous shorts. - supplements the continuous diagnostics on the actuator drive system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 1730 - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. When Performing The Actuator Circuit Test CAUTION: To ensure a proper diagnosis, repair all Short Too Complex messages first, all common door driver circuit related messages second, and all other door driver circuit related messages last. - The DRBIII(R) can display up to three Actuator Circuit Test messages at a time. After repairing each Actuator Circuit Test message, cycle the ignition switch, then rerun the Actuator Circuit Test to ensure no new messages exist. - The Short Too Complex message: indicates that a specific determination of which lines are shorted could not be made. - is caused by more than three drivers being shorted in the same direction. For example, four drivers all shorted to ground, or two or more drivers shorted with at least one driver shorted to ignition/battery and one driver shorted to ground. - Messages displaying: XXX Driver/Circuit Shorted to Ignition/ Battery will set on a per-driver basis. - XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. - the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together. - When the test returns passed, then troubleshooting should proceed to clearing faults and running the HVAC Door Recalibration system test as a final check of system health. Instrument Cluster The DR Instrument Cluster is a new type of control module that includes the hardware and software necessary to function as the cluster and the body control module. The Instrument Cluster houses the Speedometer, Tachometer, Fuel gauge, Coolant Temperature gauge, Oil Pressure gauge, and the Voltage gauge. The cluster positions all of the gauges using PCI bus messages received from the PCM. The cluster contains certain warning indicators, depending on engine type and options. Some of the indicators are hardwire inputs and some indicators are controlled via PCI bus messages. The warning chime tone generator is contained within the cluster. The cluster includes a vacuum fluorescent (VF) display for the PRNDL, Total and Trip Odometers. The VF will also display warning messages such as door ajar, low washer fluid level, engine hours, and no bus communications. The cluster has the ability to set and store DTCs, communicate on the PCI bus, display engine information, and display certain inputs using the DRBIII(R). The following systems are controlled either completely by the Instrument Cluster or in conjunction with other inputs received by hardwire or via the PCI bus: - Audible Warnings - Brake Lamp Control - Brake Transmission Shift Interlock (BTSI) - Cargo Lamp Control - Central Locking - Door Lock Inhibit - Enhanced Accident Response - Exterior Lighting Control - Exterior Lighting Fail-Safe - Heated Seat Control - Horn Control - Interior Lamp Control - Interior Lamps - Enhanced Accident Response - Interior Lamps Load Shedding - Lamp Out Indicator Control - Panel Lamps Dimming Control - Parade Mode - Power Locks - Remote Keyless Entry (RKE) - Remote Radio Switch Interface - Rolling Door Locks - Turn Signal and Hazard Warning Lamp Control - Vacuum Fluorescent Display Synchronization - Vehicle Theft Security System (VTSS) CAUTION: Instrument clusters used in this model automatically configure themselves for compatibility with the features and optional equipment in the vehicle in which they are initially installed. The instrument cluster is programmed to do this by embedding the Vehicle Identification Number (VIN) and other information critical to proper cluster operation in electronic memory. This embedded information is learned through electronic messages received from other electronic modules in the vehicle over the Programmable Communications Interface (PCI) data bus, and through certain hard wired inputs received when the cluster is connected to the vehicle electrically. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 1731 Once configured, the instrument cluster memory may be irreparably damaged and certain irreversible configuration errors may occur if the cluster is connected electrically to another vehicle; or, if an electronic module from another vehicle is connected that provides data to the instrument cluster (including odometer values) that conflicts with that which was previously learned and stored. Therefore, the practice of exchanging (swapping) instrument clusters and other electronic modules in this vehicle with those removed from another vehicle must always be avoided. Failure to observe this caution may result in instrument cluster damage, which is not reimbursable under the terms of the product warranty. Service replacement instrument clusters are provided with the correct VIN, and the certified odometer and engine hours values embedded in cluster memory, but will otherwise be automatically configured for compatibility with the features and optional equipment in the vehicle in which they are initially installed. DIAGNOSTIC SELF TEST The Instrument Cluster is capable of performing a Diagnostic Self Test. This self test can be initiated manually by depressing and holding the trip reset button while cycling the ignition from the Off to the On position. The self test can also be activated using the DRBIII(R). During the self test, all of the PCI bus indicators will be illuminated. The speedometer, tachometer, fuel gauge, oil pressure gauge, coolant temperature gauge, and voltage gauge will position at their calibration points. The VF display will illuminate all segments and also display the software version. The chime will sound. When the self test is complete, the cluster will return to normal operation. Turning the ignition to the Off position or the cluster detecting engine RPM greater than 0 (zero) will stop the self test. Interior Lighting The Instrument Cluster controls the Interior/ Courtesy Lamps. The Instrument Cluster activates the courtesy lamps when either a Dome Lamp switch is turned on or a door is opened. The Instrument Cluster also monitors the output of the Glove Box and Map lamps. The Cargo lamps are controlled by the Instrument Cluster, it receives an output message from the Headlamp switch to turn on the lamps. The Instrument Cluster provides battery protection by shutting down the interior lamps when a door or courtesy/map lamp is left on or open. Power Door Locks/Remote Keyless Entry The Instrument Cluster in response to the door lock switches or the RKE module directly controls the power door lock motors. The Instrument Cluster monitors the activation of the door lock motors and will set diagnostic trouble codes when there is an open or short condition. When there is a lock or unlock input from a switch or RKE command, the Instrument Cluster will activate the appropriate driver for 300 milliseconds. If a lock or unlock switch remains active, the request will be ignored until the switch transitions back to off. The lock switches are resistive multiplexed input devices hardwired to the Instrument Cluster. AUTOMATIC DOOR LOCKS The Instrument Cluster will automatically lock all the doors when the vehicle speed exceeds 15 MPH (24 KM/H), throttle position exceeds 10 percent and all the doors are closed. If a door is opened the Automatic Door Lock feature shall reset and the Instrument Cluster will lock the doors when the above conditions are met. This feature is programmable by the customer or the DRBIII(R). CENTRAL LOCKING/UNLOCKING The Instrument Cluster will lock all doors when the cylinder lock switch is activated in the "lock" position. When the Instrument Cluster receives an unlock command from the driver cylinder lock switch, it will unlock only that door. If the Instrument Cluster receives a second command within a 5-second period it will unlock all the remaining doors. The illuminated entry will activate during door unlock. DOOR LOCK INHIBIT When the key is in the ignition, in any position, and either front door is open, the door lock switches LOCK functions are disabled. The UNLOCK functions are still functional. This protects against locking the vehicle with the keys still in the ignition. The RKE transmitter will still lock the doors as usual. ENHANCED ACCIDENT RESPONSE Upon detection of an airbag deployment by way of the PCI bus, the Instrument Cluster shall: - Immediately disable the power door lock output - Unlock all doors by activating the door unlock output for approximately 300 milliseconds. - After actuating the door unlock output, allow the door lock motors to be activated if the door lock input has been inactive (not erratic) for 2 seconds since the reception of the airbag deployment message. Remote Keyless Entry The remote keyless entry (RKE) feature is used to control the power door locks and panic feature by using a remote transmitter (keyfob) and receiver located within the instrument cluster. The instrument cluster RKE feature controls the driver door unlock, all doors lock/unlock, horn chirp enabled/ disable, optical chirp enabled/disable, illuminated entry, the panic feature, initiate customer programming, and arming/disarming the Vehicle Theft Security System. When a valid lock message is received from the receiver, the instrument cluster will: - Arm the Vehicle Theft Security System (if equipped and all conditions are met). - Turn off the illuminated entry feature. - Activate the door lock motors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > System Description > Page 1732 - Transmit a PCI bus message to the FCM to perform horn chirp. When a valid unlock code is received from the receiver, the instrument cluster will: - Disarm the Vehicle Theft Security System (if equipped and previously set). - Activate the illuminated entry and cargo lamp. - Activate the driver door unlock motor (if customer programmed for driver door only unlock). - Transmit a PCI bus message to the FCM for optical chirp. Vehicle Theft Security System The Instrument Cluster controls the Vehicle Theft Security System (VTSS). When the VTSS is armed it will monitor the status of the ignition and door ajar switches. If the alarm is tripped it will sound the vehicles horn, flash the exterior lamps and the VTSS indicator located in the instrument cluster. The Instrument Cluster will enable the VTSS feature once it has received PCI bus messages from the Sentry Key Immobilizer Module and has also detected the driver cylinder lock switch being cycled to the lock/unlock position. Arming the system is accomplished following a normal exit sequence of removing the key from the ignition, opening the door pressing the power lock button to lock and closing the door, by using a cylinder lock switch or by pressing the RKE lock button. After all the doors are closed, the VTSS indicator will flash quickly for sixteen-seconds indicating the pre-arm process, after which it will flash at a slower rate indicating the system is armed. If during the pre-arm process a door is opened, the ignition is turned to the Run/Start position or if a RKE unlock button is pressed the system will exit the pre-arming process. Disarming can be accomplished with a RKE unlock, turning the ignition on with a valid Sentry key or unlocking the vehicle with a cylinder lock switch. The Alarming state will last for 18 minutes after which it will time out and return to the armed state. A tamper alert feature will alert the customer to the alarm being tripped while they were away upon returning to the vehicle by flashing the VTSS indicator for 30 seconds after the system has been disarmed. All of the switches for the VTSS system can be monitored using the DRBIII(R). The DRBIII(R) is also useful for a customer complaint of the alarm going off with no apparent reason by viewing the VTSS last alarm caused by display. Windshield Wipers/Washers The Instrument Cluster controls the wiper/ washer system. The instrument cluster receives a signal from the Multifunction Switch wipe position. The instrument cluster sends the message to the Front Control Module (FCM), sending the command to turn the wiper/washers on. Two relays, the High/Low relay and the On/Off relay also control the wipers. Both are located in the PDC or Integrated Power Module. Telecommunications HANDS FREE PHONE The vehicle telecommunications system consists of a Hands Free Module, Rear view Mirror, and a Blue-tooth Hands Free Profile enabled cell phone. The system allows vehicle occupants to use voice recognition technology to make, receive and screen phone calls without physically handling a cell phone. The system has a programmable phone book that can prevent the vehicle operator from becoming distracted searching for a specific number. Seven different wireless phones can be programmed to operate each individual system. Each of the seven phones is given a rank of priority when programmed. Incoming phone messages are transmitted to the vehicle occupants through the vehicles audio system when the ignition is on and the wireless phone is on. Upon receiving the signal from an incoming phone call, the vehicle audio system will fade out the current CD/DVD or radio output. The vehicle occupants are then directed to accept or reject the call. Outgoing audio messages are received through the microphone located in the rearview mirror then transmitted via hardwire to the Hands Free Module and finally transmitted through the wireless phone. Volume of the voice prompts and incoming conversation is controlled using the vehicles' radio audio controls and steering wheel controls if equipped. The rearview mirror contains a Phone Switch, Voice Recognition Switch and a microphone. The rear view mirror transmits these inputs via hardwired circuits to the Hands Free Module. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures Air Bag System Test 1 SYMPTOM AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES POSSIBLE CAUSES - Airbag warning indicator on without active trouble codes - Instrument cluster problems AM/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE this symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Amplifier Pretest Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1735 Test 1 SYMPTOM AMPLIFIER PRETEST POSSIBLE CAUSES - Amplifier pretest - No fault message displayed Any Station Preset Switch Inoperative Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Balance Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1736 Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure CD Eject Switch Inoperative Test 1 SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Equalizer Inoperative Test 1 SYMPTOM EQUALIZER INOPERATIVE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1737 TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure FF/RW Switch Inoperative Test 1 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure HOUR/MINUTE Switches Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1738 Test 1 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Pause/Play Switch Inoperative Test 1 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure PWR Switch Inoperative Test 1 SYMPTOM PWR SWITCH INOPERATIVE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1739 TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Scan Switch Inoperative Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Seek Switch Inoperative Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Set Switch Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1740 Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tape Eject Switch Inoperative Test 1 SYMPTOM TAPE EJECT INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1741 TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Chime Inoperative Test 1 SYMPTOM CHIME INOPERATIVE POSSIBLE CAUSES - Actuate chime with DRBIII(R) - Instrument cluster - chime inoperative Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1742 Test 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER DOOR OPEN KEY REMOVED POSSIBLE CAUSES - Key-in IGN SW status - Key-in ignition switch shorted - Key-in ignition SW sense short to ground - Instrument cluster Key In Ignition and Drivers Door Open Chime Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1743 Test 1 - 3 Test 4 - 5 SYMPTOM KEY IN IGNITION AND DRIVERS DOOR OPEN CHIME INOPERATIVE POSSIBLE CAUSES - Observe the key-in ignition switch status - Key-in ignition switch open - Key-in ignition switch ground circuit open - Key-in ignition switch sense circuit open - Instrument cluster - incorrect key-in ignition switch status Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1744 Vehicle Speed Warning Chime Problem Test 1 SYMPTOM VEHICLE SPEED WARNING CHIME PROBLEM POSSIBLE CAUSES - Incorrect country code programmed in instrument cluster - Instrument cluster Average Fuel Economy Inaccurate or Wrong Test 1 SYMPTOM AVERAGE FUEL ECONOMY INACCURATE OR WRONG POSSIBLE CAUSES - CMTC CMTC or EVIC Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1745 Test 1 - 3 SYMPTOM CMTC OR EVIC INOPERATIVE POSSIBLE CAUSES - Fused B(+) circuit open - Fused ignition switch output circuit open - Ground circuit open - Compass/mini-trip computer Compass Test Failure Test 1 SYMPTOM COMPASS TEST FAILURE POSSIBLE CAUSES - Compass/Mini-trip computer Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1746 Distance to Empty Inaccurate or Wrong Test 1 SYMPTOM DISTANCE TO EMPTY INACCURATE OR WRONG TEST NOTE This symptom is diagnosed using the test AVERAGE FUEL ECONOMY INACCURATE OR WRONG. POSSIBLE CAUSES - CMTC Elapsed Ignition on Time Inaccurate or Wrong Test 1 SYMPTOM ELAPSED IGNITION ON TIME INACCURATE OR WRONG TEST NOTE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1747 This symptom is diagnosed using the test AVERAGE FUEL ECONOMY INACCURATE OR WRONG. POSSIBLE CAUSES - CMTC Temperature Display Inaccurate or Inoperative Test 1 - 2 SYMPTOM TEMPERATURE DISPLAY INACCURATE OR INOPERATIVE POSSIBLE CAUSES - Ambient temperature sensor - Compass/Mini-trip computer Trip Odometer Inaccurate or Wrong Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1748 Test 1 SYMPTOM TRIP ODOMETER INACCURATE OR WRONG TEST NOTE This symptom is diagnosed using the test AVERAGE FUEL ECONOMY INACCURATE OR WRONG. POSSIBLE CAUSES - CMTC Driver Door Ajar Circuit Open Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1749 Test 1 - 4 SYMPTOM DRIVER DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Driver door ajar switch - Driver door ajar switch ground circuit open - Driver door ajar switch sense circuit open - Instrument cluster-driver door ajar open Driver Door Ajar Circuit Shorted to Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1750 Test 1 - 3 SYMPTOM DRIVER DOOR AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Driver door ajar switch shorted to ground - Driver door ajar switch sense circuit shorted to ground - Instrument cluster - driver door ajar shorted Left Rear Door Ajar Circuit Open Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1751 Test 1 - 4 SYMPTOM LEFT REAR DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Left rear door ajar switch - Left rear door ajar switch ground circuit open - Left rear door ajar switch sense circuit open - Instrument cluster - left rear door ajar open Left Rear Door Ajar Circuit Shorted to Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1752 Test 1 - 3 SYMPTOM LEFT REAR DOOR AJAR CIRCUIT SHORT TO GROUND POSSIBLE CAUSES - Left rear door ajar switch shorted to ground - Left rear door ajar switch sense circuit shorted to ground - Instrument cluster - driver door ajar shorted Passenger Door Ajar Circuit Shorted to Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1753 Test 1 - 3 SYMPTOM PASSENGER DOOR AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Passenger door ajar switch shorted to ground - Passenger door ajar switch sense circuit shorted to ground - Instrument cluster - passenger door ajar shorted Passenger Door Ajar CKT Open Test 1 - 4 SYMPTOM PASSENGER DOOR AJAR CKT OPEN POSSIBLE CAUSES - Passenger door ajar switch - Passenger door ajar switch ground circuit open - Passenger door ajar switch sense circuit open - Instrument cluster - passenger door ajar open Right Rear Door Ajar Circuit Open Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1754 Test 1 - 4 SYMPTOM RIGHT REAR DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Right rear door ajar switch - Right rear door ajar switch ground circuit open - Right rear door ajar switch sense circuit open - Instrument cluster - right rear door ajar open Right Rear Door Ajar Circuit Shorted to Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1755 Test 1 - 3 SYMPTOM RIGHT REAR DOOR AJAR CIRCUIT SHORT TO GROUND POSSIBLE CAUSES - Right rear door ajar switch shorted to ground - Right rear door ajar switch sense circuit shorted to ground - Instrument cluster - right rear door ajar shorted A/C Heater Control Illumination Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1756 Test 1 - 3 Test 4 SYMPTOM A/C - HEATER CONTROL ILLUMINATION INOPERATIVE POSSIBLE CAUSES - Check for instrument cluster (MIC) DTCs - Inoperative bulb(s) - A/C - heater control module - Panel lamps driver circuit open - Instrument cluster A/C Status Indicator Flashing Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1757 Test 1 - 2 Test 3 SYMPTOM A/C STATUS INDICATOR FLASHING POSSIBLE CAUSES - A/C cooldown test needs to be run - HVAC door recalibration needs to be run A/C Status Indicator Will Not Illuminate - A/C Heater Control Without EBL SW Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1758 Test 1 SYMPTOM A/C STATUS INDICATOR WILL NOT ILLUMINATE -- A/C - HEATER CONTROL WITHOUT EBL SW POSSIBLE CAUSES - HVAC door recalibration failed - A/C - Heater control module Blend/Mode/Recirc Door Operation Improper - Dual-Zone Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1759 Test 4 - 6 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1760 Test 7 - 8 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER - DUAL-ZONE POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTCs - Check for HVAC door recalibration fault messages - Mode door actuator(s)/linkage(s)/door(s) - Passenger blend door actuator/linkage/door - Driver blend door actuator/linkage/door - Recirculation door actuator/linkage/door Blend/Mode/Recirc Door Operation Improper - Single-Zone Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1761 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1762 Test 4 - 6 Test 7 SYMPTOM Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1763 BLEND/MODE/RECIRC DOOR OPERATION IMPROPER - SINGLE-ZONE POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTCs - Check for HVAC door recalibration fault messages - Mode door actuator(s)/linkage(s)/door(s) - Blend door actuator/linkage/door - Recirculation door actuator/linkage/door Blower Motor Inoperative Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1764 Test 4 - 8 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1765 Test 9 - 10 SYMPTOM BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - IPM fuse #4 - Blower motor feed circuit shorted to ground - Fused B(+) shorted to ground - Blower motor shorted to ground - Blower motor - Blower motor high driver circuit open - Ground circuit open - A/C - heater control module open - Blower motor feed circuit open - Fused B(+) circuit open - Ignition switch open Blower Motor Speeds Incorrect Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1766 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1767 Test 4 - 6 SYMPTOM BLOWER MOTOR SPEEDS INCORRECT POSSIBLE CAUSES - Blower motor driver circuit(s) shorted to ground - A/C - heater control module - Blower motor driver circuit(s) shorted to voltage - Blower motor driver circuits shorted together - A/C - heater control module - speeds incorrect - Blower motor driver circuit(s) open - Blower motor resistor block - open speed EBL Status Indicator Flashing Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1768 Test 1 - 2 Test 3 SYMPTOM EBL STATUS INDICATOR FLASHING TEST NOTE This symptom is diagnosed using the test A/C STATUS INDICATOR FLASHING. POSSIBLE CAUSES - A/C cooldown test needs to be run - HVAC door recalibration needs to be run HVAC System Test Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1769 Test 1 - 2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1770 Test 3 - 4 SYMPTOM HVAC SYSTEM TEST POSSIBLE CAUSES - Attempt to communicate with the PCM - Check for HVAC related DTCs in the PCM - Check for active HVAC DTCs and system test fault messages - Check for HVAC related DTCs in the PCM - Manual A/C system test Horn Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1771 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1772 Test 4 - 8 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1773 Test 9 - 11 SYMPTOM HORNS INOPERATIVE POSSIBLE CAUSES - Horn ground circuit open - Horn relay output circuit open - Horns - Instrument cluster - DTC present - Clockspring - Front control module - Fuse #45 - Horn switch - Horn switch ground - Horn switch sense open - Integrated power module All Gauges Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1774 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1775 Test 4 - 7 Test 8 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1776 SYMPTOM ALL GAUGES INOPERATIVE POSSIBLE CAUSES - No response - PCI BUS - PCI BUS - powertrain control module - PCI BUS - instrument cluster - Fused ignition switch output circuit (unlock/run) short to ground - Instrument cluster ground circuit open - Fused ignition switch output (run/start) circuit open - Fused ignition switch output (run/start) circuit short to ground - Fused ignition switch output (unlock/run) circuit open - Instrument cluster Any PCI Indicator Inoperative Test 1 - 4 SYMPTOM ANY PCI INDICATOR INOPERATIVE POSSIBLE CAUSES - Indicator message not received - No response - instrument cluster Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1777 - No response - PCI BUS - No response - PCI BUS - powertrain control module - Instrument cluster Brake Warning Indicator Always On Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1778 Test 4 - 5 SYMPTOM BRAKE WARNING INDICATOR ALWAYS ON POSSIBLE CAUSES - Brake fluid level switch - Brake fluid level switch sense circuit short to ground - Park brake switch - Park brake switch sense circuit short to ground - Control module - Instrument cluster Brake Warning Indicator Inoperative Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1779 Test 4 - 7 SYMPTOM BRAKE WARNING INDICATOR INOPERATIVE POSSIBLE CAUSES - Brake fluid level switch ground circuit open - Brake fluid level switch - Brake fluid level switch sense circuit open - Park brake switch - Park brake switch sense circuit open - Control module - Instrument cluster Fuel Gauge Inaccurate Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1780 Test 1 - 3 SYMPTOM FUEL GAUGE INACCURATE POSSIBLE CAUSES - DTC present - Instrument cluster - Fuel level sensor wiring - Fuel level sensor One Gauge Inoperative - Gas Engines Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1781 Test 1 - 2 SYMPTOM ONE GAUGE INOPERATIVE - GAS ENGINES POSSIBLE CAUSES - Powertrain control module DTCs - Intermittent condition - Instrument cluster PRNDL Not Displaying Correct Position (EATX Vehicles) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1782 Test 1 - 2 SYMPTOM PRNDL NOT DISPLAYING CORRECT POSITION (EATX VEHICLES) POSSIBLE CAUSES - DTC present - Instrument cluster - Intermittent condition Seat Belt Warning Indicator Always Off Test 1 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS OFF POSSIBLE CAUSES - Seat belt switch sense circuit short to ground - Instrument cluster Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1783 Seat Belt Warning Indicator Always Off - Standard Cab Test 1 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS OFF - STANDARD CAB POSSIBLE CAUSES - Seat belt switch sense circuit short to ground - Instrument cluster Seat Belt Warning Indicator Always on Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1784 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS ON POSSIBLE CAUSES - Seat belt switch - Seat belt switch ground circuit open - Seat belt switch sense circuit open - Instrument cluster Seat Belt Warning Indicator Always on - Standard Cab Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1785 Test 4 - 5 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS ON - STANDARD CAB POSSIBLE CAUSES - Fused ignition switch output (run-acc) circuit open - Seat belt tensioner reducer - Seat belt switch - Seat belt switch ground circuit open - Seat belt switch sense circuit open - Instrument cluster All Door Locks Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1786 Test 1 - 3 SYMPTOM ALL DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - DTC present - Fuse #22 open - Fuse B+ circuit open - Instrument cluster - open circuit Automatic (Rolling) Door Locks Inoperative Test 1 - 4 SYMPTOM AUTO (ROLLING) DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Check the door ajar switch status - With the DRB check for PCM DTC's - With the DRB enable auto door locks - Instrument cluster - auto door locks fail Cylinder Lock Switch Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1787 Test 1 - 3 Test 4 SYMPTOM CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Cylinder lock switch ground open - Cylinder lock switch MUX circuit open - Cylinder lock switch open - Instrument cluster - open Cylinder Lock Switch Will Not Arm and/or Disarm Alarm Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1788 Test 1 - 3 Test 4 SYMPTOM CYLINDER LOCK SWITCH WILL NOT ARM AND/OR DISARM ALARM TEST NOTE This symptom is diagnosed using the test CYLINDER LOCK SWITCH INOPERATIVE. POSSIBLE CAUSES - DTC present - Cylinder lock switch ground open - Cylinder lock switch MUX circuit open - Cylinder lock switch open - Instrument cluster - open Door Lock Inhibit Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1789 Test 1 SYMPTOM DOOR LOCK INHIBIT INOPERATIVE POSSIBLE CAUSES - Chime inoperative - Instrument cluster - door lock inhibit inoperative Left Doors Fail to Lock and Unlock - Quad Cab Test 1 - 4 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1790 Test 5 SYMPTOM LEFT DOORS FAIL TO LOCK AND UNLOCK - QUAD CAB POSSIBLE CAUSES - DTC present - Instrument cluster - door lock driver left doors open - Door unlock driver left doors wire open - Door lock driver left doors wire open - Door lock motor One Door Lock Motor Inoperative Test 1 SYMPTOM ONE DOOR LOCK MOTOR INOPERATIVE POSSIBLE CAUSES - Door lock motor open - Check door lock motor circuit Right Doors Fail to Lock and Unlock - Quad Cab Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1791 Test 1 - 4 Test 5 SYMPTOM RIGHT DOORS FAIL TO LOCK AND UNLOCK - QUAD CAB POSSIBLE CAUSES - DTC present - Instrument cluster - door lock driver right doors open - Door unlock driver right doors wire open - Door lock driver right doors wire open - Door lock motor RKE Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1792 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1793 Test 4 - 6 SYMPTOM RKE INOPERATIVE POSSIBLE CAUSES - Test transmitter with tester - RKE transmitter not programmed - DTC present - Transmitter not programmed - Substitute transmitter - Remote keyless entry module - RKE open - RKE module Alarm Trips On Its Own Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1794 Test 1 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSES - DRB display last VTSS cause - Intermittent condition Driver Door Does Not Trip VTSS Test 1 - 3 SYMPTOM DRIVER DOOR DOES NOT TRIP VTSS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1795 POSSIBLE CAUSES - Driver door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Headlamps Fail to Flash When Alarm Is Tripped Test 1 SYMPTOM HEADLAMPS FAIL TO FLASH WHEN ALARM IS TRIPPED POSSIBLE CAUSES - FCM DTCs or exterior lamp operation - Instrument cluster Horn Fails to Sound When Alarm Is Tripped Test 1 - 2 SYMPTOM HORN FAILS TO SOUND WHEN ALARM IS TRIPPED POSSIBLE CAUSES - DTC present - Horn circuit - Instrument cluster - VTSS Left Rear Door Does Not Trip VTSS (4 Door) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1796 Test 1 - 3 SYMPTOM LEFT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Passenger Door Does Not Trip VTSS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1797 Test 1 - 3 SYMPTOM PASSENGER DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Right Rear Door Does Not Trip VTSS (4 Door) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1798 Test 1 - 3 SYMPTOM RIGHT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSES - Passenger door ajar circuit malfunction - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster VTSS Will Not Arm Properly Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1799 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1800 Test 4 - 8 SYMPTOM VTSS WILL NOT ARM PROPERLY POSSIBLE CAUSES - VTSS not enabled - Check for DTCs and VTSS arming inhibitors - Check for SKIM no response - Cylinder lock switch ground open - Instrument cluster - Cylinder lock switch MUX circuit open - Cylinder lock switch open - Instrument cluster - cylinder lock switch MUX open Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1801 Body Control Module: Component Tests and General Diagnostics Six Step Troubleshooting Procedure Diagnosis of the body system 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 Road Testing Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. WARNING: REASSEMBLE ALL COMPONENTS BEFORE ROAD TESTING A VEHICLE. DO NOT TRY TO READ THE DRBIII(R) SCREEN OR OTHER TEST EQUIPMENT DURING A TEST DRIVE. DO NOT HANG THE DRBIII(R) OR OTHER TEST EQUIPMENT FROM THE REARVIEW MIRROR DURING A TEST DRIVE. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRBIII(R) OR OTHER TEST EQUIPMENT. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. Vehicle Preparation For Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Glossary of Terms ABS antilock brake system ACM airbag control module ACT actuator AECM airbag electronic control module (ACM) ASDM airbag system diagnostic module (ACM) BCM body control module BTSI brake transmission shift interlock CAB controller antilock brake CMTC compass/mini-trip computer CPA connector positive assurance DAB driver airbag DLC data link connector DTC diagnostic trouble code EBL electric back lite (rear window defogger) ECM engine control module EVIC electronic vehicle information center FCM front control module HFM hands free module HVAC heater ventilation, air conditioning IC instrument cluster (MIC) IPM integrated power module JB junction block MIC mechanical instrument cluster NGC next generation controller ODO odometer OR occupant restraint controller PAB passenger airbag PCI Programmable Communication Interface (vehicle communication bus) PCM powertrain control module PDC power distribution center PWM pulse width modulated RKE remote keyless entry RX receive SBS seat belt switch SBT seat belt tensioner SKIM sentry key immobilizer module SKIS sentry key immobilizer system SRS supplemental restraint system SUV sport utility vehicle Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1802 TCCM transfer case control module TCM transmission control module TX transmit UGDO universal garage door opener VFD vacuum fluorescent display VTSS vehicle theft security system Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1803 Body Control Module: Scan Tool Testing and Procedures Diagnostic Trouble Code DRB III Error Messages and Blank Screen Under normal operation, the DRBIII(R) will display one of only two error messages: - User-Requested WARM Boot or User Requested COLD Boot. If the DRBIII(R) should display any other error message, record the entire display and call the STAR Center. This is a sample of such an error message display. - User-Requested WARM Boot by pressing MORE and NO at the same time. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1804 ver: 2.29 date: 1 Oct 93 file: key_itf.cc date: Jan 12 1994 line: 544 err: 0x1 User-Requested WARM Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. or User-Requested COLD Boot by pressing MORE and YES at the same time. ver: 2.29 date: 1 Oct 99 file: keyhnd1.cc date: Mar 8 2000 line:1297 err: 0x1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRBIII(R) DOES NOT POWER UP If the LEDs do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRBIII(R). Check for proper ground connection at DLC cavities 4 and 5. If all connections are proper between the DRBIII(R) and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRBIII(R) may be the result of faulty cable or vehicle wiring. DRBIII(R) Scan Tool DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. DRB III Safety Information WARNING: EXCEEDING THE LIMITS OF THE DRBIII(R) MULTIMETER IS DANGEROUS. READ ALL DRBIII(R) INSTRUCTIONS BEFORE USING THE MULTIMETER. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. - Follow the vehicle manufacturer's service specifications at all times. - Do not use the DRBIII(R) if it has been damaged. - Do not use the test leads if the insulation is damaged or if metal is exposed. - To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. - Choose the proper range and functions for the measurement. Do not try voltage or current measurement that may exceed the rated capacity. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Symptom Related Diagnostic Procedures > Page 1805 - Do not exceed the limits shown in the table below: - Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. - Use caution when measuring voltage above 25v DC or 25v AC. - Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. - When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. - When measuring current, connect the meter in series with the load. - Disconnect the live test lead before disconnecting the common test lead. - When using the meter function, keep the DRBIII(R) away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Page 1806 Body Control Module: Tools and Equipment DRBIII(R) (diagnostic read-out box) Jumper wires Ohmmeter Voltmeter Test Light 8310 Airbag System Load Tool 8443 SRS Airbag System Load Tool 8815 Diagnostic Pinout Box Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Customer Interest: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Powertrain Control Module: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 1820 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 1821 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 1822 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Powertrain Control Module: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 1832 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 1833 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 1834 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Locations > Component Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Locations > Component Locations > Page 1837 Powertrain Control Module: Connector Locations Right Rear Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Locations > Component Locations > Page 1838 Right Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Locations > Component Locations > Page 1839 Right Rear Engine Wiring (SRT-10) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Connector Views Powertrain Control Module: Connector Views Module-Powertrain Control C1 (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Connector Views > Page 1842 Module-Powertrain Control C2 (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Connector Views > Page 1843 Module-Powertrain Control C3 (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM Powertrain Control Module: Description and Operation PCM The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - EATX module (if equipped) - Engine coolant temperature sensor - Fuel level (through J1850 circuitry) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 1846 - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission converter clutch circuit. Driven through J1850 circuits. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 1847 Powertrain Control Module: Description and Operation Modes of Operation As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (02S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (02S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the 02S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The 02S sensor heater element is energized via the ASD or 02S heater relay. The 02S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 1848 This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. - When engine has reached operating temperature, the PCM will begin monitoring 02S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (02S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 1849 ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 1850 Powertrain Control Module: Description and Operation 5 Volt Supplies Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 1851 Powertrain Control Module: Description and Operation Ignition Circuit Sense This circuit ties the ignition switch to the Powertrain Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 1852 Powertrain Control Module: Description and Operation PCM The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - EATX module (if equipped) - Engine coolant temperature sensor Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 1853 - Fuel level (through J1850 circuitry) - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission converter clutch circuit. Driven through J1850 circuits. Modes of Operation As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (02S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (02S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the 02S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 1854 - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The 02S sensor heater element is energized via the ASD or 02S heater relay. The 02S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. - When engine has reached operating temperature, the PCM will begin monitoring 02S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 1855 When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (02S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > PCM > Page 1856 Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 Volt Supplies Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). Ignition Circuit Sense This circuit ties the ignition switch to the Powertrain Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Power Grounds The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: - Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors Sensor Return The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > PCM/ECM/SKIM Programming Powertrain Control Module: Service and Repair PCM/ECM/SKIM Programming NOTE: Before replacing the Powertrain Control Module (PCM) or Engine Control Module (ECM), be certain to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM/ECM driver/control circuit failures are caused by internal component failures (i.e. relays and solenoids) and shorted circuits (i.e. pull-ups, drivers, and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has been set. When a Powertrain Control Module (PCM) for a gasoline engine, or a Engine Control Module for a diesel engine and the Sentry Key Immobilizer Module (SKIM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM/ECM. 2. Program the new SKIM. 3. Replace all ignition keys and program them into the new SKIM. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > PCM/ECM/SKIM Programming > Page 1859 Powertrain Control Module: Service and Repair Programming the PCM/ECM/SKIM The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKIM is replaced, it is necessary to program the Secret Key into the new modules using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool menu for the module being replaced as appropriate. NOTE: - Be certain to enter the correct country code for the SKIM. If the incorrect country code is programmed into the SKIM, it cannot be changed and the SKIM must be replaced. - If the PCM/ECM and the SKIM are replaced at the same time, all vehicle ignition keys will need to be replaced and the new keys programmed into the new SKIM. - Programming the PCM/ECM or SKIM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > PCM/ECM/SKIM Programming > Page 1860 Powertrain Control Module: Service and Repair Programming Ignition Keys to the SKIM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKIM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKIM. To program ignition keys into the SKIM, follow the programming steps outlined in the diagnostic scan tool for "Program Ignition Keys or Key FOBs" under the "SKIM" menu item. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM, that key has acquired the Secret Key for that SKIM and cannot be transferred to any other SKIM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - Programming Not Attempted - The scan tool attempts to read the programmed key status and there are no keys programmed into SKIM memory. - Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program an ignition key transponder due to one of the following: The ignition key transponder is faulty. - The ignition key transponder is or has been already programmed to another vehicle. - 8 Keys Already Learned, Programming Not Done - The SKIM transponder ID memory is full. - Learned Key In Ignition - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKIM memory. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > PCM/ECM/SKIM Programming > Page 1861 Powertrain Control Module: Service and Repair Module - Powertrain Control CAUTION: - Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using the DRB scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. - Use the DRB scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. REMOVAL The PCM (1) is located in the engine compartment attached to the dash panel (3). To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > PCM/ECM/SKIM Programming > Page 1862 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors (four 38-way connectors if equipped with NGC) from PCM (1). 4. Remove three PCM mounting bolts (3) and remove PCM from vehicle. INSTALLATION 1. Install PCM (3) and 3 mounting bolts (4) to vehicle. 2. Tighten bolts. Refer to torque specifications. 3. Check pin connectors in the PCM and the three 32-way connectors (four 38-way connectors if equipped with NGC) for corrosion or damage. Also, the pin heights in connectors should all be same. Repair as necessary before installing connectors. 4. Install three 32-way connectors (four 38-way connectors if equipped with NGC). 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install negative battery cable. 7. The 5.7L V-8 engine is equipped with a fully electronic accelerator pedal position sensor. If equipped with a 5.7L, also perform the following 3 steps: a. Connect negative battery cable to battery. b. Turn ignition switch ON, but do not crank engine. c. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn electrical parameters. d. The DRB III(R) Scan Tool may also be used to learn electrical parameters. Go to the Miscellaneous menu, and then select ETC Learn. 8. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set. 9. If necessary, use DRB III(R) Scan Tool to erase any Diagnostic Trouble Codes (DTC's) from PCM. Also use the DRB scan tool to reprogram new PCM with vehicles original Vehicle Identification Number (VIN) and original vehicle mileage. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1866 Main Relay (Computer/Fuel System): Description and Operation PCM OUTPUT The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. PCM OUTPUT The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1867 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1868 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Wiring Diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations Integrated Power Module Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 1872 Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 1873 Oxygen Sensor Relay: Description and Operation DESCRIPTION The Oxygen Sensors (02S) are attached to, and protrude into the vehicle exhaust system Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors Federal Emission Packages Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2) With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor The downstream sensor (1/2) is located just after the main catalytic convertor California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as ill and 2/1) and 2 downstream (referred to as 1/2 and 2/2) With this emission pack-age, the right upstream sensor (2/i) is located in the right exhaust downpipe just before the mini-catalytic convertor The left upstream sensor (1/i) is located in the left exhaust downpipe just before the mini-catalytic convertor The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1880 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1881 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1882 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1883 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1884 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1885 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1886 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1887 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1888 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1889 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1890 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1891 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1892 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1893 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1894 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1895 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1896 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1897 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1898 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1899 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 1900 Fuel Pump Relay: Description and Operation The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shut-down the ground circuit to the fuel pump relay in approximately 1 - 3 seconds unless the engine is operating or the starter motor is engaged. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 1901 Fuel Pump Relay: Service and Repair REMOVAL The fuel pump relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations Right Battery Tray Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1908 Main Relay (Computer/Fuel System): Description and Operation PCM OUTPUT The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. PCM OUTPUT The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1909 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1910 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Wiring Diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Diagrams Relay-Ignition Run-ACC (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Left Front Facia And Battery Tray Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 1924 Battery Temperature Sensor: Connector Locations Left Rear Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 1925 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 1926 Left Front Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 1927 Integrated Power Module And Fan Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1928 Sensor-Battery Temperature Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1929 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1930 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. 1. Remove battery. Refer to Battery for procedures. Battery Temperature Sensor Location 2. Pry sensor straight up from battery tray mounting hole to gain access to electrical connector. 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. 1. Pull electrical connector up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Refer to Battery for procedures. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams Sensor-Camshaft Position (Gas) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 1934 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor is located above the water pump and under the throttle body. The camshaft position sensor (1) provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses. The PCM determines crankshaft position from the camshaft position sensor and crankshaft position sensor inputs. The PCM uses the input to determine fuel injection synchronization and to determine which ignition coil to energize. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 1935 The camshaft position sensor detects when a step down (1) in the camshaft sprocket passes beneath it. When the sensor detects the step down, the input voltage from the sensor to the PCM switches from low (0.3 volts) to high (5 volts). As the step up returns to the sensor, the input voltage switches back to low (0.3 volts). The paper spacer is not used on 8.3L motors. Don't use at all. It plugs up the oil pickup screen. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 1936 Camshaft Position Sensor: Service and Repair REMOVAL 8.3L - REPLACING WITH NEW SENSOR The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. If a new replacement camshaft position sensor is to be installed, use this procedure. 1. Disconnect the sensor wiring harness connector from sensor. 2. Remove the sensor mounting bolt. 3. Carefully pry the sensor from the timing chain case/cover in a rocking action with two small screwdrivers. 4. Remove the sensor from vehicle. 8.3L - REPLACING OLD SENSOR WITH ORIGINAL The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. If the original camshaft position sensor is to be removed and installed, such as when servicing the timing chain, timing gears or timing chain cover, use this procedure. 1. Disconnect the sensor harness connector from the sensor. 2. Scribe the sensor for location depth. 3. Remove the sensor mounting bolt. 4. Carefully pry the sensor from the timing chain case/cover in a rocking action with two small screwdrivers. 5. Remove the sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 8.3L - INSTALLATION - WITH NEW SENSOR The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. 1. Apply a small amount of engine oil to the sensor O-ring. A low (step down) and high (step up) area are machined into the camshaft drive gear. The sensor is positioned in the timing gear cover so that a small air gap exists between the face of sensor and the high machined area of cam gear. Before the sensor is installed, the cam gear may have to be rotated. This is to allow the high machined area (step up) on the gear to be directly in front of the sensor mounting hole opening on the timing gear cover. Do not install sensor with gear positioned at low area. When the engine is started, the sensor will be broken. 2. Using a 1/2 in. wide metal ruler, measure the distance from the cam gear to the face of the sensor mounting hole opening on the timing gear cover. 3. If the dimension is approximately 1-15/32 inches or less, it is OK to install sensor. 4. If the dimension is approximately 1-5/8 inches or more, the cam gear will have to be rotated. 5. Attach a socket to the vibration damper mounting bolt and rotate engine until the 1-15/32 inch dimension is attained. 6. Install the sensor into the timing case/cover with a slight rocking action. Do not twist the sensor into position as damage to the O-ring may result. Push the sensor all the way into the cover until the rib material on the sensor contacts the camshaft gear. 7. Install the mounting bolt and tighten to 10.7 N.m (95 in.lbs.) torque. 8. Connect sensor wiring harness to engine harness. When the engine is started, the rib material will be sheared off the face of sensor. This will automatically set sensor air gap. 8.3L - REPLACING OLD SENSOR WITH ORIGINAL The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. When installing a used camshaft position sensor, the sensor depth must be adjusted to prevent contact with the camshaft gear (sprocket). 1. Apply a small amount of engine oil to the sensor O-ring. A low and high area are machined into the camshaft drive gear. The sensor is positioned in the timing gear cover so that a small air gap exists between the face of sensor and the high machined area of cam gear. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 1937 Before the sensor is installed, the cam gear may have to be rotated. This is to allow the high machined area on the gear to be directly in front of the sensor mounting hole opening on the timing gear cover. Do not install sensor with gear positioned at low area. When the engine is started, the sensor will be broken. 2. Using a 1/2 in. wide metal ruler, measure the distance from the cam gear to the face of the sensor mounting hole opening on the timing gear cover. 3. If the dimension is approximately 1-15/32 inches or less, it is OK to install sensor. 4. If the dimension is approximately 1-5/8 inches or more, the cam gear will have to be rotated. 5. Attach a socket to the vibration damper mounting bolt and rotate engine until the 1-15/32 inch dimension is attained. 6. Install the sensor into the timing case/cover with a slight rocking action until the sensor is aligned to scribe line. The paper spacer can be used if reinstalling a used sensor. 7. Install sensor mounting bolt and tighten to 10.7 N.m (95 in.lbs.) torque. 8. Connect engine wiring harness to sensor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations Crankshaft Position Sensor: Locations The sensor is located at the rear lower passenger side of motor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 1941 Sensor-Crankshaft Position (5.7L/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 1942 Crankshaft Position Sensor: Service and Repair REMOVAL The sensor is located at the rear lower passenger side of motor. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting bolt. 3. Pull sensor out. A light tap to top of sensor may ease removal. INSTALLATION 1. Slide the sensor into the hole. 2. Install and tighten the mounting bolt to 11 Nm (95 in. lbs.) torque. 3. Connect the electrical connector to the sensor and lock. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Sensor-Fuel Level Sending Unit Fuel Level Sensor: Locations Sensor-Fuel Level Sending Unit The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Sensor-Fuel Level Sending Unit > Page 1950 Fuel Level Sensor: Locations Fuel Pump Module The fuel pump module assembly is located on the top of the fuel tank. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1951 Fuel Level Sensor: Description and Operation 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 variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit 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 diagnostic 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1952 Fuel Level Sensor: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation. 2. Disconnect 4-wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. Refer to Special Tools in Wiring for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4-wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/ Installation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Left Front Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 1956 Sensor-Intake Air Temperature (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 1957 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL NOTE: Take care not to damage the thermistor pill when removing the sensor. 1. Remove the battery cover and disconnect the negative battery cable. 2. Disconnect the electrical connector from the inlet temperature sensor. 3. Remove sensor from inlet hose. INSTALLATION NOTE: Take care not to damage the open thermistor pill when installing the sensor. 1. Install sensor , use a little water to aid in insertion of sensor. 2. Make sure that the rib on the sensor matches up with the rib on the inlet hose. The thermistor pill should be in direct contact with the inlet air stream. 3. Connect the electrical connector. 4. Connect the negative battery cable and install battery cover. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1961 Knock Sensor: Diagrams Sensor-Knock No.1 (5.7L/SRT) Sensor-Knock No.2 (5.7L/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1962 Knock Sensor: Description and Operation The sensors are used only with 3.7L V-6, 4.7L V-8 and 5.7L V-8 engines. On 3.7L V-6 and 4.7L V-8 engines, the 2 knock sensors are bolted into the cylinder block under the intake manifold. On 5.7L V-8 engines, 2 knock sensors are also used. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. 3.7L V-6/4.7L V-8/5.7L V-8 Engines Only Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations Manifold Pressure/Vacuum Sensor: Component Locations The MAP sensor (2) mounts to the drivers side intake manifold plenum. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations > Page 1967 Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1968 Sensor-Map (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1969 Manifold Pressure/Vacuum Sensor: Description and Operation The MAP sensor (2) mounts to the drivers side intake manifold plenum. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum. During key-on (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in. Hg. If a storm goes through, it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1970 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL The manifold absolute pressure sensor is mounted on the drivers side of the intake manifold. 1. Disconnect the electrical connector from the MAP sensor. 2. Remove MAP sensor mounting screws. INSTALLATION 1. Install the MAP sensor to the intake manifold. 2. Install MAP sensor mounting screws and tighten mounting screws to 4 Nm (35 in. lbs.). 3. Connect the electrical connector to the MAP sensor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Right Front Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1976 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1977 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1978 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1979 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1980 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1981 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1982 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1983 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1984 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1985 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1986 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1987 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1988 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1989 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1990 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1991 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1992 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1993 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1994 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1995 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1996 Sensor-Engine Oil Pressure (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations 4 Sensor Vehicle 2 Sensor Vehicle (1 = Downstream, 2 = Upstream) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2001 Oxygen Sensor: Connector Locations Left Transmission (RFE) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2002 Right Transmission (RFE) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2003 Manual Transmission (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2004 Transmission And Exhaust (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2005 Oxygen Sensor: Diagrams Sensor-Oxygen-Left Front (SRT) Sensor-Oxygen-Left Rear (SRT) Sensor-Oxygen-Right Front (SRT) Sensor-Oxygen-Right Rear (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2006 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2007 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the engine or emission package, the vehicle ] may use a total of either 2 or 4 sensors. Federal Emission Packages : Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2008 Oxygen Sensor: Service and Repair REMOVAL CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support vehicle. 2. Disconnect wire connector from O2S sensor. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in exhaust pipe using appropriate tap. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. 1. Install O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect O2S sensor wire connector. 3. Lower vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations The TPS (1) is mounted on the passenger side of the throttle body. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2012 Throttle Position Sensor: Description and Operation The TPS (1) is mounted on the passenger side of the throttle body. The sensor connects to the throttle blade shaft. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from .26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2013 Throttle Position Sensor: Service and Repair REMOVAL The TPS is attached to the throttle body. 1. Disconnect the TPS electrical connector. 2. Remove the TPS mounting screws. 3. Remove the TPS. INSTALLATION The TPS is attached to the throttle body. The throttle shaft end of the throttle body slides into a socket in the TPS. When indexed correctly, the TPS can rotate a few degrees to line up the mounting screw holes with the screw holes in the throttle body. If the sensor will not rotate into place, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS has slight tension when rotated to align the mounting holes. 1. Install TPS and mounting screws. 2. Attach electrical connector to the TPS. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Left Front Facia And Battery Tray Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations The TPS (1) is mounted on the passenger side of the throttle body. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2021 Throttle Position Sensor: Description and Operation The TPS (1) is mounted on the passenger side of the throttle body. The sensor connects to the throttle blade shaft. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from .26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2022 Throttle Position Sensor: Service and Repair REMOVAL The TPS is attached to the throttle body. 1. Disconnect the TPS electrical connector. 2. Remove the TPS mounting screws. 3. Remove the TPS. INSTALLATION The TPS is attached to the throttle body. The throttle shaft end of the throttle body slides into a socket in the TPS. When indexed correctly, the TPS can rotate a few degrees to line up the mounting screw holes with the screw holes in the throttle body. If the sensor will not rotate into place, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS has slight tension when rotated to align the mounting holes. 1. Install TPS and mounting screws. 2. Attach electrical connector to the TPS. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams Sensor-Camshaft Position (Gas) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2027 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor is located above the water pump and under the throttle body. The camshaft position sensor (1) provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses. The PCM determines crankshaft position from the camshaft position sensor and crankshaft position sensor inputs. The PCM uses the input to determine fuel injection synchronization and to determine which ignition coil to energize. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2028 The camshaft position sensor detects when a step down (1) in the camshaft sprocket passes beneath it. When the sensor detects the step down, the input voltage from the sensor to the PCM switches from low (0.3 volts) to high (5 volts). As the step up returns to the sensor, the input voltage switches back to low (0.3 volts). The paper spacer is not used on 8.3L motors. Don't use at all. It plugs up the oil pickup screen. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2029 Camshaft Position Sensor: Service and Repair REMOVAL 8.3L - REPLACING WITH NEW SENSOR The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. If a new replacement camshaft position sensor is to be installed, use this procedure. 1. Disconnect the sensor wiring harness connector from sensor. 2. Remove the sensor mounting bolt. 3. Carefully pry the sensor from the timing chain case/cover in a rocking action with two small screwdrivers. 4. Remove the sensor from vehicle. 8.3L - REPLACING OLD SENSOR WITH ORIGINAL The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. If the original camshaft position sensor is to be removed and installed, such as when servicing the timing chain, timing gears or timing chain cover, use this procedure. 1. Disconnect the sensor harness connector from the sensor. 2. Scribe the sensor for location depth. 3. Remove the sensor mounting bolt. 4. Carefully pry the sensor from the timing chain case/cover in a rocking action with two small screwdrivers. 5. Remove the sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 8.3L - INSTALLATION - WITH NEW SENSOR The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. 1. Apply a small amount of engine oil to the sensor O-ring. A low (step down) and high (step up) area are machined into the camshaft drive gear. The sensor is positioned in the timing gear cover so that a small air gap exists between the face of sensor and the high machined area of cam gear. Before the sensor is installed, the cam gear may have to be rotated. This is to allow the high machined area (step up) on the gear to be directly in front of the sensor mounting hole opening on the timing gear cover. Do not install sensor with gear positioned at low area. When the engine is started, the sensor will be broken. 2. Using a 1/2 in. wide metal ruler, measure the distance from the cam gear to the face of the sensor mounting hole opening on the timing gear cover. 3. If the dimension is approximately 1-15/32 inches or less, it is OK to install sensor. 4. If the dimension is approximately 1-5/8 inches or more, the cam gear will have to be rotated. 5. Attach a socket to the vibration damper mounting bolt and rotate engine until the 1-15/32 inch dimension is attained. 6. Install the sensor into the timing case/cover with a slight rocking action. Do not twist the sensor into position as damage to the O-ring may result. Push the sensor all the way into the cover until the rib material on the sensor contacts the camshaft gear. 7. Install the mounting bolt and tighten to 10.7 N.m (95 in.lbs.) torque. 8. Connect sensor wiring harness to engine harness. When the engine is started, the rib material will be sheared off the face of sensor. This will automatically set sensor air gap. 8.3L - REPLACING OLD SENSOR WITH ORIGINAL The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. When installing a used camshaft position sensor, the sensor depth must be adjusted to prevent contact with the camshaft gear (sprocket). 1. Apply a small amount of engine oil to the sensor O-ring. A low and high area are machined into the camshaft drive gear. The sensor is positioned in the timing gear cover so that a small air gap exists between the face of sensor and the high machined area of cam gear. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2030 Before the sensor is installed, the cam gear may have to be rotated. This is to allow the high machined area on the gear to be directly in front of the sensor mounting hole opening on the timing gear cover. Do not install sensor with gear positioned at low area. When the engine is started, the sensor will be broken. 2. Using a 1/2 in. wide metal ruler, measure the distance from the cam gear to the face of the sensor mounting hole opening on the timing gear cover. 3. If the dimension is approximately 1-15/32 inches or less, it is OK to install sensor. 4. If the dimension is approximately 1-5/8 inches or more, the cam gear will have to be rotated. 5. Attach a socket to the vibration damper mounting bolt and rotate engine until the 1-15/32 inch dimension is attained. 6. Install the sensor into the timing case/cover with a slight rocking action until the sensor is aligned to scribe line. The paper spacer can be used if reinstalling a used sensor. 7. Install sensor mounting bolt and tighten to 10.7 N.m (95 in.lbs.) torque. 8. Connect engine wiring harness to sensor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations Crankshaft Position Sensor: Locations The sensor is located at the rear lower passenger side of motor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2034 Sensor-Crankshaft Position (5.7L/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2035 Crankshaft Position Sensor: Service and Repair REMOVAL The sensor is located at the rear lower passenger side of motor. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting bolt. 3. Pull sensor out. A light tap to top of sensor may ease removal. INSTALLATION 1. Slide the sensor into the hole. 2. Install and tighten the mounting bolt to 11 Nm (95 in. lbs.) torque. 3. Connect the electrical connector to the sensor and lock. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 IGNITION SWITCH DESCRIPTION The ignition switch (5) is located on the steering column (4). It is used as the main on/off switching device for most electrical components. The mechanical key cylinder is used to engage/disengage the electrical ignition switch. OPERATION Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the shift cable. This interlock device is used to lock the transmission shifter in the PARK position when the key cylinder is in any position and the brake pedal is not depressed. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2040 Ignition Switch Lock Cylinder: Service and Repair KEY CYLINDER REMOVAL The ignition key (1) must be in the key cylinder (2) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at side of key cylinder assembly (2). a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. INSTALLATION The ignition key (1) must be in the key cylinder (2) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (2) with the ignition switch. 2. Push the key cylinder (2) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2044 Knock Sensor: Diagrams Sensor-Knock No.1 (5.7L/SRT) Sensor-Knock No.2 (5.7L/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2045 Knock Sensor: Description and Operation The sensors are used only with 3.7L V-6, 4.7L V-8 and 5.7L V-8 engines. On 3.7L V-6 and 4.7L V-8 engines, the 2 knock sensors are bolted into the cylinder block under the intake manifold. On 5.7L V-8 engines, 2 knock sensors are also used. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. 3.7L V-6/4.7L V-8/5.7L V-8 Engines Only Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel System Pressure ......................................................................................................................... ............................................ 400 ± 34 kPa (58 ± 2 psi) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2050 Fuel Pressure: Testing and Inspection Test 1 - 2 SYMPTOM FUEL PRESSURE LEAK DOWN POSSIBLE CAUSES - Faulty fuel pump module - Fuel injectors(s) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2054 Idle Speed: Description and Operation The idle air control motor is mounted at the front right of the intake manifold. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. 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. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. 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. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications 8.3L - FIRING ORDER 1-10-9-4-3-6-5-8-7-2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2063 Firing Order: Mechanical Specifications Firing Order ......................................................................................................................................... ................................................ 1-10-9-4-3-6-5-8-7-2 The cylinders are number from front to rear as follows: - on the left bank - 1-3-5-7-9 - on the right bank - 2-4-6-8-10 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2071 Ignition Cable: Description and Operation Spark plug cables are sometimes referred to as secondary ignition wires, or secondary ignition cables. Plug cables are used only on the 5.7L V-8 engine. The spark plug cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of non metallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Plug cables are used only on the 5.7L V-8 engine. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2072 Ignition Cable: Service and Repair REMOVAL Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. 1. Release the fuel pressure. 2. Disconnect the negative battery cable. 3. Remove the air cleaner assembly. 4. Remove the Intake Manifold, refer to the Engine/Manifolds/Intake Manifold for more information. 5. Use the following procedure when removing the high tension cable from the spark plug. Grasp the terminal as close as possible to the spark plug. Rotate the cover boot 1/2 turn slightly and pull straight up in a steady motion.Do not use pliers and do not pull the cable at an angle. Doing so will damage the insulation, cable terminal or the spark plug insulator. Wipe spark plug insulator clean before reinstalling cable. 6. Remove spark plug cable from coil first. 7. Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. INSTALLATION Install cables into the proper engine cylinder firing order sequence. Refer to Specifications. When replacing the spark plug and coil cables, route the cables correctly and secure them in the proper retainers. Failure to route the cables properly may cause the radio to reproduce ignition noise. It could also cause cross-ignition of the plugs, or, may 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. Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. The system uses two epoxy filled coil packs mounted on engine block post in the valley under the intake manifold. The rear coil pack, contains 3 separate coils and fires cylinders 1, 2, 3, 4, 6, and 7. The front coil pack, contains 2 individual coils and fires cylinders 5, 8, 9, and 10. NOTE: When replacing the spark plug and coil cables, route the cables correctly and secure them in the proper retainers. Failure to route the cables properly may cause the radio to reproduce ignition noise. It could also cause cross-ignition of the plugs, or, may short-circuit the cables to ground. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2073 1. Install wire separator clip on double ended stud on rear of engine block first. This is the wire separator clip closest to the ignition coil insulator boots. 2. Connector coil insulator boots over respective ignition coil side post. Take care to match cylinder number on ignition coil with cylinder number on ignition cables. Also, make sure to hear the audible click while making the connection to the coil post. 3. Sequentially install wires into separators clips mounted on double ended studs mounted on the outer side of valve cover and and. Start from the rear and work forward to the front of the engine. 4. After installing all wires into separator clips, install spark plug insulator boots over respective spark plugs sequentially from back of engine towards the front of engine. Make sure to hear the audible click during installation of spark plug boots. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2074 5. Install Intake Manifold. 6. Install Air Cleaner Assembly. 7. Connect the negative battery cable. 8. Use a diagnostic scan tool to pressurize the fuel system. Check for leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications > Page 2079 Spark Plug: Mechanical Specifications Gap Spark Plug Gap ................................................................................................................................... ....................................................... 0.033 to 0.038 in. Torque Spark Plug tightening torque ............................................................................................................... ...................................................... 27 Nm (20 ft.lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2080 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ................................................................. RC12ECC Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2081 Spark Plug: Description and Operation Resistor type spark plugs are used on all engines. Sixteen spark plugs (2 per cylinder) are used with 5.7L V-8 engines. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2082 Spark Plug: Testing and Inspection To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. Always use the recommended torque when tightening spark plugs. Incorrect torque can distort the spark plug and change plug gap. It can also pull the plug threads and do possible damage to both the spark plug and the cylinder head. 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. Replace spark plugs at the intervals recommended in the Lubrication and Maintenance section. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Spark plug resistance values range from 6,000 to 20,000 ohms (when checked with at least a 1000 volt spark plug tester). Do not use an ohmmeter to check the resistance values of the spark plugs. In accurate readings will result. NORMAL OPERATING 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 (.001 in) per 3200 km (2000 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 may be 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 CRASH ENCRUSTED Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2083 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 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 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2084 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 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2085 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 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 2000 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2086 Spark Plug: Adjustments CLEANING AND ADJUSTMENT The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. Adjust spark plug gap with a gap gauging tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Left Front Facia And Battery Tray Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Left Front Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 2094 Sensor-Intake Air Temperature (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 2095 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL NOTE: Take care not to damage the thermistor pill when removing the sensor. 1. Remove the battery cover and disconnect the negative battery cable. 2. Disconnect the electrical connector from the inlet temperature sensor. 3. Remove sensor from inlet hose. INSTALLATION NOTE: Take care not to damage the open thermistor pill when installing the sensor. 1. Install sensor , use a little water to aid in insertion of sensor. 2. Make sure that the rib on the sensor matches up with the rib on the inlet hose. The thermistor pill should be in direct contact with the inlet air stream. 3. Connect the electrical connector. 4. Connect the negative battery cable and install battery cover. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 2100 Battery Temperature Sensor: Connector Locations Left Rear Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 2101 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 2102 Left Front Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 2103 Integrated Power Module And Fan Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2104 Sensor-Battery Temperature Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2105 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2106 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. 1. Remove battery. Refer to Battery for procedures. Battery Temperature Sensor Location 2. Pry sensor straight up from battery tray mounting hole to gain access to electrical connector. 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. 1. Pull electrical connector up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Refer to Battery for procedures. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2111 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2112 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2113 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2114 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2115 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2116 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2117 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2118 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2119 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2120 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2121 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2122 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2123 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2124 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2125 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2126 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2127 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2128 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2129 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2130 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2131 Body Control Module: Electrical Diagrams Airbag System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2132 Premium Audio System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2133 Base Audio System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2134 Remote Radio Controls Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2135 PCI Bus Communication Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2136 PCM Communication - JTEC PCM Communication - NGC Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2137 ECM Communication - Diesel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2138 Door Ajar System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2139 Heated Mirror System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2140 Rear Window Defogger Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2141 Exterior Lights Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2142 Heating A/C System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2143 Horn System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2144 Instrument Cluster Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2145 Overhead Console Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2146 Power Door Locks Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2147 Telecommunications - Hands Free System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2148 Vehicle Theft Security System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2149 Wipers Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information SERVICING SUB-ASSEMBLIES Some components of the body system are intended to be serviced as an assembly only. Attempting to remove or repair certain system subcomponents may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures should be serviced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 2152 Body Control Module: Vehicle Damage Warnings ELECTRICAL TESTING PRECAUTIONS Before disconnecting any control module, make sure the ignition is "off". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description Body Control Module: Description and Operation System Description IDENTIFICATION OF SYSTEM The vehicle systems that are part of the "body" system are: - Airbag - Audio (with amplifier on premium systems) - Chime - Communication - Door Ajar System - Electrically heated system - Exterior lighting - Heating and A/C - Horn - Instrument Cluster - Interior Lighting - Memory Seat - Overhead Console - Power Door Lock/RKE - Power windows - Telecommunications (hands free phone) - Vehicle theft security system (VTSS) - Windshield Wiper and Washer SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 2004 DR consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI 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 information to perform its function. It will only respond to messages "addressed" to it through binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the communication section of this general information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2155 Body Control Module: Description and Operation Functional Operation Airbag System The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end or side collisions. The system is most effective when used in conjunction with the seat belt system. On some models the ACM supports Seat Belt Tensioners, Passenger Airbag Off Switch, and others Impact Sensor. It may be necessary to use the DRBIII(R) to reconfigure the ACM to the vehicle equipment. The airbag control module (ACM) is an electronic module that monitors the airbag system for proper operation, stores diagnostic trouble code (DTCs), controls the airbag warning lamp and contains the sensor and actuator that is responsible for driver, passenger, and curtain airbag deployment. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTCs) to the technician through the DRBIII(R) via the PCI bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Electro/Mechanical Instrument Cluster (EMIC) from the ACM via the PCI bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the "run" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6-8 seconds. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds, then goes off, there is usually an intermittent problem in the system. 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 OR DEATH. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. The DR will have two Airbag Control Modules. Each ACM is specifically calibrated for one body type, light duty or heavy duty. To determine the body types the ACM monitors the PCI Bus for a message containing the complete VIN. The ACM uses the 6th digit of the VIN to identify the heavy duty or light duty vehicle. The 6th digit of the VIN will be a number 1 for light-duty vehicle and a 2, 3 or 4 for heavy-duty vehicle. If the PCI Bus VIN message 6th character matches the ACM body type, the VIN will be stored within 5.6 seconds after ignition on. After the VIN is stored, the ACM verifies PCI Bus VIN message within 2.6 seconds after the ignition is turned on. If two valid matching PCI Bus VIN messages are not received within 5.6 seconds the ACM will set a Missing Original VIN DTC. If the ACM and PCM module types, 6th character of the VIN, light-duty or heavy-duty do not match the Calibration Mismatch DTC will be set. CAUTION: Therefore, the practice of exchanging (swapping) airbag control modules, instrument clusters, powertrain control modules and other electronic modules in this vehicle with those removed from another vehicle must always be avoided. DRIVER AIRBAG The airbag protective trim cover is the most visible part of the driver side airbag system. 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. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and hybrid inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. CLOCKSPRING The clockspring is mounted on the steering column behind the steering wheel. This assembly consist of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wiring and the driver airbag, the horn, and the vehicle speed control switches if equipped. The clockspring must be properly centered when it is reinstalled on the steering column following any service procedure, or it could be damaged. The clockspring cannot be repaired and it must be replaced. PASSENGER AIRBAG When supplied with the proper electrical signal the passenger airbag inflator or inflators discharge the gas directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2156 WARNING: THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE.BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. PASSENGER AIRBAG ON-OFF SWITCH The Passenger Airbag On-Off Switch allows the customer to turn the passenger airbag function ON or OFF. The OFF indicator will be illuminated whenever the switch is turned to the off position and for 2 seconds at ignition on for an indicator bulb test. The switch assembly is mounted in the center of instrument panel to make the OFF indicator visible to all front seat occupants. WARNING: TO AVOID PERSONAL INJURY OR DEATH, ALWAYS CHECK THE PASSENGER AIRBAG ON-OFF SWITCH POSITION BEFORE DRIVING THE VEHICLE. A SWITCH IN THE WRONG POSITION INCREASES THE RISK OF SERIOUS INJURY OR DEATH IN A COLLISION. To operate, insert the ignition key into the switch keyhole, push key in to release the internal plunger, and rotate to the desired switch position. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. The ignition key is the only key or object that should ever be inserted into the switch. NOTE: Do not turn the On-Off switch with the ignition on. The ACM continuously monitors the resistance of the Passenger Airbag On-Off Switch circuits to identify the switch position and provide circuit diagnostics. The on-off switch ON position resistance is 175 to 190 ohms and the OFF position resistance is 820 to 870 ohms. If the on-off switch circuits are open, shorted to ground or battery the ACM will set active and stored DTC. Upon receiving a switch diagnostic trouble code the airbag warning indicator, in the instrument cluster, will be turned on by the ACM. Whenever the airbag warning indicator is illuminated, the ACM should be the first module interrogated. SEAT BELT TENSIONER Front seat belt systems incorporate Tensioner Modules (SET). At the onset of an impact event each tensioner uses a pyrotechnic device, which is triggered simultaneously with the airbags, to rapidly retract the seat belts. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. The ACM module monitors the Seat Belt Tensioners circuit resistance and reports active and stored DTC's if any problem is found. SIDE IMPACT SENSORS The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration and when combined with the ACM Accelerometer provides verification of the direction and severity of a side impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Airbag Control Module. The ACM microprocessor continuously monitors all of the passive restraint system electrical circuits to determine the system readiness. If the ACM detects a system fault, it sets a Diagnostic Trouble Code and controls the airbag warning indicator operation accordingly. The side impact sensors receive battery current and ground through dedicated driver and passenger sensor signal and ground circuits from the ACM. The impact sensors and the ACM communicate by modulating the current in the sensor signal circuit. If the sensor is dropped it must be replaced. Disconnect the battery or remove both airbag fuses before servicing impact sensors. CAUTION: Do not remove or install the impact sensors while the sensor is attached to the vehicle wiring. CURTAIN AIRBAGS The Left and Right curtain airbags are located in the outboard edge of the roof under the headliner, just above the door openings. When supplied with the proper electrical signal the inflator can discharge the compress gas directly into the curtain airbag. Upon deployment, the curtain will tear open the headliner allowing the curtain airbag to fully deploy between the headliner and seat. The curtain airbag cannot be repaired and must be replaced if deployed or in any way damaged. WARNING: THE CURTAIN AIRBAG CONTAINS AN INERT GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2157 SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. SPECIAL TOOLS Some airbag diagnostic test use special tools, airbag load tools, 8310 and 8443 for testing squib circuits. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of an Driver or Passenger Airbag, curtain airbag, clockspring, or seat belt tensioner (use a jumper if needed). Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective component has been removed from the system and should be replaced. If the DTC is still active, continue this process until all component in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed the squib wiring can be tested for open and shorted conditions. AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRBIII(R). Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. ACTIVE CODES The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. STORED CODES Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned off. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. Maintain a safe distance from all airbags while performing the following inspection. If no obvious problems are found, erase stored codes, and with the ignition "on" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Audio System The factory installed radio receiver communicates on the Programmable Communication Interface (PCI) data bus network. The PCI Bus inputs into the Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2158 radio are used for VF dimming and remote steering wheel controls. All the radios are capable of displaying faults and allowing certain actuation tests through the use of the DRBIII(R). When attempting to perform PCI Bus diagnostics, the first step is to identify the radio in use in the vehicle. When trouble shooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term output refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio, or wiring could be at fault. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit, A faulty speaker could not cause this DTC. REMOTE RADIO CONTROLS These radios can be controlled via remote radio switches (optional). These switches are located on the back side of the steering wheel. They control mode, preset, seek up, seek down, volume up and volume down functions. These functions are inputs to the Instrument Cluster (MIC) and can be read with the DRBIII(R). The switches are a multiplexed signal to the MIC. The radio control MUX circuit is a 5 volt line that is pulled to ground through different value resistors built into the switches. This causes a voltage drop to be seen by the MIC and it sends a specific message to the radio on the PCI Bus circuit. The radio then responses to the message. This circuit is fairly simple to troubleshoot. The circuit must be complete from the switches in the steering wheel to the MIC. The ground must be complete so that the switches can cause the voltage drop for the MIC to see. The circuit passes through the clockspring so continuity through this devise must be verified. AMPLIFIER (PREMIUM SYSTEM) The Premium Audio Amplifier uses a microprocessor for audio digital signal processing (DSP) and system diagnostics. DSP provides a more accurate and consistent match of the audio system equalization to the vehicle interior. The DR Ram amplifier has six channels for superior sound quality. The amplifier reads the VIN from the PCI bus and sets itself to match the vehicle. The amplifier will send four beeps to the vehicle speakers at ignition on, if it does not read the VIN correctly. A replacement amplifier may beep at the first power up, but if these beeps are heard after the first ignition on, the DRBIII(R) should be used to verify the amplifier is connected to the PCI bus and that the VIN on the PCI bus is correct. The amplifier, wiring to the speakers and the speakers work independently from the radio. The amplifier's microprocessor supports several diagnostic functions. Tests can be run from the DRBIII(R) that will help in diagnosing audio system problems. The DRBIII(R) can display fault messages when an input or output problem to the amplifier is detected. The amplifier can detect wiring shorts and suggest which wires are likely to be shorted. The amplifier can send test signals that can be used to verify that the amplifier, speakers, and wiring to the speakers are operating properly. The amplifier can also be used to test if the radio is sending audio signals to it. The DRBIII(R) can be used to verify the amplifier equalization setting matches the vehicle, in case there is a sound quality complaint. Using the DRBIII(R) audio system diagnostics can determine the nature of the problem. Diagnostic tests the Amplifier can perform through the DRBIII(R): Continuous Tone Test - This test will send a continuous tone to each speaker and will verify the integrity of an individual channel. PCI Amplifier Test - This test will detect a PCI bus or checksum failure. Input Test - This test will detect the activity on the amplifiers input channels from the radio. Speaker Output Test - This test will detect the activity on the amplifiers output channels to the speakers NAVIGATION RADIO The optional navigation radio system receives GPS signals from up to eight satellites to display the position and direction of the vehicle. Map information is supplied through a DVD-ROM. An electronic gyrosensor and the vehicle's speed sensor enable the system to display the present vehicle position even in locations where GPS signals may be blocked. When a destination is selected, the navigation system uses information from the map to quickly calculate a route. As the vehicle is driven along the chosen route, the operator is guided with pictorial displays and voice prompts. For complete operating instructions, refer to the manual included with the vehicle. Communication The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25. Additional tracer colors may be added to the violet in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on this vehicle: - Front Control Module - Airbag Control Module - Controller Antilock Brake Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2159 - A/C Heater Control Module - Powertrain Control Module (gas only) - Engine Control Module (diesel only) - Radio - Amplifier (if equipped) - Hands Free Module - Transfer Case Control Module (if equipped) - Sentry Key Immobilizer Module - Compass Mini-Trip Computer (if equipped) - Electro/Mechanical Instrument Cluster Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRBIII(R) lab scope. The 12v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open PCI circuit at the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: - All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - Dashed lines in the overhead console ambient temperature display - No response received from any module on the PCI bus (except the ECM/PCM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRBIII(R). Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRBIII(R). If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRBIII(R) may display "BUS ± SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRBIII(R) and in noway indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2160 NOTE: The 2004 DR 3.7L, 4.7L, and 5.7L vehicles are equipped with the Powertrain Control Module and Transmission Control Module combined in a single control module. This module is the Next Generation Controller (NGC) for DaimlerChrysler and will be referred to as the Powertrain Control Module (PCM). The PCM has four color coded connectors C1/A through C4/D, (C1/A BLK, C2/B - ORANGE, C3/C - WHITE, C4/D -GREEN), with each connector containing 38 pins. The 5.9L Electronic Fuel Injection 24 valve Turbo Diesel has an Engine control module (ECM) CM845. New Diagnostic procedures and New DTC numbers are two of the changes you will see which reflect the new combined module technology. There are new Verification tests and module replacement procedures for the new PCM. Two tools are required to diagnose and repair the PCM terminals and harness connectors: 1. Miller #3638 Terminal Removal Pick must be used to release the connector terminals or harness and connector damage will occur. 2. Miller #8815 Pinout Box must be used to probe the PCM terminals or terminal damage will occur. Door Ajar System The door ajar state is used as an input for various control modules on the vehicle. The DRBIII(R) will display the state of the door ajar switches in Inputs/ Outputs. It's important to note, that when a door is closed, the switch state on the DRBIII(R) will show OPEN, and when the door is open, the switch state will show CLOSED. During diagnosis, if a door is closed and the DRBIII(R) displays the switch state as CLOSED, it indicates a shorted Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2161 door ajar circuit. If the door is open and the DRBIII(R) displays the switch state as OPEN, it indicates an open door ajar circuit. Compass Mini-Trip Computer (CMTC) When equipped, the Compass/Mini Trip Computer (CMTC) is located in the overhead console. The CMTC supplements the standard vehicle instrumentation. The CMTC uses a vacuum fluorescent (VF) display to supply the vehicle operator with a compass heading, outdoor temperature, average fuel economy, distance to empty, trip odometer, and elapsed ignition on time. If equipped, the CMTC is also available with an integrated Universal Garage Door Opener (UGDO) known as "HomeLink ■. The CMTC function buttons are labeled C/T, RESET, STEP, and US/M. The three UGDO buttons are labeled with dots to indicate the channel number. Most of the CMTC display information is received over the PCI bus. The CMTC sends and receives data over the PCI bus, communicating with the FCM (Diesel), PCM (3.7L, 4.7L, 5.7L), and the Instrument Cluster. VEHICLE INFORMATION DISPLAY The CMTC provides the following functions: - Compass direction - Outside temperature - Elapsed ignition on time - Distance to empty - Average fuel economy - Trip Odometer The CMTC will not display information for any of the screens for which it did not receive the proper PCI bus data. Refer to the symptom list in the Overhead Console section for problems related to the CMTC. The CMTC receives the following messages from the Instrument Cluster: - Verification of US/Metric status - VF display dimming brightness and exterior lamp status - Trip Odometer data The CMTC receives the following message from the PCM: - Vehicle Speed US/M BUTTON The US/M button is used to toggle the display between English and Metric measurement units. STEP BUTTON The STEP Button can be used in one of the following ways: 1. To sequentially select one of 4 displays or blank display in the following order: - Average Fuel Economy - Distance to Empty - Trip Odometer - Time Elapsed . Off (Blank) 2. To set the magnetic variance zone when VARIANCE = X (X = 1 - 15) is indicated in the VF display. RESET BUTTON The RESET Button has two different functions: 1. To clear the trip functions that may be reset 2. To enter and exit the diagnostic mode Pressing the RESET button once will clear the trip function that is currently being displayed and the CMTC will send a PCI bus beep request to the Instrument Cluster. If the RESET button is pressed again within 3 seconds, the CMTC will reset ALL of the trip functions and an additional beep request is sent to the Instrument Cluster. The trip functions that may be reset are: - Average Fuel Economy - Trip Odometer - Elapsed Time A reset will only occur if one of the trip functions that may be reset is currently being displayed. The CMTC module will send a beep request to the Instrument Cluster. Simultaneously pressing the RESET button and the C/T button while turning the ignition from Off to On will enter the CMTC into the self-diagnostic mode. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2162 COMPASS/TEMPERATURE (C/T) BUTTON Actuating the Compass/Temperature Button (C/T) will cause the CMTC to display the compass and temperature information. This function will operate from another traveler display. The CMTC simultaneously displays the compass reading and the outside temperature. Outside temperature information is received via the PCI bus from the FCM. The CMTC module internally senses and calculates the compass direction. TRAVELER DISPLAY FUNCTIONS Using the STEP button will change the CMTC between modes of operation and display the appropriate information according to data received from the PCI Bus. COMPASS OPERATION Upon ignition on, if the calibration information stored in the CMTC memory is within the normal range, the CMTC will perform in slow Auto-Cal mode. In slow Auto-Cal mode, the CMTC continuously compensates for the slowly changing magnetic field of the vehicle. The compass module detects changes in the vehicle magnetism and makes appropriate internal corrections to ensure proper displayed direction. However, if the calibration information stored in the CMTC memory is not within the normal range at ignition on, the CMTC will enter fast Auto-Cal. CAL is displayed along with the temperature. Auto activation of the fast Auto-Cal mode will also occur when the CMTC is subjected to high magnetic field strength levels, which cause all compass readings to be erroneous for a continuous period of five (5) minutes . During fast Auto-Cal, CAL will be displayed along with the temperature. Fast Auto-Cal can also be performed manually, by pressing and holding the RESET button for 10 seconds during the Compass/Temperature display mode. SETTING MAGNETIC ZONE VARIANCE Variance is the difference between magnetic North and geographic North. For proper compass function, the correct variance zone must be set. Refer to the Zone Variance map for the correct zone. Follow these steps to check or change the variance zone: - The ignition switch must be in the On position and the CMTC display must not be blank. - If the compass/temperature data is not currently being displayed, momentarily press and release the C/T button to display compass/temp information. - Press and hold the RESET button until VARIANCE = XX is displayed. The CMTC will display the variance zone stored in memory and the word VARIANCE. - Use the STEP button to select the proper variance zone number, 1 through 15. - After selecting the proper zone number, momentarily press and release the RESET button. The variance zone is then stored in the memory and the CMTC returns to normal operation. COMPASS CALIBRATION The compass module has 2 types of auto-calibration; slow-cal and fast-cal. Slow-cal ensures that during normal vehicle operation the compass performs auto-calibration functions to keep the compass sensors in their proper operating range. Whenever the ignition is On and the CMTC receives PC I bus data indicating that engine RPM is greater than zero, auto-calibration is performed continuously. If the calibration information stored in the compass module memory is not within the normal range after a power-up cycle, the compass will display CAL. The CMTC will enter into the fast-cal mode until calibration is complete. To enter the compass into Manual Calibration mode, perform the following steps: - Drive the vehicle to an area away from any large metal objects or overhead power lines. - Ensure that the proper variance zone is selected. See "Setting Magnetic Zone Variance." - The ignition switch must be in the On position and the CMTC display must not be blank. - Press the C/T button to view the Compass/ Temperature display. - Press and hold the RESET button until CAL is displayed, then release the button. - Drive slowly, less than 5 MPH (8KPH) in at least 1 complete 360-degree circle. - CAL will remain illuminated to alert the driver that the compass is in the calibration mode. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2163 - After calibration is complete, CAL will turn off. If the compass appears blank, unable to be calibrated, or the compass displays false indications, the vehicle must be demagnetized. Refer to Compass Demagnetizing Procedure. SELF-CHECK DIAGNOSTICS The CMTC is capable of performing a diagnostic self check on its internal functions. CMTC diagnostics may be performed using a DRBIII(R) or by using the following procedure: 1. With the ignition switch in the OFF position, depress and hold the RESET and the C/T buttons. 2. Turn the ignition switch to the ON position. 3. Continue to hold both buttons until the software versions are displayed, then release the buttons. 4. All of the VFD segments will illuminate for 2-4 seconds. Check for segments that do not illuminate or illuminate all the time. 5. When the self-check is complete the CMTC will display one of the following messages: - PASS - FAIL - NO BUS 6. To exit the self-check mode, depress the RESET button or cycle the ignition switch and the CMTC will return to normal operation. If a Communication fault is displayed, refer to the symptom list. If a FAILED SELF TEST is displayed, the CMTC must be replaced. AMBIENT TEMPERATURE SENSOR The ambient air temperature is monitored by the FCM or the PCM and displayed by the CMTC. For Diesel equipped vehicles, the FCM receives a hardwire input from the ambient temperature sensor (ATS). For 3.7L, 4.7L and 5.7L equipped vehicles, the PCM receives the hardwire input from the ATS. The ATS is a variable resistor that operates on a 5-volt reference signal circuit hardwired from the FCM or PCM. The resistance in the ATS changes as the outside temperature rises or falls. The FCM or PCM senses the change in reference voltage through the ATS resistor. Based on the resistance of the ATS, the FCM or PCM is programmed to correspond to a specific temperature. The FCM or PCM stores and niters the ambient temperature data and transmits this data to the CMTC via the PCI Bus. The ATS cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. AMBIENT TEMPERATURE SENSOR FAULT CODES The outside temperature function is supported by the ambient temperature sensor (ATS), a signal and ground circuit hardwired to the FCM or the PCM, and the CMTC display. If the CMTC display indicates 54° C (130° F) or the ATS sense circuit is open, the temp display will be 54° C (130° F) to indicate an OPEN circuit condition. If the CMTC display indicates -40° C (-40° F) or the ATS sense circuit is shorted to ground, the temp display will be -40° C (-40° F) to indicate a SHORT circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the CMTC VFD can be tested. The ATS is supported by the FCM or PCM. Ambient Temperature Sensor DTCs will be recorded in the FCM or PCM. The ATS can be diagnosed using the following Sensor Test. Test the ATS circuits using the diagnostics in the Body Diagnostic Procedures Manual. If the CMTC passes the self test, and the ATS, the circuits, and PCI bus communications are confirmed to be OK, but the CMTC temperature display is inoperative or incorrect, replace the FCM or PCM as required. AMBIENT TEMPERATURE SENSOR TEST 1. Turn the ignition OFF. 2. Disconnect the ATS harness connector. 3. Measure the resistance of the ATS using the following min/max values: - 0° C (32° F) Sensor Resistance = 29.33 - 35.99 Kiloohms - 10° C (50° F) Sensor Resistance = 17.99 - 21.81 Kiloohms - 20° C (68° F) Sensor Resistance = 11.37 - 13.61 Kiloohms - 25° C (77° F) Sensor Resistance = 9.12 - 10.86 Kiloohms 30° C (86° F) Sensor Resistance = 7.37 - 8.75 Kiloohms - 40° C (104° F) Sensor Resistance = 4.90 - 5.75 Kiloohms The sensor resistance should read between these min/max values. If the resistance values are not OK, replace the Sensor. HOMELINK(R) UNIVERSAL TRANSMITTER If equipped, the HomeLink(R) Universal Transmitter is integrated into the overhead console. For added security it will operate home security systems that use coded signals known generically as Rolling Codes. The overhead console display provides visual feedback to the driver, indicating which HomeLink(R) transmitter channel button is being pressed. The HomeLink(R) can learn and store up to three separate transmitter radio frequency codes to operate garage door openers, security gates, and security lighting. The HomeLink ■ buttons are marked with one, two, or three dots. For complete information, refer to Universal Transmitter. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2164 Electrically Heated Systems HEATED MIRROR RELAY A button located on the HVAC control head controls the Heated Mirror Relay, which is located in the IPM. The HVAC control will ground the Heated Mirror Relay Control circuit to energize this relay. The relay control circuit is continuously monitored for certain malfunctions that the HVAC will report as DTCs. Exterior Lighting System The Instrument Cluster monitors the Headlamp Switch and Multifunctions Switch on its MUX line. The Instrument Cluster sends a PCI bus message to the Front Control Module (FCM) to actuate the Headlamps ON when the ignition switch is ON and when an open or short failure occurs on the headlamps switch input circuit to the instrument cluster. If the exterior lamps are left ON and the ignition switch OFF for more than 5 minutes, the FCM will turn the exterior lamps off. This feature prevents the battery from being discharged when the Exterior Lamps have been left ON. Front Control Module The Front Control Module (FCM) is a microprocessor-based electrical control and interface center located in the engine compartment. When it is mated to the Power Distribution Center (PDC), it is referred to as the Integrated Power Module (IPM). The IPM, with its fuses and relays provides power and signal distribution throughout most of the vehicle. The FCM receives hardwired analog and resistor multiplexed inputs as well as digital electronic inputs from other electronic modules in the vehicle electrical system through its connection to the IPM and the Programmable Communications Interface (PCI) data bus network. Based on these inputs and programming, the FCM uses high side drivers to provide direct power feeds and low side drivers to provide relay control for some of the vehicle's most critical electrical systems. The FCM provides the following features: Controlled Feeds: - Brake lights - Headlamp power - Turn signals (front & rear) - Windshield washer pump motor Relay Controls - Adjustable pedals relay (when equipped) - Fog lamp relay (when equipped) - Horn relay - Park lamp relay - Trailer tow relays - Wiper on/off relay - Wiper high/low relay Electrical Inputs - Module battery supply - Power ground - Ignition switch RUN or START position status . PCI bus - Wiper park switch - Washer fluid level switch - Ambient Temperature sensor - Battery (+) connection detection CONTROLLED POWER FEEDS Headlamp Power The headlamp switch is a direct input to the instrument cluster which is sometimes known as the Cab Control Node (CCN). The instrument cluster sends a Programmable Communications Interface (PCI) bus message to the FCM informing it of a headlamp switch status change. The FCM then turns power on or off (depending on the bus message) to the headlamps through four "fuseless" circuits. These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied to each filament in a separate circuit. For vehicles equipped with Daytime Running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination levels. Washer Pump Motor The washer switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus message to the FCM informing it of a request to wash. The washer pump motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition, the FCM electronically protects the washer pump motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2165 If the FCM receives a prolonged request to wash lasting 30 seconds or more, it will treat the request as a stuck switch condition and deactivate the washer pump motor. The FCM will not reactivate the washer pump motor until there is at least a two second break in the request to wash from the instrument cluster. RELAY CONTROLS Adjustable Pedals Relay If equipped, the adjustable pedals relay, when not activated, supplies fused battery power to the adjustable pedals switch. If the FCM receives a bus message that the vehicle is in reverse or that the cruise control is engaged, it will apply a ground to the adjustable pedals relay control circuit. The ground will activate the relay which will open the power circuit to the adjustable pedals switch The relay control circuit is continuously monitored for malfunctions which the FCM will report as DTCs. Fog Lamp Relay If equipped, the fog lamp switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to turn on the fog lamp relay. The fog lamp relay is then actuated by the FCM through low side control. This circuit is electronically controlled and continuously monitored for malfunctions. Horn Relay The Horn Relay, which is internal to the IPM, is controlled by the FCM through PCI bus messages from the instrument cluster. These bus messages will be sent when either the horn switch is pressed which is hard wired to the instrument cluster, panic mode is requested from the RKE or for vehicle theft security reasons (if equipped). The relay control circuit is continuously monitored for malfunctions that the FCM will report as DTCs. The park lamp switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the park lamp relay. The park lamp relay is then actuated through the low side control circuit. This circuit is electronically controlled and continuously monitored for malfunctions. Wiper High/Low Relay The wiper switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the wiper high/ low relay. The relay switches power between the low speed and high speed of the wiper motor. The wiper high/low relay is then actuated through the low side control circuit. This circuit is electronically controlled and continuously monitored for malfunctions. Wiper On/Off Relay The wiper switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the wiper on/off relay. The wiper on/off relay is then actuated through the low side control circuit. This relay switches power to the wiper high/low relay. This circuit is electronically controlled and continuously monitored for malfunctions. ELECTRICAL INPUTS Module Battery Supply 12 Volt input for all FCM functions except headlamp operation. Power Ground Ground source for all FCM functions Ignition Switch RUN or START Position Status 12 volt input to inform the FCM of the ignition switch status for related FCM functions. PCI Bus Approximately 7.5 volt input to allow the FCM to communicate with other modules on the PCI bus. Wiper Park Switch Ground input used to determine the park placement of the wipers. The ground is also used as feedback to the FCM to determine wiper operating mode. Washer Fluid Level Switch Ground input from the washer fluid level switch which closes when washer fluid is low. Battery (+) Connection Detection 12 volt supply used to monitor battery connection to the IPM. The battery connection to the IPM uses an internal switch to check integrity of the connection and that the Connector Positive Assurance (CPA) is engaged. If the CPA is not properly engaged, a voltage is sent to the FCM to be interpreted as an unseated connector which will set a Diagnostic Trouble Code (DTC). Heating & A/C System SYSTEM AVAILABILITY - Depending on the model, either a Single-Zone or Dual-Zone HVAC system is available in these vehicles. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2166 SYSTEM CONTROLS The Heater Control Module: is fully addressable with the DRBIII(R). - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - controls heated mirror and EBL operation (if equipped). - controls electric door actuator operation. The A/C-Heater Control Module: is fully addressable with the DRBIII(R). - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - provides an A/C request to the Powertrain Control Module (PCM) over the PCI Bus when compressor operation is desired. - controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - controls heated mirror and EBL operation (if equipped). - controls electric door actuator operation. - A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C -Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. The Single-Zone HVAC system uses: one, two-wire electric blend door actuator. - two, two-wire electric mode door actuators. - one, two-wire electric recirculation door actuator. The Dual-Zone HVAC system uses: two, two-wire electric blend door actuators. - two, two-wire electric mode door actuators. - one, two-wire electric recirculation door actuator. SYSTEM REVISIONS The 2004 DR, HVAC system remains carryover from 2003. SYSTEM DIAGNOSTICS Fault detection is through active and stored Diagnostic Trouble Codes (DTCs) . DTCs are displayed by the DRBIII(R). Active DTCs are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTCs are those which occurred in the system since the A/C-Heater Control Module received the last "clear diagnostic info" message. The A/C Cooldown Test: is actuated with the DRBIII(R). - checks A/C system performance based on evaporator temperature sensor input. - will not run if ambient temperature is below 12.7° C (55° F). - will pass if the evaporator temperature drops 6.7° C (20° F) within two minutes of starting the test. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. - will cause the A/C mode switch status indicator to flash while the test is running. - If the test fails, the status indicator will continue to flash until either the test returns passed or the ignition key is cycled. It will also prevent the EBL mode switch status indicator from indicating EBL operating status. However, the EBL mode switch will continue to function in this state. The HVAC Door Recalibration function: is actuated with the DRBIII(R). - monitors for door span faults. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. - will cause the EBL mode switch status indicator to flash while the test is running. - If the test fails, the status indicator will continue to flash until either the test returns passed or the ignition key is cycled. It will also prevent the A/C mode switch status indicator from indicating A/C operating status. However, the A/C mode switch will continue to function in this state. The Actuator Circuit Test: is actuated with the DRBIII(R). - monitors for shorted actuator circuits. - allows service to easily diagnose and troubleshoot up to three simultaneous shorts. - supplements the continuous diagnostics on the actuator drive system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2167 - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. When Performing The Actuator Circuit Test CAUTION: To ensure a proper diagnosis, repair all Short Too Complex messages first, all common door driver circuit related messages second, and all other door driver circuit related messages last. - The DRBIII(R) can display up to three Actuator Circuit Test messages at a time. After repairing each Actuator Circuit Test message, cycle the ignition switch, then rerun the Actuator Circuit Test to ensure no new messages exist. - The Short Too Complex message: indicates that a specific determination of which lines are shorted could not be made. - is caused by more than three drivers being shorted in the same direction. For example, four drivers all shorted to ground, or two or more drivers shorted with at least one driver shorted to ignition/battery and one driver shorted to ground. - Messages displaying: XXX Driver/Circuit Shorted to Ignition/ Battery will set on a per-driver basis. - XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. - the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together. - When the test returns passed, then troubleshooting should proceed to clearing faults and running the HVAC Door Recalibration system test as a final check of system health. Instrument Cluster The DR Instrument Cluster is a new type of control module that includes the hardware and software necessary to function as the cluster and the body control module. The Instrument Cluster houses the Speedometer, Tachometer, Fuel gauge, Coolant Temperature gauge, Oil Pressure gauge, and the Voltage gauge. The cluster positions all of the gauges using PCI bus messages received from the PCM. The cluster contains certain warning indicators, depending on engine type and options. Some of the indicators are hardwire inputs and some indicators are controlled via PCI bus messages. The warning chime tone generator is contained within the cluster. The cluster includes a vacuum fluorescent (VF) display for the PRNDL, Total and Trip Odometers. The VF will also display warning messages such as door ajar, low washer fluid level, engine hours, and no bus communications. The cluster has the ability to set and store DTCs, communicate on the PCI bus, display engine information, and display certain inputs using the DRBIII(R). The following systems are controlled either completely by the Instrument Cluster or in conjunction with other inputs received by hardwire or via the PCI bus: - Audible Warnings - Brake Lamp Control - Brake Transmission Shift Interlock (BTSI) - Cargo Lamp Control - Central Locking - Door Lock Inhibit - Enhanced Accident Response - Exterior Lighting Control - Exterior Lighting Fail-Safe - Heated Seat Control - Horn Control - Interior Lamp Control - Interior Lamps - Enhanced Accident Response - Interior Lamps Load Shedding - Lamp Out Indicator Control - Panel Lamps Dimming Control - Parade Mode - Power Locks - Remote Keyless Entry (RKE) - Remote Radio Switch Interface - Rolling Door Locks - Turn Signal and Hazard Warning Lamp Control - Vacuum Fluorescent Display Synchronization - Vehicle Theft Security System (VTSS) CAUTION: Instrument clusters used in this model automatically configure themselves for compatibility with the features and optional equipment in the vehicle in which they are initially installed. The instrument cluster is programmed to do this by embedding the Vehicle Identification Number (VIN) and other information critical to proper cluster operation in electronic memory. This embedded information is learned through electronic messages received from other electronic modules in the vehicle over the Programmable Communications Interface (PCI) data bus, and through certain hard wired inputs received when the cluster is connected to the vehicle electrically. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2168 Once configured, the instrument cluster memory may be irreparably damaged and certain irreversible configuration errors may occur if the cluster is connected electrically to another vehicle; or, if an electronic module from another vehicle is connected that provides data to the instrument cluster (including odometer values) that conflicts with that which was previously learned and stored. Therefore, the practice of exchanging (swapping) instrument clusters and other electronic modules in this vehicle with those removed from another vehicle must always be avoided. Failure to observe this caution may result in instrument cluster damage, which is not reimbursable under the terms of the product warranty. Service replacement instrument clusters are provided with the correct VIN, and the certified odometer and engine hours values embedded in cluster memory, but will otherwise be automatically configured for compatibility with the features and optional equipment in the vehicle in which they are initially installed. DIAGNOSTIC SELF TEST The Instrument Cluster is capable of performing a Diagnostic Self Test. This self test can be initiated manually by depressing and holding the trip reset button while cycling the ignition from the Off to the On position. The self test can also be activated using the DRBIII(R). During the self test, all of the PCI bus indicators will be illuminated. The speedometer, tachometer, fuel gauge, oil pressure gauge, coolant temperature gauge, and voltage gauge will position at their calibration points. The VF display will illuminate all segments and also display the software version. The chime will sound. When the self test is complete, the cluster will return to normal operation. Turning the ignition to the Off position or the cluster detecting engine RPM greater than 0 (zero) will stop the self test. Interior Lighting The Instrument Cluster controls the Interior/ Courtesy Lamps. The Instrument Cluster activates the courtesy lamps when either a Dome Lamp switch is turned on or a door is opened. The Instrument Cluster also monitors the output of the Glove Box and Map lamps. The Cargo lamps are controlled by the Instrument Cluster, it receives an output message from the Headlamp switch to turn on the lamps. The Instrument Cluster provides battery protection by shutting down the interior lamps when a door or courtesy/map lamp is left on or open. Power Door Locks/Remote Keyless Entry The Instrument Cluster in response to the door lock switches or the RKE module directly controls the power door lock motors. The Instrument Cluster monitors the activation of the door lock motors and will set diagnostic trouble codes when there is an open or short condition. When there is a lock or unlock input from a switch or RKE command, the Instrument Cluster will activate the appropriate driver for 300 milliseconds. If a lock or unlock switch remains active, the request will be ignored until the switch transitions back to off. The lock switches are resistive multiplexed input devices hardwired to the Instrument Cluster. AUTOMATIC DOOR LOCKS The Instrument Cluster will automatically lock all the doors when the vehicle speed exceeds 15 MPH (24 KM/H), throttle position exceeds 10 percent and all the doors are closed. If a door is opened the Automatic Door Lock feature shall reset and the Instrument Cluster will lock the doors when the above conditions are met. This feature is programmable by the customer or the DRBIII(R). CENTRAL LOCKING/UNLOCKING The Instrument Cluster will lock all doors when the cylinder lock switch is activated in the "lock" position. When the Instrument Cluster receives an unlock command from the driver cylinder lock switch, it will unlock only that door. If the Instrument Cluster receives a second command within a 5-second period it will unlock all the remaining doors. The illuminated entry will activate during door unlock. DOOR LOCK INHIBIT When the key is in the ignition, in any position, and either front door is open, the door lock switches LOCK functions are disabled. The UNLOCK functions are still functional. This protects against locking the vehicle with the keys still in the ignition. The RKE transmitter will still lock the doors as usual. ENHANCED ACCIDENT RESPONSE Upon detection of an airbag deployment by way of the PCI bus, the Instrument Cluster shall: - Immediately disable the power door lock output - Unlock all doors by activating the door unlock output for approximately 300 milliseconds. - After actuating the door unlock output, allow the door lock motors to be activated if the door lock input has been inactive (not erratic) for 2 seconds since the reception of the airbag deployment message. Remote Keyless Entry The remote keyless entry (RKE) feature is used to control the power door locks and panic feature by using a remote transmitter (keyfob) and receiver located within the instrument cluster. The instrument cluster RKE feature controls the driver door unlock, all doors lock/unlock, horn chirp enabled/ disable, optical chirp enabled/disable, illuminated entry, the panic feature, initiate customer programming, and arming/disarming the Vehicle Theft Security System. When a valid lock message is received from the receiver, the instrument cluster will: - Arm the Vehicle Theft Security System (if equipped and all conditions are met). - Turn off the illuminated entry feature. - Activate the door lock motors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2169 - Transmit a PCI bus message to the FCM to perform horn chirp. When a valid unlock code is received from the receiver, the instrument cluster will: - Disarm the Vehicle Theft Security System (if equipped and previously set). - Activate the illuminated entry and cargo lamp. - Activate the driver door unlock motor (if customer programmed for driver door only unlock). - Transmit a PCI bus message to the FCM for optical chirp. Vehicle Theft Security System The Instrument Cluster controls the Vehicle Theft Security System (VTSS). When the VTSS is armed it will monitor the status of the ignition and door ajar switches. If the alarm is tripped it will sound the vehicles horn, flash the exterior lamps and the VTSS indicator located in the instrument cluster. The Instrument Cluster will enable the VTSS feature once it has received PCI bus messages from the Sentry Key Immobilizer Module and has also detected the driver cylinder lock switch being cycled to the lock/unlock position. Arming the system is accomplished following a normal exit sequence of removing the key from the ignition, opening the door pressing the power lock button to lock and closing the door, by using a cylinder lock switch or by pressing the RKE lock button. After all the doors are closed, the VTSS indicator will flash quickly for sixteen-seconds indicating the pre-arm process, after which it will flash at a slower rate indicating the system is armed. If during the pre-arm process a door is opened, the ignition is turned to the Run/Start position or if a RKE unlock button is pressed the system will exit the pre-arming process. Disarming can be accomplished with a RKE unlock, turning the ignition on with a valid Sentry key or unlocking the vehicle with a cylinder lock switch. The Alarming state will last for 18 minutes after which it will time out and return to the armed state. A tamper alert feature will alert the customer to the alarm being tripped while they were away upon returning to the vehicle by flashing the VTSS indicator for 30 seconds after the system has been disarmed. All of the switches for the VTSS system can be monitored using the DRBIII(R). The DRBIII(R) is also useful for a customer complaint of the alarm going off with no apparent reason by viewing the VTSS last alarm caused by display. Windshield Wipers/Washers The Instrument Cluster controls the wiper/ washer system. The instrument cluster receives a signal from the Multifunction Switch wipe position. The instrument cluster sends the message to the Front Control Module (FCM), sending the command to turn the wiper/washers on. Two relays, the High/Low relay and the On/Off relay also control the wipers. Both are located in the PDC or Integrated Power Module. Telecommunications HANDS FREE PHONE The vehicle telecommunications system consists of a Hands Free Module, Rear view Mirror, and a Blue-tooth Hands Free Profile enabled cell phone. The system allows vehicle occupants to use voice recognition technology to make, receive and screen phone calls without physically handling a cell phone. The system has a programmable phone book that can prevent the vehicle operator from becoming distracted searching for a specific number. Seven different wireless phones can be programmed to operate each individual system. Each of the seven phones is given a rank of priority when programmed. Incoming phone messages are transmitted to the vehicle occupants through the vehicles audio system when the ignition is on and the wireless phone is on. Upon receiving the signal from an incoming phone call, the vehicle audio system will fade out the current CD/DVD or radio output. The vehicle occupants are then directed to accept or reject the call. Outgoing audio messages are received through the microphone located in the rearview mirror then transmitted via hardwire to the Hands Free Module and finally transmitted through the wireless phone. Volume of the voice prompts and incoming conversation is controlled using the vehicles' radio audio controls and steering wheel controls if equipped. The rearview mirror contains a Phone Switch, Voice Recognition Switch and a microphone. The rear view mirror transmits these inputs via hardwired circuits to the Hands Free Module. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures Air Bag System Test 1 SYMPTOM AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES POSSIBLE CAUSES - Airbag warning indicator on without active trouble codes - Instrument cluster problems AM/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE this symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Amplifier Pretest Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2172 Test 1 SYMPTOM AMPLIFIER PRETEST POSSIBLE CAUSES - Amplifier pretest - No fault message displayed Any Station Preset Switch Inoperative Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Balance Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2173 Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure CD Eject Switch Inoperative Test 1 SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Equalizer Inoperative Test 1 SYMPTOM EQUALIZER INOPERATIVE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2174 TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure FF/RW Switch Inoperative Test 1 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure HOUR/MINUTE Switches Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2175 Test 1 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Pause/Play Switch Inoperative Test 1 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure PWR Switch Inoperative Test 1 SYMPTOM PWR SWITCH INOPERATIVE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2176 TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Scan Switch Inoperative Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Seek Switch Inoperative Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Set Switch Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2177 Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tape Eject Switch Inoperative Test 1 SYMPTOM TAPE EJECT INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2178 TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Chime Inoperative Test 1 SYMPTOM CHIME INOPERATIVE POSSIBLE CAUSES - Actuate chime with DRBIII(R) - Instrument cluster - chime inoperative Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2179 Test 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER DOOR OPEN KEY REMOVED POSSIBLE CAUSES - Key-in IGN SW status - Key-in ignition switch shorted - Key-in ignition SW sense short to ground - Instrument cluster Key In Ignition and Drivers Door Open Chime Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2180 Test 1 - 3 Test 4 - 5 SYMPTOM KEY IN IGNITION AND DRIVERS DOOR OPEN CHIME INOPERATIVE POSSIBLE CAUSES - Observe the key-in ignition switch status - Key-in ignition switch open - Key-in ignition switch ground circuit open - Key-in ignition switch sense circuit open - Instrument cluster - incorrect key-in ignition switch status Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2181 Vehicle Speed Warning Chime Problem Test 1 SYMPTOM VEHICLE SPEED WARNING CHIME PROBLEM POSSIBLE CAUSES - Incorrect country code programmed in instrument cluster - Instrument cluster Average Fuel Economy Inaccurate or Wrong Test 1 SYMPTOM AVERAGE FUEL ECONOMY INACCURATE OR WRONG POSSIBLE CAUSES - CMTC CMTC or EVIC Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2182 Test 1 - 3 SYMPTOM CMTC OR EVIC INOPERATIVE POSSIBLE CAUSES - Fused B(+) circuit open - Fused ignition switch output circuit open - Ground circuit open - Compass/mini-trip computer Compass Test Failure Test 1 SYMPTOM COMPASS TEST FAILURE POSSIBLE CAUSES - Compass/Mini-trip computer Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2183 Distance to Empty Inaccurate or Wrong Test 1 SYMPTOM DISTANCE TO EMPTY INACCURATE OR WRONG TEST NOTE This symptom is diagnosed using the test AVERAGE FUEL ECONOMY INACCURATE OR WRONG. POSSIBLE CAUSES - CMTC Elapsed Ignition on Time Inaccurate or Wrong Test 1 SYMPTOM ELAPSED IGNITION ON TIME INACCURATE OR WRONG TEST NOTE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2184 This symptom is diagnosed using the test AVERAGE FUEL ECONOMY INACCURATE OR WRONG. POSSIBLE CAUSES - CMTC Temperature Display Inaccurate or Inoperative Test 1 - 2 SYMPTOM TEMPERATURE DISPLAY INACCURATE OR INOPERATIVE POSSIBLE CAUSES - Ambient temperature sensor - Compass/Mini-trip computer Trip Odometer Inaccurate or Wrong Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2185 Test 1 SYMPTOM TRIP ODOMETER INACCURATE OR WRONG TEST NOTE This symptom is diagnosed using the test AVERAGE FUEL ECONOMY INACCURATE OR WRONG. POSSIBLE CAUSES - CMTC Driver Door Ajar Circuit Open Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2186 Test 1 - 4 SYMPTOM DRIVER DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Driver door ajar switch - Driver door ajar switch ground circuit open - Driver door ajar switch sense circuit open - Instrument cluster-driver door ajar open Driver Door Ajar Circuit Shorted to Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2187 Test 1 - 3 SYMPTOM DRIVER DOOR AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Driver door ajar switch shorted to ground - Driver door ajar switch sense circuit shorted to ground - Instrument cluster - driver door ajar shorted Left Rear Door Ajar Circuit Open Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2188 Test 1 - 4 SYMPTOM LEFT REAR DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Left rear door ajar switch - Left rear door ajar switch ground circuit open - Left rear door ajar switch sense circuit open - Instrument cluster - left rear door ajar open Left Rear Door Ajar Circuit Shorted to Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2189 Test 1 - 3 SYMPTOM LEFT REAR DOOR AJAR CIRCUIT SHORT TO GROUND POSSIBLE CAUSES - Left rear door ajar switch shorted to ground - Left rear door ajar switch sense circuit shorted to ground - Instrument cluster - driver door ajar shorted Passenger Door Ajar Circuit Shorted to Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2190 Test 1 - 3 SYMPTOM PASSENGER DOOR AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Passenger door ajar switch shorted to ground - Passenger door ajar switch sense circuit shorted to ground - Instrument cluster - passenger door ajar shorted Passenger Door Ajar CKT Open Test 1 - 4 SYMPTOM PASSENGER DOOR AJAR CKT OPEN POSSIBLE CAUSES - Passenger door ajar switch - Passenger door ajar switch ground circuit open - Passenger door ajar switch sense circuit open - Instrument cluster - passenger door ajar open Right Rear Door Ajar Circuit Open Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2191 Test 1 - 4 SYMPTOM RIGHT REAR DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Right rear door ajar switch - Right rear door ajar switch ground circuit open - Right rear door ajar switch sense circuit open - Instrument cluster - right rear door ajar open Right Rear Door Ajar Circuit Shorted to Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2192 Test 1 - 3 SYMPTOM RIGHT REAR DOOR AJAR CIRCUIT SHORT TO GROUND POSSIBLE CAUSES - Right rear door ajar switch shorted to ground - Right rear door ajar switch sense circuit shorted to ground - Instrument cluster - right rear door ajar shorted A/C Heater Control Illumination Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2193 Test 1 - 3 Test 4 SYMPTOM A/C - HEATER CONTROL ILLUMINATION INOPERATIVE POSSIBLE CAUSES - Check for instrument cluster (MIC) DTCs - Inoperative bulb(s) - A/C - heater control module - Panel lamps driver circuit open - Instrument cluster A/C Status Indicator Flashing Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2194 Test 1 - 2 Test 3 SYMPTOM A/C STATUS INDICATOR FLASHING POSSIBLE CAUSES - A/C cooldown test needs to be run - HVAC door recalibration needs to be run A/C Status Indicator Will Not Illuminate - A/C Heater Control Without EBL SW Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2195 Test 1 SYMPTOM A/C STATUS INDICATOR WILL NOT ILLUMINATE -- A/C - HEATER CONTROL WITHOUT EBL SW POSSIBLE CAUSES - HVAC door recalibration failed - A/C - Heater control module Blend/Mode/Recirc Door Operation Improper - Dual-Zone Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2196 Test 4 - 6 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2197 Test 7 - 8 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER - DUAL-ZONE POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTCs - Check for HVAC door recalibration fault messages - Mode door actuator(s)/linkage(s)/door(s) - Passenger blend door actuator/linkage/door - Driver blend door actuator/linkage/door - Recirculation door actuator/linkage/door Blend/Mode/Recirc Door Operation Improper - Single-Zone Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2198 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2199 Test 4 - 6 Test 7 SYMPTOM Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2200 BLEND/MODE/RECIRC DOOR OPERATION IMPROPER - SINGLE-ZONE POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTCs - Check for HVAC door recalibration fault messages - Mode door actuator(s)/linkage(s)/door(s) - Blend door actuator/linkage/door - Recirculation door actuator/linkage/door Blower Motor Inoperative Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2201 Test 4 - 8 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2202 Test 9 - 10 SYMPTOM BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - IPM fuse #4 - Blower motor feed circuit shorted to ground - Fused B(+) shorted to ground - Blower motor shorted to ground - Blower motor - Blower motor high driver circuit open - Ground circuit open - A/C - heater control module open - Blower motor feed circuit open - Fused B(+) circuit open - Ignition switch open Blower Motor Speeds Incorrect Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2203 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2204 Test 4 - 6 SYMPTOM BLOWER MOTOR SPEEDS INCORRECT POSSIBLE CAUSES - Blower motor driver circuit(s) shorted to ground - A/C - heater control module - Blower motor driver circuit(s) shorted to voltage - Blower motor driver circuits shorted together - A/C - heater control module - speeds incorrect - Blower motor driver circuit(s) open - Blower motor resistor block - open speed EBL Status Indicator Flashing Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2205 Test 1 - 2 Test 3 SYMPTOM EBL STATUS INDICATOR FLASHING TEST NOTE This symptom is diagnosed using the test A/C STATUS INDICATOR FLASHING. POSSIBLE CAUSES - A/C cooldown test needs to be run - HVAC door recalibration needs to be run HVAC System Test Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2206 Test 1 - 2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2207 Test 3 - 4 SYMPTOM HVAC SYSTEM TEST POSSIBLE CAUSES - Attempt to communicate with the PCM - Check for HVAC related DTCs in the PCM - Check for active HVAC DTCs and system test fault messages - Check for HVAC related DTCs in the PCM - Manual A/C system test Horn Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2208 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2209 Test 4 - 8 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2210 Test 9 - 11 SYMPTOM HORNS INOPERATIVE POSSIBLE CAUSES - Horn ground circuit open - Horn relay output circuit open - Horns - Instrument cluster - DTC present - Clockspring - Front control module - Fuse #45 - Horn switch - Horn switch ground - Horn switch sense open - Integrated power module All Gauges Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2211 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2212 Test 4 - 7 Test 8 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2213 SYMPTOM ALL GAUGES INOPERATIVE POSSIBLE CAUSES - No response - PCI BUS - PCI BUS - powertrain control module - PCI BUS - instrument cluster - Fused ignition switch output circuit (unlock/run) short to ground - Instrument cluster ground circuit open - Fused ignition switch output (run/start) circuit open - Fused ignition switch output (run/start) circuit short to ground - Fused ignition switch output (unlock/run) circuit open - Instrument cluster Any PCI Indicator Inoperative Test 1 - 4 SYMPTOM ANY PCI INDICATOR INOPERATIVE POSSIBLE CAUSES - Indicator message not received - No response - instrument cluster Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2214 - No response - PCI BUS - No response - PCI BUS - powertrain control module - Instrument cluster Brake Warning Indicator Always On Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2215 Test 4 - 5 SYMPTOM BRAKE WARNING INDICATOR ALWAYS ON POSSIBLE CAUSES - Brake fluid level switch - Brake fluid level switch sense circuit short to ground - Park brake switch - Park brake switch sense circuit short to ground - Control module - Instrument cluster Brake Warning Indicator Inoperative Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2216 Test 4 - 7 SYMPTOM BRAKE WARNING INDICATOR INOPERATIVE POSSIBLE CAUSES - Brake fluid level switch ground circuit open - Brake fluid level switch - Brake fluid level switch sense circuit open - Park brake switch - Park brake switch sense circuit open - Control module - Instrument cluster Fuel Gauge Inaccurate Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2217 Test 1 - 3 SYMPTOM FUEL GAUGE INACCURATE POSSIBLE CAUSES - DTC present - Instrument cluster - Fuel level sensor wiring - Fuel level sensor One Gauge Inoperative - Gas Engines Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2218 Test 1 - 2 SYMPTOM ONE GAUGE INOPERATIVE - GAS ENGINES POSSIBLE CAUSES - Powertrain control module DTCs - Intermittent condition - Instrument cluster PRNDL Not Displaying Correct Position (EATX Vehicles) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2219 Test 1 - 2 SYMPTOM PRNDL NOT DISPLAYING CORRECT POSITION (EATX VEHICLES) POSSIBLE CAUSES - DTC present - Instrument cluster - Intermittent condition Seat Belt Warning Indicator Always Off Test 1 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS OFF POSSIBLE CAUSES - Seat belt switch sense circuit short to ground - Instrument cluster Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2220 Seat Belt Warning Indicator Always Off - Standard Cab Test 1 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS OFF - STANDARD CAB POSSIBLE CAUSES - Seat belt switch sense circuit short to ground - Instrument cluster Seat Belt Warning Indicator Always on Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2221 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS ON POSSIBLE CAUSES - Seat belt switch - Seat belt switch ground circuit open - Seat belt switch sense circuit open - Instrument cluster Seat Belt Warning Indicator Always on - Standard Cab Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2222 Test 4 - 5 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS ON - STANDARD CAB POSSIBLE CAUSES - Fused ignition switch output (run-acc) circuit open - Seat belt tensioner reducer - Seat belt switch - Seat belt switch ground circuit open - Seat belt switch sense circuit open - Instrument cluster All Door Locks Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2223 Test 1 - 3 SYMPTOM ALL DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - DTC present - Fuse #22 open - Fuse B+ circuit open - Instrument cluster - open circuit Automatic (Rolling) Door Locks Inoperative Test 1 - 4 SYMPTOM AUTO (ROLLING) DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Check the door ajar switch status - With the DRB check for PCM DTC's - With the DRB enable auto door locks - Instrument cluster - auto door locks fail Cylinder Lock Switch Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2224 Test 1 - 3 Test 4 SYMPTOM CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Cylinder lock switch ground open - Cylinder lock switch MUX circuit open - Cylinder lock switch open - Instrument cluster - open Cylinder Lock Switch Will Not Arm and/or Disarm Alarm Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2225 Test 1 - 3 Test 4 SYMPTOM CYLINDER LOCK SWITCH WILL NOT ARM AND/OR DISARM ALARM TEST NOTE This symptom is diagnosed using the test CYLINDER LOCK SWITCH INOPERATIVE. POSSIBLE CAUSES - DTC present - Cylinder lock switch ground open - Cylinder lock switch MUX circuit open - Cylinder lock switch open - Instrument cluster - open Door Lock Inhibit Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2226 Test 1 SYMPTOM DOOR LOCK INHIBIT INOPERATIVE POSSIBLE CAUSES - Chime inoperative - Instrument cluster - door lock inhibit inoperative Left Doors Fail to Lock and Unlock - Quad Cab Test 1 - 4 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2227 Test 5 SYMPTOM LEFT DOORS FAIL TO LOCK AND UNLOCK - QUAD CAB POSSIBLE CAUSES - DTC present - Instrument cluster - door lock driver left doors open - Door unlock driver left doors wire open - Door lock driver left doors wire open - Door lock motor One Door Lock Motor Inoperative Test 1 SYMPTOM ONE DOOR LOCK MOTOR INOPERATIVE POSSIBLE CAUSES - Door lock motor open - Check door lock motor circuit Right Doors Fail to Lock and Unlock - Quad Cab Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2228 Test 1 - 4 Test 5 SYMPTOM RIGHT DOORS FAIL TO LOCK AND UNLOCK - QUAD CAB POSSIBLE CAUSES - DTC present - Instrument cluster - door lock driver right doors open - Door unlock driver right doors wire open - Door lock driver right doors wire open - Door lock motor RKE Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2229 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2230 Test 4 - 6 SYMPTOM RKE INOPERATIVE POSSIBLE CAUSES - Test transmitter with tester - RKE transmitter not programmed - DTC present - Transmitter not programmed - Substitute transmitter - Remote keyless entry module - RKE open - RKE module Alarm Trips On Its Own Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2231 Test 1 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSES - DRB display last VTSS cause - Intermittent condition Driver Door Does Not Trip VTSS Test 1 - 3 SYMPTOM DRIVER DOOR DOES NOT TRIP VTSS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2232 POSSIBLE CAUSES - Driver door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Headlamps Fail to Flash When Alarm Is Tripped Test 1 SYMPTOM HEADLAMPS FAIL TO FLASH WHEN ALARM IS TRIPPED POSSIBLE CAUSES - FCM DTCs or exterior lamp operation - Instrument cluster Horn Fails to Sound When Alarm Is Tripped Test 1 - 2 SYMPTOM HORN FAILS TO SOUND WHEN ALARM IS TRIPPED POSSIBLE CAUSES - DTC present - Horn circuit - Instrument cluster - VTSS Left Rear Door Does Not Trip VTSS (4 Door) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2233 Test 1 - 3 SYMPTOM LEFT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Passenger Door Does Not Trip VTSS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2234 Test 1 - 3 SYMPTOM PASSENGER DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Right Rear Door Does Not Trip VTSS (4 Door) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2235 Test 1 - 3 SYMPTOM RIGHT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSES - Passenger door ajar circuit malfunction - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster VTSS Will Not Arm Properly Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2236 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2237 Test 4 - 8 SYMPTOM VTSS WILL NOT ARM PROPERLY POSSIBLE CAUSES - VTSS not enabled - Check for DTCs and VTSS arming inhibitors - Check for SKIM no response - Cylinder lock switch ground open - Instrument cluster - Cylinder lock switch MUX circuit open - Cylinder lock switch open - Instrument cluster - cylinder lock switch MUX open Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2238 Body Control Module: Component Tests and General Diagnostics Six Step Troubleshooting Procedure Diagnosis of the body system 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 Road Testing Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. WARNING: REASSEMBLE ALL COMPONENTS BEFORE ROAD TESTING A VEHICLE. DO NOT TRY TO READ THE DRBIII(R) SCREEN OR OTHER TEST EQUIPMENT DURING A TEST DRIVE. DO NOT HANG THE DRBIII(R) OR OTHER TEST EQUIPMENT FROM THE REARVIEW MIRROR DURING A TEST DRIVE. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRBIII(R) OR OTHER TEST EQUIPMENT. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. Vehicle Preparation For Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Glossary of Terms ABS antilock brake system ACM airbag control module ACT actuator AECM airbag electronic control module (ACM) ASDM airbag system diagnostic module (ACM) BCM body control module BTSI brake transmission shift interlock CAB controller antilock brake CMTC compass/mini-trip computer CPA connector positive assurance DAB driver airbag DLC data link connector DTC diagnostic trouble code EBL electric back lite (rear window defogger) ECM engine control module EVIC electronic vehicle information center FCM front control module HFM hands free module HVAC heater ventilation, air conditioning IC instrument cluster (MIC) IPM integrated power module JB junction block MIC mechanical instrument cluster NGC next generation controller ODO odometer OR occupant restraint controller PAB passenger airbag PCI Programmable Communication Interface (vehicle communication bus) PCM powertrain control module PDC power distribution center PWM pulse width modulated RKE remote keyless entry RX receive SBS seat belt switch SBT seat belt tensioner SKIM sentry key immobilizer module SKIS sentry key immobilizer system SRS supplemental restraint system SUV sport utility vehicle Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2239 TCCM transfer case control module TCM transmission control module TX transmit UGDO universal garage door opener VFD vacuum fluorescent display VTSS vehicle theft security system Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2240 Body Control Module: Scan Tool Testing and Procedures Diagnostic Trouble Code DRB III Error Messages and Blank Screen Under normal operation, the DRBIII(R) will display one of only two error messages: - User-Requested WARM Boot or User Requested COLD Boot. If the DRBIII(R) should display any other error message, record the entire display and call the STAR Center. This is a sample of such an error message display. - User-Requested WARM Boot by pressing MORE and NO at the same time. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2241 ver: 2.29 date: 1 Oct 93 file: key_itf.cc date: Jan 12 1994 line: 544 err: 0x1 User-Requested WARM Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. or User-Requested COLD Boot by pressing MORE and YES at the same time. ver: 2.29 date: 1 Oct 99 file: keyhnd1.cc date: Mar 8 2000 line:1297 err: 0x1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRBIII(R) DOES NOT POWER UP If the LEDs do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRBIII(R). Check for proper ground connection at DLC cavities 4 and 5. If all connections are proper between the DRBIII(R) and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRBIII(R) may be the result of faulty cable or vehicle wiring. DRBIII(R) Scan Tool DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. DRB III Safety Information WARNING: EXCEEDING THE LIMITS OF THE DRBIII(R) MULTIMETER IS DANGEROUS. READ ALL DRBIII(R) INSTRUCTIONS BEFORE USING THE MULTIMETER. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. - Follow the vehicle manufacturer's service specifications at all times. - Do not use the DRBIII(R) if it has been damaged. - Do not use the test leads if the insulation is damaged or if metal is exposed. - To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. - Choose the proper range and functions for the measurement. Do not try voltage or current measurement that may exceed the rated capacity. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2242 - Do not exceed the limits shown in the table below: - Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. - Use caution when measuring voltage above 25v DC or 25v AC. - Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. - When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. - When measuring current, connect the meter in series with the load. - Disconnect the live test lead before disconnecting the common test lead. - When using the meter function, keep the DRBIII(R) away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2243 Body Control Module: Tools and Equipment DRBIII(R) (diagnostic read-out box) Jumper wires Ohmmeter Voltmeter Test Light 8310 Airbag System Load Tool 8443 SRS Airbag System Load Tool 8815 Diagnostic Pinout Box Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams Sensor-Camshaft Position (Gas) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2247 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor is located above the water pump and under the throttle body. The camshaft position sensor (1) provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses. The PCM determines crankshaft position from the camshaft position sensor and crankshaft position sensor inputs. The PCM uses the input to determine fuel injection synchronization and to determine which ignition coil to energize. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2248 The camshaft position sensor detects when a step down (1) in the camshaft sprocket passes beneath it. When the sensor detects the step down, the input voltage from the sensor to the PCM switches from low (0.3 volts) to high (5 volts). As the step up returns to the sensor, the input voltage switches back to low (0.3 volts). The paper spacer is not used on 8.3L motors. Don't use at all. It plugs up the oil pickup screen. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2249 Camshaft Position Sensor: Service and Repair REMOVAL 8.3L - REPLACING WITH NEW SENSOR The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. If a new replacement camshaft position sensor is to be installed, use this procedure. 1. Disconnect the sensor wiring harness connector from sensor. 2. Remove the sensor mounting bolt. 3. Carefully pry the sensor from the timing chain case/cover in a rocking action with two small screwdrivers. 4. Remove the sensor from vehicle. 8.3L - REPLACING OLD SENSOR WITH ORIGINAL The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. If the original camshaft position sensor is to be removed and installed, such as when servicing the timing chain, timing gears or timing chain cover, use this procedure. 1. Disconnect the sensor harness connector from the sensor. 2. Scribe the sensor for location depth. 3. Remove the sensor mounting bolt. 4. Carefully pry the sensor from the timing chain case/cover in a rocking action with two small screwdrivers. 5. Remove the sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 8.3L - INSTALLATION - WITH NEW SENSOR The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. 1. Apply a small amount of engine oil to the sensor O-ring. A low (step down) and high (step up) area are machined into the camshaft drive gear. The sensor is positioned in the timing gear cover so that a small air gap exists between the face of sensor and the high machined area of cam gear. Before the sensor is installed, the cam gear may have to be rotated. This is to allow the high machined area (step up) on the gear to be directly in front of the sensor mounting hole opening on the timing gear cover. Do not install sensor with gear positioned at low area. When the engine is started, the sensor will be broken. 2. Using a 1/2 in. wide metal ruler, measure the distance from the cam gear to the face of the sensor mounting hole opening on the timing gear cover. 3. If the dimension is approximately 1-15/32 inches or less, it is OK to install sensor. 4. If the dimension is approximately 1-5/8 inches or more, the cam gear will have to be rotated. 5. Attach a socket to the vibration damper mounting bolt and rotate engine until the 1-15/32 inch dimension is attained. 6. Install the sensor into the timing case/cover with a slight rocking action. Do not twist the sensor into position as damage to the O-ring may result. Push the sensor all the way into the cover until the rib material on the sensor contacts the camshaft gear. 7. Install the mounting bolt and tighten to 10.7 N.m (95 in.lbs.) torque. 8. Connect sensor wiring harness to engine harness. When the engine is started, the rib material will be sheared off the face of sensor. This will automatically set sensor air gap. 8.3L - REPLACING OLD SENSOR WITH ORIGINAL The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. When installing a used camshaft position sensor, the sensor depth must be adjusted to prevent contact with the camshaft gear (sprocket). 1. Apply a small amount of engine oil to the sensor O-ring. A low and high area are machined into the camshaft drive gear. The sensor is positioned in the timing gear cover so that a small air gap exists between the face of sensor and the high machined area of cam gear. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2250 Before the sensor is installed, the cam gear may have to be rotated. This is to allow the high machined area on the gear to be directly in front of the sensor mounting hole opening on the timing gear cover. Do not install sensor with gear positioned at low area. When the engine is started, the sensor will be broken. 2. Using a 1/2 in. wide metal ruler, measure the distance from the cam gear to the face of the sensor mounting hole opening on the timing gear cover. 3. If the dimension is approximately 1-15/32 inches or less, it is OK to install sensor. 4. If the dimension is approximately 1-5/8 inches or more, the cam gear will have to be rotated. 5. Attach a socket to the vibration damper mounting bolt and rotate engine until the 1-15/32 inch dimension is attained. 6. Install the sensor into the timing case/cover with a slight rocking action until the sensor is aligned to scribe line. The paper spacer can be used if reinstalling a used sensor. 7. Install sensor mounting bolt and tighten to 10.7 N.m (95 in.lbs.) torque. 8. Connect engine wiring harness to sensor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations Crankshaft Position Sensor: Locations The sensor is located at the rear lower passenger side of motor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2254 Sensor-Crankshaft Position (5.7L/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2255 Crankshaft Position Sensor: Service and Repair REMOVAL The sensor is located at the rear lower passenger side of motor. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting bolt. 3. Pull sensor out. A light tap to top of sensor may ease removal. INSTALLATION 1. Slide the sensor into the hole. 2. Install and tighten the mounting bolt to 11 Nm (95 in. lbs.) torque. 3. Connect the electrical connector to the sensor and lock. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Component Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Component Locations > Page 2260 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Connector Views Data Link Connector Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 2263 Data Link Connector: Description and Operation The Data Link Connector (DLC) (3) is a 16-way molded plastic connector insulator on a dedicated take out of the instrument panel wire harness. This connector is located at the lower edge of the instrument panel, outboard of the steering column. The connector insulator is retained by integral snap features within a rectangular cutout in the stamped metal lower instrument panel reinforcement (2), just below the lower edge of the instrument panel steering column opening cover (1). The Data Link Connector (DLC) is an industry-standard 16-way connector that permits the connection of a diagnostic scan tool to the Programmable Communications Interface (PCI) data bus for interfacing with, configuring, and retrieving Diagnostic Trouble Code (DTC) data from the electronic modules that reside on the data bus network within the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Technical Service Bulletins > Safety Systems - Inadvertent Damage/Disabling Electronic Throttle Actuator: Technical Service Bulletins Safety Systems - Inadvertent Damage/Disabling NUMBER: 08-027-04 GROUP: Electrical DATE: July 30, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-017-01, DATED SEPTEMBER 21, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND YEARS. SUBJECT: Safety Systems - Vehicle Modifications/Repair MODELS: 2002 - **2003** (AB) Ram Van/Wagon 2002 - **2004** (AN) Dakota 2002 (BR/BE) Ram Pickup **2004 - 2005 (CS) Pacifica** 2002 - **2003** (DN) Durango **2003 - 2005 (DR/DH) Ram Pickup** **2004 - 2005 (HB) Durange 2002 - **2005** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 2002 - **2005** (KJ) Liberty 2002 - **2004** (LH) Concorde/Intrepid/300M **2005 (LX) 300/Magnum ** **2005 (ND) Dakota** 2002 (PG) PT Cruiser (International Markets) 2002 - **2005** (PL) Neon 2002 - **2003** (PR) Prowler 2002 - **2005** (PT) Chrysler PT Cruiser 2002 - **2005** (RS) Town & Country/Caravan/Voyager 2002 - **2005** (RG) Chrysler Voyager (International Markets) 2002 (SR) Viper 2002 - **2005** (ST) Sebring Coupe/Stratus Coupe 2002 - **2005** (TJ) Wrangler **2002 - 2005 (VA) Sprinter** 2002 - **2004** (WJ) Grand Cherokee **2005 (WK) Grand Cherokee** Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Technical Service Bulletins > Safety Systems - Inadvertent Damage/Disabling > Page 2268 2002 - **2004** (WG) Grand Cherokee (International Markets) **2005 (WH) Grand Cherokee (International Markets)** **2003 - 2005 (ZB) Viper** **2004 - 2005 (ZH) Crossfire** DISCUSSION: Current DaimlerChrysler vehicles may contain any or all of the following safety Systems: driver airbags, passenger airbags, side curtain airbags, side seat airbags, seat belt pre-tensioners, anti-lock brakes, electronic throttle control, or traction control. All these systems contain multiple sophisticated sensitive electrical and mechanical components. The location and function of all safety system components must be determined before performing repairs; including accident, mechanical or electrical, or vehicle modifications such as adding an after-market sunroof. WARNING: ANY INADVERTENT SAFETY SYSTEM COMPONENT OR ASSOCIATED WIRING DAMAGE/MODIFICATION OR COMPONENT LOCATION CHANGE MAY DISABLE ANY OF THE SAFETY SYSTEMS. Refer to the appropriate vehicle Service Information to determine location and function of all safety systems before servicing vehicle. All systems should be checked for functionality after the vehicle modifications/repairs are complete. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Indicator > Component Information > Description and Operation Electronic Throttle Control Indicator: Description and Operation An Electronic Throttle Control (ETC) indicator is standard equipment on all gasoline engine instrument clusters. However, on vehicles not equipped with the I/I optional 5.7 liter gasoline engine, this indicator is electronically disabled. The ETC indicator is located on the right side of the instrument cluster, to the right of the engine temperature gauge. The ETC indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Electronic Throttle Control" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ETC indicator is serviced as a unit with the instrument cluster. The Electronic Throttle Control (ETC) indicator gives an indication to the vehicle operator when the ETC system is faulty or inoperative. The ETC indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The ETC indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the ETC indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the ETC indicator is illuminated for about six seconds. The entire six second bulb test is a function of the PCM. - ETC Lamp-On Message - Each time the cluster receives a lamp-on message from the PCM, the ETC indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the PCM message. The indicator remains illuminated solid or continues to flash for about twelve seconds or until the cluster receives a lamp-off message from the PCM, whichever is longer. If the indicator is illuminated solid with the engine running the vehicle will usually remain drivable. If the indicator is flashing with the engine running the vehicle may require towing. A flashing indicator means the ETC system requires immediate service. - Communication Error - If the cluster receives no ETC lamp messages for three consecutive seconds, the ETC indicator is illuminated. The indicator remains illuminated until the cluster receives a single lamp-off message from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the ETC indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The actuator test illumination of the ETC indicator is a function of the PCM. The PCM continually monitors the ETC system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-on or lamp-off messages to the instrument cluster. If the PCM sends a lamp-on message after the bulb test, it indicates that the PCM has detected a system malfunction and/or that the ETC system is inoperative. The PCM will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ETC indicator fails to illuminate due to an open or short in the cluster ETC indicator circuit, the cluster sends a message notifying the PCM of the condition, the instrument cluster and the PCM will each store a DTC. For proper diagnosis of the ETC system, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the ETC indicator, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Powertrain Control Module: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2285 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2286 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2287 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Powertrain Control Module: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2297 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2298 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2299 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 2302 Powertrain Control Module: Connector Locations Right Rear Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 2303 Right Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 2304 Right Rear Engine Wiring (SRT-10) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Connector Views Powertrain Control Module: Connector Views Module-Powertrain Control C1 (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Connector Views > Page 2307 Module-Powertrain Control C2 (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Connector Views > Page 2308 Module-Powertrain Control C3 (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Powertrain Control Module: Description and Operation PCM The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - EATX module (if equipped) - Engine coolant temperature sensor - Fuel level (through J1850 circuitry) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2311 - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission converter clutch circuit. Driven through J1850 circuits. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2312 Powertrain Control Module: Description and Operation Modes of Operation As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (02S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (02S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the 02S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The 02S sensor heater element is energized via the ASD or 02S heater relay. The 02S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2313 This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. - When engine has reached operating temperature, the PCM will begin monitoring 02S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (02S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2314 ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2315 Powertrain Control Module: Description and Operation 5 Volt Supplies Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2316 Powertrain Control Module: Description and Operation Ignition Circuit Sense This circuit ties the ignition switch to the Powertrain Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2317 Powertrain Control Module: Description and Operation PCM The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - EATX module (if equipped) - Engine coolant temperature sensor Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2318 - Fuel level (through J1850 circuitry) - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission converter clutch circuit. Driven through J1850 circuits. Modes of Operation As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (02S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (02S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the 02S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2319 - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The 02S sensor heater element is energized via the ASD or 02S heater relay. The 02S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. - When engine has reached operating temperature, the PCM will begin monitoring 02S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2320 When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (02S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2321 Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 Volt Supplies Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). Ignition Circuit Sense This circuit ties the ignition switch to the Powertrain Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Power Grounds The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: - Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors Sensor Return The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > PCM/ECM/SKIM Programming Powertrain Control Module: Service and Repair PCM/ECM/SKIM Programming NOTE: Before replacing the Powertrain Control Module (PCM) or Engine Control Module (ECM), be certain to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM/ECM driver/control circuit failures are caused by internal component failures (i.e. relays and solenoids) and shorted circuits (i.e. pull-ups, drivers, and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has been set. When a Powertrain Control Module (PCM) for a gasoline engine, or a Engine Control Module for a diesel engine and the Sentry Key Immobilizer Module (SKIM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM/ECM. 2. Program the new SKIM. 3. Replace all ignition keys and program them into the new SKIM. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > PCM/ECM/SKIM Programming > Page 2324 Powertrain Control Module: Service and Repair Programming the PCM/ECM/SKIM The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKIM is replaced, it is necessary to program the Secret Key into the new modules using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool menu for the module being replaced as appropriate. NOTE: - Be certain to enter the correct country code for the SKIM. If the incorrect country code is programmed into the SKIM, it cannot be changed and the SKIM must be replaced. - If the PCM/ECM and the SKIM are replaced at the same time, all vehicle ignition keys will need to be replaced and the new keys programmed into the new SKIM. - Programming the PCM/ECM or SKIM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > PCM/ECM/SKIM Programming > Page 2325 Powertrain Control Module: Service and Repair Programming Ignition Keys to the SKIM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKIM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKIM. To program ignition keys into the SKIM, follow the programming steps outlined in the diagnostic scan tool for "Program Ignition Keys or Key FOBs" under the "SKIM" menu item. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM, that key has acquired the Secret Key for that SKIM and cannot be transferred to any other SKIM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - Programming Not Attempted - The scan tool attempts to read the programmed key status and there are no keys programmed into SKIM memory. - Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program an ignition key transponder due to one of the following: The ignition key transponder is faulty. - The ignition key transponder is or has been already programmed to another vehicle. - 8 Keys Already Learned, Programming Not Done - The SKIM transponder ID memory is full. - Learned Key In Ignition - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKIM memory. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > PCM/ECM/SKIM Programming > Page 2326 Powertrain Control Module: Service and Repair Module - Powertrain Control CAUTION: - Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using the DRB scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. - Use the DRB scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. REMOVAL The PCM (1) is located in the engine compartment attached to the dash panel (3). To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > PCM/ECM/SKIM Programming > Page 2327 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors (four 38-way connectors if equipped with NGC) from PCM (1). 4. Remove three PCM mounting bolts (3) and remove PCM from vehicle. INSTALLATION 1. Install PCM (3) and 3 mounting bolts (4) to vehicle. 2. Tighten bolts. Refer to torque specifications. 3. Check pin connectors in the PCM and the three 32-way connectors (four 38-way connectors if equipped with NGC) for corrosion or damage. Also, the pin heights in connectors should all be same. Repair as necessary before installing connectors. 4. Install three 32-way connectors (four 38-way connectors if equipped with NGC). 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install negative battery cable. 7. The 5.7L V-8 engine is equipped with a fully electronic accelerator pedal position sensor. If equipped with a 5.7L, also perform the following 3 steps: a. Connect negative battery cable to battery. b. Turn ignition switch ON, but do not crank engine. c. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn electrical parameters. d. The DRB III(R) Scan Tool may also be used to learn electrical parameters. Go to the Miscellaneous menu, and then select ETC Learn. 8. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set. 9. If necessary, use DRB III(R) Scan Tool to erase any Diagnostic Trouble Codes (DTC's) from PCM. Also use the DRB scan tool to reprogram new PCM with vehicles original Vehicle Identification Number (VIN) and original vehicle mileage. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Sensor-Fuel Level Sending Unit Fuel Level Sensor: Locations Sensor-Fuel Level Sending Unit The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Sensor-Fuel Level Sending Unit > Page 2335 Fuel Level Sensor: Locations Fuel Pump Module The fuel pump module assembly is located on the top of the fuel tank. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2336 Fuel Level Sensor: Description and Operation 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 variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit 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 diagnostic 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2337 Fuel Level Sensor: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation. 2. Disconnect 4-wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. Refer to Special Tools in Wiring for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4-wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/ Installation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations > Component Locations 3.7L Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations > Component Locations > Page 2342 Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations > Page 2343 Motor-IAC (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations > Page 2344 Idle Air Control (IAC) Motor: Description and Operation The idle air control motor is mounted at the front right of the intake manifold. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations > Page 2345 Idle Air Control (IAC) Motor: Service and Repair REMOVAL The IAC motor is inserted into a housing at the front of the intake manifold. The IAC motor and housing are serviced together. 1. Remove housing to manifold screws. Remove IAC motor and housing. 2. Disconnect the electrical connector from IAC motor. INSTALLATION The IAC motor is inserted into a housing at the front of the intake manifold. The IAC motor and housing are serviced together. 1. Attach electrical connector to IAC motor. 2. Install IAC motor into and housing on manifold. Tighten mounting screws to 4 Nm (35 in. lbs.) torque. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2350 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2351 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2352 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2353 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2354 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2355 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2356 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2357 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2358 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2359 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2360 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2361 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2362 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2363 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2364 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2365 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2366 Information Bus: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2367 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2368 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2369 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2370 Information Bus: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-18-2 (Gas) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2371 8w-18-3 (Gas) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2372 8w-18-4 (Diesel) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2373 8w-18-5 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2374 8w-18-6 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2375 Information Bus: Description and Operation The DaimlerChrysler Programmable Communication Interface (PCI) data bus system is a single wire multiplex system used for vehicle communications on many DaimlerChrysler Corporation vehicles. Multiplexing is a system that enables the transmission of several messages over a single channel or circuit. All DaimlerChrysler vehicles use this principle for communication between various microprocessor-based electronic control modules. The PCI data bus exceeds the Society of Automotive Engineers (SAE) J1850 Standard for Class B Multiplexing. Many of the electronic control modules in a vehicle require information from the same sensing device. In the past, if information from one sensing device was required by several controllers, a wire from each controller needed to be connected in parallel to that sensor. In addition, each controller utilizing analog sensors required an Analog/Digital (A/D) converter in order to "read" these sensor inputs. Multiplexing reduces wire harness complexity, sensor current loads and controller hardware because each sensing device is connected to only one controller, which reads and distributes the sensor information to the other controllers over the data bus. Also, because each controller on the data bus can access the controller sensor inputs to every other controller on the data bus, more function and feature capabilities are possible. In addition to reducing wire harness complexity, component sensor current loads and controller hardware, multiplexing offers a diagnostic advantage. A multiplex system allows the information flowing between controllers to be monitored using a diagnostic scan tool. The DaimlerChrysler system allows an electronic control module to broadcast message data out onto the bus where all other electronic control modules can "hear" the messages that are being sent. When a module hears a message on the data bus that it requires, it relays that message to its microprocessor. Each module ignores the messages on the data bus that are being sent to other electronic control modules. Data exchange between modules is achieved by serial transmission of encoded data over a single wire broadcast network. The wire colors used for the PCI data bus circuits are yellow with a violet tracer, or violet with a yellow tracer, depending upon the application. The PCI data bus messages are carried over the bus in the form of Variable Pulse Width Modulated (VPWM) signals. The PCI data bus speed is an average 10.4 Kilo-bits per second (Kbps). By comparison, the prior two-wire Chrysler Collision Detection (CCD) data bus system is designed to run at 7.8125 Kbps. The voltage network used to transmit messages requires biasing and termination. Each module on the PCI data bus system provides its own biasing and termination. Each module (also referred to as a node) terminates the bus through a terminating resistor and a terminating capacitor. There are two types of nodes on the bus. The dominant node terminates the bus through a 1 KW resistor and a 3300 pF capacitor. The Powertrain Control Module (PCM) is the only dominant node for the PCI data bus system. A standard node terminates the bus through an 11 KW resistor and a 330 pF capacitor. The modules bias the bus when transmitting a message. The PCI bus uses low and high voltage levels to generate signals. Low voltage is around zero volts and the high voltage is about seven and one-half volts. The low and high voltage levels are generated by means of variable-pulse width modulation to form signals of varying length. The Variable Pulse Width Modulation (VPWM) used in PCI bus messaging is a method in which both the state of the bus and the width of the pulse are used to encode bit information. A "zero" bit is defined as a short low pulse or a long high pulse. A "one" bit is defined as a long low pulse or a short high pulse. A low (passive) state on the bus does not necessarily mean a zero bit. It also depends upon pulse width. If the width is short, it stands for a zero bit. If the width is long, it stands for a one bit. Similarly, a high (active) state does not necessarily mean a one bit. This too depends upon pulse width. If the width is short, it stands for a one bit. If the width is long, it stands for a zero bit. In the case where there are successive zero or one data bits, both the state of the bus and the width of the pulse are changed alternately. This encoding scheme is used for two reasons. First, this ensures that only one symbol per transition and one transition per symbol exists. On each transition, every transmitting module must decode the symbol on the bus and begin timing of the next symbol. Since timing of the next symbol begins with the last transition detected on the bus, all of the modules are re-synchronized with each symbol. This ensures that there are no accumulated timing errors during PCI data bus communication. The second reason for this encoding scheme is to guarantee that the zero bit is the dominant bit on the bus. When two modules are transmitting simultaneously on the bus, there must be some form of arbitration to determine which module will gain control. A data collision occurs when two modules are transmitting different messages at the same time. When a module is transmitting on the bus, it is reading the bus at the same time to ensure message integrity. When a collision is detected, the module that transmitted the one bit stops sending messages over the bus until the bus becomes idle. Each module is capable of transmitting and receiving data simultaneously. The typical PCI bus message has the following four components: - Message Header - One to three bytes in length. The header contains information identifying the message type and length, message priority, target module(s) and sending module. - Data Byte(s) - This is the actual message that is being sent. - Cyclic Redundancy Check (CRC) Byte - This byte is used to detect errors during a message transmission. - In-Frame Response (IFR) byte(s) - If a response is required from the target module(s), it can be sent during this frame. This function is described in greater detail in the following paragraph. The IFR consists of one or more bytes, which are transmitted during a message. If the sending module requires information to be received immediately, the target module(s) can send data over the bus during the original message. This allows the sending module to receive time-critical information without having to wait for the target module to access the bus. After the IFR is received, the sending module broadcasts an End of Frame (EOF) message and releases control of the bus. The PCI data bus can be monitored using a diagnostic scan tool. It is possible, however, for the bus to pass all diagnostic scan tool tests and still be faulty if the voltage parameters are all within the specified range and false messages are being sent. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2379 Knock Sensor: Diagrams Sensor-Knock No.1 (5.7L/SRT) Sensor-Knock No.2 (5.7L/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2380 Knock Sensor: Description and Operation The sensors are used only with 3.7L V-6, 4.7L V-8 and 5.7L V-8 engines. On 3.7L V-6 and 4.7L V-8 engines, the 2 knock sensors are bolted into the cylinder block under the intake manifold. On 5.7L V-8 engines, 2 knock sensors are also used. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. 3.7L V-6/4.7L V-8/5.7L V-8 Engines Only Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2384 Main Relay (Computer/Fuel System): Description and Operation PCM OUTPUT The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. PCM OUTPUT The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2385 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2386 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Wiring Diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. This indicator is located on the left side of the instrument cluster, to the left of the voltage gauge. The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for "Engine" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or the Engine Control Module (ECM) on vehicles with a diesel engine has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM or ECM over the Programmable Communications Interface (PCI) data bus. The MIL Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the MIL for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the indicator is illuminated for about two seconds as a bulb test. The entire bulb test is a function of the PCM or ECM. - MIL Lamp-On Message - Each time the cluster receives a MIL lamp-on message from the PCM or ECM, the indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the PCM or ECM message. For some DTC's, if a problem does not recur, the PCM or ECM will send a lamp-off message automatically. Other DTC's may require that a fault be repaired and the PCM or ECM be reset before a lamp-off message will be sent. - Communication Error - If the cluster receives no messages from the PCM or ECM for about ten seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the PCM or ECM. - Actuator Test - Each time the cluster is put through the actuator test, the MIL indicator will be turned on during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. On vehicles with a diesel engine, the ECM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM or ECM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For further diagnosis of the MIL or the instrument cluster circuitry that controls the LED, refer to testing. If the instrument cluster turns on the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the MIL, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations Manifold Pressure/Vacuum Sensor: Component Locations The MAP sensor (2) mounts to the drivers side intake manifold plenum. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations > Page 2394 Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2395 Sensor-Map (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2396 Manifold Pressure/Vacuum Sensor: Description and Operation The MAP sensor (2) mounts to the drivers side intake manifold plenum. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum. During key-on (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in. Hg. If a storm goes through, it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2397 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL The manifold absolute pressure sensor is mounted on the drivers side of the intake manifold. 1. Disconnect the electrical connector from the MAP sensor. 2. Remove MAP sensor mounting screws. INSTALLATION 1. Install the MAP sensor to the intake manifold. 2. Install MAP sensor mounting screws and tighten mounting screws to 4 Nm (35 in. lbs.). 3. Connect the electrical connector to the MAP sensor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Right Front Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2403 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2404 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2405 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2406 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2407 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2408 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2409 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2410 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2411 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2412 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2413 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2414 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2415 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2416 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2417 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2418 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2419 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2420 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2421 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2422 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2423 Sensor-Engine Oil Pressure (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations 4 Sensor Vehicle 2 Sensor Vehicle (1 = Downstream, 2 = Upstream) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2428 Oxygen Sensor: Connector Locations Left Transmission (RFE) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2429 Right Transmission (RFE) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2430 Manual Transmission (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2431 Transmission And Exhaust (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2432 Oxygen Sensor: Diagrams Sensor-Oxygen-Left Front (SRT) Sensor-Oxygen-Left Rear (SRT) Sensor-Oxygen-Right Front (SRT) Sensor-Oxygen-Right Rear (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2433 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2434 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the engine or emission package, the vehicle ] may use a total of either 2 or 4 sensors. Federal Emission Packages : Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2435 Oxygen Sensor: Service and Repair REMOVAL CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support vehicle. 2. Disconnect wire connector from O2S sensor. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in exhaust pipe using appropriate tap. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. 1. Install O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect O2S sensor wire connector. 3. Lower vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations Integrated Power Module Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2439 Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2440 Oxygen Sensor Relay: Description and Operation DESCRIPTION The Oxygen Sensors (02S) are attached to, and protrude into the vehicle exhaust system Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors Federal Emission Packages Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2) With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor The downstream sensor (1/2) is located just after the main catalytic convertor California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as ill and 2/1) and 2 downstream (referred to as 1/2 and 2/2) With this emission pack-age, the right upstream sensor (2/i) is located in the right exhaust downpipe just before the mini-catalytic convertor The left upstream sensor (1/i) is located in the left exhaust downpipe just before the mini-catalytic convertor The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2446 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2447 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2448 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2449 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2450 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2451 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2452 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2453 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2454 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2455 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2456 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2457 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2458 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2459 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2460 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2461 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2462 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2463 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2464 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2465 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2466 Body Control Module: Electrical Diagrams Airbag System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2467 Premium Audio System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2468 Base Audio System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2469 Remote Radio Controls Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2470 PCI Bus Communication Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2471 PCM Communication - JTEC PCM Communication - NGC Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2472 ECM Communication - Diesel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2473 Door Ajar System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2474 Heated Mirror System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2475 Rear Window Defogger Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2476 Exterior Lights Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2477 Heating A/C System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2478 Horn System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2479 Instrument Cluster Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2480 Overhead Console Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2481 Power Door Locks Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2482 Telecommunications - Hands Free System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2483 Vehicle Theft Security System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 2484 Wipers Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information SERVICING SUB-ASSEMBLIES Some components of the body system are intended to be serviced as an assembly only. Attempting to remove or repair certain system subcomponents may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures should be serviced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 2487 Body Control Module: Vehicle Damage Warnings ELECTRICAL TESTING PRECAUTIONS Before disconnecting any control module, make sure the ignition is "off". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description Body Control Module: Description and Operation System Description IDENTIFICATION OF SYSTEM The vehicle systems that are part of the "body" system are: - Airbag - Audio (with amplifier on premium systems) - Chime - Communication - Door Ajar System - Electrically heated system - Exterior lighting - Heating and A/C - Horn - Instrument Cluster - Interior Lighting - Memory Seat - Overhead Console - Power Door Lock/RKE - Power windows - Telecommunications (hands free phone) - Vehicle theft security system (VTSS) - Windshield Wiper and Washer SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 2004 DR consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI 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 information to perform its function. It will only respond to messages "addressed" to it through binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the communication section of this general information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2490 Body Control Module: Description and Operation Functional Operation Airbag System The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end or side collisions. The system is most effective when used in conjunction with the seat belt system. On some models the ACM supports Seat Belt Tensioners, Passenger Airbag Off Switch, and others Impact Sensor. It may be necessary to use the DRBIII(R) to reconfigure the ACM to the vehicle equipment. The airbag control module (ACM) is an electronic module that monitors the airbag system for proper operation, stores diagnostic trouble code (DTCs), controls the airbag warning lamp and contains the sensor and actuator that is responsible for driver, passenger, and curtain airbag deployment. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTCs) to the technician through the DRBIII(R) via the PCI bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Electro/Mechanical Instrument Cluster (EMIC) from the ACM via the PCI bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the "run" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6-8 seconds. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds, then goes off, there is usually an intermittent problem in the system. 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 OR DEATH. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. The DR will have two Airbag Control Modules. Each ACM is specifically calibrated for one body type, light duty or heavy duty. To determine the body types the ACM monitors the PCI Bus for a message containing the complete VIN. The ACM uses the 6th digit of the VIN to identify the heavy duty or light duty vehicle. The 6th digit of the VIN will be a number 1 for light-duty vehicle and a 2, 3 or 4 for heavy-duty vehicle. If the PCI Bus VIN message 6th character matches the ACM body type, the VIN will be stored within 5.6 seconds after ignition on. After the VIN is stored, the ACM verifies PCI Bus VIN message within 2.6 seconds after the ignition is turned on. If two valid matching PCI Bus VIN messages are not received within 5.6 seconds the ACM will set a Missing Original VIN DTC. If the ACM and PCM module types, 6th character of the VIN, light-duty or heavy-duty do not match the Calibration Mismatch DTC will be set. CAUTION: Therefore, the practice of exchanging (swapping) airbag control modules, instrument clusters, powertrain control modules and other electronic modules in this vehicle with those removed from another vehicle must always be avoided. DRIVER AIRBAG The airbag protective trim cover is the most visible part of the driver side airbag system. 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. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and hybrid inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. CLOCKSPRING The clockspring is mounted on the steering column behind the steering wheel. This assembly consist of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wiring and the driver airbag, the horn, and the vehicle speed control switches if equipped. The clockspring must be properly centered when it is reinstalled on the steering column following any service procedure, or it could be damaged. The clockspring cannot be repaired and it must be replaced. PASSENGER AIRBAG When supplied with the proper electrical signal the passenger airbag inflator or inflators discharge the gas directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2491 WARNING: THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE.BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. PASSENGER AIRBAG ON-OFF SWITCH The Passenger Airbag On-Off Switch allows the customer to turn the passenger airbag function ON or OFF. The OFF indicator will be illuminated whenever the switch is turned to the off position and for 2 seconds at ignition on for an indicator bulb test. The switch assembly is mounted in the center of instrument panel to make the OFF indicator visible to all front seat occupants. WARNING: TO AVOID PERSONAL INJURY OR DEATH, ALWAYS CHECK THE PASSENGER AIRBAG ON-OFF SWITCH POSITION BEFORE DRIVING THE VEHICLE. A SWITCH IN THE WRONG POSITION INCREASES THE RISK OF SERIOUS INJURY OR DEATH IN A COLLISION. To operate, insert the ignition key into the switch keyhole, push key in to release the internal plunger, and rotate to the desired switch position. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. The ignition key is the only key or object that should ever be inserted into the switch. NOTE: Do not turn the On-Off switch with the ignition on. The ACM continuously monitors the resistance of the Passenger Airbag On-Off Switch circuits to identify the switch position and provide circuit diagnostics. The on-off switch ON position resistance is 175 to 190 ohms and the OFF position resistance is 820 to 870 ohms. If the on-off switch circuits are open, shorted to ground or battery the ACM will set active and stored DTC. Upon receiving a switch diagnostic trouble code the airbag warning indicator, in the instrument cluster, will be turned on by the ACM. Whenever the airbag warning indicator is illuminated, the ACM should be the first module interrogated. SEAT BELT TENSIONER Front seat belt systems incorporate Tensioner Modules (SET). At the onset of an impact event each tensioner uses a pyrotechnic device, which is triggered simultaneously with the airbags, to rapidly retract the seat belts. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. The ACM module monitors the Seat Belt Tensioners circuit resistance and reports active and stored DTC's if any problem is found. SIDE IMPACT SENSORS The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration and when combined with the ACM Accelerometer provides verification of the direction and severity of a side impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Airbag Control Module. The ACM microprocessor continuously monitors all of the passive restraint system electrical circuits to determine the system readiness. If the ACM detects a system fault, it sets a Diagnostic Trouble Code and controls the airbag warning indicator operation accordingly. The side impact sensors receive battery current and ground through dedicated driver and passenger sensor signal and ground circuits from the ACM. The impact sensors and the ACM communicate by modulating the current in the sensor signal circuit. If the sensor is dropped it must be replaced. Disconnect the battery or remove both airbag fuses before servicing impact sensors. CAUTION: Do not remove or install the impact sensors while the sensor is attached to the vehicle wiring. CURTAIN AIRBAGS The Left and Right curtain airbags are located in the outboard edge of the roof under the headliner, just above the door openings. When supplied with the proper electrical signal the inflator can discharge the compress gas directly into the curtain airbag. Upon deployment, the curtain will tear open the headliner allowing the curtain airbag to fully deploy between the headliner and seat. The curtain airbag cannot be repaired and must be replaced if deployed or in any way damaged. WARNING: THE CURTAIN AIRBAG CONTAINS AN INERT GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2492 SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. SPECIAL TOOLS Some airbag diagnostic test use special tools, airbag load tools, 8310 and 8443 for testing squib circuits. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of an Driver or Passenger Airbag, curtain airbag, clockspring, or seat belt tensioner (use a jumper if needed). Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective component has been removed from the system and should be replaced. If the DTC is still active, continue this process until all component in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed the squib wiring can be tested for open and shorted conditions. AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRBIII(R). Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. ACTIVE CODES The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. STORED CODES Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned off. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. Maintain a safe distance from all airbags while performing the following inspection. If no obvious problems are found, erase stored codes, and with the ignition "on" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Audio System The factory installed radio receiver communicates on the Programmable Communication Interface (PCI) data bus network. The PCI Bus inputs into the Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2493 radio are used for VF dimming and remote steering wheel controls. All the radios are capable of displaying faults and allowing certain actuation tests through the use of the DRBIII(R). When attempting to perform PCI Bus diagnostics, the first step is to identify the radio in use in the vehicle. When trouble shooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term output refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio, or wiring could be at fault. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit, A faulty speaker could not cause this DTC. REMOTE RADIO CONTROLS These radios can be controlled via remote radio switches (optional). These switches are located on the back side of the steering wheel. They control mode, preset, seek up, seek down, volume up and volume down functions. These functions are inputs to the Instrument Cluster (MIC) and can be read with the DRBIII(R). The switches are a multiplexed signal to the MIC. The radio control MUX circuit is a 5 volt line that is pulled to ground through different value resistors built into the switches. This causes a voltage drop to be seen by the MIC and it sends a specific message to the radio on the PCI Bus circuit. The radio then responses to the message. This circuit is fairly simple to troubleshoot. The circuit must be complete from the switches in the steering wheel to the MIC. The ground must be complete so that the switches can cause the voltage drop for the MIC to see. The circuit passes through the clockspring so continuity through this devise must be verified. AMPLIFIER (PREMIUM SYSTEM) The Premium Audio Amplifier uses a microprocessor for audio digital signal processing (DSP) and system diagnostics. DSP provides a more accurate and consistent match of the audio system equalization to the vehicle interior. The DR Ram amplifier has six channels for superior sound quality. The amplifier reads the VIN from the PCI bus and sets itself to match the vehicle. The amplifier will send four beeps to the vehicle speakers at ignition on, if it does not read the VIN correctly. A replacement amplifier may beep at the first power up, but if these beeps are heard after the first ignition on, the DRBIII(R) should be used to verify the amplifier is connected to the PCI bus and that the VIN on the PCI bus is correct. The amplifier, wiring to the speakers and the speakers work independently from the radio. The amplifier's microprocessor supports several diagnostic functions. Tests can be run from the DRBIII(R) that will help in diagnosing audio system problems. The DRBIII(R) can display fault messages when an input or output problem to the amplifier is detected. The amplifier can detect wiring shorts and suggest which wires are likely to be shorted. The amplifier can send test signals that can be used to verify that the amplifier, speakers, and wiring to the speakers are operating properly. The amplifier can also be used to test if the radio is sending audio signals to it. The DRBIII(R) can be used to verify the amplifier equalization setting matches the vehicle, in case there is a sound quality complaint. Using the DRBIII(R) audio system diagnostics can determine the nature of the problem. Diagnostic tests the Amplifier can perform through the DRBIII(R): Continuous Tone Test - This test will send a continuous tone to each speaker and will verify the integrity of an individual channel. PCI Amplifier Test - This test will detect a PCI bus or checksum failure. Input Test - This test will detect the activity on the amplifiers input channels from the radio. Speaker Output Test - This test will detect the activity on the amplifiers output channels to the speakers NAVIGATION RADIO The optional navigation radio system receives GPS signals from up to eight satellites to display the position and direction of the vehicle. Map information is supplied through a DVD-ROM. An electronic gyrosensor and the vehicle's speed sensor enable the system to display the present vehicle position even in locations where GPS signals may be blocked. When a destination is selected, the navigation system uses information from the map to quickly calculate a route. As the vehicle is driven along the chosen route, the operator is guided with pictorial displays and voice prompts. For complete operating instructions, refer to the manual included with the vehicle. Communication The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25. Additional tracer colors may be added to the violet in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on this vehicle: - Front Control Module - Airbag Control Module - Controller Antilock Brake Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2494 - A/C Heater Control Module - Powertrain Control Module (gas only) - Engine Control Module (diesel only) - Radio - Amplifier (if equipped) - Hands Free Module - Transfer Case Control Module (if equipped) - Sentry Key Immobilizer Module - Compass Mini-Trip Computer (if equipped) - Electro/Mechanical Instrument Cluster Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRBIII(R) lab scope. The 12v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open PCI circuit at the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: - All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - Dashed lines in the overhead console ambient temperature display - No response received from any module on the PCI bus (except the ECM/PCM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRBIII(R). Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRBIII(R). If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRBIII(R) may display "BUS ± SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRBIII(R) and in noway indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2495 NOTE: The 2004 DR 3.7L, 4.7L, and 5.7L vehicles are equipped with the Powertrain Control Module and Transmission Control Module combined in a single control module. This module is the Next Generation Controller (NGC) for DaimlerChrysler and will be referred to as the Powertrain Control Module (PCM). The PCM has four color coded connectors C1/A through C4/D, (C1/A BLK, C2/B - ORANGE, C3/C - WHITE, C4/D -GREEN), with each connector containing 38 pins. The 5.9L Electronic Fuel Injection 24 valve Turbo Diesel has an Engine control module (ECM) CM845. New Diagnostic procedures and New DTC numbers are two of the changes you will see which reflect the new combined module technology. There are new Verification tests and module replacement procedures for the new PCM. Two tools are required to diagnose and repair the PCM terminals and harness connectors: 1. Miller #3638 Terminal Removal Pick must be used to release the connector terminals or harness and connector damage will occur. 2. Miller #8815 Pinout Box must be used to probe the PCM terminals or terminal damage will occur. Door Ajar System The door ajar state is used as an input for various control modules on the vehicle. The DRBIII(R) will display the state of the door ajar switches in Inputs/ Outputs. It's important to note, that when a door is closed, the switch state on the DRBIII(R) will show OPEN, and when the door is open, the switch state will show CLOSED. During diagnosis, if a door is closed and the DRBIII(R) displays the switch state as CLOSED, it indicates a shorted Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2496 door ajar circuit. If the door is open and the DRBIII(R) displays the switch state as OPEN, it indicates an open door ajar circuit. Compass Mini-Trip Computer (CMTC) When equipped, the Compass/Mini Trip Computer (CMTC) is located in the overhead console. The CMTC supplements the standard vehicle instrumentation. The CMTC uses a vacuum fluorescent (VF) display to supply the vehicle operator with a compass heading, outdoor temperature, average fuel economy, distance to empty, trip odometer, and elapsed ignition on time. If equipped, the CMTC is also available with an integrated Universal Garage Door Opener (UGDO) known as "HomeLink ■. The CMTC function buttons are labeled C/T, RESET, STEP, and US/M. The three UGDO buttons are labeled with dots to indicate the channel number. Most of the CMTC display information is received over the PCI bus. The CMTC sends and receives data over the PCI bus, communicating with the FCM (Diesel), PCM (3.7L, 4.7L, 5.7L), and the Instrument Cluster. VEHICLE INFORMATION DISPLAY The CMTC provides the following functions: - Compass direction - Outside temperature - Elapsed ignition on time - Distance to empty - Average fuel economy - Trip Odometer The CMTC will not display information for any of the screens for which it did not receive the proper PCI bus data. Refer to the symptom list in the Overhead Console section for problems related to the CMTC. The CMTC receives the following messages from the Instrument Cluster: - Verification of US/Metric status - VF display dimming brightness and exterior lamp status - Trip Odometer data The CMTC receives the following message from the PCM: - Vehicle Speed US/M BUTTON The US/M button is used to toggle the display between English and Metric measurement units. STEP BUTTON The STEP Button can be used in one of the following ways: 1. To sequentially select one of 4 displays or blank display in the following order: - Average Fuel Economy - Distance to Empty - Trip Odometer - Time Elapsed . Off (Blank) 2. To set the magnetic variance zone when VARIANCE = X (X = 1 - 15) is indicated in the VF display. RESET BUTTON The RESET Button has two different functions: 1. To clear the trip functions that may be reset 2. To enter and exit the diagnostic mode Pressing the RESET button once will clear the trip function that is currently being displayed and the CMTC will send a PCI bus beep request to the Instrument Cluster. If the RESET button is pressed again within 3 seconds, the CMTC will reset ALL of the trip functions and an additional beep request is sent to the Instrument Cluster. The trip functions that may be reset are: - Average Fuel Economy - Trip Odometer - Elapsed Time A reset will only occur if one of the trip functions that may be reset is currently being displayed. The CMTC module will send a beep request to the Instrument Cluster. Simultaneously pressing the RESET button and the C/T button while turning the ignition from Off to On will enter the CMTC into the self-diagnostic mode. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2497 COMPASS/TEMPERATURE (C/T) BUTTON Actuating the Compass/Temperature Button (C/T) will cause the CMTC to display the compass and temperature information. This function will operate from another traveler display. The CMTC simultaneously displays the compass reading and the outside temperature. Outside temperature information is received via the PCI bus from the FCM. The CMTC module internally senses and calculates the compass direction. TRAVELER DISPLAY FUNCTIONS Using the STEP button will change the CMTC between modes of operation and display the appropriate information according to data received from the PCI Bus. COMPASS OPERATION Upon ignition on, if the calibration information stored in the CMTC memory is within the normal range, the CMTC will perform in slow Auto-Cal mode. In slow Auto-Cal mode, the CMTC continuously compensates for the slowly changing magnetic field of the vehicle. The compass module detects changes in the vehicle magnetism and makes appropriate internal corrections to ensure proper displayed direction. However, if the calibration information stored in the CMTC memory is not within the normal range at ignition on, the CMTC will enter fast Auto-Cal. CAL is displayed along with the temperature. Auto activation of the fast Auto-Cal mode will also occur when the CMTC is subjected to high magnetic field strength levels, which cause all compass readings to be erroneous for a continuous period of five (5) minutes . During fast Auto-Cal, CAL will be displayed along with the temperature. Fast Auto-Cal can also be performed manually, by pressing and holding the RESET button for 10 seconds during the Compass/Temperature display mode. SETTING MAGNETIC ZONE VARIANCE Variance is the difference between magnetic North and geographic North. For proper compass function, the correct variance zone must be set. Refer to the Zone Variance map for the correct zone. Follow these steps to check or change the variance zone: - The ignition switch must be in the On position and the CMTC display must not be blank. - If the compass/temperature data is not currently being displayed, momentarily press and release the C/T button to display compass/temp information. - Press and hold the RESET button until VARIANCE = XX is displayed. The CMTC will display the variance zone stored in memory and the word VARIANCE. - Use the STEP button to select the proper variance zone number, 1 through 15. - After selecting the proper zone number, momentarily press and release the RESET button. The variance zone is then stored in the memory and the CMTC returns to normal operation. COMPASS CALIBRATION The compass module has 2 types of auto-calibration; slow-cal and fast-cal. Slow-cal ensures that during normal vehicle operation the compass performs auto-calibration functions to keep the compass sensors in their proper operating range. Whenever the ignition is On and the CMTC receives PC I bus data indicating that engine RPM is greater than zero, auto-calibration is performed continuously. If the calibration information stored in the compass module memory is not within the normal range after a power-up cycle, the compass will display CAL. The CMTC will enter into the fast-cal mode until calibration is complete. To enter the compass into Manual Calibration mode, perform the following steps: - Drive the vehicle to an area away from any large metal objects or overhead power lines. - Ensure that the proper variance zone is selected. See "Setting Magnetic Zone Variance." - The ignition switch must be in the On position and the CMTC display must not be blank. - Press the C/T button to view the Compass/ Temperature display. - Press and hold the RESET button until CAL is displayed, then release the button. - Drive slowly, less than 5 MPH (8KPH) in at least 1 complete 360-degree circle. - CAL will remain illuminated to alert the driver that the compass is in the calibration mode. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2498 - After calibration is complete, CAL will turn off. If the compass appears blank, unable to be calibrated, or the compass displays false indications, the vehicle must be demagnetized. Refer to Compass Demagnetizing Procedure. SELF-CHECK DIAGNOSTICS The CMTC is capable of performing a diagnostic self check on its internal functions. CMTC diagnostics may be performed using a DRBIII(R) or by using the following procedure: 1. With the ignition switch in the OFF position, depress and hold the RESET and the C/T buttons. 2. Turn the ignition switch to the ON position. 3. Continue to hold both buttons until the software versions are displayed, then release the buttons. 4. All of the VFD segments will illuminate for 2-4 seconds. Check for segments that do not illuminate or illuminate all the time. 5. When the self-check is complete the CMTC will display one of the following messages: - PASS - FAIL - NO BUS 6. To exit the self-check mode, depress the RESET button or cycle the ignition switch and the CMTC will return to normal operation. If a Communication fault is displayed, refer to the symptom list. If a FAILED SELF TEST is displayed, the CMTC must be replaced. AMBIENT TEMPERATURE SENSOR The ambient air temperature is monitored by the FCM or the PCM and displayed by the CMTC. For Diesel equipped vehicles, the FCM receives a hardwire input from the ambient temperature sensor (ATS). For 3.7L, 4.7L and 5.7L equipped vehicles, the PCM receives the hardwire input from the ATS. The ATS is a variable resistor that operates on a 5-volt reference signal circuit hardwired from the FCM or PCM. The resistance in the ATS changes as the outside temperature rises or falls. The FCM or PCM senses the change in reference voltage through the ATS resistor. Based on the resistance of the ATS, the FCM or PCM is programmed to correspond to a specific temperature. The FCM or PCM stores and niters the ambient temperature data and transmits this data to the CMTC via the PCI Bus. The ATS cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. AMBIENT TEMPERATURE SENSOR FAULT CODES The outside temperature function is supported by the ambient temperature sensor (ATS), a signal and ground circuit hardwired to the FCM or the PCM, and the CMTC display. If the CMTC display indicates 54° C (130° F) or the ATS sense circuit is open, the temp display will be 54° C (130° F) to indicate an OPEN circuit condition. If the CMTC display indicates -40° C (-40° F) or the ATS sense circuit is shorted to ground, the temp display will be -40° C (-40° F) to indicate a SHORT circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the CMTC VFD can be tested. The ATS is supported by the FCM or PCM. Ambient Temperature Sensor DTCs will be recorded in the FCM or PCM. The ATS can be diagnosed using the following Sensor Test. Test the ATS circuits using the diagnostics in the Body Diagnostic Procedures Manual. If the CMTC passes the self test, and the ATS, the circuits, and PCI bus communications are confirmed to be OK, but the CMTC temperature display is inoperative or incorrect, replace the FCM or PCM as required. AMBIENT TEMPERATURE SENSOR TEST 1. Turn the ignition OFF. 2. Disconnect the ATS harness connector. 3. Measure the resistance of the ATS using the following min/max values: - 0° C (32° F) Sensor Resistance = 29.33 - 35.99 Kiloohms - 10° C (50° F) Sensor Resistance = 17.99 - 21.81 Kiloohms - 20° C (68° F) Sensor Resistance = 11.37 - 13.61 Kiloohms - 25° C (77° F) Sensor Resistance = 9.12 - 10.86 Kiloohms 30° C (86° F) Sensor Resistance = 7.37 - 8.75 Kiloohms - 40° C (104° F) Sensor Resistance = 4.90 - 5.75 Kiloohms The sensor resistance should read between these min/max values. If the resistance values are not OK, replace the Sensor. HOMELINK(R) UNIVERSAL TRANSMITTER If equipped, the HomeLink(R) Universal Transmitter is integrated into the overhead console. For added security it will operate home security systems that use coded signals known generically as Rolling Codes. The overhead console display provides visual feedback to the driver, indicating which HomeLink(R) transmitter channel button is being pressed. The HomeLink(R) can learn and store up to three separate transmitter radio frequency codes to operate garage door openers, security gates, and security lighting. The HomeLink ■ buttons are marked with one, two, or three dots. For complete information, refer to Universal Transmitter. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2499 Electrically Heated Systems HEATED MIRROR RELAY A button located on the HVAC control head controls the Heated Mirror Relay, which is located in the IPM. The HVAC control will ground the Heated Mirror Relay Control circuit to energize this relay. The relay control circuit is continuously monitored for certain malfunctions that the HVAC will report as DTCs. Exterior Lighting System The Instrument Cluster monitors the Headlamp Switch and Multifunctions Switch on its MUX line. The Instrument Cluster sends a PCI bus message to the Front Control Module (FCM) to actuate the Headlamps ON when the ignition switch is ON and when an open or short failure occurs on the headlamps switch input circuit to the instrument cluster. If the exterior lamps are left ON and the ignition switch OFF for more than 5 minutes, the FCM will turn the exterior lamps off. This feature prevents the battery from being discharged when the Exterior Lamps have been left ON. Front Control Module The Front Control Module (FCM) is a microprocessor-based electrical control and interface center located in the engine compartment. When it is mated to the Power Distribution Center (PDC), it is referred to as the Integrated Power Module (IPM). The IPM, with its fuses and relays provides power and signal distribution throughout most of the vehicle. The FCM receives hardwired analog and resistor multiplexed inputs as well as digital electronic inputs from other electronic modules in the vehicle electrical system through its connection to the IPM and the Programmable Communications Interface (PCI) data bus network. Based on these inputs and programming, the FCM uses high side drivers to provide direct power feeds and low side drivers to provide relay control for some of the vehicle's most critical electrical systems. The FCM provides the following features: Controlled Feeds: - Brake lights - Headlamp power - Turn signals (front & rear) - Windshield washer pump motor Relay Controls - Adjustable pedals relay (when equipped) - Fog lamp relay (when equipped) - Horn relay - Park lamp relay - Trailer tow relays - Wiper on/off relay - Wiper high/low relay Electrical Inputs - Module battery supply - Power ground - Ignition switch RUN or START position status . PCI bus - Wiper park switch - Washer fluid level switch - Ambient Temperature sensor - Battery (+) connection detection CONTROLLED POWER FEEDS Headlamp Power The headlamp switch is a direct input to the instrument cluster which is sometimes known as the Cab Control Node (CCN). The instrument cluster sends a Programmable Communications Interface (PCI) bus message to the FCM informing it of a headlamp switch status change. The FCM then turns power on or off (depending on the bus message) to the headlamps through four "fuseless" circuits. These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied to each filament in a separate circuit. For vehicles equipped with Daytime Running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination levels. Washer Pump Motor The washer switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus message to the FCM informing it of a request to wash. The washer pump motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition, the FCM electronically protects the washer pump motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2500 If the FCM receives a prolonged request to wash lasting 30 seconds or more, it will treat the request as a stuck switch condition and deactivate the washer pump motor. The FCM will not reactivate the washer pump motor until there is at least a two second break in the request to wash from the instrument cluster. RELAY CONTROLS Adjustable Pedals Relay If equipped, the adjustable pedals relay, when not activated, supplies fused battery power to the adjustable pedals switch. If the FCM receives a bus message that the vehicle is in reverse or that the cruise control is engaged, it will apply a ground to the adjustable pedals relay control circuit. The ground will activate the relay which will open the power circuit to the adjustable pedals switch The relay control circuit is continuously monitored for malfunctions which the FCM will report as DTCs. Fog Lamp Relay If equipped, the fog lamp switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to turn on the fog lamp relay. The fog lamp relay is then actuated by the FCM through low side control. This circuit is electronically controlled and continuously monitored for malfunctions. Horn Relay The Horn Relay, which is internal to the IPM, is controlled by the FCM through PCI bus messages from the instrument cluster. These bus messages will be sent when either the horn switch is pressed which is hard wired to the instrument cluster, panic mode is requested from the RKE or for vehicle theft security reasons (if equipped). The relay control circuit is continuously monitored for malfunctions that the FCM will report as DTCs. The park lamp switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the park lamp relay. The park lamp relay is then actuated through the low side control circuit. This circuit is electronically controlled and continuously monitored for malfunctions. Wiper High/Low Relay The wiper switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the wiper high/ low relay. The relay switches power between the low speed and high speed of the wiper motor. The wiper high/low relay is then actuated through the low side control circuit. This circuit is electronically controlled and continuously monitored for malfunctions. Wiper On/Off Relay The wiper switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the wiper on/off relay. The wiper on/off relay is then actuated through the low side control circuit. This relay switches power to the wiper high/low relay. This circuit is electronically controlled and continuously monitored for malfunctions. ELECTRICAL INPUTS Module Battery Supply 12 Volt input for all FCM functions except headlamp operation. Power Ground Ground source for all FCM functions Ignition Switch RUN or START Position Status 12 volt input to inform the FCM of the ignition switch status for related FCM functions. PCI Bus Approximately 7.5 volt input to allow the FCM to communicate with other modules on the PCI bus. Wiper Park Switch Ground input used to determine the park placement of the wipers. The ground is also used as feedback to the FCM to determine wiper operating mode. Washer Fluid Level Switch Ground input from the washer fluid level switch which closes when washer fluid is low. Battery (+) Connection Detection 12 volt supply used to monitor battery connection to the IPM. The battery connection to the IPM uses an internal switch to check integrity of the connection and that the Connector Positive Assurance (CPA) is engaged. If the CPA is not properly engaged, a voltage is sent to the FCM to be interpreted as an unseated connector which will set a Diagnostic Trouble Code (DTC). Heating & A/C System SYSTEM AVAILABILITY - Depending on the model, either a Single-Zone or Dual-Zone HVAC system is available in these vehicles. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2501 SYSTEM CONTROLS The Heater Control Module: is fully addressable with the DRBIII(R). - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - controls heated mirror and EBL operation (if equipped). - controls electric door actuator operation. The A/C-Heater Control Module: is fully addressable with the DRBIII(R). - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - provides an A/C request to the Powertrain Control Module (PCM) over the PCI Bus when compressor operation is desired. - controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - controls heated mirror and EBL operation (if equipped). - controls electric door actuator operation. - A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C -Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. The Single-Zone HVAC system uses: one, two-wire electric blend door actuator. - two, two-wire electric mode door actuators. - one, two-wire electric recirculation door actuator. The Dual-Zone HVAC system uses: two, two-wire electric blend door actuators. - two, two-wire electric mode door actuators. - one, two-wire electric recirculation door actuator. SYSTEM REVISIONS The 2004 DR, HVAC system remains carryover from 2003. SYSTEM DIAGNOSTICS Fault detection is through active and stored Diagnostic Trouble Codes (DTCs) . DTCs are displayed by the DRBIII(R). Active DTCs are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTCs are those which occurred in the system since the A/C-Heater Control Module received the last "clear diagnostic info" message. The A/C Cooldown Test: is actuated with the DRBIII(R). - checks A/C system performance based on evaporator temperature sensor input. - will not run if ambient temperature is below 12.7° C (55° F). - will pass if the evaporator temperature drops 6.7° C (20° F) within two minutes of starting the test. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. - will cause the A/C mode switch status indicator to flash while the test is running. - If the test fails, the status indicator will continue to flash until either the test returns passed or the ignition key is cycled. It will also prevent the EBL mode switch status indicator from indicating EBL operating status. However, the EBL mode switch will continue to function in this state. The HVAC Door Recalibration function: is actuated with the DRBIII(R). - monitors for door span faults. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. - will cause the EBL mode switch status indicator to flash while the test is running. - If the test fails, the status indicator will continue to flash until either the test returns passed or the ignition key is cycled. It will also prevent the A/C mode switch status indicator from indicating A/C operating status. However, the A/C mode switch will continue to function in this state. The Actuator Circuit Test: is actuated with the DRBIII(R). - monitors for shorted actuator circuits. - allows service to easily diagnose and troubleshoot up to three simultaneous shorts. - supplements the continuous diagnostics on the actuator drive system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2502 - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. When Performing The Actuator Circuit Test CAUTION: To ensure a proper diagnosis, repair all Short Too Complex messages first, all common door driver circuit related messages second, and all other door driver circuit related messages last. - The DRBIII(R) can display up to three Actuator Circuit Test messages at a time. After repairing each Actuator Circuit Test message, cycle the ignition switch, then rerun the Actuator Circuit Test to ensure no new messages exist. - The Short Too Complex message: indicates that a specific determination of which lines are shorted could not be made. - is caused by more than three drivers being shorted in the same direction. For example, four drivers all shorted to ground, or two or more drivers shorted with at least one driver shorted to ignition/battery and one driver shorted to ground. - Messages displaying: XXX Driver/Circuit Shorted to Ignition/ Battery will set on a per-driver basis. - XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. - the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together. - When the test returns passed, then troubleshooting should proceed to clearing faults and running the HVAC Door Recalibration system test as a final check of system health. Instrument Cluster The DR Instrument Cluster is a new type of control module that includes the hardware and software necessary to function as the cluster and the body control module. The Instrument Cluster houses the Speedometer, Tachometer, Fuel gauge, Coolant Temperature gauge, Oil Pressure gauge, and the Voltage gauge. The cluster positions all of the gauges using PCI bus messages received from the PCM. The cluster contains certain warning indicators, depending on engine type and options. Some of the indicators are hardwire inputs and some indicators are controlled via PCI bus messages. The warning chime tone generator is contained within the cluster. The cluster includes a vacuum fluorescent (VF) display for the PRNDL, Total and Trip Odometers. The VF will also display warning messages such as door ajar, low washer fluid level, engine hours, and no bus communications. The cluster has the ability to set and store DTCs, communicate on the PCI bus, display engine information, and display certain inputs using the DRBIII(R). The following systems are controlled either completely by the Instrument Cluster or in conjunction with other inputs received by hardwire or via the PCI bus: - Audible Warnings - Brake Lamp Control - Brake Transmission Shift Interlock (BTSI) - Cargo Lamp Control - Central Locking - Door Lock Inhibit - Enhanced Accident Response - Exterior Lighting Control - Exterior Lighting Fail-Safe - Heated Seat Control - Horn Control - Interior Lamp Control - Interior Lamps - Enhanced Accident Response - Interior Lamps Load Shedding - Lamp Out Indicator Control - Panel Lamps Dimming Control - Parade Mode - Power Locks - Remote Keyless Entry (RKE) - Remote Radio Switch Interface - Rolling Door Locks - Turn Signal and Hazard Warning Lamp Control - Vacuum Fluorescent Display Synchronization - Vehicle Theft Security System (VTSS) CAUTION: Instrument clusters used in this model automatically configure themselves for compatibility with the features and optional equipment in the vehicle in which they are initially installed. The instrument cluster is programmed to do this by embedding the Vehicle Identification Number (VIN) and other information critical to proper cluster operation in electronic memory. This embedded information is learned through electronic messages received from other electronic modules in the vehicle over the Programmable Communications Interface (PCI) data bus, and through certain hard wired inputs received when the cluster is connected to the vehicle electrically. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2503 Once configured, the instrument cluster memory may be irreparably damaged and certain irreversible configuration errors may occur if the cluster is connected electrically to another vehicle; or, if an electronic module from another vehicle is connected that provides data to the instrument cluster (including odometer values) that conflicts with that which was previously learned and stored. Therefore, the practice of exchanging (swapping) instrument clusters and other electronic modules in this vehicle with those removed from another vehicle must always be avoided. Failure to observe this caution may result in instrument cluster damage, which is not reimbursable under the terms of the product warranty. Service replacement instrument clusters are provided with the correct VIN, and the certified odometer and engine hours values embedded in cluster memory, but will otherwise be automatically configured for compatibility with the features and optional equipment in the vehicle in which they are initially installed. DIAGNOSTIC SELF TEST The Instrument Cluster is capable of performing a Diagnostic Self Test. This self test can be initiated manually by depressing and holding the trip reset button while cycling the ignition from the Off to the On position. The self test can also be activated using the DRBIII(R). During the self test, all of the PCI bus indicators will be illuminated. The speedometer, tachometer, fuel gauge, oil pressure gauge, coolant temperature gauge, and voltage gauge will position at their calibration points. The VF display will illuminate all segments and also display the software version. The chime will sound. When the self test is complete, the cluster will return to normal operation. Turning the ignition to the Off position or the cluster detecting engine RPM greater than 0 (zero) will stop the self test. Interior Lighting The Instrument Cluster controls the Interior/ Courtesy Lamps. The Instrument Cluster activates the courtesy lamps when either a Dome Lamp switch is turned on or a door is opened. The Instrument Cluster also monitors the output of the Glove Box and Map lamps. The Cargo lamps are controlled by the Instrument Cluster, it receives an output message from the Headlamp switch to turn on the lamps. The Instrument Cluster provides battery protection by shutting down the interior lamps when a door or courtesy/map lamp is left on or open. Power Door Locks/Remote Keyless Entry The Instrument Cluster in response to the door lock switches or the RKE module directly controls the power door lock motors. The Instrument Cluster monitors the activation of the door lock motors and will set diagnostic trouble codes when there is an open or short condition. When there is a lock or unlock input from a switch or RKE command, the Instrument Cluster will activate the appropriate driver for 300 milliseconds. If a lock or unlock switch remains active, the request will be ignored until the switch transitions back to off. The lock switches are resistive multiplexed input devices hardwired to the Instrument Cluster. AUTOMATIC DOOR LOCKS The Instrument Cluster will automatically lock all the doors when the vehicle speed exceeds 15 MPH (24 KM/H), throttle position exceeds 10 percent and all the doors are closed. If a door is opened the Automatic Door Lock feature shall reset and the Instrument Cluster will lock the doors when the above conditions are met. This feature is programmable by the customer or the DRBIII(R). CENTRAL LOCKING/UNLOCKING The Instrument Cluster will lock all doors when the cylinder lock switch is activated in the "lock" position. When the Instrument Cluster receives an unlock command from the driver cylinder lock switch, it will unlock only that door. If the Instrument Cluster receives a second command within a 5-second period it will unlock all the remaining doors. The illuminated entry will activate during door unlock. DOOR LOCK INHIBIT When the key is in the ignition, in any position, and either front door is open, the door lock switches LOCK functions are disabled. The UNLOCK functions are still functional. This protects against locking the vehicle with the keys still in the ignition. The RKE transmitter will still lock the doors as usual. ENHANCED ACCIDENT RESPONSE Upon detection of an airbag deployment by way of the PCI bus, the Instrument Cluster shall: - Immediately disable the power door lock output - Unlock all doors by activating the door unlock output for approximately 300 milliseconds. - After actuating the door unlock output, allow the door lock motors to be activated if the door lock input has been inactive (not erratic) for 2 seconds since the reception of the airbag deployment message. Remote Keyless Entry The remote keyless entry (RKE) feature is used to control the power door locks and panic feature by using a remote transmitter (keyfob) and receiver located within the instrument cluster. The instrument cluster RKE feature controls the driver door unlock, all doors lock/unlock, horn chirp enabled/ disable, optical chirp enabled/disable, illuminated entry, the panic feature, initiate customer programming, and arming/disarming the Vehicle Theft Security System. When a valid lock message is received from the receiver, the instrument cluster will: - Arm the Vehicle Theft Security System (if equipped and all conditions are met). - Turn off the illuminated entry feature. - Activate the door lock motors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2504 - Transmit a PCI bus message to the FCM to perform horn chirp. When a valid unlock code is received from the receiver, the instrument cluster will: - Disarm the Vehicle Theft Security System (if equipped and previously set). - Activate the illuminated entry and cargo lamp. - Activate the driver door unlock motor (if customer programmed for driver door only unlock). - Transmit a PCI bus message to the FCM for optical chirp. Vehicle Theft Security System The Instrument Cluster controls the Vehicle Theft Security System (VTSS). When the VTSS is armed it will monitor the status of the ignition and door ajar switches. If the alarm is tripped it will sound the vehicles horn, flash the exterior lamps and the VTSS indicator located in the instrument cluster. The Instrument Cluster will enable the VTSS feature once it has received PCI bus messages from the Sentry Key Immobilizer Module and has also detected the driver cylinder lock switch being cycled to the lock/unlock position. Arming the system is accomplished following a normal exit sequence of removing the key from the ignition, opening the door pressing the power lock button to lock and closing the door, by using a cylinder lock switch or by pressing the RKE lock button. After all the doors are closed, the VTSS indicator will flash quickly for sixteen-seconds indicating the pre-arm process, after which it will flash at a slower rate indicating the system is armed. If during the pre-arm process a door is opened, the ignition is turned to the Run/Start position or if a RKE unlock button is pressed the system will exit the pre-arming process. Disarming can be accomplished with a RKE unlock, turning the ignition on with a valid Sentry key or unlocking the vehicle with a cylinder lock switch. The Alarming state will last for 18 minutes after which it will time out and return to the armed state. A tamper alert feature will alert the customer to the alarm being tripped while they were away upon returning to the vehicle by flashing the VTSS indicator for 30 seconds after the system has been disarmed. All of the switches for the VTSS system can be monitored using the DRBIII(R). The DRBIII(R) is also useful for a customer complaint of the alarm going off with no apparent reason by viewing the VTSS last alarm caused by display. Windshield Wipers/Washers The Instrument Cluster controls the wiper/ washer system. The instrument cluster receives a signal from the Multifunction Switch wipe position. The instrument cluster sends the message to the Front Control Module (FCM), sending the command to turn the wiper/washers on. Two relays, the High/Low relay and the On/Off relay also control the wipers. Both are located in the PDC or Integrated Power Module. Telecommunications HANDS FREE PHONE The vehicle telecommunications system consists of a Hands Free Module, Rear view Mirror, and a Blue-tooth Hands Free Profile enabled cell phone. The system allows vehicle occupants to use voice recognition technology to make, receive and screen phone calls without physically handling a cell phone. The system has a programmable phone book that can prevent the vehicle operator from becoming distracted searching for a specific number. Seven different wireless phones can be programmed to operate each individual system. Each of the seven phones is given a rank of priority when programmed. Incoming phone messages are transmitted to the vehicle occupants through the vehicles audio system when the ignition is on and the wireless phone is on. Upon receiving the signal from an incoming phone call, the vehicle audio system will fade out the current CD/DVD or radio output. The vehicle occupants are then directed to accept or reject the call. Outgoing audio messages are received through the microphone located in the rearview mirror then transmitted via hardwire to the Hands Free Module and finally transmitted through the wireless phone. Volume of the voice prompts and incoming conversation is controlled using the vehicles' radio audio controls and steering wheel controls if equipped. The rearview mirror contains a Phone Switch, Voice Recognition Switch and a microphone. The rear view mirror transmits these inputs via hardwired circuits to the Hands Free Module. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures Air Bag System Test 1 SYMPTOM AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES POSSIBLE CAUSES - Airbag warning indicator on without active trouble codes - Instrument cluster problems AM/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE this symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Amplifier Pretest Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2507 Test 1 SYMPTOM AMPLIFIER PRETEST POSSIBLE CAUSES - Amplifier pretest - No fault message displayed Any Station Preset Switch Inoperative Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Balance Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2508 Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure CD Eject Switch Inoperative Test 1 SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Equalizer Inoperative Test 1 SYMPTOM EQUALIZER INOPERATIVE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2509 TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure FF/RW Switch Inoperative Test 1 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure HOUR/MINUTE Switches Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2510 Test 1 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Pause/Play Switch Inoperative Test 1 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure PWR Switch Inoperative Test 1 SYMPTOM PWR SWITCH INOPERATIVE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2511 TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Scan Switch Inoperative Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Seek Switch Inoperative Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Set Switch Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2512 Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tape Eject Switch Inoperative Test 1 SYMPTOM TAPE EJECT INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2513 TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Chime Inoperative Test 1 SYMPTOM CHIME INOPERATIVE POSSIBLE CAUSES - Actuate chime with DRBIII(R) - Instrument cluster - chime inoperative Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2514 Test 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER DOOR OPEN KEY REMOVED POSSIBLE CAUSES - Key-in IGN SW status - Key-in ignition switch shorted - Key-in ignition SW sense short to ground - Instrument cluster Key In Ignition and Drivers Door Open Chime Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2515 Test 1 - 3 Test 4 - 5 SYMPTOM KEY IN IGNITION AND DRIVERS DOOR OPEN CHIME INOPERATIVE POSSIBLE CAUSES - Observe the key-in ignition switch status - Key-in ignition switch open - Key-in ignition switch ground circuit open - Key-in ignition switch sense circuit open - Instrument cluster - incorrect key-in ignition switch status Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2516 Vehicle Speed Warning Chime Problem Test 1 SYMPTOM VEHICLE SPEED WARNING CHIME PROBLEM POSSIBLE CAUSES - Incorrect country code programmed in instrument cluster - Instrument cluster Average Fuel Economy Inaccurate or Wrong Test 1 SYMPTOM AVERAGE FUEL ECONOMY INACCURATE OR WRONG POSSIBLE CAUSES - CMTC CMTC or EVIC Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2517 Test 1 - 3 SYMPTOM CMTC OR EVIC INOPERATIVE POSSIBLE CAUSES - Fused B(+) circuit open - Fused ignition switch output circuit open - Ground circuit open - Compass/mini-trip computer Compass Test Failure Test 1 SYMPTOM COMPASS TEST FAILURE POSSIBLE CAUSES - Compass/Mini-trip computer Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2518 Distance to Empty Inaccurate or Wrong Test 1 SYMPTOM DISTANCE TO EMPTY INACCURATE OR WRONG TEST NOTE This symptom is diagnosed using the test AVERAGE FUEL ECONOMY INACCURATE OR WRONG. POSSIBLE CAUSES - CMTC Elapsed Ignition on Time Inaccurate or Wrong Test 1 SYMPTOM ELAPSED IGNITION ON TIME INACCURATE OR WRONG TEST NOTE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2519 This symptom is diagnosed using the test AVERAGE FUEL ECONOMY INACCURATE OR WRONG. POSSIBLE CAUSES - CMTC Temperature Display Inaccurate or Inoperative Test 1 - 2 SYMPTOM TEMPERATURE DISPLAY INACCURATE OR INOPERATIVE POSSIBLE CAUSES - Ambient temperature sensor - Compass/Mini-trip computer Trip Odometer Inaccurate or Wrong Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2520 Test 1 SYMPTOM TRIP ODOMETER INACCURATE OR WRONG TEST NOTE This symptom is diagnosed using the test AVERAGE FUEL ECONOMY INACCURATE OR WRONG. POSSIBLE CAUSES - CMTC Driver Door Ajar Circuit Open Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2521 Test 1 - 4 SYMPTOM DRIVER DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Driver door ajar switch - Driver door ajar switch ground circuit open - Driver door ajar switch sense circuit open - Instrument cluster-driver door ajar open Driver Door Ajar Circuit Shorted to Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2522 Test 1 - 3 SYMPTOM DRIVER DOOR AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Driver door ajar switch shorted to ground - Driver door ajar switch sense circuit shorted to ground - Instrument cluster - driver door ajar shorted Left Rear Door Ajar Circuit Open Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2523 Test 1 - 4 SYMPTOM LEFT REAR DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Left rear door ajar switch - Left rear door ajar switch ground circuit open - Left rear door ajar switch sense circuit open - Instrument cluster - left rear door ajar open Left Rear Door Ajar Circuit Shorted to Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2524 Test 1 - 3 SYMPTOM LEFT REAR DOOR AJAR CIRCUIT SHORT TO GROUND POSSIBLE CAUSES - Left rear door ajar switch shorted to ground - Left rear door ajar switch sense circuit shorted to ground - Instrument cluster - driver door ajar shorted Passenger Door Ajar Circuit Shorted to Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2525 Test 1 - 3 SYMPTOM PASSENGER DOOR AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Passenger door ajar switch shorted to ground - Passenger door ajar switch sense circuit shorted to ground - Instrument cluster - passenger door ajar shorted Passenger Door Ajar CKT Open Test 1 - 4 SYMPTOM PASSENGER DOOR AJAR CKT OPEN POSSIBLE CAUSES - Passenger door ajar switch - Passenger door ajar switch ground circuit open - Passenger door ajar switch sense circuit open - Instrument cluster - passenger door ajar open Right Rear Door Ajar Circuit Open Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2526 Test 1 - 4 SYMPTOM RIGHT REAR DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Right rear door ajar switch - Right rear door ajar switch ground circuit open - Right rear door ajar switch sense circuit open - Instrument cluster - right rear door ajar open Right Rear Door Ajar Circuit Shorted to Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2527 Test 1 - 3 SYMPTOM RIGHT REAR DOOR AJAR CIRCUIT SHORT TO GROUND POSSIBLE CAUSES - Right rear door ajar switch shorted to ground - Right rear door ajar switch sense circuit shorted to ground - Instrument cluster - right rear door ajar shorted A/C Heater Control Illumination Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2528 Test 1 - 3 Test 4 SYMPTOM A/C - HEATER CONTROL ILLUMINATION INOPERATIVE POSSIBLE CAUSES - Check for instrument cluster (MIC) DTCs - Inoperative bulb(s) - A/C - heater control module - Panel lamps driver circuit open - Instrument cluster A/C Status Indicator Flashing Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2529 Test 1 - 2 Test 3 SYMPTOM A/C STATUS INDICATOR FLASHING POSSIBLE CAUSES - A/C cooldown test needs to be run - HVAC door recalibration needs to be run A/C Status Indicator Will Not Illuminate - A/C Heater Control Without EBL SW Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2530 Test 1 SYMPTOM A/C STATUS INDICATOR WILL NOT ILLUMINATE -- A/C - HEATER CONTROL WITHOUT EBL SW POSSIBLE CAUSES - HVAC door recalibration failed - A/C - Heater control module Blend/Mode/Recirc Door Operation Improper - Dual-Zone Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2531 Test 4 - 6 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2532 Test 7 - 8 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER - DUAL-ZONE POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTCs - Check for HVAC door recalibration fault messages - Mode door actuator(s)/linkage(s)/door(s) - Passenger blend door actuator/linkage/door - Driver blend door actuator/linkage/door - Recirculation door actuator/linkage/door Blend/Mode/Recirc Door Operation Improper - Single-Zone Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2533 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2534 Test 4 - 6 Test 7 SYMPTOM Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2535 BLEND/MODE/RECIRC DOOR OPERATION IMPROPER - SINGLE-ZONE POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTCs - Check for HVAC door recalibration fault messages - Mode door actuator(s)/linkage(s)/door(s) - Blend door actuator/linkage/door - Recirculation door actuator/linkage/door Blower Motor Inoperative Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2536 Test 4 - 8 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2537 Test 9 - 10 SYMPTOM BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - IPM fuse #4 - Blower motor feed circuit shorted to ground - Fused B(+) shorted to ground - Blower motor shorted to ground - Blower motor - Blower motor high driver circuit open - Ground circuit open - A/C - heater control module open - Blower motor feed circuit open - Fused B(+) circuit open - Ignition switch open Blower Motor Speeds Incorrect Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2538 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2539 Test 4 - 6 SYMPTOM BLOWER MOTOR SPEEDS INCORRECT POSSIBLE CAUSES - Blower motor driver circuit(s) shorted to ground - A/C - heater control module - Blower motor driver circuit(s) shorted to voltage - Blower motor driver circuits shorted together - A/C - heater control module - speeds incorrect - Blower motor driver circuit(s) open - Blower motor resistor block - open speed EBL Status Indicator Flashing Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2540 Test 1 - 2 Test 3 SYMPTOM EBL STATUS INDICATOR FLASHING TEST NOTE This symptom is diagnosed using the test A/C STATUS INDICATOR FLASHING. POSSIBLE CAUSES - A/C cooldown test needs to be run - HVAC door recalibration needs to be run HVAC System Test Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2541 Test 1 - 2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2542 Test 3 - 4 SYMPTOM HVAC SYSTEM TEST POSSIBLE CAUSES - Attempt to communicate with the PCM - Check for HVAC related DTCs in the PCM - Check for active HVAC DTCs and system test fault messages - Check for HVAC related DTCs in the PCM - Manual A/C system test Horn Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2543 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2544 Test 4 - 8 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2545 Test 9 - 11 SYMPTOM HORNS INOPERATIVE POSSIBLE CAUSES - Horn ground circuit open - Horn relay output circuit open - Horns - Instrument cluster - DTC present - Clockspring - Front control module - Fuse #45 - Horn switch - Horn switch ground - Horn switch sense open - Integrated power module All Gauges Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2546 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2547 Test 4 - 7 Test 8 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2548 SYMPTOM ALL GAUGES INOPERATIVE POSSIBLE CAUSES - No response - PCI BUS - PCI BUS - powertrain control module - PCI BUS - instrument cluster - Fused ignition switch output circuit (unlock/run) short to ground - Instrument cluster ground circuit open - Fused ignition switch output (run/start) circuit open - Fused ignition switch output (run/start) circuit short to ground - Fused ignition switch output (unlock/run) circuit open - Instrument cluster Any PCI Indicator Inoperative Test 1 - 4 SYMPTOM ANY PCI INDICATOR INOPERATIVE POSSIBLE CAUSES - Indicator message not received - No response - instrument cluster Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2549 - No response - PCI BUS - No response - PCI BUS - powertrain control module - Instrument cluster Brake Warning Indicator Always On Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2550 Test 4 - 5 SYMPTOM BRAKE WARNING INDICATOR ALWAYS ON POSSIBLE CAUSES - Brake fluid level switch - Brake fluid level switch sense circuit short to ground - Park brake switch - Park brake switch sense circuit short to ground - Control module - Instrument cluster Brake Warning Indicator Inoperative Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2551 Test 4 - 7 SYMPTOM BRAKE WARNING INDICATOR INOPERATIVE POSSIBLE CAUSES - Brake fluid level switch ground circuit open - Brake fluid level switch - Brake fluid level switch sense circuit open - Park brake switch - Park brake switch sense circuit open - Control module - Instrument cluster Fuel Gauge Inaccurate Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2552 Test 1 - 3 SYMPTOM FUEL GAUGE INACCURATE POSSIBLE CAUSES - DTC present - Instrument cluster - Fuel level sensor wiring - Fuel level sensor One Gauge Inoperative - Gas Engines Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2553 Test 1 - 2 SYMPTOM ONE GAUGE INOPERATIVE - GAS ENGINES POSSIBLE CAUSES - Powertrain control module DTCs - Intermittent condition - Instrument cluster PRNDL Not Displaying Correct Position (EATX Vehicles) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2554 Test 1 - 2 SYMPTOM PRNDL NOT DISPLAYING CORRECT POSITION (EATX VEHICLES) POSSIBLE CAUSES - DTC present - Instrument cluster - Intermittent condition Seat Belt Warning Indicator Always Off Test 1 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS OFF POSSIBLE CAUSES - Seat belt switch sense circuit short to ground - Instrument cluster Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2555 Seat Belt Warning Indicator Always Off - Standard Cab Test 1 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS OFF - STANDARD CAB POSSIBLE CAUSES - Seat belt switch sense circuit short to ground - Instrument cluster Seat Belt Warning Indicator Always on Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2556 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS ON POSSIBLE CAUSES - Seat belt switch - Seat belt switch ground circuit open - Seat belt switch sense circuit open - Instrument cluster Seat Belt Warning Indicator Always on - Standard Cab Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2557 Test 4 - 5 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS ON - STANDARD CAB POSSIBLE CAUSES - Fused ignition switch output (run-acc) circuit open - Seat belt tensioner reducer - Seat belt switch - Seat belt switch ground circuit open - Seat belt switch sense circuit open - Instrument cluster All Door Locks Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2558 Test 1 - 3 SYMPTOM ALL DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - DTC present - Fuse #22 open - Fuse B+ circuit open - Instrument cluster - open circuit Automatic (Rolling) Door Locks Inoperative Test 1 - 4 SYMPTOM AUTO (ROLLING) DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Check the door ajar switch status - With the DRB check for PCM DTC's - With the DRB enable auto door locks - Instrument cluster - auto door locks fail Cylinder Lock Switch Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2559 Test 1 - 3 Test 4 SYMPTOM CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Cylinder lock switch ground open - Cylinder lock switch MUX circuit open - Cylinder lock switch open - Instrument cluster - open Cylinder Lock Switch Will Not Arm and/or Disarm Alarm Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2560 Test 1 - 3 Test 4 SYMPTOM CYLINDER LOCK SWITCH WILL NOT ARM AND/OR DISARM ALARM TEST NOTE This symptom is diagnosed using the test CYLINDER LOCK SWITCH INOPERATIVE. POSSIBLE CAUSES - DTC present - Cylinder lock switch ground open - Cylinder lock switch MUX circuit open - Cylinder lock switch open - Instrument cluster - open Door Lock Inhibit Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2561 Test 1 SYMPTOM DOOR LOCK INHIBIT INOPERATIVE POSSIBLE CAUSES - Chime inoperative - Instrument cluster - door lock inhibit inoperative Left Doors Fail to Lock and Unlock - Quad Cab Test 1 - 4 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2562 Test 5 SYMPTOM LEFT DOORS FAIL TO LOCK AND UNLOCK - QUAD CAB POSSIBLE CAUSES - DTC present - Instrument cluster - door lock driver left doors open - Door unlock driver left doors wire open - Door lock driver left doors wire open - Door lock motor One Door Lock Motor Inoperative Test 1 SYMPTOM ONE DOOR LOCK MOTOR INOPERATIVE POSSIBLE CAUSES - Door lock motor open - Check door lock motor circuit Right Doors Fail to Lock and Unlock - Quad Cab Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2563 Test 1 - 4 Test 5 SYMPTOM RIGHT DOORS FAIL TO LOCK AND UNLOCK - QUAD CAB POSSIBLE CAUSES - DTC present - Instrument cluster - door lock driver right doors open - Door unlock driver right doors wire open - Door lock driver right doors wire open - Door lock motor RKE Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2564 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2565 Test 4 - 6 SYMPTOM RKE INOPERATIVE POSSIBLE CAUSES - Test transmitter with tester - RKE transmitter not programmed - DTC present - Transmitter not programmed - Substitute transmitter - Remote keyless entry module - RKE open - RKE module Alarm Trips On Its Own Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2566 Test 1 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSES - DRB display last VTSS cause - Intermittent condition Driver Door Does Not Trip VTSS Test 1 - 3 SYMPTOM DRIVER DOOR DOES NOT TRIP VTSS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2567 POSSIBLE CAUSES - Driver door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Headlamps Fail to Flash When Alarm Is Tripped Test 1 SYMPTOM HEADLAMPS FAIL TO FLASH WHEN ALARM IS TRIPPED POSSIBLE CAUSES - FCM DTCs or exterior lamp operation - Instrument cluster Horn Fails to Sound When Alarm Is Tripped Test 1 - 2 SYMPTOM HORN FAILS TO SOUND WHEN ALARM IS TRIPPED POSSIBLE CAUSES - DTC present - Horn circuit - Instrument cluster - VTSS Left Rear Door Does Not Trip VTSS (4 Door) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2568 Test 1 - 3 SYMPTOM LEFT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Passenger Door Does Not Trip VTSS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2569 Test 1 - 3 SYMPTOM PASSENGER DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Right Rear Door Does Not Trip VTSS (4 Door) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2570 Test 1 - 3 SYMPTOM RIGHT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSES - Passenger door ajar circuit malfunction - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster VTSS Will Not Arm Properly Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2571 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2572 Test 4 - 8 SYMPTOM VTSS WILL NOT ARM PROPERLY POSSIBLE CAUSES - VTSS not enabled - Check for DTCs and VTSS arming inhibitors - Check for SKIM no response - Cylinder lock switch ground open - Instrument cluster - Cylinder lock switch MUX circuit open - Cylinder lock switch open - Instrument cluster - cylinder lock switch MUX open Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2573 Body Control Module: Component Tests and General Diagnostics Six Step Troubleshooting Procedure Diagnosis of the body system 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 Road Testing Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. WARNING: REASSEMBLE ALL COMPONENTS BEFORE ROAD TESTING A VEHICLE. DO NOT TRY TO READ THE DRBIII(R) SCREEN OR OTHER TEST EQUIPMENT DURING A TEST DRIVE. DO NOT HANG THE DRBIII(R) OR OTHER TEST EQUIPMENT FROM THE REARVIEW MIRROR DURING A TEST DRIVE. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRBIII(R) OR OTHER TEST EQUIPMENT. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. Vehicle Preparation For Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Glossary of Terms ABS antilock brake system ACM airbag control module ACT actuator AECM airbag electronic control module (ACM) ASDM airbag system diagnostic module (ACM) BCM body control module BTSI brake transmission shift interlock CAB controller antilock brake CMTC compass/mini-trip computer CPA connector positive assurance DAB driver airbag DLC data link connector DTC diagnostic trouble code EBL electric back lite (rear window defogger) ECM engine control module EVIC electronic vehicle information center FCM front control module HFM hands free module HVAC heater ventilation, air conditioning IC instrument cluster (MIC) IPM integrated power module JB junction block MIC mechanical instrument cluster NGC next generation controller ODO odometer OR occupant restraint controller PAB passenger airbag PCI Programmable Communication Interface (vehicle communication bus) PCM powertrain control module PDC power distribution center PWM pulse width modulated RKE remote keyless entry RX receive SBS seat belt switch SBT seat belt tensioner SKIM sentry key immobilizer module SKIS sentry key immobilizer system SRS supplemental restraint system SUV sport utility vehicle Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2574 TCCM transfer case control module TCM transmission control module TX transmit UGDO universal garage door opener VFD vacuum fluorescent display VTSS vehicle theft security system Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2575 Body Control Module: Scan Tool Testing and Procedures Diagnostic Trouble Code DRB III Error Messages and Blank Screen Under normal operation, the DRBIII(R) will display one of only two error messages: - User-Requested WARM Boot or User Requested COLD Boot. If the DRBIII(R) should display any other error message, record the entire display and call the STAR Center. This is a sample of such an error message display. - User-Requested WARM Boot by pressing MORE and NO at the same time. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2576 ver: 2.29 date: 1 Oct 93 file: key_itf.cc date: Jan 12 1994 line: 544 err: 0x1 User-Requested WARM Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. or User-Requested COLD Boot by pressing MORE and YES at the same time. ver: 2.29 date: 1 Oct 99 file: keyhnd1.cc date: Mar 8 2000 line:1297 err: 0x1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRBIII(R) DOES NOT POWER UP If the LEDs do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRBIII(R). Check for proper ground connection at DLC cavities 4 and 5. If all connections are proper between the DRBIII(R) and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRBIII(R) may be the result of faulty cable or vehicle wiring. DRBIII(R) Scan Tool DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. DRB III Safety Information WARNING: EXCEEDING THE LIMITS OF THE DRBIII(R) MULTIMETER IS DANGEROUS. READ ALL DRBIII(R) INSTRUCTIONS BEFORE USING THE MULTIMETER. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. - Follow the vehicle manufacturer's service specifications at all times. - Do not use the DRBIII(R) if it has been damaged. - Do not use the test leads if the insulation is damaged or if metal is exposed. - To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. - Choose the proper range and functions for the measurement. Do not try voltage or current measurement that may exceed the rated capacity. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2577 - Do not exceed the limits shown in the table below: - Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. - Use caution when measuring voltage above 25v DC or 25v AC. - Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. - When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. - When measuring current, connect the meter in series with the load. - Disconnect the live test lead before disconnecting the common test lead. - When using the meter function, keep the DRBIII(R) away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2578 Body Control Module: Tools and Equipment DRBIII(R) (diagnostic read-out box) Jumper wires Ohmmeter Voltmeter Test Light 8310 Airbag System Load Tool 8443 SRS Airbag System Load Tool 8815 Diagnostic Pinout Box Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Customer Interest: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Powertrain Control Module: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2592 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2593 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2594 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Powertrain Control Module: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Powertrain Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2604 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2605 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2606 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 2609 Powertrain Control Module: Connector Locations Right Rear Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 2610 Right Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 2611 Right Rear Engine Wiring (SRT-10) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Connector Views Powertrain Control Module: Connector Views Module-Powertrain Control C1 (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Connector Views > Page 2614 Module-Powertrain Control C2 (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Connector Views > Page 2615 Module-Powertrain Control C3 (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM Powertrain Control Module: Description and Operation PCM The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - EATX module (if equipped) - Engine coolant temperature sensor - Fuel level (through J1850 circuitry) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2618 - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission converter clutch circuit. Driven through J1850 circuits. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2619 Powertrain Control Module: Description and Operation Modes of Operation As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (02S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (02S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the 02S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The 02S sensor heater element is energized via the ASD or 02S heater relay. The 02S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2620 This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. - When engine has reached operating temperature, the PCM will begin monitoring 02S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (02S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2621 ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2622 Powertrain Control Module: Description and Operation 5 Volt Supplies Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2623 Powertrain Control Module: Description and Operation Ignition Circuit Sense This circuit ties the ignition switch to the Powertrain Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2624 Powertrain Control Module: Description and Operation PCM The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - EATX module (if equipped) - Engine coolant temperature sensor Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2625 - Fuel level (through J1850 circuitry) - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission converter clutch circuit. Driven through J1850 circuits. Modes of Operation As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (02S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (02S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the 02S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2626 - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The 02S sensor heater element is energized via the ASD or 02S heater relay. The 02S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. - When engine has reached operating temperature, the PCM will begin monitoring 02S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2627 When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (02S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the 02S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > PCM > Page 2628 Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 Volt Supplies Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). Ignition Circuit Sense This circuit ties the ignition switch to the Powertrain Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Power Grounds The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: - Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors Sensor Return The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > PCM/ECM/SKIM Programming Powertrain Control Module: Service and Repair PCM/ECM/SKIM Programming NOTE: Before replacing the Powertrain Control Module (PCM) or Engine Control Module (ECM), be certain to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM/ECM driver/control circuit failures are caused by internal component failures (i.e. relays and solenoids) and shorted circuits (i.e. pull-ups, drivers, and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has been set. When a Powertrain Control Module (PCM) for a gasoline engine, or a Engine Control Module for a diesel engine and the Sentry Key Immobilizer Module (SKIM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM/ECM. 2. Program the new SKIM. 3. Replace all ignition keys and program them into the new SKIM. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > PCM/ECM/SKIM Programming > Page 2631 Powertrain Control Module: Service and Repair Programming the PCM/ECM/SKIM The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKIM is replaced, it is necessary to program the Secret Key into the new modules using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool menu for the module being replaced as appropriate. NOTE: - Be certain to enter the correct country code for the SKIM. If the incorrect country code is programmed into the SKIM, it cannot be changed and the SKIM must be replaced. - If the PCM/ECM and the SKIM are replaced at the same time, all vehicle ignition keys will need to be replaced and the new keys programmed into the new SKIM. - Programming the PCM/ECM or SKIM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > PCM/ECM/SKIM Programming > Page 2632 Powertrain Control Module: Service and Repair Programming Ignition Keys to the SKIM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKIM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKIM. To program ignition keys into the SKIM, follow the programming steps outlined in the diagnostic scan tool for "Program Ignition Keys or Key FOBs" under the "SKIM" menu item. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM, that key has acquired the Secret Key for that SKIM and cannot be transferred to any other SKIM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - Programming Not Attempted - The scan tool attempts to read the programmed key status and there are no keys programmed into SKIM memory. - Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program an ignition key transponder due to one of the following: The ignition key transponder is faulty. - The ignition key transponder is or has been already programmed to another vehicle. - 8 Keys Already Learned, Programming Not Done - The SKIM transponder ID memory is full. - Learned Key In Ignition - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKIM memory. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > PCM/ECM/SKIM Programming > Page 2633 Powertrain Control Module: Service and Repair Module - Powertrain Control CAUTION: - Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using the DRB scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. - Use the DRB scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. REMOVAL The PCM (1) is located in the engine compartment attached to the dash panel (3). To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > PCM/ECM/SKIM Programming > Page 2634 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors (four 38-way connectors if equipped with NGC) from PCM (1). 4. Remove three PCM mounting bolts (3) and remove PCM from vehicle. INSTALLATION 1. Install PCM (3) and 3 mounting bolts (4) to vehicle. 2. Tighten bolts. Refer to torque specifications. 3. Check pin connectors in the PCM and the three 32-way connectors (four 38-way connectors if equipped with NGC) for corrosion or damage. Also, the pin heights in connectors should all be same. Repair as necessary before installing connectors. 4. Install three 32-way connectors (four 38-way connectors if equipped with NGC). 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install negative battery cable. 7. The 5.7L V-8 engine is equipped with a fully electronic accelerator pedal position sensor. If equipped with a 5.7L, also perform the following 3 steps: a. Connect negative battery cable to battery. b. Turn ignition switch ON, but do not crank engine. c. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn electrical parameters. d. The DRB III(R) Scan Tool may also be used to learn electrical parameters. Go to the Miscellaneous menu, and then select ETC Learn. 8. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set. 9. If necessary, use DRB III(R) Scan Tool to erase any Diagnostic Trouble Codes (DTC's) from PCM. Also use the DRB scan tool to reprogram new PCM with vehicles original Vehicle Identification Number (VIN) and original vehicle mileage. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2638 Main Relay (Computer/Fuel System): Description and Operation PCM OUTPUT The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. PCM OUTPUT The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2639 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2640 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Wiring Diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations Integrated Power Module Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2644 Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2645 Oxygen Sensor Relay: Description and Operation DESCRIPTION The Oxygen Sensors (02S) are attached to, and protrude into the vehicle exhaust system Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors Federal Emission Packages Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2) With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor The downstream sensor (1/2) is located just after the main catalytic convertor California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as ill and 2/1) and 2 downstream (referred to as 1/2 and 2/2) With this emission pack-age, the right upstream sensor (2/i) is located in the right exhaust downpipe just before the mini-catalytic convertor The left upstream sensor (1/i) is located in the left exhaust downpipe just before the mini-catalytic convertor The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Left Front Facia And Battery Tray Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 2654 Battery Temperature Sensor: Connector Locations Left Rear Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 2655 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 2656 Left Front Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 2657 Integrated Power Module And Fan Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2658 Sensor-Battery Temperature Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2659 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2660 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. 1. Remove battery. Refer to Battery for procedures. Battery Temperature Sensor Location 2. Pry sensor straight up from battery tray mounting hole to gain access to electrical connector. 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. 1. Pull electrical connector up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Refer to Battery for procedures. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams Sensor-Camshaft Position (Gas) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2664 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor is located above the water pump and under the throttle body. The camshaft position sensor (1) provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses. The PCM determines crankshaft position from the camshaft position sensor and crankshaft position sensor inputs. The PCM uses the input to determine fuel injection synchronization and to determine which ignition coil to energize. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2665 The camshaft position sensor detects when a step down (1) in the camshaft sprocket passes beneath it. When the sensor detects the step down, the input voltage from the sensor to the PCM switches from low (0.3 volts) to high (5 volts). As the step up returns to the sensor, the input voltage switches back to low (0.3 volts). The paper spacer is not used on 8.3L motors. Don't use at all. It plugs up the oil pickup screen. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2666 Camshaft Position Sensor: Service and Repair REMOVAL 8.3L - REPLACING WITH NEW SENSOR The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. If a new replacement camshaft position sensor is to be installed, use this procedure. 1. Disconnect the sensor wiring harness connector from sensor. 2. Remove the sensor mounting bolt. 3. Carefully pry the sensor from the timing chain case/cover in a rocking action with two small screwdrivers. 4. Remove the sensor from vehicle. 8.3L - REPLACING OLD SENSOR WITH ORIGINAL The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. If the original camshaft position sensor is to be removed and installed, such as when servicing the timing chain, timing gears or timing chain cover, use this procedure. 1. Disconnect the sensor harness connector from the sensor. 2. Scribe the sensor for location depth. 3. Remove the sensor mounting bolt. 4. Carefully pry the sensor from the timing chain case/cover in a rocking action with two small screwdrivers. 5. Remove the sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 8.3L - INSTALLATION - WITH NEW SENSOR The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. 1. Apply a small amount of engine oil to the sensor O-ring. A low (step down) and high (step up) area are machined into the camshaft drive gear. The sensor is positioned in the timing gear cover so that a small air gap exists between the face of sensor and the high machined area of cam gear. Before the sensor is installed, the cam gear may have to be rotated. This is to allow the high machined area (step up) on the gear to be directly in front of the sensor mounting hole opening on the timing gear cover. Do not install sensor with gear positioned at low area. When the engine is started, the sensor will be broken. 2. Using a 1/2 in. wide metal ruler, measure the distance from the cam gear to the face of the sensor mounting hole opening on the timing gear cover. 3. If the dimension is approximately 1-15/32 inches or less, it is OK to install sensor. 4. If the dimension is approximately 1-5/8 inches or more, the cam gear will have to be rotated. 5. Attach a socket to the vibration damper mounting bolt and rotate engine until the 1-15/32 inch dimension is attained. 6. Install the sensor into the timing case/cover with a slight rocking action. Do not twist the sensor into position as damage to the O-ring may result. Push the sensor all the way into the cover until the rib material on the sensor contacts the camshaft gear. 7. Install the mounting bolt and tighten to 10.7 N.m (95 in.lbs.) torque. 8. Connect sensor wiring harness to engine harness. When the engine is started, the rib material will be sheared off the face of sensor. This will automatically set sensor air gap. 8.3L - REPLACING OLD SENSOR WITH ORIGINAL The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. When installing a used camshaft position sensor, the sensor depth must be adjusted to prevent contact with the camshaft gear (sprocket). 1. Apply a small amount of engine oil to the sensor O-ring. A low and high area are machined into the camshaft drive gear. The sensor is positioned in the timing gear cover so that a small air gap exists between the face of sensor and the high machined area of cam gear. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2667 Before the sensor is installed, the cam gear may have to be rotated. This is to allow the high machined area on the gear to be directly in front of the sensor mounting hole opening on the timing gear cover. Do not install sensor with gear positioned at low area. When the engine is started, the sensor will be broken. 2. Using a 1/2 in. wide metal ruler, measure the distance from the cam gear to the face of the sensor mounting hole opening on the timing gear cover. 3. If the dimension is approximately 1-15/32 inches or less, it is OK to install sensor. 4. If the dimension is approximately 1-5/8 inches or more, the cam gear will have to be rotated. 5. Attach a socket to the vibration damper mounting bolt and rotate engine until the 1-15/32 inch dimension is attained. 6. Install the sensor into the timing case/cover with a slight rocking action until the sensor is aligned to scribe line. The paper spacer can be used if reinstalling a used sensor. 7. Install sensor mounting bolt and tighten to 10.7 N.m (95 in.lbs.) torque. 8. Connect engine wiring harness to sensor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations Crankshaft Position Sensor: Locations The sensor is located at the rear lower passenger side of motor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2671 Sensor-Crankshaft Position (5.7L/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 2672 Crankshaft Position Sensor: Service and Repair REMOVAL The sensor is located at the rear lower passenger side of motor. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting bolt. 3. Pull sensor out. A light tap to top of sensor may ease removal. INSTALLATION 1. Slide the sensor into the hole. 2. Install and tighten the mounting bolt to 11 Nm (95 in. lbs.) torque. 3. Connect the electrical connector to the sensor and lock. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Sensor-Fuel Level Sending Unit Fuel Level Sensor: Locations Sensor-Fuel Level Sending Unit The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Sensor-Fuel Level Sending Unit > Page 2680 Fuel Level Sensor: Locations Fuel Pump Module The fuel pump module assembly is located on the top of the fuel tank. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2681 Fuel Level Sensor: Description and Operation 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 variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit 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 diagnostic 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2682 Fuel Level Sensor: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation. 2. Disconnect 4-wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. Refer to Special Tools in Wiring for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4-wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/ Installation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Left Front Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 2686 Sensor-Intake Air Temperature (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 2687 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL NOTE: Take care not to damage the thermistor pill when removing the sensor. 1. Remove the battery cover and disconnect the negative battery cable. 2. Disconnect the electrical connector from the inlet temperature sensor. 3. Remove sensor from inlet hose. INSTALLATION NOTE: Take care not to damage the open thermistor pill when installing the sensor. 1. Install sensor , use a little water to aid in insertion of sensor. 2. Make sure that the rib on the sensor matches up with the rib on the inlet hose. The thermistor pill should be in direct contact with the inlet air stream. 3. Connect the electrical connector. 4. Connect the negative battery cable and install battery cover. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2691 Knock Sensor: Diagrams Sensor-Knock No.1 (5.7L/SRT) Sensor-Knock No.2 (5.7L/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2692 Knock Sensor: Description and Operation The sensors are used only with 3.7L V-6, 4.7L V-8 and 5.7L V-8 engines. On 3.7L V-6 and 4.7L V-8 engines, the 2 knock sensors are bolted into the cylinder block under the intake manifold. On 5.7L V-8 engines, 2 knock sensors are also used. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. 3.7L V-6/4.7L V-8/5.7L V-8 Engines Only Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations Manifold Pressure/Vacuum Sensor: Component Locations The MAP sensor (2) mounts to the drivers side intake manifold plenum. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations > Page 2697 Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2698 Sensor-Map (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2699 Manifold Pressure/Vacuum Sensor: Description and Operation The MAP sensor (2) mounts to the drivers side intake manifold plenum. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum. During key-on (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in. Hg. If a storm goes through, it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2700 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL The manifold absolute pressure sensor is mounted on the drivers side of the intake manifold. 1. Disconnect the electrical connector from the MAP sensor. 2. Remove MAP sensor mounting screws. INSTALLATION 1. Install the MAP sensor to the intake manifold. 2. Install MAP sensor mounting screws and tighten mounting screws to 4 Nm (35 in. lbs.). 3. Connect the electrical connector to the MAP sensor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Right Front Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2706 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2707 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2708 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2709 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2710 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2711 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2712 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2713 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2714 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2715 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2716 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2717 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2718 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2719 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2720 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2721 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2722 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2723 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2724 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2725 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2726 Sensor-Engine Oil Pressure (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations 4 Sensor Vehicle 2 Sensor Vehicle (1 = Downstream, 2 = Upstream) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2731 Oxygen Sensor: Connector Locations Left Transmission (RFE) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2732 Right Transmission (RFE) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2733 Manual Transmission (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2734 Transmission And Exhaust (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2735 Oxygen Sensor: Diagrams Sensor-Oxygen-Left Front (SRT) Sensor-Oxygen-Left Rear (SRT) Sensor-Oxygen-Right Front (SRT) Sensor-Oxygen-Right Rear (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2736 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2737 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the engine or emission package, the vehicle ] may use a total of either 2 or 4 sensors. Federal Emission Packages : Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2738 Oxygen Sensor: Service and Repair REMOVAL CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support vehicle. 2. Disconnect wire connector from O2S sensor. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in exhaust pipe using appropriate tap. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. 1. Install O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect O2S sensor wire connector. 3. Lower vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations The TPS (1) is mounted on the passenger side of the throttle body. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2742 Throttle Position Sensor: Description and Operation The TPS (1) is mounted on the passenger side of the throttle body. The sensor connects to the throttle blade shaft. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from .26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2743 Throttle Position Sensor: Service and Repair REMOVAL The TPS is attached to the throttle body. 1. Disconnect the TPS electrical connector. 2. Remove the TPS mounting screws. 3. Remove the TPS. INSTALLATION The TPS is attached to the throttle body. The throttle shaft end of the throttle body slides into a socket in the TPS. When indexed correctly, the TPS can rotate a few degrees to line up the mounting screw holes with the screw holes in the throttle body. If the sensor will not rotate into place, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS has slight tension when rotated to align the mounting holes. 1. Install TPS and mounting screws. 2. Attach electrical connector to the TPS. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations The TPS (1) is mounted on the passenger side of the throttle body. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2747 Throttle Position Sensor: Description and Operation The TPS (1) is mounted on the passenger side of the throttle body. The sensor connects to the throttle blade shaft. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from .26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2748 Throttle Position Sensor: Service and Repair REMOVAL The TPS is attached to the throttle body. 1. Disconnect the TPS electrical connector. 2. Remove the TPS mounting screws. 3. Remove the TPS. INSTALLATION The TPS is attached to the throttle body. The throttle shaft end of the throttle body slides into a socket in the TPS. When indexed correctly, the TPS can rotate a few degrees to line up the mounting screw holes with the screw holes in the throttle body. If the sensor will not rotate into place, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS has slight tension when rotated to align the mounting holes. 1. Install TPS and mounting screws. 2. Attach electrical connector to the TPS. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation CONVERTER - CATALYTIC DESCRIPTION WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. CAUTION: 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. The stainless steel catalytic converter body is designed to last the life of the vehicle. 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. Unleaded gasoline must be used to avoid contaminating the catalyst core. 50 State emission vehicles incorporate two mini catalytic converters located after the exhaust manifolds and before the inline catalytic converter. OPERATION The catalytic converter captures and burns any unburned fuel mixture exiting the combustion chambers during the exhaust stroke of the engine. This process aids in reducing emissions output. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 2753 Catalytic Converter: Service and Repair CONVERTER - CATALYTIC 8.3L ENGINE 1. Raise and support vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Disconnect oxygen sensor electrical connectors. 4. Remove LH exhaust pipe to manifold bolts (2), retainers and nuts (1). 5. Remove LH catalytic converter to muffler clamp nuts (4). 6. Rotate LH catalytic converters (6) from the muffler (5). 7. Remove RH exhaust pipe to manifold bolts (2), retainers and nuts (1). 8. Remove RH catalytic converter to muffler clamp nuts (4). 9. Rotate RH catalytic converter (3) from the muffler (5). 10. Remove clamps and nuts (4). 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. If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber mallet may indicate a damaged core. INSTALLATION 1. Make sure catalytic converters (3, 6) and mufflers (5) are free of burrs. 2. Insert RH catalytic converter (3) into muffler (5). 3. Make sure the alignment tang on the catalytic converter (3) seats in the alignment slot on the muffler (5). 4. Position the catalytic converter (3) to the exhaust manifold. Install and hand tighten bolts (2), retainers and nuts (1). 5. Insert LH catalytic converter (6) into muffler (5). 6. Make sure the alignment tang on the catalytic converter (6) seats in the alignment slot on the muffler (5). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 2754 7. Position the catalytic converter (6) to the exhaust manifold. Install and hand tighten bolts (2), retainers and nuts (1) 8. Check the exhaust system for contact with the body panels. A minimum of 25.4 mm (1.0 inch) is required between the exhaust system components and body/frame parts. Clearance between catalytic converter and frame is 15 mm (0.59 inch). Make the necessary adjustments, if needed. 9. Tighten catalytic converter to exhaust manifold bolts (2) to 20.3 Nm (15 ft. lbs.) torque. 10. Tighten the clamp nuts to 54.2 Nm (40 ft. lbs.) torque. 11. Lower the vehicle. 12. Start the engine and inspect for exhaust leaks. and exhaust system. Repair exhaust leaks as necessary. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Component Locations Canister Purge Solenoid: Component Locations The duty cycle EVAP canister purge solenoid is located in the engine compartment. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Component Locations > Page 2760 Canister Purge Solenoid: Connector Locations Left Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Component Locations > Page 2761 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2762 Solenoid-EVAP/Purge (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2763 Canister Purge Solenoid: Description and Operation The duty cycle EVAP canister purge solenoid is located in the engine compartment. It is attached to the side of the Power Distribution Center (PDC). The Powertrain Control Module (PCM) operates the solenoid. 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 de-energizes 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. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2764 Canister Purge Solenoid: Service and Repair REMOVAL The duty cycle EVAP canister purge solenoid (3) is located in the engine compartment. It is attached to the side of the Power Distribution Center (PDC). 1. Disconnect electrical wiring connector at solenoid. 2. Disconnect vacuum harness (2) at solenoid. 3. Remove solenoid from mounting bracket. INSTALLATION 1. Install solenoid assembly to mounting bracket. 2. Connect vacuum harness. 3. Connect electrical connector. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Evaporative Emission Control Canister: Locations EVAP canisters (5) are located near the front of the fuel tank. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2768 Evaporative Emission Control Canister: Description and Operation Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2769 Two EVAP canisters are used. Depending on vehicle model and fuel tank size, the canisters may be mounted either vertically or horizontally. These maintenance free, EVAP canisters (5) are located near the front of the fuel tank. Two EVAP canisters are used. Depending on vehicle model and fuel tank size, the canisters may be mounted either vertically or horizontally. The EVAP canisters are filled with granules of an activated carbon mixture. Fuel vapors entering the EVAP canisters are absorbed by the charcoal granules. Fuel tank pressure vents into the EVAP canisters. Fuel vapors are temporarily held in the canisters until they can be drawn into the intake manifold. The duty cycle EVAP canister purge solenoid allows the EVAP canisters to be purged at predetermined times and at certain engine operating conditions. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2770 Evaporative Emission Control Canister: Service and Repair REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2771 Two EVAP canisters are used. Depending on vehicle model and fuel tank size, the canisters may be mounted either vertically or horizontally. These maintenance free, EVAP canisters (5) are located near the front of the fuel tank. Type 1 Canisters Use the following procedure for vertically mounted canisters. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2772 1. Raise and support vehicle. 2. Certain models, equipped with a certain fuel tank size, may require the removal of the fuel tank skid plate and/or the transfer case skid plate to gain access to the EVAP canister(s). Remove necessary skid plates. 3. Remove fuel tubes/lines at each EVAP canister. Note location of tubes/lines before removal for easier installation. 4. Remove lower support bracket (4). 5. Remove mounting nuts (1) at top of each canister. 6. Remove each canister from upper support bracket. Type 2 Canisters Use the following procedure for horizontally mounted canisters. 1. Raise and support vehicle. 2. Certain models, equipped with a certain fuel tank size, may require the removal of the fuel tank skid plate and/or the transfer case skid plate to gain access to the EVAP canister(s). Remove necessary skid plates. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2773 3. Remove fuel tubes/lines (1) at each EVAP canister. Note location of tubes/lines before removal for easier installation. Remove bolts (6). 4. Remove nut (1) and remove NVLD filter (2). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2774 5. Remove nuts (4) and remove NVLD filter support bracket (2). Remove upper canister. 6. Remove nuts (5) and remove lower canister (6). Slip lower canister pins (7) from rubber grommets. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2775 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2776 Two EVAP canisters are used. Depending on vehicle model and fuel tank size, the canisters may be mounted either vertically or horizontally. These maintenance free, EVAP canisters (5) are located near the front of the fuel tank. Type 1 Canisters Use the following procedure for vertically mounted canisters. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2777 1. Place each canister (5) and (6) into upper support bracket and install nuts. Refer to Torque Specifications. 2. Install lower support bracket (4). Refer to Torque Specifications. 3. Carefully install vapor/vacuum lines. The vapor/vacuum lines and hoses must be firmly connected. Also check the vapor/vacuum lines at the NVLD Pump, 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. 4. If necessary, install skid plate(s). Type 2 Canisters Use the following procedure for horizontally mounted canisters. 1. Slip lower canister pins (7) into rubber grommets. Install lower canister (6) and nuts (5). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2778 2. Install upper canister (1). Install NVLD filter support bracket (2) and install nuts (4). 3. Install NVLD filter (2) and nut (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2779 4. Carefully install vapor/vacuum lines, and fuel tubes/lines (1) to each EVAP canister. Install bolts (6). 5. The vapor/vacuum lines and hoses must be firmly connected. Also check the vapor/vacuum lines at the NVLD Pump, 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. 6. If necessary, install skid plate(s). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Diagrams Assembly - Natural Vacuum Leak Detection (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Leak Detection Pump Leak Detection Pump: Locations Leak Detection Pump The Leak Detection Pump (LDP) (4) and LDP filter are attached to the front of the EVAP canister mounting bracket. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Leak Detection Pump > Page 2787 Leak Detection Pump: Locations Natural Vac Leak Detection Equipped With Horizontally Mounted EVAP Canisters The NVLD pump (4) is attached to the EVAP canister. Equipped With Vertically Mounted EVAP Canisters Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Leak Detection Pump > Page 2788 The NVLD pump (4) is located at the front of fuel tank. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Leak Detection Pump Leak Detection Pump: Description and Operation Leak Detection Pump Vehicles equipped with JTEC engine control modules use a leak detection pump. Vehicles equipped with NGC engine control modules use an NVLD pump. Refer to Natural Vacuum - Leak Detection (NVLD) for additional information. 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 onboard 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. 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. 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" H2O (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. LDP AT REST (NOT POWERED) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Leak Detection Pump > Page 2791 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. 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. DIAPHRAGM DOWNWARD MOVEMENT Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Leak Detection Pump > Page 2792 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 PCM 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 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. If the system does not pass the EVAP Leak Detection Test, the following DTCs may be set: - P0442 - EVAP LEAK MONITOR 0.040 inches LEAK DETECTED - P0455 - EVAP LEAK MONITOR LARGE LEAK DETECTED - P0456 - EVAP LEAK MONITOR 0.020 inches LEAK DETECTED Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Leak Detection Pump > Page 2793 - P1486 - EVAP LEAK MON PINCHED HOSE FOUND - P1494 - LEAK DETECTION PUMP SW OR MECH FAULT - P1495 - LEAK DETECTION PUMP SOLENOID CIRCUIT Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Leak Detection Pump > Page 2794 Leak Detection Pump: Description and Operation Natural Vac Leak Detection Vehicles equipped with an NGC Powertrain Control Module (PCM) use a Natural Vacuum Leak Detection (NVLD) pump and system. Vehicles equipped with a JTEC PCM use an LDP (Leak Detection Pump). Refer to Leak Detection Pump (LDP) for additional information. The NVLD pump is located in the same area as the leak detection pump. Refer to NVLD Removal/Installation for additional information. The Natural Vacuum Leak Detection (NVLD) system is the new generation evaporative leak detection system that will first be used on vehicles equipped with the Next Generation Controller (NGC). This new system replaces the leak detection pump as the method of evaporative system leak detection. This is to detect a leak equivalent to a 0.020 inches (0.5 mm) hole. This system has the capability to detect holes of this size very dependably. The basic leak detection theory employed with NVLD is the "Gas Law". This is to say that the pressure in a sealed vessel will change if the temperature of the gas in the vessel changes. The vessel will only see this effect if it is indeed sealed. Even small leaks will allow the pressure in the vessel to come to equilibrium with the ambient pressure. In addition to the detection of very small leaks, this system has the capability of detecting medium as well as large evaporative system leaks. A vent valve seals the canister vent during engine off conditions. If the vapor system has a leak of less than the failure threshold, the evaporative system will be pulled into a vacuum, either due to the cool down from operating temperature or diurnal ambient temperature cycling. The diurnal effect is considered one of the primary contributors to the leak determination by this diagnostic. When the vacuum in the system exceeds about 1 inches H2O (0.25 KPA), a vacuum switch closes. The switch closure sends a signal to the NGC. The NGC, via appropriate logic strategies, utilizes the switch signal, or lack thereof, to make a determination of whether a leak is present. The NVLD device is designed with a normally open vacuum switch, a normally closed solenoid, and a seal, which is actuated by both the solenoid and a diaphragm. The NVLD is located on the atmospheric vent side of the canister. The NVLD assembly may be mounted on top of the canister outlet, or in-line between the canister and atmospheric vent filter. The normally open vacuum switch will close with about 1 inches H2O (0.25 KPA) vacuum in the evaporative system. The diaphragm actuates the switch. This is above the opening point of the fuel inlet check valve in the fill tube so cap off leaks can be detected. Submerged fill systems must have recirculation lines that do not have the in-line normally closed check valve that protects the system from failed nozzle liquid ingestion, in order to detect cap off conditions. The normally closed valve in the NVLD is intended to maintain the seal on the evaporative system during the engine off condition. If vacuum in the evaporative system exceeds 3 inches to 6 inches H2O (0.75 to 1.5 KPA), the valve will be pulled off the seat, opening the seal. This will protect the system from excessive vacuum as well as allowing sufficient purge flow in the event that the solenoid was to become inoperative. The solenoid actuates the valve to unseal the canister vent while the engine is running. It also will be used to close the vent during the medium and large leak tests and during the purge flow check. This solenoid requires an initial 1.5 amps of current to pull the valve open, but after 100 milli-seconds, will be duty cycled down to an average of about 150 mA for the remainder of the drive cycle. Another feature in the device is a diaphragm that will open the seal in the NVLD with pressure in the evaporative system. The device will "blow off' at about 0.5 inches H2O (0.12 KPA) pressure to permit the venting of vapors during refueling. An added benefit to this is that it will also allow the tank to "breathe" during increasing temperatures, thus limiting the pressure in the tank to this low level. This is beneficial because the induced vacuum during a subsequent declining temperature will achieve the switch closed (pass threshold) sooner than if the tank had to decay from a built up pressure. The device itself has 3 wires: Switch sense, solenoid driver and ground. It also includes a resistor to protect the switch from a short to battery or a short to ground. The NGC utilizes a high-side driver to energize and duty-cycle the solenoid. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump Leak Detection Pump: Service and Repair Leak Detection Pump REMOVAL The Leak Detection Pump (LDP) (4) and LDP filter are attached to the front of the EVAP canister mounting bracket. This is located near the front of the fuel tank. The LDP and LDP filter are replaced (serviced) as one unit. 1. Raise and support vehicle. 2. Certain models, equipped with a certain fuel tank size, may require the removal of the fuel tank skid plate and/or the transfer case skid plate to gain access to the leak pump. Remove necessary skid plates. 3. Carefully remove hose at LDP filter. 4. Remove LDP filter mounting bolt and remove from vehicle. 5. Carefully remove vapor/vacuum lines at LDP. 6. Disconnect electrical connector at LDR 7. Remove LDP mounting bolt and remove LDP from vehicle. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 2797 The LDP (4) and LDP filter are attached to the front of the EVAP canister mounting bracket. The LDP and LDP filter are replaced (serviced) as one unit. 1. Install LDP to mounting bracket. Refer to Torque Specifications. 2. Install LDP filter to mounting bracket. Refer to Torque Specifications. 3. Carefully install vapor/vacuum lines to LDP, and install hose to LDP filter. 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. 4. Connect electrical connector to LDP. 5. If necessary, install skid plate(s). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 2798 Leak Detection Pump: Service and Repair Natural Vac Leak Detection Pump Equipped With Horizontally Mounted EVAP Canisters REMOVAL The NVLD pump (4) is attached to the EVAP canister. 1. Raise and support vehicle. 2. Certain models, equipped with a certain fuel tank size, may require the removal of the fuel tank skid plate and/or the transfer case skid plate to gain access to the leak pump. Remove necessary skid plates. 3. Disconnect electrical connector at NVLD assembly. 4. Carefully disconnect vapor lines from NVLD assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 2799 5. Lift tab on NVLD assembly and twist assembly counterclockwise. 6. Pull NVLD pump out to remove from EVAP canister. 7. Remove O-ring from EVAP canister. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 2800 INSTALLATION The NVLD pump (4) is attached to the EVAP canister. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 2801 1. Install new O-ring to EVAP canister. 2. Align NVLD assembly into EVAP canister. 3. Rotate NVLD assembly until alignment tab drops into slot. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 2802 4. Connect electrical connector to NVLD assembly. 5. Carefully install vapor/vacuum lines to NVLD pump. The vapor/vacuum lines and hoses must be firmly connected. Check the vapor/vacuum lines at the NVLD pump, filter and EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 6. If necessary, install skid plate(s). Equipped With Vertically Mounted EVAP Canisters REMOVAL The NVLD pump (4) is located at the front of fuel tank. 1. Raise and support vehicle. 2. Certain models, equipped with a certain fuel tank size, may require the removal of the fuel tank skid plate and/or the transfer case skid plate to gain access to the leak pump. Remove necessary skid plates. 3. Disconnect electrical connector at pump. 4. Carefully remove vapor/vacuum hoses at pump. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 2803 5. The NVLD pump snaps into the EVAP canister. Press on release tab (2) while rotating pump from canister. INSTALLATION The NVLD pump (4) is located at the front of fuel tank. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 2804 1. Snap NVLD pump (1) to EVAP canister until tab (2) engages. 2. Connect electrical connector to NVLD pump. 3. Carefully install vapor/vacuum lines to NVLD pump. The vapor/vacuum lines and hoses must be firmly connected. Check the vapor/vacuum lines at the NVLD pump, filter and EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 4. If equipped, install skid plate(s). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > System Information > Description and Operation Refueling Vapor Recovery System: Description and Operation The ORVR (On-Board Refueling Vapor Recovery) system consists of a unique fuel tank, flow management valve, fluid control valve, one-way check valve and vapor canister. The ORVR (On-Board Refueling Vapor Recovery) system is used to remove excess fuel tank vapors. This is done while the vehicle is being refueled. Fuel flowing into the fuel filler tube (approx. 1 inches I.D.) creates an aspiration effect drawing air into the fuel fill tube. During refueling, the fuel tank is vented to the EVAP canister to capture escaping vapors. With air flowing into the filler tube, there are no fuel vapors escaping to the atmosphere. Once the refueling vapors are captured by the EVAP canister, the vehicle's computer controlled purge system draws vapor out of the canister for the engine to burn. The vapor flow is metered by the purge solenoid so that there is no, or minimal impact on driveability or tailpipe emissions. As fuel starts to flow through the fuel fill tube, it opens the normally closed check valve and enters the fuel tank. Vapor or air is expelled from the tank through the control valve and on to the vapor canister. Vapor is absorbed in the EVAP canister until vapor flow in the lines stops. This stoppage occurs following fuel shut-off, or by having the fuel level in the tank rise high enough to close the control valve. This control valve contains a float that rises to seal the large diameter vent path to the EVAP canister. At this point in the refueling process, fuel tank pressure increases, the check valve closes (preventing liquid fuel from spiting back at the operator), and fuel then rises up the fuel filler tube to shut off the dispensing nozzle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Positive Crankcase Ventilation Valve: Locations PCV FILTER The crankcase breather/filter is no longer used with the 3.9L, 5.2L or 5.9L engine. PCV VALVE All 3.9L V-6 and 5.2L/5.9L V-8 gas powered engines are equipped with a closed crankcase ventilation system and a positive crankcase ventilation (PCV) valve. The 8.0L V-10 engine is not equipped with a PCV valve. Refer to Crankcase Ventilation System-8.0L V-10 Engine for information. Fig. 4 Typical PCV Valve/Hose (Non-California Shown) This system consists of a PCV valve mounted on the cylinder head (valve) cover with a hose extending from the valve to the intake manifold. Another hose connects the opposite cylinder head (valve) cover to the air cleaner housing to provide a source of clean air for the system. A separate crankcase breather/filter is not used. Fig. 5 Typical Closed Crankcase Ventilation System The PCV system operates by engine intake manifold vacuum. Filtered air is routed into the crankcase through the air cleaner hose. The metered air, along with crankcase vapors, are drawn through the PCV valve and into a passage in the intake manifold. The PCV system manages crankcase Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 2812 pressure and meters blow by gases to the intake system, reducing engine sludge formation. The PCV valve contains a spring loaded plunger. This plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum. Fig. 6 Engine Off Or Engine Pop-Back - No Vapor Flow When the engine is not operating or during an engine pop-back, the spring forces the plunger back against the seat. This will prevent vapors from flowing through the valve. Fig. 7 High Intake Manifold Vacuum - Minimal Vapor Flow During periods of high manifold vacuum, such as idle or cruising speeds, vacuum is sufficient to completely compress spring. It will then pull the plunger to the top of the valve. In this position there is minimal vapor flow through the valve. Fig. 8 High Intake Manifold Vacuum - Maximum Vapor Flow During periods of moderate manifold vacuum, the plunger is only pulled part way back from inlet. This results in maximum vapor flow through the valve. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel System Pressure ......................................................................................................................... ............................................ 400 ± 34 kPa (58 ± 2 psi) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 2817 Fuel Pressure: Testing and Inspection Test 1 - 2 SYMPTOM FUEL PRESSURE LEAK DOWN POSSIBLE CAUSES - Faulty fuel pump module - Fuel injectors(s) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. 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. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. 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. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 2824 Idle Speed: Description and Operation The idle air control motor is mounted at the front right of the intake manifold. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair Accelerator Pedal: Service and Repair REMOVAL The following procedure applies only to vehicles without the Adjustable Pedal Package (code XAP). The accelerator pedal is serviced as a complete assembly including the bracket. The accelerator cable is connected to the upper part of the accelerator pedal arm by a plastic retainer (clip) (2).This plastic retainer snaps into the top of the accelerator pedal arm. 1. From inside the vehicle, hold up accelerator pedal. Remove plastic cable retainer (clip) and throttle cable core wire from upper end of accelerator pedal arm. Plastic cable retainer (clip) snaps into pedal arm. 2. Remove 2 accelerator pedal mounting bracket nuts. Remove accelerator pedal assembly. INSTALLATION 1. Place accelerator pedal assembly over 2 studs. 2. Install and tighten 2 mounting nuts. Refer to Torque Specifications. 3. Slide throttle cable into opening slot in top of pedal arm. 4. Push plastic cable retainer (clip) into accelerator pedal arm opening until it snaps into place. 5. Before starting engine, operate accelerator pedal to check for any binding. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Left Front Facia And Battery Tray Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications Fuel: Specifications Fuel Selection ...................................................................................................................................... ................................... 91 Octane, (R+M)/2 Method Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation Fuel Filler Cap: Description and Operation The plastic fuel tank filler tube cap is threaded onto the end of the fuel fill tube. Certain models are equipped with a 1/4 turn cap. The loss of any fuel or vapor out of fuel filler tube is prevented by the use of a pressure-vacuum fuel fill cap. Relief valves inside the cap will release fuel tank pressure at predetermined pressures. Fuel tank vacuum will also be released at predetermined values. This cap must be replaced by a similar unit if replacement is necessary. This is in order for the system to remain effective. CAUTION: Remove fill cap before servicing any fuel system component to relieve tank pressure. If equipped with a Leak Detection Pump (LDP), or NVLD system, the cap must be tightened securely. If cap is left loose, a Diagnostic Trouble Code (DTC) may be set. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Page 2837 Fuel Filler Cap: Service and Repair REMOVAL/INSTALLATION If replacement of the 1/4 turn fuel tank filler tube cap is necessary, it must be replaced with an identical cap to be sure of correct system operation. CAUTION: Remove the fuel tank filler tube cap to relieve fuel tank pressure. The cap must be removed prior to disconnecting any fuel system component or before draining the fuel tank. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. 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. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. 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. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications Fuel Injector: Specifications Information not supplied by manufacturer. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2845 Fuel Injector: Diagrams Injector-Fuel-No.1 (SRT) Injector-Fuel-No.10 (SRT) Injector-Fuel-No.2 (SRT) Injector-Fuel-No.3 (SRT) Injector-Fuel-No.4 (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2846 Injector-Fuel-No.5 (SRT) Injector-Fuel-No.6 (SRT) Injector-Fuel-No.7 (SRT) Injector-Fuel-No.8 (SRT) Injector-Fuel-No.9 (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2847 Fuel Injector: Description and Operation An individual fuel injector (1) is used for each individual cylinder. The top (fuel entry) end of the injector (1) is attached into an opening on the fuel rail. 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. 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. Battery voltage is supplied to the injectors through the ASD relay. The PCM determines injector pulse width based on various inputs. PCM OUTPUT The nozzle 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 with its respective cylinder number. 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. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2848 Battery voltage (12 volts +) is supplied to the injectors through the ASD relay. The ASD relay will shut-down the 12 volt power source to the fuel injectors if the PCM senses the ignition is on, but the engine is not running. This occurs after the engine has not been running for approximately 1.8 seconds. The PCM determines injector on-time (pulse width) based on various inputs. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2849 Fuel Injector: Service and Repair REMOVAL 1. Release fuel system pressure. Refer to Fuel Pressure Release Procedure. 2. Remove the battery cover and disconnect negative battery cable. 3. Remove the air cleaner assembly, refer to the Engine/Air Intake System/Air Cleaner Housing for more information. 4. Disconnect the electrical connector to the MAP sensor and Coolant Temperature sensor. 5. Disconnect the electrical connector to the TPS and Idle Air Control. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2850 6. Remove the wiring harness from the wiring clips under thew throttle body. 7. Disconnect the electrical connector from the fuel injectors. 8. Disconnect the fuel line quick connector. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2851 9. Remove the bolts for the fuel rail. 10. Pull fuel rail and injectors straight up and out of the intake manifold. 11. Move the fuel rail forward and out from under the intake manifold and throttle body. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2852 12. Remove the fuel injector from the fuel rail. INSTALLATION 1. Install the fuel injectors to the fuel rail. 2. Install fuel rail under throttle body. 3. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector. 4. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail bolts to 12 Nm (105 in. lbs.). 5. Attach electrical connectors to fuel injectors. 6. Connect the electrical connector to the MAP sensor and Coolant Temperature sensor. 7. Connect the electrical connector to the TPS and Idle Air Control. 8. Install the wiring harness to the wiring clips under the throttle body. 9. Connect fuel supply tube to fuel rail. Refer to Quick Connect Fittings in the Fuel Delivery section 10. Install the negative battery cable and install the battery cover. 11. Install the air cleaner assembly, refer to the Engine/Air Intake System/Air Cleaner Housing for more information. 12. Use the DRBIII(R) scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair Fuel Line Coupler: Service and Repair Different types of quick-connect fittings are used to attach the various fuel system components, lines and tubes. These are: a single-button type, a two-button type, a pinch type, a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. Some may require the use of a special tool for disconnection and removal. Refer to Quick-Connect Fittings Removal/Installation for more information. CAUTION: - Before separating a quick-connect fitting, pay attention to what type of fitting is being used by referring to Quick-Connect Fitting Removal. This will prevent unnecessary fitting or fitting latch breakage. - The interior components (O-rings, clips) of quick-connect fittings are not serviced separately, but new plastic spacers and latches are available for some types. If service parts are not available, do not attempt to repair the damaged fitting or fuel line (tube). If repair is necessary, replace the complete fuel line (tube) assembly. STANDARD PROCEDURE - QUICK-CONNECT FITTINGS Different types of quick-connect fittings are used to attach the various fuel system components, lines and tubes. These are: a single-button type, a two-button type, a pinch type, a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. Some may require the use of a special tool for disconnection and removal. DISCONNECTING WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSE, FITTING OR LINE, FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO FUEL SYSTEM PRESSURE RELEASE PROCEDURE. CAUTION: Before separating a quick-connect fitting, pay attention to what type of fitting is being used by referring to Quick-Connect Fitting Removal. This will prevent unnecessary fitting or fitting latch breakage. CAUTION: The interior components (O-rings, clips) of quick-connect fittings are not serviced separately, but new plastic spacers and latches are available for some types. If service parts are not available, do not attempt to repair the damaged fitting or fuel line (tube). If repair is necessary, replace the complete fuel line (tube) assembly. 1. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure. 2. Disconnect negative battery cable from battery. 3. Clean fitting of any foreign material before disassembly. 4. Single-Button Type Fitting: This type of fitting is equipped with a single push-button (2) located on the quick-connect fitting. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 2856 5. The push-button is attached to two internal latches (1).To disconnect, press on push-button with your thumb and unlatch fitting from fuel line. Special tools are not required for disconnection. DO NOT ATTEMPT TO PRY OR PULL UP ON PUSH-BUTTON. LATCHES WILL BE BROKEN. 6. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure. 7. Disconnect negative battery cable from battery. 8. Clean fitting of any foreign material before disassembly. 9. 2-Button Type Fitting: This type of fitting (1) is equipped with a push-button located on each side of quick-connect fitting (2). Press on both buttons simultaneously for removal. Special tools are not required for disconnection. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 2857 10. Pinch-Type Fitting: This fitting (1) is equipped with two finger tabs (2). Pinch both tabs together while removing fitting. Special tools are not required for disconnection. 11. Single-Tab Type Fitting: This type of fitting (3) is equipped with a single pull tab (1). The tab is removable. After tab is removed, quick-connect fitting can be separated from fuel system component. Special tools are not required for disconnection. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 2858 12. Press release tab on side of fitting to release pull tab (1). If release tab is not pressed prior to releasing pull tab, pull tab will be damaged. 13. While pressing release tab on side of fitting, use screwdriver (2) to pry up pull tab. 14. Raise pull tab until it separates from quick-connect fitting. 15. Two-Tab Type Fitting: This type of fitting (2) is equipped with tabs located on both sides of fitting (1).The tabs are supplied for disconnecting quickconnect fitting from component being serviced. a. To disconnect quick-connect fitting, squeeze plastic retainer tabs (1) against sides of quickconnect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. b. Pull fitting from fuel system component being serviced. c. The plastic retainer will remain on component being serviced after fitting is disconnected. The O-rings and spacer will remain in quick-connect fitting connector body. 16. Plastic Retainer Ring Type Fitting: This type of fitting can be identified by the use of a full-round plastic retainer ring (4) usually black in color. a. To release fuel system component from quickconnect fitting, firmly push fitting towards component being serviced while firmly pushing plastic retainer ring into fitting (6). With plastic ring depressed, pull fitting from component. The plastic retainer ring must be pressed squarely into fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in disconnection. b. After disconnection, plastic retainer ring will remain with quick-connect fitting connector body. c. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 2859 17. Latch Clips - Type 1: Depending on vehicle model and engine, 2 different types of safety latch clips are used. Type-1 (4) is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel line after latch clip is removed. The latch clip may be used on certain fuel line/ fuel rail connection, or to join fuel lines together. 18. Pry up on latch clip with a screwdriver (3). 19. Slide latch clip toward fuel rail while lifting with screwdriver. 20. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line (1).Use tool to release locking fingers in end of line. 21. With special tool still inserted, pull fuel line from fuel rail. 22. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line. 23. Disconnect quick-connect fitting from fuel system component being serviced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 2860 24. Latch Clips -Type 2: Depending on vehicle model and engine, 2 different types of safety latch clips are used. Type-1 is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel line after latch clip is removed. The latch clip may be used on certain fuel line/ fuel rail connection, or to join fuel lines together. 25. Type 2: Separate and unlatch 2 small arms (1) on end of clip and swing away from fuel line. 26. Slide latch clip toward fuel rail while lifting with screwdriver. 27. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line (1).Use tool to release locking fingers in end of line. 28. With special tool still inserted, pull fuel line from fuel rail. 29. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line. 30. Disconnect quick-connect fitting from fuel system component being serviced. CONNECTING 1. Inspect quick-connect fitting body and fuel system component for damage. Replace as necessary. 2. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 3. Insert quick-connect fitting into fuel tube or fuel system component until built-on stop on fuel tube or component rests against back of fitting. 4. Continue pushing until a click is felt. 5. Single-tab type fitting: Push new tab down until it locks into place in quick-connect fitting. 6. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 7. Latch Clip Equipped: Install latch clip (snaps into position). If latch clip will not fit, this indicates fuel line is not properly installed to fuel rail (or other fuel line). Recheck fuel line connection. 8. Connect negative cable to battery. 9. Start engine and check for leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Fuel Filter/Pressure Regulator Fuel Pressure Regulator: Locations Fuel Filter/Pressure Regulator A combination of fuel filter and fuel pressure regulator (3) is located on the top of the fuel pump module. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Fuel Filter/Pressure Regulator > Page 2865 Fuel Pressure Regulator: Locations Fuel Pump Module The fuel pump module assembly is located on the top of the fuel tank. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 2866 Fuel Pressure Regulator: Description and Operation A combination fuel filter and fuel pressure regulator (3) 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. 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 58 ± 2 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. Refer to Fuel Pump Description and Operation for more information. If fuel pressure at the pressure regulator exceeds approximately 60 psi, an internal diaphragm opens and excess fuel pressure is routed back into the tank through the bottom of pressure regulator. 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. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel System Pressure ......................................................................................................................... ............................................ 400 ± 34 kPa (58 ± 2 psi) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 2871 Fuel Pressure: Testing and Inspection Test 1 - 2 SYMPTOM FUEL PRESSURE LEAK DOWN POSSIBLE CAUSES - Faulty fuel pump module - Fuel injectors(s) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2877 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2878 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2879 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2880 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2881 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2882 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2883 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2884 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2885 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2886 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2887 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2888 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2889 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2890 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2891 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2892 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2893 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2894 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2895 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2896 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 2897 Fuel Pump Relay: Description and Operation The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shut-down the ground circuit to the fuel pump relay in approximately 1 - 3 seconds unless the engine is operating or the starter motor is engaged. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 2898 Fuel Pump Relay: Service and Repair REMOVAL The fuel pump relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Locations Fuel Pump Pickup Filter: Locations The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Locations > Page 2902 Fuel Pump Pickup Filter: Service and Repair REMOVAL The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (1). The fuel pump module is located inside of fuel tank. 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 (2) at bottom of module with 2 screwdrivers. Filter is snapped to module. 4. Clean bottom of pump module. INSTALLATION The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module. The fuel pump module is located inside of fuel tank. 1. Snap new filter to bottom of module. Be sure O-ring is in correct position. 2. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation Fuel Rail: Description and Operation The fuel injector rail is used to mount the fuel injectors to the engine. High pressure from the fuel pump is routed to the fuel rail. The fuel rail then supplies the necessary fuel to each individual fuel injector. A quick-connect fitting with a safety latch clip is used to attach the fuel line to the fuel rail. The fuel rail is not repairable. CAUTION: The left and right sections of the fuel rail are connected with either a flexible connecting hose, or joints. Do not attempt to separate the rail halves at these connecting hose or joints. Due to the design of the connecting hose or joint, it does not use any clamps. Never attempt to install a clamping device of any kind to the hose or joint. When removing the fuel rail assembly for any reason, be careful not to bend or kink the connecting hose or joint. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 2906 Fuel Rail: Service and Repair REMOVAL 1. Disconnect the electrical connector to the MAP sensor (2) and Coolant Temperature sensor (3). 2. Release fuel system pressure. Refer to Fuel Pressure Release Procedure. 3. Disconnect negative battery cable. 4. Remove the air cleaner assembly, refer to the Engine/Air Intake System/Air Cleaner Housing for more information. 5. Disconnect the electrical connector to the TPS (1) and Idle Air Control. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 2907 6. Remove the wiring harness from the wiring clips under the throttle body. 7. Disconnect the electrical connector from the fuel injectors. 8. Disconnect the fuel line quick connector. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 2908 9. Remove the bolts for the fuel rail. 10. Pull fuel rail and injectors straight up and out of the intake manifold. 11. Move the fuel rail forward and out from under the intake manifold and throttle body. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 2909 12. Remove the fuel injector from the fuel rail. INSTALLATION 1. Install the fuel injectors to the fuel rail. 2. Install fuel rail under throttle body. 3. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector. 4. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail bolts to 12 Nm (105 in. lbs.). 5. Attach electrical connectors to fuel injectors. 6. Connect the electrical connector to the MAP sensor and Coolant Temperature sensor. 7. Connect the electrical connector to the TPS and Idle Air Control. 8. Install the wiring harness to the wiring clips under the throttle body. 9. Connect fuel supply tube to fuel rail. Refer to Quick Connect Fittings in the Fuel Delivery section 10. Install the negative battery cable. 11. Install the air cleaner assembly, refer to the Engine/Air Intake System/Air Cleaner Housing for more information. 12. Use the DRBIII(R) scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Sensor-Fuel Level Sending Unit Fuel Gauge Sender: Locations Sensor-Fuel Level Sending Unit The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Sensor-Fuel Level Sending Unit > Page 2915 Fuel Gauge Sender: Locations Fuel Pump Module The fuel pump module assembly is located on the top of the fuel tank. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2918 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2919 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2920 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2921 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2922 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2923 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2924 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2925 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2926 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2927 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2928 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2929 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2930 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2931 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2932 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2933 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2934 Fuel Gauge Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2935 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2936 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2937 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Page 2938 Fuel Gauge Sender: Description and Operation 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 variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit 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 diagnostic 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Page 2939 Fuel Gauge Sender: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation. 2. Disconnect 4-wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. Refer to Special Tools in Wiring for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4-wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/ Installation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations Chassis Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 2943 Module-Fuel Pump Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 2944 Fuel Tank Unit: Service and Repair REMOVAL WARNING: THE FUEL SYSTEM MAY BE UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING THE FUEL PUMP MODULE, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. 1. Drain and remove fuel tank. Refer to Fuel Tank Removal/ Installation. 2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose. 3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5). 4. Install 1/2 inches drive breaker bar (1) to tool 9340 (3). 5. Rotate breaker bar counter-clockwise to remove lockring (5). 6. Remove lockring. The module will spring up slightly when lockring is removed. 7. Remove module from fuel tank. Be careful not to bend float arm while removing. INSTALLATION 1. Using a new seal (gasket), position fuel pump module into opening in fuel tank. 2. Position lockring (5) over top of fuel pump module. 3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle. 4. Install Special Tool 9340 (3) to lockring. 5. Install 1/2 inches drive breaker (1) into Special Tool 9340 (3). 6. Tighten lockring (clockwise) until all seven notches have engaged. 7. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations > Component Locations 3.7L Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations > Component Locations > Page 2949 Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations > Page 2950 Motor-IAC (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations > Page 2951 Idle Air Control (IAC) Motor: Description and Operation The idle air control motor is mounted at the front right of the intake manifold. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Locations > Page 2952 Idle Air Control (IAC) Motor: Service and Repair REMOVAL The IAC motor is inserted into a housing at the front of the intake manifold. The IAC motor and housing are serviced together. 1. Remove housing to manifold screws. Remove IAC motor and housing. 2. Disconnect the electrical connector from IAC motor. INSTALLATION The IAC motor is inserted into a housing at the front of the intake manifold. The IAC motor and housing are serviced together. 1. Attach electrical connector to IAC motor. 2. Install IAC motor into and housing on manifold. Tighten mounting screws to 4 Nm (35 in. lbs.) torque. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Locations Right Battery Tray Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2960 Main Relay (Computer/Fuel System): Description and Operation PCM OUTPUT The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. PCM OUTPUT The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2961 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2962 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Wiring Diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2969 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2970 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2971 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2972 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2973 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2974 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2975 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2976 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2977 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2978 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2979 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2980 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2981 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2982 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2983 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2984 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2985 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2986 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2987 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2988 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 2989 Fuel Pump Relay: Description and Operation The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shut-down the ground circuit to the fuel pump relay in approximately 1 - 3 seconds unless the engine is operating or the starter motor is engaged. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 2990 Fuel Pump Relay: Service and Repair REMOVAL The fuel pump relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations Right Battery Tray Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2997 Main Relay (Computer/Fuel System): Description and Operation PCM OUTPUT The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. PCM OUTPUT The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2998 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2999 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Wiring Diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Left Front Facia And Battery Tray Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations The TPS (1) is mounted on the passenger side of the throttle body. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3007 Throttle Position Sensor: Description and Operation The TPS (1) is mounted on the passenger side of the throttle body. The sensor connects to the throttle blade shaft. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from .26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3008 Throttle Position Sensor: Service and Repair REMOVAL The TPS is attached to the throttle body. 1. Disconnect the TPS electrical connector. 2. Remove the TPS mounting screws. 3. Remove the TPS. INSTALLATION The TPS is attached to the throttle body. The throttle shaft end of the throttle body slides into a socket in the TPS. When indexed correctly, the TPS can rotate a few degrees to line up the mounting screw holes with the screw holes in the throttle body. If the sensor will not rotate into place, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS has slight tension when rotated to align the mounting holes. 1. Install TPS and mounting screws. 2. Attach electrical connector to the TPS. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 18-016-05 > Apr > 05 > Fuel System MIL ON/Possible DTC's P2174/P2175 Throttle Body: Customer Interest Fuel System - MIL ON/Possible DTC's P2174/P2175 NUMBER: 18-016-05 GROUP: Vehicle Performance DATE: April 12, 2005 SUBJECT: Throttle Body Coking OVERVIEW: This bulletin involves cleaning the throttle body. MODELS: 2004 (DR) Ram Truck 2004 (HB) Durango NOTE: This condition is rarely experienced on vehicles with less than 50,000 miles. SYMPTOM/CONDITION: The vehicle operator may describe MIL illumination. The technician may find one or more of the following DTC's: P2174 - Low Airflow/Restriction Detected (Instant Accumulation) P2175 - Low Airflow/Restriction Detected (Slow Accumulation) Using a Scan Tool (DRBIII(R) or StarSCAN(R)) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. Inspect the air induction system including the air filter element, resonator, air induction hoses and throttle body, for restriction and/or large accumulations of silty deposits on air flow surfaces. If accumulation of silty deposits are present in the throttle body and /or behind the throttle plate, perform the appropriate Repair Procedure. PARTS REQUIRED 1. Remove the throttle body from the intake manifold. Refer to the service information available in TechCONNECT or the Ram Truck service manual (publication no. 81-370-04059), Section 14 Fuel Injection, Throttle Body, Removal, page 14-36. CAUTION: Use only Mopar Brake Parts Cleaner, p/n 04897150AB or 04897151AB, as the use of other cleaners may damage components of the throttle body. Use this cleaner only in a well ventilated area. Do not let this cleaner come in contact with the skin. Rubber or butyl gloves are recommended. Wash thoroughly after use. Avoid eye contact. Avoid ingesting. 2. While holding the throttle open, spray the throttle body bore with Mopar Brake Parts Cleaner, p/n 04897150AB or 04897151AB. Spray the entire throttle body bore and the manifold side of the throttle plate. 3. Use a soft cloth to help break loose deposits to clean the throttle body bore and throttle plate. While holding the throttle open, clean both the top and bottom of the throttle body bore. Also clean the manifold side and edges of the throttle plate. NOTE: Take due care not to scratch, bend, or dent throttle plate and/or throttle body bore. NOTE: Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 18-016-05 > Apr > 05 > Fuel System MIL ON/Possible DTC's P2174/P2175 > Page 3017 It is important this cleaning operation be performed thoroughly and completely. The edge of the throttle plate and the portion of the throttle body bore that is in the closest proximity to the closed throttle plate is the most critical area where the cleaning should be concentrated. This area must be free of all deposits when the cleaning is completed. 4. Spray the throttle body with, Mopar Brake Parts Cleaner, p/n 04897150AB or 04897151AB, and then blow dry with compressed shop air. Inspect for any foreign material which may have been left behind during the cleaning process. CAUTION: Do not apply shop air pressure directly into the throttle shaft and throttle body housing holes. 5. Open and close the throttle plate on the throttle body to verify that there is no increased effort when moving from the closed position. If the condition is corrected, proceed to the next step. If the increased effort still exists, then some other condition exists with the throttle body and further diagnosis and repair will be necessary and will not be covered by this repair procedure. 6. Install the throttle body on the intake manifold. 7. Open and close the throttle to verify that there is no increased effort when moving from the closed throttle position. If the condition is corrected, proceed to the next step. If the increased effort still exists, then some other condition exists with the throttle linkage and further diagnosis and repair will be necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer This bulletin is supplied as technical information only and is not an authorization for repairs. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 18-016-05 > Apr > 05 > Fuel System - MIL ON/Possible DTC's P2174/P2175 Throttle Body: All Technical Service Bulletins Fuel System - MIL ON/Possible DTC's P2174/P2175 NUMBER: 18-016-05 GROUP: Vehicle Performance DATE: April 12, 2005 SUBJECT: Throttle Body Coking OVERVIEW: This bulletin involves cleaning the throttle body. MODELS: 2004 (DR) Ram Truck 2004 (HB) Durango NOTE: This condition is rarely experienced on vehicles with less than 50,000 miles. SYMPTOM/CONDITION: The vehicle operator may describe MIL illumination. The technician may find one or more of the following DTC's: P2174 - Low Airflow/Restriction Detected (Instant Accumulation) P2175 - Low Airflow/Restriction Detected (Slow Accumulation) Using a Scan Tool (DRBIII(R) or StarSCAN(R)) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. Inspect the air induction system including the air filter element, resonator, air induction hoses and throttle body, for restriction and/or large accumulations of silty deposits on air flow surfaces. If accumulation of silty deposits are present in the throttle body and /or behind the throttle plate, perform the appropriate Repair Procedure. PARTS REQUIRED 1. Remove the throttle body from the intake manifold. Refer to the service information available in TechCONNECT or the Ram Truck service manual (publication no. 81-370-04059), Section 14 Fuel Injection, Throttle Body, Removal, page 14-36. CAUTION: Use only Mopar Brake Parts Cleaner, p/n 04897150AB or 04897151AB, as the use of other cleaners may damage components of the throttle body. Use this cleaner only in a well ventilated area. Do not let this cleaner come in contact with the skin. Rubber or butyl gloves are recommended. Wash thoroughly after use. Avoid eye contact. Avoid ingesting. 2. While holding the throttle open, spray the throttle body bore with Mopar Brake Parts Cleaner, p/n 04897150AB or 04897151AB. Spray the entire throttle body bore and the manifold side of the throttle plate. 3. Use a soft cloth to help break loose deposits to clean the throttle body bore and throttle plate. While holding the throttle open, clean both the top and bottom of the throttle body bore. Also clean the manifold side and edges of the throttle plate. NOTE: Take due care not to scratch, bend, or dent throttle plate and/or throttle body bore. NOTE: Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 18-016-05 > Apr > 05 > Fuel System - MIL ON/Possible DTC's P2174/P2175 > Page 3023 It is important this cleaning operation be performed thoroughly and completely. The edge of the throttle plate and the portion of the throttle body bore that is in the closest proximity to the closed throttle plate is the most critical area where the cleaning should be concentrated. This area must be free of all deposits when the cleaning is completed. 4. Spray the throttle body with, Mopar Brake Parts Cleaner, p/n 04897150AB or 04897151AB, and then blow dry with compressed shop air. Inspect for any foreign material which may have been left behind during the cleaning process. CAUTION: Do not apply shop air pressure directly into the throttle shaft and throttle body housing holes. 5. Open and close the throttle plate on the throttle body to verify that there is no increased effort when moving from the closed position. If the condition is corrected, proceed to the next step. If the increased effort still exists, then some other condition exists with the throttle body and further diagnosis and repair will be necessary and will not be covered by this repair procedure. 6. Install the throttle body on the intake manifold. 7. Open and close the throttle to verify that there is no increased effort when moving from the closed throttle position. If the condition is corrected, proceed to the next step. If the increased effort still exists, then some other condition exists with the throttle linkage and further diagnosis and repair will be necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer This bulletin is supplied as technical information only and is not an authorization for repairs. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 3024 Throttle Body: Description and Operation The throttle body is located on the intake manifold. Fuel does not enter the intake manifold through the throttle body. Fuel is sprayed into the manifold by the fuel injectors. Filtered air from the air cleaner enters the intake manifold through the throttle body. The throttle body 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. 5.7L V-8 Engine: The throttle body on the 5.7L engine is an electrically controlled unit. A mechanical cable is not used to connect the throttle body to the accelerator pedal . The Accelerator Pedal Position Sensor (APPS) along with inputs from other sensors sets the throttle blade to pre-determined positions. Except 5.7L V-8 Engine: Certain sensors are attached to the throttle body. The accelerator pedal cable, speed control cable and transmission control cable (when equipped) are connected to the throttle body linkage 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 PCM. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 3025 Throttle Body: Service and Repair REMOVAL 1. Remove the throttle cable. 2. Remove the battery cover and disconnect the negative battery cable. 3. Remove the air cleaner assembly, refer to the Engine/Air Intake System/Air Cleaner Housing for more information. 4. Disconnect the TPS electrical connector. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 3026 5. Remove the throttle body bolts. 6. Remove the throttle body wiring clips. 7. Remove the throttle body. INSTALLATION 1. Mount throttle body and wiring clips , tighten bolts to 12 Nm (105 in. lbs.). 2. Connect electrical connector to throttle position sensor. 3. Install the throttle cable. 4. Install the air cleaner housing, refer to Engine/Air Intake System/Air Cleaner Housing. 5. Connect the negative battery cable and install the battery cover. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations The TPS (1) is mounted on the passenger side of the throttle body. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3030 Throttle Position Sensor: Description and Operation The TPS (1) is mounted on the passenger side of the throttle body. The sensor connects to the throttle blade shaft. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from .26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3031 Throttle Position Sensor: Service and Repair REMOVAL The TPS is attached to the throttle body. 1. Disconnect the TPS electrical connector. 2. Remove the TPS mounting screws. 3. Remove the TPS. INSTALLATION The TPS is attached to the throttle body. The throttle shaft end of the throttle body slides into a socket in the TPS. When indexed correctly, the TPS can rotate a few degrees to line up the mounting screw holes with the screw holes in the throttle body. If the sensor will not rotate into place, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS has slight tension when rotated to align the mounting holes. 1. Install TPS and mounting screws. 2. Attach electrical connector to the TPS. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications 8.3L - FIRING ORDER 1-10-9-4-3-6-5-8-7-2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications > Page 3037 Firing Order: Mechanical Specifications Firing Order ......................................................................................................................................... ................................................ 1-10-9-4-3-6-5-8-7-2 The cylinders are number from front to rear as follows: - on the left bank - 1-3-5-7-9 - on the right bank - 2-4-6-8-10 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams Sensor-Camshaft Position (Gas) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3045 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor is located above the water pump and under the throttle body. The camshaft position sensor (1) provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses. The PCM determines crankshaft position from the camshaft position sensor and crankshaft position sensor inputs. The PCM uses the input to determine fuel injection synchronization and to determine which ignition coil to energize. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3046 The camshaft position sensor detects when a step down (1) in the camshaft sprocket passes beneath it. When the sensor detects the step down, the input voltage from the sensor to the PCM switches from low (0.3 volts) to high (5 volts). As the step up returns to the sensor, the input voltage switches back to low (0.3 volts). The paper spacer is not used on 8.3L motors. Don't use at all. It plugs up the oil pickup screen. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3047 Camshaft Position Sensor: Service and Repair REMOVAL 8.3L - REPLACING WITH NEW SENSOR The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. If a new replacement camshaft position sensor is to be installed, use this procedure. 1. Disconnect the sensor wiring harness connector from sensor. 2. Remove the sensor mounting bolt. 3. Carefully pry the sensor from the timing chain case/cover in a rocking action with two small screwdrivers. 4. Remove the sensor from vehicle. 8.3L - REPLACING OLD SENSOR WITH ORIGINAL The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. If the original camshaft position sensor is to be removed and installed, such as when servicing the timing chain, timing gears or timing chain cover, use this procedure. 1. Disconnect the sensor harness connector from the sensor. 2. Scribe the sensor for location depth. 3. Remove the sensor mounting bolt. 4. Carefully pry the sensor from the timing chain case/cover in a rocking action with two small screwdrivers. 5. Remove the sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 8.3L - INSTALLATION - WITH NEW SENSOR The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. 1. Apply a small amount of engine oil to the sensor O-ring. A low (step down) and high (step up) area are machined into the camshaft drive gear. The sensor is positioned in the timing gear cover so that a small air gap exists between the face of sensor and the high machined area of cam gear. Before the sensor is installed, the cam gear may have to be rotated. This is to allow the high machined area (step up) on the gear to be directly in front of the sensor mounting hole opening on the timing gear cover. Do not install sensor with gear positioned at low area. When the engine is started, the sensor will be broken. 2. Using a 1/2 in. wide metal ruler, measure the distance from the cam gear to the face of the sensor mounting hole opening on the timing gear cover. 3. If the dimension is approximately 1-15/32 inches or less, it is OK to install sensor. 4. If the dimension is approximately 1-5/8 inches or more, the cam gear will have to be rotated. 5. Attach a socket to the vibration damper mounting bolt and rotate engine until the 1-15/32 inch dimension is attained. 6. Install the sensor into the timing case/cover with a slight rocking action. Do not twist the sensor into position as damage to the O-ring may result. Push the sensor all the way into the cover until the rib material on the sensor contacts the camshaft gear. 7. Install the mounting bolt and tighten to 10.7 N.m (95 in.lbs.) torque. 8. Connect sensor wiring harness to engine harness. When the engine is started, the rib material will be sheared off the face of sensor. This will automatically set sensor air gap. 8.3L - REPLACING OLD SENSOR WITH ORIGINAL The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. When installing a used camshaft position sensor, the sensor depth must be adjusted to prevent contact with the camshaft gear (sprocket). 1. Apply a small amount of engine oil to the sensor O-ring. A low and high area are machined into the camshaft drive gear. The sensor is positioned in the timing gear cover so that a small air gap exists between the face of sensor and the high machined area of cam gear. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3048 Before the sensor is installed, the cam gear may have to be rotated. This is to allow the high machined area on the gear to be directly in front of the sensor mounting hole opening on the timing gear cover. Do not install sensor with gear positioned at low area. When the engine is started, the sensor will be broken. 2. Using a 1/2 in. wide metal ruler, measure the distance from the cam gear to the face of the sensor mounting hole opening on the timing gear cover. 3. If the dimension is approximately 1-15/32 inches or less, it is OK to install sensor. 4. If the dimension is approximately 1-5/8 inches or more, the cam gear will have to be rotated. 5. Attach a socket to the vibration damper mounting bolt and rotate engine until the 1-15/32 inch dimension is attained. 6. Install the sensor into the timing case/cover with a slight rocking action until the sensor is aligned to scribe line. The paper spacer can be used if reinstalling a used sensor. 7. Install sensor mounting bolt and tighten to 10.7 N.m (95 in.lbs.) torque. 8. Connect engine wiring harness to sensor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Description and Operation Condenser: Description and Operation The condenser is located in the air flow next to 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 air passes through the condenser fins, the high-pressure refrigerant gas within the A/C condenser gives up its heat. The refrigerant then condenses as it leaves the A/C condenser and becomes a high-pressure liquid. 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 at 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 A/C condenser service. The A/C condenser cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations Crankshaft Position Sensor: Locations The sensor is located at the rear lower passenger side of motor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 3055 Sensor-Crankshaft Position (5.7L/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 3056 Crankshaft Position Sensor: Service and Repair REMOVAL The sensor is located at the rear lower passenger side of motor. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting bolt. 3. Pull sensor out. A light tap to top of sensor may ease removal. INSTALLATION 1. Slide the sensor into the hole. 2. Install and tighten the mounting bolt to 11 Nm (95 in. lbs.) torque. 3. Connect the electrical connector to the sensor and lock. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 3060 Ignition Cable: Description and Operation Spark plug cables are sometimes referred to as secondary ignition wires, or secondary ignition cables. Plug cables are used only on the 5.7L V-8 engine. The spark plug cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of non metallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Plug cables are used only on the 5.7L V-8 engine. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 3061 Ignition Cable: Service and Repair REMOVAL Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. 1. Release the fuel pressure. 2. Disconnect the negative battery cable. 3. Remove the air cleaner assembly. 4. Remove the Intake Manifold, refer to the Engine/Manifolds/Intake Manifold for more information. 5. Use the following procedure when removing the high tension cable from the spark plug. Grasp the terminal as close as possible to the spark plug. Rotate the cover boot 1/2 turn slightly and pull straight up in a steady motion.Do not use pliers and do not pull the cable at an angle. Doing so will damage the insulation, cable terminal or the spark plug insulator. Wipe spark plug insulator clean before reinstalling cable. 6. Remove spark plug cable from coil first. 7. Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. INSTALLATION Install cables into the proper engine cylinder firing order sequence. Refer to Specifications. When replacing the spark plug and coil cables, route the cables correctly and secure them in the proper retainers. Failure to route the cables properly may cause the radio to reproduce ignition noise. It could also cause cross-ignition of the plugs, or, may 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. Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. The system uses two epoxy filled coil packs mounted on engine block post in the valley under the intake manifold. The rear coil pack, contains 3 separate coils and fires cylinders 1, 2, 3, 4, 6, and 7. The front coil pack, contains 2 individual coils and fires cylinders 5, 8, 9, and 10. NOTE: When replacing the spark plug and coil cables, route the cables correctly and secure them in the proper retainers. Failure to route the cables properly may cause the radio to reproduce ignition noise. It could also cause cross-ignition of the plugs, or, may short-circuit the cables to ground. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 3062 1. Install wire separator clip on double ended stud on rear of engine block first. This is the wire separator clip closest to the ignition coil insulator boots. 2. Connector coil insulator boots over respective ignition coil side post. Take care to match cylinder number on ignition coil with cylinder number on ignition cables. Also, make sure to hear the audible click while making the connection to the coil post. 3. Sequentially install wires into separators clips mounted on double ended studs mounted on the outer side of valve cover and and. Start from the rear and work forward to the front of the engine. 4. After installing all wires into separator clips, install spark plug insulator boots over respective spark plugs sequentially from back of engine towards the front of engine. Make sure to hear the audible click during installation of spark plug boots. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 3063 5. Install Intake Manifold. 6. Install Air Cleaner Assembly. 7. Connect the negative battery cable. 8. Use a diagnostic scan tool to pressurize the fuel system. Check for leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3067 Ignition Coil: Diagrams Coil - Ignition - Left (SRT) Coil - Ignition-Right (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3068 Ignition Coil: Description and Operation One coil capacitor is used. It is located in the right-rear section of the engine compartment. The coil capacitor(s) help dampen the amount of conducted electrical noise to the camshaft position sensor, crankshaft position sensor, and throttle position sensor. This noise is generated on the 12V supply wire to the ignition coils and fuel injectors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil Ignition Coil: Service and Repair Ignition Coil REMOVAL 1. Release the fuel pressure. 2. Disconnect the negative battery cable. 3. Remove the air cleaner assembly. 4. Remove the Intake Manifold. 5. Unlock and disconnect the electrical connector at the ignition coils and. 6. Twist and remove the ignition cables from the ignition coil. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil > Page 3071 7. Remove the 4 bolts. 8. Remove ignition coil. INSTALLATION The system uses two epoxy filled coil packs mounted on engine block post under the intake manifold. The rear coil pack, contains 3 separate coils and fires cylinders 1, 2, 3, 4, 6, and 7. The front coil pack, contains 2 individual coils and fires cylinders 5, 8, 9, and 10. 1. Install coil packs. Tighten mounting screws to 11 N.m (95 in.lbs.) torque. 2. Install ignition cables to ignition coil. 3. Connect and lock the electrical connector at the ignition coils and. 4. Install Intake Manifold. 5. Install Air Cleaner Assembly. 6. Connect the negative battery cable. 7. Use a diagnostic scan tool to pressurize the fuel system. Check for leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil > Page 3072 Ignition Coil: Service and Repair Ignition Coil Capacitor REMOVAL The coil capacitor is located in the right-rear section of the engine compartment. It is attached with a mounting stud and nut. 1. Disconnect electrical connector at capacitor. 2. Remove mounting nut and remove ground strap. 3. Remove capacitor. INSTALLATION 1. Position capacitor to mounting stud. 2. Position ground strap to mounting stud. 3. Tighten nut to 7 Nm (60 in. lbs.) torque. 4. Connect electrical connector to coil capacitor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Diagrams Relay-Ignition Run-ACC (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Adjuster > Component Information > Description and Operation Ignition Timing Adjuster: Description and Operation Ignition timing is not adjustable on any engine. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3082 Knock Sensor: Diagrams Sensor-Knock No.1 (5.7L/SRT) Sensor-Knock No.2 (5.7L/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3083 Knock Sensor: Description and Operation The sensors are used only with 3.7L V-6, 4.7L V-8 and 5.7L V-8 engines. On 3.7L V-6 and 4.7L V-8 engines, the 2 knock sensors are bolted into the cylinder block under the intake manifold. On 5.7L V-8 engines, 2 knock sensors are also used. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. 3.7L V-6/4.7L V-8/5.7L V-8 Engines Only Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Diagrams Relay-Ignition Run-ACC (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams Sensor-Camshaft Position (Gas) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3092 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor is located above the water pump and under the throttle body. The camshaft position sensor (1) provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses. The PCM determines crankshaft position from the camshaft position sensor and crankshaft position sensor inputs. The PCM uses the input to determine fuel injection synchronization and to determine which ignition coil to energize. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3093 The camshaft position sensor detects when a step down (1) in the camshaft sprocket passes beneath it. When the sensor detects the step down, the input voltage from the sensor to the PCM switches from low (0.3 volts) to high (5 volts). As the step up returns to the sensor, the input voltage switches back to low (0.3 volts). The paper spacer is not used on 8.3L motors. Don't use at all. It plugs up the oil pickup screen. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3094 Camshaft Position Sensor: Service and Repair REMOVAL 8.3L - REPLACING WITH NEW SENSOR The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. If a new replacement camshaft position sensor is to be installed, use this procedure. 1. Disconnect the sensor wiring harness connector from sensor. 2. Remove the sensor mounting bolt. 3. Carefully pry the sensor from the timing chain case/cover in a rocking action with two small screwdrivers. 4. Remove the sensor from vehicle. 8.3L - REPLACING OLD SENSOR WITH ORIGINAL The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. If the original camshaft position sensor is to be removed and installed, such as when servicing the timing chain, timing gears or timing chain cover, use this procedure. 1. Disconnect the sensor harness connector from the sensor. 2. Scribe the sensor for location depth. 3. Remove the sensor mounting bolt. 4. Carefully pry the sensor from the timing chain case/cover in a rocking action with two small screwdrivers. 5. Remove the sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 8.3L - INSTALLATION - WITH NEW SENSOR The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. 1. Apply a small amount of engine oil to the sensor O-ring. A low (step down) and high (step up) area are machined into the camshaft drive gear. The sensor is positioned in the timing gear cover so that a small air gap exists between the face of sensor and the high machined area of cam gear. Before the sensor is installed, the cam gear may have to be rotated. This is to allow the high machined area (step up) on the gear to be directly in front of the sensor mounting hole opening on the timing gear cover. Do not install sensor with gear positioned at low area. When the engine is started, the sensor will be broken. 2. Using a 1/2 in. wide metal ruler, measure the distance from the cam gear to the face of the sensor mounting hole opening on the timing gear cover. 3. If the dimension is approximately 1-15/32 inches or less, it is OK to install sensor. 4. If the dimension is approximately 1-5/8 inches or more, the cam gear will have to be rotated. 5. Attach a socket to the vibration damper mounting bolt and rotate engine until the 1-15/32 inch dimension is attained. 6. Install the sensor into the timing case/cover with a slight rocking action. Do not twist the sensor into position as damage to the O-ring may result. Push the sensor all the way into the cover until the rib material on the sensor contacts the camshaft gear. 7. Install the mounting bolt and tighten to 10.7 N.m (95 in.lbs.) torque. 8. Connect sensor wiring harness to engine harness. When the engine is started, the rib material will be sheared off the face of sensor. This will automatically set sensor air gap. 8.3L - REPLACING OLD SENSOR WITH ORIGINAL The camshaft position sensor is located on the timing chain case above the water pump and under the throttle body. When installing a used camshaft position sensor, the sensor depth must be adjusted to prevent contact with the camshaft gear (sprocket). 1. Apply a small amount of engine oil to the sensor O-ring. A low and high area are machined into the camshaft drive gear. The sensor is positioned in the timing gear cover so that a small air gap exists between the face of sensor and the high machined area of cam gear. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3095 Before the sensor is installed, the cam gear may have to be rotated. This is to allow the high machined area on the gear to be directly in front of the sensor mounting hole opening on the timing gear cover. Do not install sensor with gear positioned at low area. When the engine is started, the sensor will be broken. 2. Using a 1/2 in. wide metal ruler, measure the distance from the cam gear to the face of the sensor mounting hole opening on the timing gear cover. 3. If the dimension is approximately 1-15/32 inches or less, it is OK to install sensor. 4. If the dimension is approximately 1-5/8 inches or more, the cam gear will have to be rotated. 5. Attach a socket to the vibration damper mounting bolt and rotate engine until the 1-15/32 inch dimension is attained. 6. Install the sensor into the timing case/cover with a slight rocking action until the sensor is aligned to scribe line. The paper spacer can be used if reinstalling a used sensor. 7. Install sensor mounting bolt and tighten to 10.7 N.m (95 in.lbs.) torque. 8. Connect engine wiring harness to sensor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations Crankshaft Position Sensor: Locations The sensor is located at the rear lower passenger side of motor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 3099 Sensor-Crankshaft Position (5.7L/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations > Page 3100 Crankshaft Position Sensor: Service and Repair REMOVAL The sensor is located at the rear lower passenger side of motor. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting bolt. 3. Pull sensor out. A light tap to top of sensor may ease removal. INSTALLATION 1. Slide the sensor into the hole. 2. Install and tighten the mounting bolt to 11 Nm (95 in. lbs.) torque. 3. Connect the electrical connector to the sensor and lock. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 IGNITION SWITCH DESCRIPTION The ignition switch (5) is located on the steering column (4). It is used as the main on/off switching device for most electrical components. The mechanical key cylinder is used to engage/disengage the electrical ignition switch. OPERATION Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the shift cable. This interlock device is used to lock the transmission shifter in the PARK position when the key cylinder is in any position and the brake pedal is not depressed. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 3105 Ignition Switch Lock Cylinder: Service and Repair KEY CYLINDER REMOVAL The ignition key (1) must be in the key cylinder (2) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at side of key cylinder assembly (2). a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. INSTALLATION The ignition key (1) must be in the key cylinder (2) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (2) with the ignition switch. 2. Push the key cylinder (2) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Left Rear Engine (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3109 Knock Sensor: Diagrams Sensor-Knock No.1 (5.7L/SRT) Sensor-Knock No.2 (5.7L/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3110 Knock Sensor: Description and Operation The sensors are used only with 3.7L V-6, 4.7L V-8 and 5.7L V-8 engines. On 3.7L V-6 and 4.7L V-8 engines, the 2 knock sensors are bolted into the cylinder block under the intake manifold. On 5.7L V-8 engines, 2 knock sensors are also used. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. 3.7L V-6/4.7L V-8/5.7L V-8 Engines Only Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Electrical Specifications Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Electrical Specifications > Page 3115 Spark Plug: Mechanical Specifications Gap Spark Plug Gap ................................................................................................................................... ....................................................... 0.033 to 0.038 in. Torque Spark Plug tightening torque ............................................................................................................... ...................................................... 27 Nm (20 ft.lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3116 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ................................................................. RC12ECC Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3117 Spark Plug: Description and Operation Resistor type spark plugs are used on all engines. Sixteen spark plugs (2 per cylinder) are used with 5.7L V-8 engines. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3118 Spark Plug: Testing and Inspection To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. Always use the recommended torque when tightening spark plugs. Incorrect torque can distort the spark plug and change plug gap. It can also pull the plug threads and do possible damage to both the spark plug and the cylinder head. 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. Replace spark plugs at the intervals recommended in the Lubrication and Maintenance section. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Spark plug resistance values range from 6,000 to 20,000 ohms (when checked with at least a 1000 volt spark plug tester). Do not use an ohmmeter to check the resistance values of the spark plugs. In accurate readings will result. NORMAL OPERATING 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 (.001 in) per 3200 km (2000 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 may be 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 CRASH ENCRUSTED Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3119 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 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 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3120 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 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3121 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 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 2000 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3122 Spark Plug: Adjustments CLEANING AND ADJUSTMENT The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. Adjust spark plug gap with a gap gauging tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Band Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Control Solenoid Valve: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Band Control Solenoid Valve: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Band Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Control Solenoid Valve: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Band Control Solenoid Valve: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch Control Solenoid Valve: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Clutch Control Solenoid Valve: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Control Solenoid Valve: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Clutch Control Solenoid Valve: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Technical Service Bulletins > Customer Interest for Overdrive Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls False Solenoid DTC's Set Overdrive Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Overdrive Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Overdrive Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Pressure Regulating Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Pressure Regulating Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls False Solenoid DTC's Set Shift Interlock Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Shift Interlock Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Shift Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Shift Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Throttle Valve Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls False Solenoid DTC's Set Throttle Valve Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Valve Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Throttle Valve Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Torque Converter Clutch Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Torque Converter Clutch Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this model. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. The VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator VFD displays the following characters from left to right: "P," "R," "N," "D," "2," and "1". Respectively, these characters represent the park, reverse, neutral, drive, second gear, and first gear positions of the transmission gear selector lever on the steering column. The VFD illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps Off) the gear selector VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are On), the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned On during daylight hours. The gear selector indicator VFD is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission and automatic transmission model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by a dedicated Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the Off position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Programmable Communications Interface (PCI) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gear selector indicator VFD will display all of its characters at once during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On models with a TCM, the TCM continually monitors the transmission range sensor, then sends the proper gear selector indicator position messages to the instrument cluster. On models without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. On models with a TCM, for proper diagnosis of the transmission range sensor, the TCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3241 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3242 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3243 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3244 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3245 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3246 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3247 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3248 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3249 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3250 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3251 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3252 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3253 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3254 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3255 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3256 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3257 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3258 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3259 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3260 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control Transmission Control System Relay: Description and Operation Relay-Transmission Control RELAY-TRANSMISSION CONTROL 45RFE/545RFE DESCRIPTION NOTE: The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control > Page 3263 Transmission Control System Relay: Description and Operation 45RFE 4 Speed TRANSMISSION CONTROL RELAY - 45RFE/545RFE Automatic Transmission DESCRIPTION NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control > Page 3264 Transmission Control System Relay: Description and Operation 48RE Automatic Transmission The Chrysler Corporation does not list a Transmission Control Relay for the 48RE Automatic Transmission. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-027-05 > Jun > 05 > Engine Controls - MIL ON/DTC P0330P0740 Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC P0330P0740 Set NUMBER: 18-027-05 GROUP: Vehicle Performance DATE: June 4, 2005 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD JULY, 2005. SUBJECT: Flash: All Vehicles - Evaporative Leak Detection Monitor Enhancement; Ram Quad Cab vehicles - Cold Start Rough Idle and MIL Illumination with DTC's P0330, and/or P0740 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2004-2005 (DR) Ram Truck SRT 10 2004 - 2005 (ZB) Viper NOTE: This bulletin applies to vehicles equipped with an 8.3L engine (sales code EWC) built on or before February 18, 2005 (MDH 0218XX). DISCUSSION: This software provides an enhanced evaporative leak detection monitor. The software for the Ram SRT10 Quad Cab vehicles addresses the following possible conditions and/or improvements: 1. Improved idle after a cold start. 2. Cruise control overshoot. 3. A Malfunction Indicator Lamp (MIL) Illumination due to: ^ P0330-Knock Sensor 2 Circuit ^ P0740-TCC Out Of Range DIAGNOSIS: Using a Scan Tool (DRBIII(R)) and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTC's are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this service bulletin. Perform the Repair Procedure. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-027-05 > Jun > 05 > Engine Controls - MIL ON/DTC P0330P0740 Set > Page 3273 SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2005 Diagnostics". c. "All (Except Below)". d. "Engine". e. "Module Display". f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-027-05 > Jun > 05 > Engine Controls - MIL ON/DTC P0330P0740 Set > Page 3274 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-004-05 > Jan > 05 > Engine Controls - MIL ON/Erroneous DTC's P0320 & P1494 PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/Erroneous DTC's P0320 & P1494 NUMBER: 18-004-05 GROUP: Vehicle Performance DATE: January 12, 2005 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD FEBRUARY 2005. SUBJECT: Flash: Erroneous Diagnostic Trouble Codes - P0320 and P1494 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2004 (ZB) Viper 2004 (DR) Ram Truck-SRT 10 SYMPTOM/CONDITION: The following enhancements are included with this software: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following erroneous Diagnostic Trouble Codes (DTC's): ^ P0320 - No Crank Reference Signal At PCM ^ P1494 - Leak Detection Pump Switch Or Mechanical Fault DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-004-05 > Jan > 05 > Engine Controls - MIL ON/Erroneous DTC's P0320 & P1494 > Page 3279 being performed. REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 11. If the vehicle is a 2003 or later AN or 2002 or later DN or DR model, proceed to Step # 12. If not proceed Step # 15. 12. Using the DRBIII(R), determine the pinion factor stored in the Controller Anti-lock Brakes (CAB) and record it on the work order for later reference. 13. Turn the ignition switch to the "Off" position. 14. Disconnect the CAB module electrical connectors. Proceed to Step # 15. 15. Connect the DRBIII(R) to the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-004-05 > Jan > 05 > Engine Controls - MIL ON/Erroneous DTC's P0320 & P1494 > Page 3280 16. Turn the ignition to the "Run" position (engine not running). 17. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 18. 18. If the vehicle is a 2003 and later AN or 2002 or later DN or DR model, proceed to Step # 19. If not proceed to Step # 23. 19. Turn the ignition to the "Off" position. 20. Connect the CAB electrical connectors. 21. Turn the ignition switch to the "Run" position (engine not running). 22. Using the DRBIII(R), check the pinion factor in the CAB to be sure that it was not erased during the flash process. If the pinion factor is not present or is not correct, enter the correct pinion factor. Proceed to Step # 23. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 23. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-004-05 > Jan > 05 > Engine Controls - MIL ON/Erroneous DTC's P0320 & P1494 > Page 3281 Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3287 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3288 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3289 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 ^ 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 ^ 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 ^ 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 ^ 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 ^ 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 18-027-05 > Jun > 05 > Engine Controls - MIL ON/DTC P0330P0740 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0330P0740 Set NUMBER: 18-027-05 GROUP: Vehicle Performance DATE: June 4, 2005 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD JULY, 2005. SUBJECT: Flash: All Vehicles - Evaporative Leak Detection Monitor Enhancement; Ram Quad Cab vehicles - Cold Start Rough Idle and MIL Illumination with DTC's P0330, and/or P0740 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2004-2005 (DR) Ram Truck SRT 10 2004 - 2005 (ZB) Viper NOTE: This bulletin applies to vehicles equipped with an 8.3L engine (sales code EWC) built on or before February 18, 2005 (MDH 0218XX). DISCUSSION: This software provides an enhanced evaporative leak detection monitor. The software for the Ram SRT10 Quad Cab vehicles addresses the following possible conditions and/or improvements: 1. Improved idle after a cold start. 2. Cruise control overshoot. 3. A Malfunction Indicator Lamp (MIL) Illumination due to: ^ P0330-Knock Sensor 2 Circuit ^ P0740-TCC Out Of Range DIAGNOSIS: Using a Scan Tool (DRBIII(R)) and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTC's are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this service bulletin. Perform the Repair Procedure. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 18-027-05 > Jun > 05 > Engine Controls - MIL ON/DTC P0330P0740 Set > Page 3310 SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2005 Diagnostics". c. "All (Except Below)". d. "Engine". e. "Module Display". f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 18-027-05 > Jun > 05 > Engine Controls - MIL ON/DTC P0330P0740 Set > Page 3311 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 18-004-05 > Jan > 05 > Engine Controls - MIL ON/Erroneous DTC's P0320 & P1494 PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/Erroneous DTC's P0320 & P1494 NUMBER: 18-004-05 GROUP: Vehicle Performance DATE: January 12, 2005 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD FEBRUARY 2005. SUBJECT: Flash: Erroneous Diagnostic Trouble Codes - P0320 and P1494 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2004 (ZB) Viper 2004 (DR) Ram Truck-SRT 10 SYMPTOM/CONDITION: The following enhancements are included with this software: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following erroneous Diagnostic Trouble Codes (DTC's): ^ P0320 - No Crank Reference Signal At PCM ^ P1494 - Leak Detection Pump Switch Or Mechanical Fault DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 18-004-05 > Jan > 05 > Engine Controls - MIL ON/Erroneous DTC's P0320 & P1494 > Page 3316 being performed. REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 11. If the vehicle is a 2003 or later AN or 2002 or later DN or DR model, proceed to Step # 12. If not proceed Step # 15. 12. Using the DRBIII(R), determine the pinion factor stored in the Controller Anti-lock Brakes (CAB) and record it on the work order for later reference. 13. Turn the ignition switch to the "Off" position. 14. Disconnect the CAB module electrical connectors. Proceed to Step # 15. 15. Connect the DRBIII(R) to the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 18-004-05 > Jan > 05 > Engine Controls - MIL ON/Erroneous DTC's P0320 & P1494 > Page 3317 16. Turn the ignition to the "Run" position (engine not running). 17. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 18. 18. If the vehicle is a 2003 and later AN or 2002 or later DN or DR model, proceed to Step # 19. If not proceed to Step # 23. 19. Turn the ignition to the "Off" position. 20. Connect the CAB electrical connectors. 21. Turn the ignition switch to the "Run" position (engine not running). 22. Using the DRBIII(R), check the pinion factor in the CAB to be sure that it was not erased during the flash process. If the pinion factor is not present or is not correct, enter the correct pinion factor. Proceed to Step # 23. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 23. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 18-004-05 > Jan > 05 > Engine Controls - MIL ON/Erroneous DTC's P0320 & P1494 > Page 3318 Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3324 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3325 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3326 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3327 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3328 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3329 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3330 ^ 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3331 ^ 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3332 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3333 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3334 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3335 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3336 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3337 ^ 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3338 ^ 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3339 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3340 ^ 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3341 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 3342 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Band Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Control Solenoid Valve: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Band Control Solenoid Valve: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Band Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Control Solenoid Valve: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Band Control Solenoid Valve: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch Control Solenoid Valve: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Clutch Control Solenoid Valve: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Control Solenoid Valve: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Clutch Control Solenoid Valve: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Overdrive Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Overdrive Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Overdrive Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Overdrive Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Pressure Regulating Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Pressure Regulating Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Shift Interlock Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Shift Interlock Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Shift Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Shift Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Throttle Valve Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Throttle Valve Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Valve Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Throttle Valve Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Torque Converter Clutch Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Torque Converter Clutch Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Band Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Control Solenoid Valve: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Band Control Solenoid Valve: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Band Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Control Solenoid Valve: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Band Control Solenoid Valve: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Clutch Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch Control Solenoid Valve: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Clutch Control Solenoid Valve: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Clutch Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Control Solenoid Valve: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Clutch Control Solenoid Valve: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Overdrive Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Overdrive Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Overdrive Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Overdrive Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Pressure Regulating Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Pressure Regulating Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Shift Interlock Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Shift Interlock Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Shift Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Shift Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Throttle Valve Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Throttle Valve Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Throttle Valve Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Throttle Valve Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Valve Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Throttle Valve Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Torque Converter Clutch Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Torque Converter Clutch Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Control Solenoid Valve: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Band Control Solenoid Valve: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Control Solenoid Valve: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Band Control Solenoid Valve: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch Control Solenoid Valve: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Clutch Control Solenoid Valve: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Control Solenoid Valve: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Clutch Control Solenoid Valve: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3586 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3587 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3588 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3589 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3590 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Service Fill 48RE ................................................................................................................................. ....................................................................... 3.8 Liters (4.0 qts.) Overhaul Fill 48RE .............................................................................................................................. ................................................................. 14-16 Liters (29-33 pts.) Note: Dry fill capacity Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these figures may vary. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3593 Fluid - A/T: Fluid Type Specifications Automatic Transmission Fluid Type .............................................................................................................. Mopar ATF+4 Automatic Transmission Fluid Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check Fluid - A/T: Service and Repair Fluid Level and Condition Check STANDARD PROCEDURE - FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. The transmission fluid level can be checked two ways. PROCEDURE ONE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82°C (180°F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to NEUTRAL. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. 7. Remove dipstick (Fig. 89) and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough Mopar ATF +4, type 9602, to restore correct level. Do not overfill. PROCEDURE TWO 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up DRBIII scan tool and select engine. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3596 9. Adjust transmission fluid level shown on the dipstick according to the chart (Fig. 90). NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3597 Fluid - A/T: Service and Repair Fluid and Filter Replacement STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission (Fig. 98). 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and gasket away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter to valve body (Fig. 99). 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal or fiber contamination. A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompanied by slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts or debris, refer to Testing and Inspection. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3598 Check the adjustment of the front and rear bands, adjust if necessary. CLEANING 1. Using a suitable solvent, clean pan and magnet. INSTALLATION 1. Position a new transmission oil filter onto the valve body 2. Install the screws to hold the filter to the valve body Tighten the screws to 4 Nm (35 inch lbs.). 3. Clean the gasket surfaces of the transmission oil pan and transmission pan rail. NOTE:The original transmission pan oil gasket is reusable, inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket onto the oil pan. 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. For OE type reusable pan gasket: tighten the bolts to 13.6 Nm (125 inch lbs.). For aftermarket pan gasket: tighten the bolts to 17 Nm (150 inch lbs.). 7. Lower vehicle and fill transmission. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3599 Fluid - A/T: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar ATF +4, Automatic Transmission Fluid, to transmission: a. If only fluid and filter were changed, add 3 pints (1-1/2 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, or torque converter was replaced or drained, add 12 pints (6 quarts) of ATF +4 to transmission. 3. Apply parking brakes. 4. Start and run engine at normal curb idle speed. 5. Apply service brakes, shift transmission through all gear ranges then back to NEUTRAL, set parking brake, and leave engine running at curb idle speed. 6. Remove funnel, insert dipstick and check fluid level. If level is low, add fluid to bring level to MIN mark on dipstick. Check to see if the oil level is equal on both sides of the dipstick. If one side is noticeably higher than the other, the dipstick has picked up some oil from the dipstick tube. Allow the oil to drain down the dipstick tube and re-check. 7. Drive vehicle until transmission fluid is at normal operating temperature. 8. With the engine running at curb idle speed, the gear selector in NEUTRAL, and the parking brake applied, check the transmission fluid level. CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result. 9. Add fluid to bring level up to MAX arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: Customer Interest A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 3608 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: All Technical Service Bulletins A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 3614 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check Fluid Filter - A/T: Service and Repair Fluid Level and Condition Check STANDARD PROCEDURE - FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. The transmission fluid level can be checked two ways. PROCEDURE ONE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82°C (180°F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to NEUTRAL. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. 7. Remove dipstick (Fig. 89) and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough Mopar ATF +4, type 9602, to restore correct level. Do not overfill. PROCEDURE TWO 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up DRBIII scan tool and select engine. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3617 9. Adjust transmission fluid level shown on the dipstick according to the chart (Fig. 90). NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3618 Fluid Filter - A/T: Service and Repair Fluid and Filter Replacement STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission (Fig. 98). 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and gasket away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter to valve body (Fig. 99). 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal or fiber contamination. A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompanied by slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts or debris, refer to Testing and Inspection. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3619 Check the adjustment of the front and rear bands, adjust if necessary. CLEANING 1. Using a suitable solvent, clean pan and magnet. INSTALLATION 1. Position a new transmission oil filter onto the valve body 2. Install the screws to hold the filter to the valve body Tighten the screws to 4 Nm (35 inch lbs.). 3. Clean the gasket surfaces of the transmission oil pan and transmission pan rail. NOTE:The original transmission pan oil gasket is reusable, inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket onto the oil pan. 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. For OE type reusable pan gasket: tighten the bolts to 13.6 Nm (125 inch lbs.). For aftermarket pan gasket: tighten the bolts to 17 Nm (150 inch lbs.). 7. Lower vehicle and fill transmission. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3620 Fluid Filter - A/T: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar ATF +4, Automatic Transmission Fluid, to transmission: a. If only fluid and filter were changed, add 3 pints (1-1/2 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, or torque converter was replaced or drained, add 12 pints (6 quarts) of ATF +4 to transmission. 3. Apply parking brakes. 4. Start and run engine at normal curb idle speed. 5. Apply service brakes, shift transmission through all gear ranges then back to NEUTRAL, set parking brake, and leave engine running at curb idle speed. 6. Remove funnel, insert dipstick and check fluid level. If level is low, add fluid to bring level to MIN mark on dipstick. Check to see if the oil level is equal on both sides of the dipstick. If one side is noticeably higher than the other, the dipstick has picked up some oil from the dipstick tube. Allow the oil to drain down the dipstick tube and re-check. 7. Drive vehicle until transmission fluid is at normal operating temperature. 8. With the engine running at curb idle speed, the gear selector in NEUTRAL, and the parking brake applied, check the transmission fluid level. CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result. 9. Add fluid to bring level up to MAX arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > Fluid Level and Condition Check Fluid Pan: Service and Repair Fluid Level and Condition Check STANDARD PROCEDURE - FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. The transmission fluid level can be checked two ways. PROCEDURE ONE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82°C (180°F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to NEUTRAL. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. 7. Remove dipstick (Fig. 89) and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough Mopar ATF +4, type 9602, to restore correct level. Do not overfill. PROCEDURE TWO 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up DRBIII scan tool and select engine. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3625 9. Adjust transmission fluid level shown on the dipstick according to the chart (Fig. 90). NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3626 Fluid Pan: Service and Repair Fluid and Filter Replacement STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission (Fig. 98). 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and gasket away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter to valve body (Fig. 99). 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal or fiber contamination. A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompanied by slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts or debris, refer to Testing and Inspection. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3627 Check the adjustment of the front and rear bands, adjust if necessary. CLEANING 1. Using a suitable solvent, clean pan and magnet. INSTALLATION 1. Position a new transmission oil filter onto the valve body 2. Install the screws to hold the filter to the valve body Tighten the screws to 4 Nm (35 inch lbs.). 3. Clean the gasket surfaces of the transmission oil pan and transmission pan rail. NOTE:The original transmission pan oil gasket is reusable, inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket onto the oil pan. 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. For OE type reusable pan gasket: tighten the bolts to 13.6 Nm (125 inch lbs.). For aftermarket pan gasket: tighten the bolts to 17 Nm (150 inch lbs.). 7. Lower vehicle and fill transmission. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3628 Fluid Pan: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar ATF +4, Automatic Transmission Fluid, to transmission: a. If only fluid and filter were changed, add 3 pints (1-1/2 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, or torque converter was replaced or drained, add 12 pints (6 quarts) of ATF +4 to transmission. 3. Apply parking brakes. 4. Start and run engine at normal curb idle speed. 5. Apply service brakes, shift transmission through all gear ranges then back to NEUTRAL, set parking brake, and leave engine running at curb idle speed. 6. Remove funnel, insert dipstick and check fluid level. If level is low, add fluid to bring level to MIN mark on dipstick. Check to see if the oil level is equal on both sides of the dipstick. If one side is noticeably higher than the other, the dipstick has picked up some oil from the dipstick tube. Allow the oil to drain down the dipstick tube and re-check. 7. Drive vehicle until transmission fluid is at normal operating temperature. 8. With the engine running at curb idle speed, the gear selector in NEUTRAL, and the parking brake applied, check the transmission fluid level. CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result. 9. Add fluid to bring level up to MAX arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this model. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. The VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator VFD displays the following characters from left to right: "P," "R," "N," "D," "2," and "1". Respectively, these characters represent the park, reverse, neutral, drive, second gear, and first gear positions of the transmission gear selector lever on the steering column. The VFD illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps Off) the gear selector VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are On), the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned On during daylight hours. The gear selector indicator VFD is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission and automatic transmission model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by a dedicated Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the Off position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Programmable Communications Interface (PCI) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gear selector indicator VFD will display all of its characters at once during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On models with a TCM, the TCM continually monitors the transmission range sensor, then sends the proper gear selector indicator position messages to the instrument cluster. On models without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. On models with a TCM, for proper diagnosis of the transmission range sensor, the TCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Overdrive Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Overdrive Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Overdrive Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Overdrive Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Pressure Regulating Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Pressure Regulating Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3665 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3666 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3667 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3668 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3669 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3670 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3671 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3672 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3673 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3674 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3675 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3676 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3677 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3678 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3679 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3680 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3681 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3682 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3683 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3684 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control Transmission Control System Relay: Description and Operation Relay-Transmission Control RELAY-TRANSMISSION CONTROL 45RFE/545RFE DESCRIPTION NOTE: The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control > Page 3687 Transmission Control System Relay: Description and Operation 45RFE 4 Speed TRANSMISSION CONTROL RELAY - 45RFE/545RFE Automatic Transmission DESCRIPTION NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control > Page 3688 Transmission Control System Relay: Description and Operation 48RE Automatic Transmission The Chrysler Corporation does not list a Transmission Control Relay for the 48RE Automatic Transmission. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Shift Interlock Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Shift Interlock Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Shift Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Shift Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Throttle Valve Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Throttle Valve Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Throttle Valve Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Throttle Valve Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Valve Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Throttle Valve Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Torque Converter Clutch Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Torque Converter Clutch Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3747 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3748 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3749 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3750 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3751 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3752 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3753 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3754 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3755 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3756 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3757 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3758 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3759 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3760 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3761 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3762 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3763 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3764 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3765 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3766 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control Transmission Control System Relay: Description and Operation Relay-Transmission Control RELAY-TRANSMISSION CONTROL 45RFE/545RFE DESCRIPTION NOTE: The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control > Page 3769 Transmission Control System Relay: Description and Operation 45RFE 4 Speed TRANSMISSION CONTROL RELAY - 45RFE/545RFE Automatic Transmission DESCRIPTION NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control > Page 3770 Transmission Control System Relay: Description and Operation 48RE Automatic Transmission The Chrysler Corporation does not list a Transmission Control Relay for the 48RE Automatic Transmission. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair Clutch Disc: Service and Repair DISC CLUTCH - SRT-10 REMOVAL 1. Remove transmission. 2. Remove clutch housing (3) bolts and remove clutch housing from engine. 3. Mark pressure plate (1) and flywheel to maintain their position when installing clutch assembly. 4. Insert Clutch Disc Aligning Tool through the clutch disc hub to prevent the clutch disc from falling and damaging the facings. 5. Loosen pressure plate bolts (2) one or two turns at a time, in a crisscross pattern. This will release spring pressure evenly and avoid clutch cover damage. 6. Remove pressure plate assembly and disc. CLEANING Clean flywheel face with crocus cloth or 400-600 grade sandpaper, then wipe the surface with mineral spirits. If the surface is severely scored, heat checked or warped, replace the flywheel. CAUTION: Never machine the flywheel face. If flywheel surface is bad the flywheel must be replaced. Wipe the friction surface of the pressure plate with mineral spirits. INSTALLATION NOTE: Clutch disc is marked flywheel side. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Page 3778 1. Mount clutch assembly on flywheel, being careful to properly align dowels and alignment marks made before removal. If new clutch or flywheel is installed, align cover balance spot as close as possible to flywheel balance orange spot. Apply pressure to the alignment tool. Lightly tighten the clutch cover bolts enough to hold the disc in position. 2. Tighten pressure plate bolts a few turns at a time in a crisscross pattern until bolts are all seated. Then tighten bolts sequence to 30 Nm (270 inch lbs.). Remove clutch disc alignment tool. 3. Install bellhousing on engine. 4. Install transmission. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications Clutch Master/Slave Cylinder ............................................................................................................................................ DOT 4 compatible Brake Fluid Clutch Linkage ................................................................................................................................................ Multipurpose Grease, NLGI Grade 2 E.P. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair Clutch Master Cylinder: Service and Repair LINKAGE - SRT-10 REMOVAL 1. Remove nuts attaching slave cylinder to studs on clutch housing. CAUTION: The hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should never be disconnected or tampered with. Once the hydraulic line is connected to the slave cylinder, it should never be disconnected. 2. Raise and support vehicle. 3. Remove heat shield over hydraulic line. 4. Remove slave cylinder (2) from clutch housing. 5. Remove plastic clip securing the hydraulic line to the dash panel from the lower dash panel flange. 6. Remove plastic clip securing hydraulic line to the dash panel from the upper dash panel stud. 7. Lower vehicle. 8. Disconnect clutch pedal interlock switch connector (2). 9. Remove clutch master cylinder rod pin (3). 10. Verify that cap on clutch master cylinder reservoir is tight. This will avoid spillage during removal. 11. Remove clutch master cylinder nuts holding the to the dash panel. 12. Remove clutch cylinders, reservoir and connecting lines from vehicle. INSTALLATION 1. Position cylinders and connecting line in vehicle engine compartment. Position clutch hydraulic line against the dash panel and behind all engine hoses and wiring. 2. Apply a light coating of grease to the inside diameter of the master cylinder push rod 93) eye. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Page 3786 3. Install clutch master cylinder (1) on dash panel and tighten clutch master cylinder nuts to 28 Nm (21 ft. lbs.). 4. Install clutch master cylinder push rod pin. 5. Connect clutch pedal position interlock switch connector (2). 6. Install plastic clip securing hydraulic line to the dash panel into the lower dash panel flange. 7. Install plastic clip securing hydraulic line to the dash panel onto the upper dash panel stud. 8. Raise vehicle. 9. Install slave cylinder (2) and verify cylinder rod is properly seated in release lever. 10. Install and tighten slave cylinder nuts (1) to 23 Nm (17 ft. lbs.). 11. If new clutch linkage is being installed, connect the clutch hydraulic line to the clutch slave cylinder. CAUTION: Once the clutch hydraulic line is connected to the slave cylinder, it should never be disconnected. 12. Install heat shield over hydraulic line. 13. Operate linkage several times to verify proper operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair Clutch Slave Cylinder: Service and Repair LINKAGE - SRT-10 REMOVAL 1. Remove nuts attaching slave cylinder to studs on clutch housing. CAUTION: The hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should never be disconnected or tampered with. Once the hydraulic line is connected to the slave cylinder, it should never be disconnected. 2. Raise and support vehicle. 3. Remove heat shield over hydraulic line. 4. Remove slave cylinder (2) from clutch housing. 5. Remove plastic clip securing the hydraulic line to the dash panel from the lower dash panel flange. 6. Remove plastic clip securing hydraulic line to the dash panel from the upper dash panel stud. 7. Lower vehicle. 8. Disconnect clutch pedal interlock switch connector (2). 9. Remove clutch master cylinder rod pin (3). 10. Verify that cap on clutch master cylinder reservoir is tight. This will avoid spillage during removal. 11. Remove clutch master cylinder nuts holding the to the dash panel. 12. Remove clutch cylinders, reservoir and connecting lines from vehicle. INSTALLATION 1. Position cylinders and connecting line in vehicle engine compartment. Position clutch hydraulic line against the dash panel and behind all engine hoses and wiring. 2. Apply a light coating of grease to the inside diameter of the master cylinder push rod 93) eye. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Page 3790 3. Install clutch master cylinder (1) on dash panel and tighten clutch master cylinder nuts to 28 Nm (21 ft. lbs.). 4. Install clutch master cylinder push rod pin. 5. Connect clutch pedal position interlock switch connector (2). 6. Install plastic clip securing hydraulic line to the dash panel into the lower dash panel flange. 7. Install plastic clip securing hydraulic line to the dash panel onto the upper dash panel stud. 8. Raise vehicle. 9. Install slave cylinder (2) and verify cylinder rod is properly seated in release lever. 10. Install and tighten slave cylinder nuts (1) to 23 Nm (17 ft. lbs.). 11. If new clutch linkage is being installed, connect the clutch hydraulic line to the clutch slave cylinder. CAUTION: Once the clutch hydraulic line is connected to the slave cylinder, it should never be disconnected. 12. Install heat shield over hydraulic line. 13. Operate linkage several times to verify proper operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair Hydraulic Hose: Service and Repair LINKAGE - SRT-10 REMOVAL 1. Remove nuts attaching slave cylinder to studs on clutch housing. CAUTION: The hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should never be disconnected or tampered with. Once the hydraulic line is connected to the slave cylinder, it should never be disconnected. 2. Raise and support vehicle. 3. Remove heat shield over hydraulic line. 4. Remove slave cylinder (2) from clutch housing. 5. Remove plastic clip securing the hydraulic line to the dash panel from the lower dash panel flange. 6. Remove plastic clip securing hydraulic line to the dash panel from the upper dash panel stud. 7. Lower vehicle. 8. Disconnect clutch pedal interlock switch connector (2). 9. Remove clutch master cylinder rod pin (3). 10. Verify that cap on clutch master cylinder reservoir is tight. This will avoid spillage during removal. 11. Remove clutch master cylinder nuts holding the to the dash panel. 12. Remove clutch cylinders, reservoir and connecting lines from vehicle. INSTALLATION 1. Position cylinders and connecting line in vehicle engine compartment. Position clutch hydraulic line against the dash panel and behind all engine hoses and wiring. 2. Apply a light coating of grease to the inside diameter of the master cylinder push rod 93) eye. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair > Page 3794 3. Install clutch master cylinder (1) on dash panel and tighten clutch master cylinder nuts to 28 Nm (21 ft. lbs.). 4. Install clutch master cylinder push rod pin. 5. Connect clutch pedal position interlock switch connector (2). 6. Install plastic clip securing hydraulic line to the dash panel into the lower dash panel flange. 7. Install plastic clip securing hydraulic line to the dash panel onto the upper dash panel stud. 8. Raise vehicle. 9. Install slave cylinder (2) and verify cylinder rod is properly seated in release lever. 10. Install and tighten slave cylinder nuts (1) to 23 Nm (17 ft. lbs.). 11. If new clutch linkage is being installed, connect the clutch hydraulic line to the clutch slave cylinder. CAUTION: Once the clutch hydraulic line is connected to the slave cylinder, it should never be disconnected. 12. Install heat shield over hydraulic line. 13. Operate linkage several times to verify proper operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection SWITCH CLUTCH PEDAL- SRT-10 1. Disconnect the connector on the clutch position switch (1) from the vehicle wiring harness. 2. Place a ohmmeter across the terminals of the switch connector. The switch should show no continuity with the clutch pedal in the released (clutch engaged) position. 3. Slowly push the clutch pedal to the floor (clutch disengaged). The ohmmeter should show continuity just before the pedal reaches the end of its travel. 4. If the clutch switch shows continuity with clutch pedal up or no continuity with clutch pedal down, the switch is defective. The switch has no serviceable parts and should be replaced as an assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Testing and Inspection > Page 3798 Clutch Switch: Service and Repair SWITCH CLUTCH PEDAL POSITION REMOVAL 1. Disconnect the clutch pedal position switch connector. 2. Disconnect the clutch actuation rod from the clutch pedal. 3. Remove the clutch master cylinder from the toe box. 4. Remove the white clutch pedal position switch retaining clip (1). 5. Push the switch up (1) the rod (2) slightly. Then pull the bottom of the switch outward. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Testing and Inspection > Page 3799 1. Install new switch (1) as shown. Be sure that the spring loaded plunger inside the switch is slightly compressed. The plunger inside the switch must go on the narrow section of the clutch master cylinder actuation rod. Place the top of the switch against the rod. Then push the switch up slightly. This will compress the plunger. Then push the bottom of the switch against the rod. Failure to install the switch as described or forcing the switch onto the rod will crack the switch. 2. Install new white plastic retaining clip. 3. Install the clutch master cylinder back into the vehicle. 4. Reconnect the clutch switch connector. 5. Check clutch position switch operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Service and Repair Clutch Release Bearing: Service and Repair BEARING CLUTCH RELEASE - SRT-10 REMOVAL NOTE: The bearing and slave cylinder are serviced together as an assembly. Do not attempt to separate the bearing from the slave cylinder. 1. With vehicle in neutral, position vehicle on hoist. 2. Disconnect hydraulic line from hydraulic slave cylinder with Line Disconnect Tool 6638/6638A. 3. Remove transmission. 4. Remove slave cylinder (1) bolts and remove cylinder. INSTALLATION 1. Install slave cylinder (1) onto transmission (3) and tighten bolts to 22 Nm (200 inch lbs.). 2. Install transmission assembly. 3. Connect hydraulic line to slave cylinder. 4. Bleed the system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Service and Repair Clutch Release Fork: Service and Repair BEARING CLUTCH RELEASE - SRT-10 REMOVAL NOTE: The bearing and slave cylinder are serviced together as an assembly. Do not attempt to separate the bearing from the slave cylinder. 1. With vehicle in neutral, position vehicle on hoist. 2. Disconnect hydraulic line from hydraulic slave cylinder with Line Disconnect Tool 6638/6638A. 3. Remove transmission. 4. Remove slave cylinder (1) bolts and remove cylinder. INSTALLATION 1. Install slave cylinder (1) onto transmission (3) and tighten bolts to 22 Nm (200 inch lbs.). 2. Install transmission assembly. 3. Connect hydraulic line to slave cylinder. 4. Bleed the system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair Pilot Bearing: Service and Repair BEARING PILOT REMOVAL 1. Remove transmission assembly from the vehicle. 2. Remove pressure plate (2) and clutch disc. 3. Remove pilot bearing with an internal puller and slide hammer to remove. INSTALLATION 1. Clean bearing bore with solvent and wipe dry with shop towel. 2. Install new bearing (1) with clutch alignment tool (2) and letter side of the bearing (3) facing the transmission. Bearing should be flush with edge of bearing bore. CAUTION: Do not allow bearing to become cocked and do not recess bearing. 3. Install clutch disc, pressure plate and transmission. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Pressure Plate Bolts - V10 .................................................................................................................. ................................................... 30 Nm (22.5 ft. lbs.) Tighten bolts evenly and a few threads at a time in a diagonal pattern Pressure Plate Bolts-Diesel .. .............................................................................................................................................................. .... 30 Nm (22.5 ft. lbs.) V6 & V8 Engines ............................................................................................ ......................................................................................... 50 Nm (37 ft. lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 3812 Pressure Plate: Service and Repair DISC CLUTCH - SRT-10 REMOVAL 1. Remove transmission. 2. Remove clutch housing (3) bolts and remove clutch housing from engine. 3. Mark pressure plate (1) and flywheel to maintain their position when installing clutch assembly. 4. Insert Clutch Disc Aligning Tool through the clutch disc hub to prevent the clutch disc from falling and damaging the facings. 5. Loosen pressure plate bolts (2) one or two turns at a time, in a crisscross pattern. This will release spring pressure evenly and avoid clutch cover damage. 6. Remove pressure plate assembly and disc. CLEANING Clean flywheel face with crocus cloth or 400-600 grade sandpaper, then wipe the surface with mineral spirits. If the surface is severely scored, heat checked or warped, replace the flywheel. CAUTION: Never machine the flywheel face. If flywheel surface is bad the flywheel must be replaced. Wipe the friction surface of the pressure plate with mineral spirits. INSTALLATION NOTE: Clutch disc is marked flywheel side. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 3813 1. Mount clutch assembly on flywheel, being careful to properly align dowels and alignment marks made before removal. If new clutch or flywheel is installed, align cover balance spot as close as possible to flywheel balance orange spot. Apply pressure to the alignment tool. Lightly tighten the clutch cover bolts enough to hold the disc in position. 2. Tighten pressure plate bolts a few turns at a time in a crisscross pattern until bolts are all seated. Then tighten bolts sequence to 30 Nm (270 inch lbs.). Remove clutch disc alignment tool. 3. Install bellhousing on engine. 4. Install transmission. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair Differential Cover: Service and Repair COVER-DIFFERENTIAL REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Remove drain plug. 3. Remove cover bolts. 4. Remove cover and drain lubricant. INSTALLATION 1. Apply a 6.35mm (1/4 inch) bead of Mopar Silicone Rubber Sealant (1) or equivalent to the cover (2). CAUTION: If housing cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied. Failure to follow these instructions will result in a leak. 2. Install cover and identification tag. Tighten cover bolts in a criss-cross pattern to 41 Nm (30 ft. lbs.). 3. Fill differential to specifications. 4. Install fill plug. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Differential - Fluid Level Inspection Procedure Fluid - Differential: Technical Service Bulletins Differential - Fluid Level Inspection Procedure NUMBER: 03-003-06 GROUP: Axle DATE: October 20, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 03-001-04 REV. A, DATED MAY 11, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS. SUBJECT: Axle Fluid Level MODELS: 2004 (AN) Dakota **2004 - 2007** (DR/DH/D1/DC) Ram Truck **2004 - 2007** (HB/HG) Durango / Aspen **2005 - 2007** (ND) Dakota DISCUSSION: The axle fill holes on some Dodge Truck vehicle axles may be located considerably higher than the actual fluid level. Filling the axle until the fluid comes out of the fill hole will over fill the axle, which may cause fluid foaming. When checking fluid level or filling a rear axle with fluid, you must measure the distance from the bottom of the fill hole to the top of the actual fluid level. This can easily be accomplished using a pipe cleaner or piece of wire. Make a 90 degree bend in the wire 2 inches from the end. The wire can then be inserted into the axle fill hole to use as a dipstick. Measure the distance from the bend to the oil level. The fluid levels for the axles are shown in the table below. CORRECT FLUID LEVELS FOR DURANGO / ASPEN: NOTE: Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Differential - Fluid Level Inspection Procedure > Page 3822 The Trac-Lok feature is not available on Durango rear axles. Traction control is provided electronically through the ABS system. Trac-Lok additives or friction modifiers are not required. CORRECT FLUID LEVELS FOR RAM TRUCK 1500: CORRECT FLUID LEVELS FOR RAM TRUCK 2500 -3500: CORRECT FLUID LEVELS FOR DAKOTA: NOTE: The Trac-Lok feature is available on Dakota rear axles. Trac-Lok additives are required on axles equipped with Trac Lok. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Dana M60 HD/248 ............................................................................................................................... .................................................... 2.8Liters (5.9 pts.) Limited-Slip Rear Axles require the addition of 147 ml (5 oz.) Mopar limited slip additive. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 3825 Fluid - Differential: Fluid Type Specifications Limited Slip Rear Axle ......................................................................................................................... ...................................................... Mopar SAE 90W Limited-Slip Rear Axles require the addition of 147 ml (5 oz.) Mopar limited slip additive. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 9 1/4 Seals and Gaskets: Service and Repair Rear Axle - 9 1/4 Seal - Axle Shaft SEAL-AXLE SHAFT REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal (1) from the axle tube with a small pry bar. INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. 2. Coat the lip of the new seal with axle lubricant and install a seal with Installer C-4076-B and Handle C-4735-1. NOTE: When tool contacts the axle tube, the seal is installed to the correct depth. 3. Install the axle shaft (1). 4. Install differential cover and fill with gear lubricant to the bottom of the fill plug hole. Seal - Pinion SEAL-PINION REMOVAL 1. Mark universal joint, companion flange and pinion shaft for installation reference. 2. Remove propeller shaft from the companion flange. 3. Remove the brake rotors to prevent any drag. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 9 1/4 > Page 3830 4. Rotate companion flange (1) three or four times and record pinion rotating torque with an inch pound torque wrench (2). 5. Install two bolts into the companion flange threaded holes, 180° apart. Position Holder 6719A against the companion flange and install and tighten two bolts and washers into the remaining holes. 6. Hold the companion flange with Holder 6719A and remove pinion nut and washer. 7. Remove companion flange with Remover C-452 (2). 8. Remove pinion seal with pry tool or slide-hammer mounted screw. INSTALLATION 1. Apply a light coating of gear lubricant on the lip of pinion seal. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 9 1/4 > Page 3831 2. Install new pinion seal with Installer C-3860-A (2) and Handle C-4171 (1). 3. Install companion flange on the end of the shaft with the reference marks aligned. 4. Install two bolts into the threaded holes in the companion flange, 180° apart. 5. Position Holder 6719 (2) against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so holder is held to the flange. 6. Install companion flange on pinion shaft with Installer C-3718 and Holder 6719 (2). 7. Install pinion washer and a new pinion nut. The convex side of the washer must face outward. CAUTION: Never exceed the minimum tightening torque 285 Nm (210 ft. lbs.) when installing the companion flange retaining nut at this point. Failure to follow these instructions will damage the collapsible spacer. 8. Hold companion flange with Holder 6719 (2) and tighten the pinion nut with a torque set to 285 Nm (210 ft. lbs.). Rotate pinion several revolutions to ensure the bearing rollers are seated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 9 1/4 > Page 3832 9. Rotate pinion with an inch pound torque wrench (2). Rotating torque should be equal to the reading recorded during removal plus an additional 0.56 Nm (5 inch lbs.). CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If rotating torque is exceeded, a new collapsible spacer must be installed. 10. If rotating torque is low, use Holder 6719 to hold the companion flange (1) and tighten pinion 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. NOTE: The seal replacement is unacceptable if the final pinion nut torque is less than 285 Nm (210 ft. lbs.). 11. Install propeller shaft with the installation reference marks aligned. 12. Tighten the companion flange bolts to 108 Nm (80 ft. lbs.). 13. Install brake rotors. 14. Check the differential lubricant level. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 9 1/4 > Page 3833 Seals and Gaskets: Service and Repair Rear Axle - 10 1/2AA SEAL-PINION REMOVAL 1. Remove axle shafts. 2. Mark propeller shaft and pinion flange for installation reference and remove shaft. 3. Rotate pinion gear three or four times. 4. Measure and record the amount of torque necessary to rotate the pinion gear (1) with an inch pound torque wrench (2). 5. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut and washer. 6. Remove pinion flange (1) with Flange Puller 8992 (2). 7. Remove pinion shaft seal with a pry tool or slide hammer mounted screw. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 9 1/4 > Page 3834 INSTALLATION 1. Install new pinion seal with Installer 8896 (2) and Handle C-4171 (1) 2. Apply a light coat of teflon sealant to the pinion flange splines. 3. Lightly tap the pinion flange onto the pinion until a few threads are showing. 4. Install flange washer and new pinion nut. 5. Hold flange (2) with Flange Wrench 8979 (1) and tighten pinion nut until pinion end play is taken up. 6. Rotate pinion several times to seat bearings. 7. Measure pinion (1) rotating torque with an inch pound torque wrench (2) and compare it to recorded measurement. 8. Tighten pinion nut in small increments, until pinion rotating torque is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than recorded measurement. 9. Rotate pinion several times then verify pinion rotating torque again. 10. Install axle shafts. 11. Install propeller shaft with reference marks aligned. 12. Check and fill differential if necessary. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 9 1/4 > Page 3835 Seals and Gaskets: Service and Repair Rear Axle - 11 1/2AA SEAL-PINION REMOVAL 1. Remove axle shafts. 2. Mark the propeller shaft and pinion flange for installation reference. 3. Remove propeller shaft. 4. Rotate pinion gear (1) three or four times. 5. Measure and record the amount of torque necessary to rotate the pinion gear with an inch pound torque wrench (2). 6. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut. 7. Remove pinion flange (1) with Pinion Flange Puller 8992 (2) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 9 1/4 > Page 3836 8. Remove pinion shaft seal with a pry tool or slide hammer mounted screw. INSTALLATION 1. Install new pinion seal with Handle C-4171 (1) and Installer 8896 (2). 2. Apply a light coat of teflon sealant to the pinion flange splines. 3. Lightly tap the pinion flange onto the pinion until a few threads are showing. 4. Install flange washer and new pinion nut. 5. Hold pinion flange (2) with Flange Wrench 8979 (1) and tighten pinion nut until pinion end play is taken up. 6. Rotate pinion several times to seat bearings. 7. Measure pinion (1) rotating torque with an inch pound torque wrench (2) and compare it to recorded measurement. Tighten pinion nut in small increments, until pinion rotating torque is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than recorded measurement. 8. Rotate pinion several times then verify pinion rotating torque again. 9. Install axle shafts. 10. Install propeller shaft with reference marks aligned. 11. Check differential fluid level. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 9 1/4 > Page 3837 Seals and Gaskets: Service and Repair Rear Axle - 248RBI Seal - Axle Shaft SEAL-AXLE SHAFT REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal (1) from the end of the axle tube (2) with a pry bar. INSTALLATION 1. Remove any old sealer/burrs from axle tube. 2. Coat new seal lip with axle lubricant and install seal with Installer 9343 (1) and Handle C-4171(2). 3. Install axle shaft. Seal - Pinion SEAL-PINION REMOVAL 1. Remove propeller shaft. 2. Remove brake calipers to prevent any drag. 3. Rotate pinion yoke three or four times. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 9 1/4 > Page 3838 4. Record pinion gear (2) rotating torque with an inch pound torque wrench (1). 5. Hold yoke with Yoke Holder 6719A and remove pinion shaft nut and washer. 6. Remove pinion yoke (1) with Remover C-452 (2). 7. Remove pinion seal with pry tool or slide-hammer mounted screw. INSTALLATION 1. Coat lip of pinion seal with gear lubricant. 2. Install new pinion seal with Installer 9348 (2) and Handle C-4171 (1). 3. Install yoke on pinion shaft with Installer C-3718 and Yoke Holder 6719A. 4. Install pinion yoke washer with the concave surface against the yoke end. 5. Install new pinion nut. CAUTION: Never exceed minimum tightening torque when installing the pinion yoke retaining nut at this point. Failure to heed caution may result in damage. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle - 9 1/4 > Page 3839 6. Hold pinion yoke with Yoke Holder 6719A (2) and tighten nut with torque wrench (3) to 292 Nm (215 ft. lbs.). Rotate pinion shaft several revolutions to ensure bearing rollers are seated. 7. Rotate pinion (2) with a inch pound torque wrench (1). Rotating torque should be equal to reading recorded during removal, plus 0.56 Nm (5 inch lbs.). CAUTION: Never loosen pinion nut to decrease pinion rotating torque and never exceed specified preload torque. Failure to follow these instruction will result in damage. 8. If 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. 9. Install brake components. 10. Install propeller shaft. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 9 1/4 Axle Bearing: Service and Repair Rear Axle - 9 1/4 BEARING-AXLE REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal from axle tube with a small pry bar. NOTE: The seal and bearing can be removed at the same time with the bearing removal tool. 3. Remove axle shaft bearing with Bearing Remover 6310 (2) (3) (4) (5) and Foot 6310-9 (7). INSTALLATION 1. Wipe axle tube bore clean and remove any old sealer or burrs from the tube. 2. Install axle shaft bearing with Installer C-4198 and Handle C-4171. Drive bearing in until tool contacts the axle tube. NOTE: Bearing is installed with the bearing part number against the installer. 3. Coat lip of the new axle seal with axle lubricant and install with Installer C-4076-B and Handle C-4735-1. 4. Install the axle shaft (1). 5. Install differential cover and fill with gear lubricant to the bottom of the fill plug hole. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 9 1/4 > Page 3845 Axle Bearing: Service and Repair Rear Axle - 10 1/2 AA BEARING-AXLE HUB REMOVAL 1. Remove axle shaft flange bolts and remove axle shaft. 2. Remove retainer ring (1) from the axle shaft tube. 3. Remove hub bearing nut (1) locking key (2). 4. Remove hub bearing nut with Socket 8954. 5. Remove hub and bearings from the axle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 9 1/4 > Page 3846 6. Pry out hub bearing seal from the back of the hub. NOTE: The inner part of the seal (3) may stay on the axle tube (2). This part must also be removed. 7. Remove rear bearing. 8. Remove hub bearing cups with a hammer and drift. INSTALLATION 1. Install outer hub bearing cup with Installer 8961 and Handle C-4171. 2. Install inner hub bearing cup with Installer 8962 and Handle C-4171. 3. Pack bearings with the appropriate grease. 4. Install rear bearing and install new grease seal with Installer 8963 and Handle C-4171. 5. Slide hub on the axle tube and install front bearing into the hub. 6. Install hub bearing nut with Socket 8954 (1) and tighten to 30 Nm (22 ft. lbs.) while rotating the hub. 7. Back off nut about 30° and align next hub nut key slot with axle tube key slot and install locking key. End play should be 0.025 - 0.25 mm (0.001 - 0.010 inch). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 9 1/4 > Page 3847 8. Install retainer ring (1) with ring end in the key slot. 9. Install new axle shaft gasket and install axle shaft. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 9 1/4 > Page 3848 Axle Bearing: Service and Repair Rear Axle - 11 1/2 AA BEARING-AXLE HUB REMOVAL 1. Remove axle shaft flange bolts and remove shaft. 2. Remove retainer ring (1) from the axle shaft tube. 3. Remove hub bearing nut (1) locking key (2). 4. Remove hub bearing nut with Socket 8954. 5. Remove hub and bearings from the axle. 6. Pry out hub bearing seal from the back of the hub. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 9 1/4 > Page 3849 NOTE: The inner part of the seal (3) may stay on the axle tube (2). This part must also be removed. 7. Remove rear bearing. 8. Remove hub bearing cups with a hammer and drift. INSTALLATION 1. Install outer hub bearing cup with Installer 8961 and Handle C-4171. 2. Install inner hub bearing cup with Installer 8153 and Handle C-4171. 3. Pack bearings with the appropriate wheel bearing grease. 4. Install rear bearing and install new grease seal with Installer 8963 and Handle C-4171. 5. Slide hub on the axle tube and install front bearing into the hub. 6. Install hub bearing nut with Socket 8954 (1) and tighten to 30 Nm (22 ft. lbs.) while rotating the hub. 7. Back off nut about 30° and align next hub nut key slot with axle tube key slot and install locking key. NOTE: End play should be 0.025 - 0.25 mm (0.01 - 0.001 inch) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 9 1/4 > Page 3850 8. Install retainer ring (1) with ring end in the key slot (2). 9. Install new axle shaft gasket and install the axle shaft. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 9 1/4 > Page 3851 Axle Bearing: Service and Repair Rear Axle - 248RBI BEARING-AXLE REMOVAL 1. Remove axle shaft. 2. Remove axle seal with pry bar. 3. Position bearing (2) Receiver 9345 (1) on axle tube. 4. Insert bearing Remover 6310 with Foot 6310-9 (3) through receiver (2) and bearing (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle - 9 1/4 > Page 3852 5. Tighten Remove 6310 nut (1) to pull bearing (3) into the receiver (3). INSTALLATION 1. Remove any old sealer/burrs from axle tube. 2. Install axle shaft bearing with Installer 9344 (1) and Handle C-4171 (2). Drive bearing in until tool contacts the axle tube. NOTE: Bearing is installed with the bearing part number against the installer. 3. Coat new axle seal lip with axle lubricant and install with Installer 9343 and Handle C-4171. 4. Install axle shaft. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures Axle Shaft: Procedures Dana Axle Number Cross Reference New Model Number ............................................................................................................................. ..................................... Old Dana Model Number 174 ....................................................................................................................................................... .......................................................................... 28 181 ....................................................................... .......................................................................................................................................................... 30 186 .................................................................................................................................................. .................................................................... Super 30 194 .................................................................. .............................................................................................................................................................. . 35 198 ................................................................................................................................................ ...................................................................... Super 35 200 ................................................................ .............................................................................................................................................................. ... 36 216 .............................................................................................................................................. ................................................................................... 44 226 .............................................................. ........................................................................................................................................................ Super 44 229 ....................................................................................................................................... .......................................................................................... 50 248 ....................................................... .............................................................................................................................................................. ............ 60 267 ..................................................................................................................................... ............................................................................................ 70 286 ..................................................... .............................................................................................................................................................. .............. 80 First Letter of Suffix F .......................................................................................................................................................... ................................................................ Front R ................................................................................ ........................................................................................................................................... Rear Second Letter of Suffix B .......................................................................................................................................................... ................................................................ Beam I ................................................................................ ................................................................................................................................ Independent Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 3858 Third Letter of Suffix I ............................................................................................................................................................ ................................................................. Iron A ................................................................................. ................................................................................................................................. Aluminum Examples: 248FBI ................................................................................................................................................. ................... Dana 60, Front, Beam Axle, Iron 186FIA .............................................................................................................................................. Dana Super 30, Front, Independent, Aluminum 226RBA ............................................................................................................................................... Dana Super 44, Rear, Beam Axle, Aluminum Rear Axle - 10 1/2 AA SHAFT-AXLE REMOVAL 1. Remove axle shaft flange (1) bolts (2). 2. Slide axle shaft out of the axle tube. 3. Remove axle shaft gasket. INSTALLATION NOTE: Axle flange bolts must be replaced or cleaned existing bolts apply Mopar Lock N' Seal or Loctite (R) 242 on the threads. 1. Clean axle flange and hub. 2. Install new axle shaft gasket. 3. Slide axle shaft into the axle tube. 4. Install axle shaft flange (1) bolts (2) and tighten to 129 Nm (95 ft. lbs.). Rear Axle - 11 1/2 AA SHAFT-AXLE REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 3859 1. Remove axle shaft flange (1) bolts (2). 2. Slide axle shaft out of the axle tube. 3. Remove axle shaft gasket. INSTALLATION NOTE: Axle flange bolts must be replaced or use Mopar Lock N' Seal or Loctite (R) 242 on cleaned existing bolts. 1. Clean axle flange and hub. 2. Install new axle shaft gasket. 3. Slide axle shaft into the axle tube. 4. Install axle shaft flange (1) bolts (2) and tighten to 129 Nm (95 ft. lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 3860 Axle Shaft: Removal and Replacement Rear Axle - 10 1/2 AA REAR AXLE-10 1/2 AA REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Position a lift under axle and secure lift to the axle. 3. Remove all brake components. 4. Remove axle vent hose. 5. Mark propeller shaft and companion flange for installation alignment reference. 6. Remove propeller shaft. 7. Remove shock absorbers (3) from axle (2). 8. Remove U-bolts (5) from axle. 9. Remove axle from the vehicle. INSTALLATION 1. Raise axle with lift and align to the leaf spring centering bolts. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 3861 2. Install axle U-bolts (5) and tighten to 149 Nm (110 ft. lbs.). 3. Install shock absorbers to axle and tighten to specification. 4. Install all brake components. 5. Install axle vent hose. 6. Install propeller shaft with reference marks aligned and tighten to specification. 7. Fill differential to specifications. Rear Axle - 11 1/2 AA REAR AXLE - 11 1/2 AA REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Position a lift under axle and secure lift to the axle. 3. Remove all brake components. 4. Mark propeller shaft and companion flange for installation alignment reference. 5. Remove propeller shaft. 6. Remove axle vent hose. 7. Remove shock absorbers (3) from axle (2). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 3862 8. Remove U-bolts (4) from axle. 9. Remove axle from the vehicle. INSTALLATION 1. Raise axle with lift and align to the leaf spring (1) centering bolts. 2. Install axle U-bolts (5) and tighten to 149 Nm (110 ft. lbs.). 3. Install shock absorbers to axle and tighten to specification. 4. Install all brake components. 5. Install propeller shaft with reference marks aligned and tighten to specification. 6. Install axle vent hose. 7. Fill differential to specifications. 8. Remove lift from axle and lower the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel Bearing Grease ...................................................................................................... Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 3866 Wheel Bearing: Service and Repair HUB/BEARING - 4X2 REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped (4). 5. Remove the three hub/bearing mounting bolts (5) from the steering knuckle (3). 6. Slide the hub/bearing (1) out of the steering knuckle (3). NOTE: The next step excludes SAT-10. (SAT-10 does not have a dust shield) 7. Remove the brake dust shield (2). INSTALLATION 1. Install the brake dust shield (2). SRT-10 Excluded in this step. 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts (5) to 163 Nm (120 ft. lbs.) 4X2 LD. Or tighten the bolts (5) to 176 Nm (130 ft. lbs.) 4X2 HD.. 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped (4). 5. Install the wheel and tire assembly. 6. Remove the support and lower vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Independent front suspension Halfshaft nut ........................................................................................ ................................................................................................. 251 Nm (185 ft. lbs.) Link/coil suspension Axle nut step 1 .................................................................................................... ................................................................................................ 179 Nm (132 ft. lbs.) step 2 ................ .............................................................................................................................................................. ...................... 356 Nm (263 ft. lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair Center Support: Service and Repair BEARING-CENTER REMOVAL 1. Remove rear propeller shaft. 2. Make installation reference mark (1) on the two shafts. 3. Remove slip joint boot (4) clamp (3) and separate the two shafts. 4. Use hammer and punch to tap slinger away from shaft to provide room for bearing splitter. 5. Position Bearing Splitter Tool 1130 between slinger and shaft. CAUTION: Do not damage shaft spline during removal of center bearing. 6. Set shaft in press and press bearing off the shaft. INSTALLATION NOTE: Two types of center bearings are used and are not interchangeable. Install the same type as the vehicle was built with. 1. Install new slinger on shaft and drive into position with appropriate installer tool. 2. Install new center bearing (2) on shaft with Bearing Installer Tool 6052. Drive on shaft with hammer until bearing is seated. 3. Clean shaft splines and apply a coat of multi-purpose grease. 4. Align master splines and slide front and rear half-shafts together. Reposition slip yoke boot (4) and install new clamp (3). 5. Install propeller shaft in vehicle. ADJUSTMENTS Launch shudder is a vibration that occurs at first acceleration from a stop. Shudder vibration usually peaks at the engines highest torque output. Shudder is a symptom associated with vehicles using a two-piece propeller shaft. To decrease shudder, lower the center bearing in 1/8 inch increments. Use shim stock or fabricated plates. Plate stock must be used to maintain compression of the rubber insulator around the bearing. Do not use washers. Replace the original bolts with the appropriate increased length bolts. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 03-003-04 > Jun > 04 > Drivetrain - Launch Shudder Drive/Propeller Shaft: Customer Interest Drivetrain - Launch Shudder NUMBER: 03-003-04 GROUP: Differential & Drive Line DATE: June 15, 2004 SUBJECT: Launch Shudder OVERVIEW: This bulletin involves adjusting the propeller shaft working angles. MODELS: 2003 - 2004 (DR) Ram Truck NOTE: This bulletin applies to vehicles equipped with a two piece rear driveshaft. SYMPTOM/CONDITION: A vehicle may exhibit a drive line shudder or vibrations while accelerating from a stop. The condition is most noticeable under heavy throttle acceleration and is usually only present a low speeds (below 25 m.p.h.). DIAGNOSIS: Vehicles equipped with a two piece driveshaft are designed to minimize reaction forces which result from the universal joint transmitting torque at an angle. These forces can not be eliminated entirely because of the necessity to compromise joint angle selection between curb and design loading conditions. When subjected to this vibration, the vehicle experiences a shudder type disturbance, generally occurring less than 25 mph. This disturbance will increase as the suspension moves further from its design load (typically two front passengers). The forces are also torque sensitive, which means the disturbance, will be highest under wide open throttle. U-joint angles change depending upon the amount of weight applied to the vehicle bed, therefore u-joint angle readings may need to be taken with different vehicle loads in order to obtain a satisfactory compromise. The vehicle should be evaluated under the loaded condition that produces the objectionable disturbance. PARTS REQUIRED: Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 03-003-04 > Jun > 04 > Drivetrain - Launch Shudder > Page 3883 SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Inspect the suspension and drive line for any signs of worn or damaged parts. Make the necessary repairs. 2. Raise the vehicle on a hoist. The weight of the vehicle must be supported by the suspension. Make sure that the frame is as level as possible. 3. Remove universal joint snap rings if equipped, so Inclinometer No. 7663 base sits flat. 4. Rotate shaft until transmission/transfer case output yoke bearing is facing downward. NOTE: Always take measurements from front to rear and on the same side of the vehicle. 5. Place inclinometer on yoke bearing cap or pinion flange ring (A) parallel to the shaft. Center the bubble in sight glass and record measurement (Fig. 1). This measurement will give you the transmission yoke Output Angle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 03-003-04 > Jun > 04 > Drivetrain - Launch Shudder > Page 3884 6. Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing parallel to the shaft . Center the bubble in sight glass and record measurement. This measurement can also be taken at the rear end of the shaft (Fig. 2). This measurement will give you the Front Propeller Shaft Angle. 7. Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing parallel to the rear shaft and center the bubble in the sight glass and record measurement. This measurement can also be taken at the rear end of the shaft. This measurement will give you the Rear Propeller Shaft Angle. 8. Rotate propeller shaft 90 degrees and place inclinometer on rear axle pinion flange yoke bearing parallel to the shaft (Fig. 3). Center the bubble in sight glass and record measurement. This measurement will give you the Pinion Flange Input Angle or Pinion Angle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 03-003-04 > Jun > 04 > Drivetrain - Launch Shudder > Page 3885 9. To calculate the operating angle for the transmission output to front propeller shaft (A) (Fig. 4), subtract front propeller shaft angle from the transmission output shaft. To calculate the operating angle for the front to rear propeller shaft (B) (Fig. 4), subtract the front prop. rear propeller shaft angel from the front. To calculate the operating angle for the rear prop. shaft to pinion angle (C) (Fig. 4), subtract the pinion angle from the rear prop. shaft angle. The operating angles can be adjusted by moving the center carrier bearing up or down. The center bearing brackets, listed above, are available in a variety of heights. The working angles should be adjusted to provide the lowest angle possible for the output shaft to front propeller shaft, front propeller shaft to rear propeller shaft and rear propeller shaft to axle pinion. The angles must be below 3 degrees but must have a minimum angle of 1/2 degree to provide for universal joint lubrication. Determine which direction you need to move the center bearing to optimize the angles and install the appropriate bracket to obtain the minimum working angle, but still maintain at least 1/2 degree to assure that there will be some movement in the U-joint bearings (Fig. 4). TORQUE SPECIFICATIONS POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 03-003-04 > Jun > 04 > Drivetrain - Launch Shudder > Page 3886 Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 03-003-04 > Jun > 04 > Drivetrain - Launch Shudder Drive/Propeller Shaft: All Technical Service Bulletins Drivetrain - Launch Shudder NUMBER: 03-003-04 GROUP: Differential & Drive Line DATE: June 15, 2004 SUBJECT: Launch Shudder OVERVIEW: This bulletin involves adjusting the propeller shaft working angles. MODELS: 2003 - 2004 (DR) Ram Truck NOTE: This bulletin applies to vehicles equipped with a two piece rear driveshaft. SYMPTOM/CONDITION: A vehicle may exhibit a drive line shudder or vibrations while accelerating from a stop. The condition is most noticeable under heavy throttle acceleration and is usually only present a low speeds (below 25 m.p.h.). DIAGNOSIS: Vehicles equipped with a two piece driveshaft are designed to minimize reaction forces which result from the universal joint transmitting torque at an angle. These forces can not be eliminated entirely because of the necessity to compromise joint angle selection between curb and design loading conditions. When subjected to this vibration, the vehicle experiences a shudder type disturbance, generally occurring less than 25 mph. This disturbance will increase as the suspension moves further from its design load (typically two front passengers). The forces are also torque sensitive, which means the disturbance, will be highest under wide open throttle. U-joint angles change depending upon the amount of weight applied to the vehicle bed, therefore u-joint angle readings may need to be taken with different vehicle loads in order to obtain a satisfactory compromise. The vehicle should be evaluated under the loaded condition that produces the objectionable disturbance. PARTS REQUIRED: Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 03-003-04 > Jun > 04 > Drivetrain - Launch Shudder > Page 3892 SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Inspect the suspension and drive line for any signs of worn or damaged parts. Make the necessary repairs. 2. Raise the vehicle on a hoist. The weight of the vehicle must be supported by the suspension. Make sure that the frame is as level as possible. 3. Remove universal joint snap rings if equipped, so Inclinometer No. 7663 base sits flat. 4. Rotate shaft until transmission/transfer case output yoke bearing is facing downward. NOTE: Always take measurements from front to rear and on the same side of the vehicle. 5. Place inclinometer on yoke bearing cap or pinion flange ring (A) parallel to the shaft. Center the bubble in sight glass and record measurement (Fig. 1). This measurement will give you the transmission yoke Output Angle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 03-003-04 > Jun > 04 > Drivetrain - Launch Shudder > Page 3893 6. Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing parallel to the shaft . Center the bubble in sight glass and record measurement. This measurement can also be taken at the rear end of the shaft (Fig. 2). This measurement will give you the Front Propeller Shaft Angle. 7. Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing parallel to the rear shaft and center the bubble in the sight glass and record measurement. This measurement can also be taken at the rear end of the shaft. This measurement will give you the Rear Propeller Shaft Angle. 8. Rotate propeller shaft 90 degrees and place inclinometer on rear axle pinion flange yoke bearing parallel to the shaft (Fig. 3). Center the bubble in sight glass and record measurement. This measurement will give you the Pinion Flange Input Angle or Pinion Angle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 03-003-04 > Jun > 04 > Drivetrain - Launch Shudder > Page 3894 9. To calculate the operating angle for the transmission output to front propeller shaft (A) (Fig. 4), subtract front propeller shaft angle from the transmission output shaft. To calculate the operating angle for the front to rear propeller shaft (B) (Fig. 4), subtract the front prop. rear propeller shaft angel from the front. To calculate the operating angle for the rear prop. shaft to pinion angle (C) (Fig. 4), subtract the pinion angle from the rear prop. shaft angle. The operating angles can be adjusted by moving the center carrier bearing up or down. The center bearing brackets, listed above, are available in a variety of heights. The working angles should be adjusted to provide the lowest angle possible for the output shaft to front propeller shaft, front propeller shaft to rear propeller shaft and rear propeller shaft to axle pinion. The angles must be below 3 degrees but must have a minimum angle of 1/2 degree to provide for universal joint lubrication. Determine which direction you need to move the center bearing to optimize the angles and install the appropriate bracket to obtain the minimum working angle, but still maintain at least 1/2 degree to assure that there will be some movement in the U-joint bearings (Fig. 4). TORQUE SPECIFICATIONS POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 03-003-04 > Jun > 04 > Drivetrain - Launch Shudder > Page 3895 Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 3896 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 3897 Drive/Propeller Shaft: Testing and Inspection PROPELLER SHAFT VIBRATION Out-of-round tires or wheels that are out of balance, will cause a low frequency vibration. Driveline vibration can also caused by loose or damaged engine mounts. Propeller shaft vibration increases with vehicle speed. A vibration that occurs at a specific speed range, is not usually caused by an out of balance propeller shaft. Defective universal joints or an incorrect propeller shaft angle are usually the cause of such a vibration. DRIVELINE VIBRATION PROPELLER SHAFT BALANCE If propeller shaft is suspected of being out of balance, use the following procedure. NOTE: Indexing propeller shaft 180° relative to the yoke may eliminate some vibrations. 1. Raise and support vehicle. 2. Clean all foreign material from the propeller shaft and universal joints. 3. Inspect propeller shaft for missing balance weights, broken welds and bent areas. If propeller shaft is bent, it must be replaced. 4. Inspect universal joints for wear and properly installed. 5. Check propeller shaft bolt torques. 6. Remove wheels and install lug nuts to retain brake rotors. 7. Mark and number the shaft six inches from the pinion yoke end at four positions 90° apart. 8. Run and accelerate vehicle until vibration occurs. Note the intensity and speed the vibration occurred. Stop the engine. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 3898 9. Install a screw clamp at position (1). 10. Start engine and check vibration. If there is little or no change move the clamp to the next positions. Repeat the vibration test. NOTE: If there is no difference in vibration at this positions, the vibration may not be the propeller shaft. 11. If vibration decreased, install a second clamp (1) and repeat the test. 12. If additional clamp causes an additional vibration, separate the clamps 1/2 inch (1) above and below the mark. Repeat the vibration test. 13. Increase distance between the clamp screws (1) (2) and repeat test, until the least amount of vibration is noticed. Bend the slack end of the clamps so screws will not loosen. 14. If vibration remains unacceptable, repeat the procedure to the front end of the propeller shaft. 15. Install wheels and lower vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 3899 PROPELLER SHAFT RUNOUT 1. Clean propeller shaft surface, where dial indicator will contact the shaft. 2. Install dial indicator perpendicular to the shaft surface. 3. Measure runout at the center and ends of the shaft away from weld areas, so weld process does not affect measurements. 4. Refer to Runout Specifications chart. 5. If runout is out of specification, index the shaft 180° and take shaft runout measurements again. 6. If runout is now within specifications, mark shaft and yokes for proper orientation. 7. If runout is not within specifications, verify runout of the transmission/transfer case and axle are within specifications. Correct as necessary and measure propeller shaft runout again. 8. Replace propeller shaft if the runout still exceeds the limits. RUNOUT SPECIFICATIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle Drive/Propeller Shaft: Service and Repair Propeller Shaft Angle PROPELLER SHAFT ANGLE TWO PIECE PROPELLER SHAFT Two piece propeller shaft angles measurement is the same as a one-piece propeller shaft. ONE PIECE PROPELLER SHAFT This procedure applies to front and rear propeller shafts. NOTE: To obtain output angle (A) on the front propeller shaft equipped with a ON joint, place inclinometer on machined surface of the ON joint. 1. Raise vehicle and support the axles as level as possible, allowing the wheels and propeller shaft to turn. 2. Remove universal joint snap rings if equipped, so inclinometer base sits flat. 3. Rotate shaft until transmission/transfer case output yoke bearing is facing downward. NOTE: Always take measurements from front to rear and on the same side of the vehicle. 4. Place Inclinometer 7663 on yoke bearing cap or pinion flange ring parallel to the shaft. Center bubble in sight glass and record measurement (A). This measurement will give you the transmission yoke Output Angle (A). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 3902 5. Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing parallel to the shaft. Center bubble in sight glass and record measurement. This measurement can also be taken at the rear end of the shaft. This measurement will give you the Propeller Shaft Angle (C). 6. Rotate propeller shaft 90 degrees and place inclinometer on companion flange yoke bearing parallel to the shaft. Center bubble in sight glass and record measurement. This measurement will give you the pinion Companion Flange Input Angle (B). 7. Subtract smaller figure from larger (C minus A) to obtain Transmission/Transfer Case Output Operating Angle. 8. Subtract smaller figure from larger (C minus B) to obtain axle Input Operating Angle. Refer to rules and example in for additional information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 3903 RULES Good cancellation of U-Joint operating angles should be within 1 degree. - Operating angles should be less than 3 degrees. - Operating angles less than 10 degrees for double cardan U-Joint. - At least 1/2 of one degree continuous operating propeller shaft angle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 3904 Drive/Propeller Shaft: Service and Repair Shaft-Propeller Rear SHAFT-PROPELLER REAR REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Mark pinion flange (3) or yoke and propeller shaft (1) flange (4) or yoke for installation reference. 3. Mark the outline of the center bearing (1) on the crossmember for installation reference, if equipped. 4. Remove center bearing mounting nuts (3), if equipped. 5. Remove pinion flange or yoke clamp bolts. 6. Slide propeller shaft back on transmission then mark the shaft and transmission for installation reference. 7. Remove propeller shaft from transmission/transfer case. INSTALLATION 1. Slide slip yoke onto the transmission/transfer case output shaft with reference marks aligned. 2. Align and install center bearing on crossmember, if equipped and tighten nuts to 54 Nm (40 ft. lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 3905 3. Align reference marks on propeller shaft (2) and pinion flange or pinion yoke. 4. Install new companion flange (1) bolts and tighten to 15 Nm (85 ft. lbs.) 5. Install new SRT-10 yoke clamp (4) bolts and tighten to 29 Nm (22 ft. lbs.). NOTE: Companion flange bolts incorporate a Loctite (R) patch, new bolts should be used. If bolts are not available, clean bolts and apply Loctite (R) 242 to the threads. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Page 3906 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Universal Joint: Service and Repair Single Cardan With Injected Ring DISASSEMBLY - WITH INJECTED RING 1. Place shaft yoke in vise. 2. Position U-Joint press (1) with receiver (2) on propeller shaft yoke. 3. Pressed U-Joint bearing caps (1) out of shaft yoke (2). 4. Remove lower bearing cap from shaft yoke. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 3911 5. Turn shaft over and position press (1) with receiver (2) on shaft yoke. 6. Press remaining U-Joint bearing cap out of shaft yoke. 7. Remove flange (1) with U-Joint out of shaft yoke (2). 8. Position U-Joint press (2) with receiver (1) on flange. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 3912 9. Press U-Joint bearing caps (1) out of flange (2). 10. Remove bearing cap on the outside of the flange. 11. Position U-Joint press (2) with receiver (1) on flange. 12. Press remaining U-Joint bearing cap out of flange. 13. Remove U-Joint from flange. ASSEMBLY NOTE: Replacement joint has internal snap rings. 1. Place joint in flange with one bearing cap. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 3913 2. Position press (3) with receiver (1) on flange and bearing cap (2). 3. Press bearing cap until snap ring groove (1) is through the flange (2). 4. Install snap ring (2) on bearing (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 3914 5. Position press (3) with receiver (2) on remaining bearing cap (1) and flange. 6. Press bearing cap until snap ring groove is through the flange. 7. Install snap ring (1) on bearing cap (2). 8. Install flange (1) with U-Joint in yoke (2). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 3915 9. Position press (2) with receiver (1) and lower bearing cap (3) on yoke. 10. Press bearing cap until snap ring groove is through the yoke. 11. Install snap ring (2) on bearing cap (1). 12. Position press (2) with receiver (3) on remaining bearing cap (1) and yoke. 13. Press remaining bearing cap until snap ring groove is through the yoke. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 3916 14. Install snap ring (2) on bearing cap (1). With Snap Rings DISASSEMBLY - WITH SNAP RINGS 1. Tap outside of bearing cap with a drift to loosen snap ring. 2. Remove snap rings (1) from both sides of yoke. 3. Position yoke with the grease fitting if equipped, pointing up. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 3917 4. Position a socket (2) with a inside diameter large enough to receive the bearing cap, beneath the yoke on a press. 5. Place another socket with an outside diameter smaller than bearing cap on the upper bearing cap and press (1) the lower cap through the yoke. NOTE: If 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. 6. Pull bearing cap of the yoke. 7. Turn yoke over in the press and straighten the cross (1). Press the cross until the remaining bearing cap (2) can be removed. CAUTION: If cross or bearing cap are not straight during removal, the bearing cap will score the walls of the yoke bore and damage can occur. ASSEMBLY 1. Apply (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores. 2. Position cross (1) in yoke with lube fitting pointing up, if equipped. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 3918 3. Place a bearing cap (1) over the cross end (2) and align cap with yoke bore. 4. Press bearing cap into the yoke bore enough to clear snap ring groove. 5. Repeat Step 3 and Step 4 to install the opposite bearing cap. NOTE: If joint is stiff or binding, strike the yoke with a soft hammer to seat the needle bearings. 6. Add grease to lube fitting, if equipped. 7. Install propeller shaft. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 3919 Universal Joint: Service and Repair Double Cardan DISASSEMBLY 1. Remove propeller shaft. 2. Mark propeller shaft, link yoke and flange yoke for assembly reference. 3. Tap outside of the bearing cap assembly with drift to loosen snap rings. 4. Remove all bearing cap snap rings. 5. Remove grease fittings if equipped. 6. Position a socket on the press with an inside diameter large enough to receive the bearing cap under the link yoke. 7. Place another socket with an outside diameter smaller than the bearing cap on the upper bearing cap. 8. Press one bearing cap from outboard side of the link yoke, enough to grasp the cap with vise jaws. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 3920 9. Grasp protruding bearing cap with vise jaws and tap link yoke with a mallet to remove bearing cap. 10. Flip assembly and repeat Step 6, Step 7, Step 8 and Step 9 to remove the opposite bearing cap. 11. Remove cross centering kit assembly and spring. 12. Press remaining bearing caps out the other end of the link yoke. ASSEMBLY CAUTION: All alignment marks on the link yoke and propeller shaft yoke must be aligned during assembled. 1. Apply (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores. 2. Fit cross into the propeller shaft yoke. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 3921 3. Place bearing cap over the trunnion and align cap with the yoke bore. Keep needle bearings upright in the bearing cap. 4. Press bearing cap into yoke bore enough to clear snap ring groove and install snap-ring. 5. Flip propeller shaft yoke and install other bearing cap onto the opposite trunnion and install a snap ring. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 3922 6. Fit link yoke onto remaining trunnions and press both bearing caps into place and install snap rings. 7. Install centering kit assembly inside the link yoke. NOTE: Verify spring is properly positioned. 8. Place two bearing caps on opposite trunnions of the remaining cross. Fit open trunnions into the link yoke bores and bearing caps into the centering kit. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan > Page 3923 9. Press remaining two bearing caps into place and install snap rings. 10. Tap snap rings to seat them into the grooves. 11. Flexing the joint beyond center, the joint should snap over-center in both directions if correctly assembled. 12. Install propeller shaft. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Flywheel bolts ...................................................................................................................................... ..................................................... 74 Nm (55 ft. lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 3927 Flywheel: Testing and Inspection FLYWHEEL Common causes of flywheel problems: Incorrect bolt tightening - Mounting the flywheel on a dirty crankshaft flange - Improper seating on the crankshaft flange shoulder - Heat warpage - Loose flywheel to crankshaft bolts The flywheel should be replaced if warped or overheated. Do not machine the face of the flywheel to correct a warped or overheated condition. Clean the crankshaft flange and its mating surface on the flywheel before assembling. dirt/grease in this area could cause the flywheel to mix-align when installing. Use new bolts when mounting flywheel and secure the bolts with Mopar Lock and Seal or equivalent. Tighten flywheel bolts to specified torque only. Over tightening can distort the flywheel causing run out. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 3928 Flywheel: Service and Repair FLYWHEEL-SRT-10 REMOVAL 1. Remove transmission clutch housing and clutch assembly (2). 2. Remove flywheel (1) bolts and remove flywheel. INSTALLATION 1. Clean flywheel bolts and apply thread sealer. 2. Install flywheel (1) on engine and install flywheel bolts. 3. Tighten flywheel bolts to 74 Nm (55 ft. lbs.). 4. Install clutch assembly (2), clutch housing and transmission. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this model. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. The VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator VFD displays the following characters from left to right: "P," "R," "N," "D," "2," and "1". Respectively, these characters represent the park, reverse, neutral, drive, second gear, and first gear positions of the transmission gear selector lever on the steering column. The VFD illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps Off) the gear selector VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are On), the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned On during daylight hours. The gear selector indicator VFD is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission and automatic transmission model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by a dedicated Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the Off position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Programmable Communications Interface (PCI) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gear selector indicator VFD will display all of its characters at once during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On models with a TCM, the TCM continually monitors the transmission range sensor, then sends the proper gear selector indicator position messages to the instrument cluster. On models without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. On models with a TCM, for proper diagnosis of the transmission range sensor, the TCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Testing and Inspection Bell Housing: Testing and Inspection CLUTCH HOUSING The clutch housing maintains alignment between the crankshaft and transmission input shaft. Misalignment can cause clutch noise, hard shifting, incomplete release and chatter. Also premature pilot bearing, cover release fingers and clutch disc wear. In severe cases, it can cause premature wear of the transmission input shaft and front bearing. NOTE: Only the NV4500 clutch housing can be checked using the following bore and face runout procedures. The NV5600 clutch housing is a integral part of the transmission and can only be checked off the vehicle. CLUTCH HOUSING BORE RUNOUT CAUTION: On diesel engines if housing bore runout exceeds 0.015 inch, the clutch housing/transmission adapter plate must be replaced. On gas engines if housing bore runout exceeds 0.053 inch the clutch housing must be replaced. NOTE: Offset dowels are available for gas engines to correct housing bore runout. They are not available for diesel engines. 1. Remove the clutch housing. 2. Remove the clutch cover and disc. 3. Replace one of the flywheel bolts with an appropriate size threaded rod (3) that is 10 inch (25.4 cm) long. The rod will be used to mount the dial indicator. 4. Remove release fork from the clutch housing. 5. Install clutch housing. Tighten the housing bolts nearest the alignment dowels first. 6. Mount dial indicator (2) on the threaded rod (1) and position indicator plunger (3) on the clutch housing bore (4). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Testing and Inspection > Page 3938 7. Rotate crankshaft until indicator plunger is at the top of the housing bore (1). Zero the indicator at this point. 8. Rotate crankshaft and record indicator readings at eight points (45° apart) around the bore. Take measurement at least twice for accuracy. 9. Subtract each reading from the one 180° opposite to determine runout and direction. Bore runout example: - 0.000 - (-0.007) = 0.007 inch - +0.002 - (-0.010) = 0.012 inch - +0.004 - (-0.005) = 0.009 inch - -0.001 - (+0.001) = -0.002 inch In this example the largest or Total Indicator Reading (TIR) difference is 0.012 inch. This means the housing bore is offset from the crankshaft centerline by 0.006 inch which is 1/2 of 0.012 inch. The dowels (2) needed to correct this have an offset of 0.007 inch. Remove housing and install dowels with the slotted side facing out so they can be turned with a screwdriver. Then install the housing and mount the dial indicator and check bore runout again. Rotate the dowels until the TIR is less than 0.010 inch. Clutch Housing Face Runout 1. Position dial indicator (2) towards the housing face with indicator plunger (1) on the rim of the housing bore. 2. Rotate crankshaft until indicator plunger is at the 10 O'clock position and zero the dial indicator. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Testing and Inspection > Page 3939 3. Measure and record face runout (1) readings at four points 90° apart. Take measurement at least twice for accuracy. 4. Subtract lowest reading from highest to determine total runout. If low reading was minus 0.004 inch and highest reading was plus 0.009 inch the total runout is 0.013 inch. NOTE: Maximum acceptable face runout is 0.010 inch. To correct this example the shims needed between the clutch housing and transmission are: 0.009 inch at the 0.000 corner - 0.012 inch at the -0.003 corner - 0.013 inch at the -0.004 corner After installing the clutch assembly and housing, tighten the housing bolts nearest the alignment dowels first. NOTE: Shims can be made from shim stock or similar materials of the required thickness. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Testing and Inspection > Page 3940 Bell Housing: Service and Repair CLUTCH HOUSING REMOVAL 1. Remove transmission (2) and transfer case. 2. Remove starter from clutch housing. 3. Remove structural dust cover bolts from clutch housing. CAUTION: Do not remove structural dust cover from engine block. If cover is removed clutch housing and cover must be aligned with the engine. 4. Remove clutch housing (1) bolts and remove housing from the engine. INSTALLATION 1. Clean housing mounting surface of engine block (1) with wax and grease remover. 2. Verify that clutch housing alignment dowels are in good condition and properly seated. 3. Transfer slave cylinder, release fork and boot, fork pivot stud and wire/hose brackets to new housing (3). 4. Install structural dust cover (4) if removed. 5. Align and install clutch housing (3) on engine (1). Tighten housing bolts across the top of the housing first and to the following torque values: - "A" bolts 1/4in. diameter - 4.5 Nm (40 inch lbs.) - "A" bolts 3/8in. diameter - 40 Nm (30 ft. lbs.) - "A" bolts 7/16in. diameter - 68 Nm (50 ft. lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Testing and Inspection > Page 3941 - "B" bolts for 5.7L 5.9L TD/8.0L engines - 47.5 Nm (40 ft. lbs.) - "C" bolts for 5.7L engine - 68 Nm (50 ft. lbs.) - "C" bolts for 5.9L TD engine - 47.5 Nm (35 ft. lbs.) - "C" bolts for 8.0L engine - 74.5 Nm (55 ft. lbs.) 6. Install starter to clutch housing. 7. Install transmission and transfer case, if equipped. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Tremec T56 Manual Transmission ........................................................................................................................................................ 2.27 Liters (4.8 pts.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 3946 Fluid - M/T: Fluid Type Specifications Tremec T56 ................................................................................ Mopar Synthetic Manual Transmission Lubricant 75W/85 (Castrol Syntorq LT 75W/85) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Page 3947 Fluid - M/T: Service and Repair T56 TRANSMISSION DRAIN AND FILL 1. Raise and support vehicle. 2. Remove drain plug (1) on transmission tail housing and drain fluid. 3. Install drain plug. 4. Remove transmission fill plug on left side of the transmission case. 5. Fill transmission with Mopar(R) Synthetic Manual Trans Lubricant 75W-85. The transmission is full when the fluid level is even with the bottom of the fill hole. 6. Install transmission fill plug. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear Lockout > System Information > Locations Manual Transmission (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear Lockout > System Information > Locations > Page 3951 Solenoid-Reverse Lock-Out (SRT M/T) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair Input Shaft: Service and Repair SHAFT-INPUT REMOVAL NOTE: If input shaft is damaged behind the seal, the transmission must be disassembled and inspected. 1. Remove transmission from the vehicle. 2. Measure output shaft end play and record number. 3. Remove clutch slave cylinder from transmission adapter plate 4. Remove front adapter plate bolts. 5. Pry front cover adapter loose. 6. Hold input shaft while removing adapter. 7. Remove seal from transmission adapter. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Page 3955 8. Clean and inspect all sealing surfaces for wear or damage. 9. Lift cluster shaft slightly and remove input shaft from transmission. 10. Remove input shaft bearing with Splitter P-334 and a press. INSTALLATION 1. Install new seal from the fluid side with Installer 9366. 2. Install input shaft bearing on shaft with Installer 6052 and Installer MB-991317. 3. Install new bearing cup in front adapter with original shim behind cup. 4. Clean sealing surfaces of the transmission case and adapter plate. 5. Install new input shaft and adapter plate (without any Mopar(R)Gasket Maker). 6. Check output shaft end play. It should be the same as measured during the disassemble procedure. If end play is greater than original reading, install a thicker shim. If end play is less than original reading, install a thinner shim. 7. After the correct shim has been installed, remove the adapter plate and apply Mopar(R) Gasket Maker to the sealing surfaces. 8. Install adapter and tighten adapter bolts to 34 Nm (25 ft. lbs.). 9. Install transmission. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair Seals and Gaskets: Service and Repair SEAL-EXTENSION HOUSING REMOVAL NOTE: If extension housing slip yoke bushing is worn the housing must be replaced, 1. Remove propeller shaft. 2. Remove seal with a seal pick. 3. Clean and inspect extension housing where the seal was located. INSTALLATION 1. Install seal into extension housing with Installer 9372 and Handle C-4171. 2. Install propeller shaft. 3. Check transmission fluid level. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3965 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3966 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3967 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3968 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3969 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3970 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3971 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3972 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3973 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3974 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3975 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3976 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3977 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3978 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3979 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3980 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3981 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3982 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3983 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3984 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control Transmission Control System Relay: Description and Operation Relay-Transmission Control RELAY-TRANSMISSION CONTROL 45RFE/545RFE DESCRIPTION NOTE: The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control > Page 3987 Transmission Control System Relay: Description and Operation 45RFE 4 Speed TRANSMISSION CONTROL RELAY - 45RFE/545RFE Automatic Transmission DESCRIPTION NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control > Page 3988 Transmission Control System Relay: Description and Operation 48RE Automatic Transmission The Chrysler Corporation does not list a Transmission Control Relay for the 48RE Automatic Transmission. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Band Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Control Solenoid Valve: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Band Control Solenoid Valve: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Band Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Control Solenoid Valve: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Band Control Solenoid Valve: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch Control Solenoid Valve: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Clutch Control Solenoid Valve: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Clutch Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Control Solenoid Valve: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Clutch Control Solenoid Valve: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Technical Service Bulletins > Customer Interest for Overdrive Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls False Solenoid DTC's Set Overdrive Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Overdrive Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Overdrive Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Pressure Regulating Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Pressure Regulating Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls False Solenoid DTC's Set Shift Interlock Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Shift Interlock Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Shift Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Shift Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Throttle Valve Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls False Solenoid DTC's Set Throttle Valve Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Valve Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Throttle Valve Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Torque Converter Clutch Solenoid: Customer Interest A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Torque Converter Clutch Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this model. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. The VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator VFD displays the following characters from left to right: "P," "R," "N," "D," "2," and "1". Respectively, these characters represent the park, reverse, neutral, drive, second gear, and first gear positions of the transmission gear selector lever on the steering column. The VFD illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps Off) the gear selector VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are On), the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned On during daylight hours. The gear selector indicator VFD is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission and automatic transmission model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by a dedicated Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the Off position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Programmable Communications Interface (PCI) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gear selector indicator VFD will display all of its characters at once during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On models with a TCM, the TCM continually monitors the transmission range sensor, then sends the proper gear selector indicator position messages to the instrument cluster. On models without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. On models with a TCM, for proper diagnosis of the transmission range sensor, the TCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions > Page 4107 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions > Page 4108 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions > Page 4109 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions > Page 4110 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions > Page 4111 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions > Page 4112 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions > Page 4113 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions > Page 4114 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions > Page 4115 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions > Page 4116 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions > Page 4117 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions > Page 4118 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions > Page 4119 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions > Page 4120 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions > Page 4121 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions > Page 4122 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions > Page 4123 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions > Page 4124 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions > Page 4125 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Diagrams > Diagram Information and Instructions > Page 4126 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > Relay-Transmission Control Transmission Control System Relay: Description and Operation Relay-Transmission Control RELAY-TRANSMISSION CONTROL 45RFE/545RFE DESCRIPTION NOTE: The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > Relay-Transmission Control > Page 4129 Transmission Control System Relay: Description and Operation 45RFE 4 Speed TRANSMISSION CONTROL RELAY - 45RFE/545RFE Automatic Transmission DESCRIPTION NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 > Description and Operation > Relay-Transmission Control > Page 4130 Transmission Control System Relay: Description and Operation 48RE Automatic Transmission The Chrysler Corporation does not list a Transmission Control Relay for the 48RE Automatic Transmission. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Locations ABS Light: Locations The ABS indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Locations > Page 4136 ABS Light: Description and Operation ABS INDICATOR An Antilock Brake System (ABS) indicator is standard equipment on all instrument clusters. However, the instrument cluster can be programmed to disable this indicator on vehicles that are not equipped with the ABS or Rear Wheel Anti-Lock (RWAL) brake systems, which are not available in some markets. On vehicles equipped with a gasoline engine, the ABS indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. On vehicles equipped with a diesel engine, the ABS indicator is located on the right side of the instrument cluster, to the right of the engine temperature gauge. The ABS indicator consists of a stencillike cutout of the International Control and Display Symbol icon for "Failure of Anti-lock Braking System" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ABS indicator is serviced as a unit with the instrument cluster. The ABS indicator gives an indication to the vehicle operator when the ABS system is faulty or inoperative. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Programmable Communications Interface (PCI) data bus. The ABS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (RUN/START) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the ABS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the ABS indicator is illuminated by the cluster for about two seconds as a bulb test. - ABS Lamp-On Message - Each time the cluster receives a lamp-on message from the CAB, the ABS indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB, or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster receives no lamp-on or lamp-off messages from the CAB for three consecutive seconds, the ABS indicator is illuminated. The indicator remains illuminated until the cluster receives a valid message from the CAB, or until the ignition switch is turned to the Off position, whichever occurs first. Actuator Test - Each time the instrument cluster is put through the actuator test, the ABS indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. - ABS Diagnostic Test - The ABS indicator is blinked on and off by lamp-on and lamp-off messages from the CAB during the performance of the ABS diagnostic 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 lamp-on or lamp-off messages to the instrument cluster. If the CAB sends a lamp-on message after the bulb test, it indicates that the CAB has detected a system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ABS indicator fails to light due to an open or short in the cluster ABS indicator circuit, the cluster sends a message notifying the CAB of the condition, then the instrument cluster and the CAB will each store a DTC. For proper diagnosis of the antilock brake system, the CAB, the PCI data bus, or the electronic message inputs to the instrument cluster that control the ABS indicator, a DRBIII scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations Braking Sensor/Switch: Locations Fig.26 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations > Page 4140 Fig.28 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations > Page 4141 Fig.31 Left Side Engine Compartment and Hood Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations EBC 125 (RWAL) EBC 325 (ABS) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4148 Electronic Brake Control Module: Diagrams Controller Antilock Brake C1 Controller Antilock Brake C2 (ABS) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4149 Electronic Brake Control Module: Description and Operation Fig.1 Hydraulic Control Unit CONTROLLER ANTILOCK BRAKE (CAB) The Controller Antilock Brake (CAB) is mounted to the Hydraulic Control Unit (HCU) and operates the ABS system. The CAB voltage source is through the ignition switch in the RUN position. 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 III 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 is being replaced with a new CAB is must be reprogrammed with the use of a DRB III. TRW EBC 125 CONTROLLER ANTILOCK BRAKE The CAB includes a microprocessor and two solenoids that control the valves that control brake pressure during RWAL braking and circuits that: Monitor the brake switch input to tell whether or not to prepare for possible antilock braking - Monitor the brake fluid level switch input to tell whether or not the state of the hydraulics has a problem - Monitor the wheel speed sensor input to determine when a rear wheel is tending to lock up - Operate the integral hydraulic control unit (HCU) during antilock braking based on comparing the speed sensor to information programmed in memory - Detect RWAL system related problems and take diagnostic action - Able to execute self-tests and output control commands TRW EBC 325 CONTROLLER ANTILOCK BRAKE The CAB 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 ABS braking - Monitor the brake fluid level switch input to tell whether or not the state of the hydraulics has a problem - Wheel speed sensors are monitored to determine when a wheel is tending to lock up. The CAB will operate the valves in the HCU to control braking pressure during ABS braking - Detect ABS system related problems and take diagnostic action - Able to execute self-tests and output control commands Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4150 Electronic Brake Control Module: Service and Repair REMOVAL 1. Remove the negative battery cable from the battery. 2. Pull up on the CAB harness connector release and remove connector. 3. Remove the CAB mounting bolts. 4. Remove the pump connector from the CAB. 5. Remove the CAB from the HCU. INSTALLATION NOTE: If the CAB is being replaced with a new CAB is must be reprogrammed with the use of a DRB III. 1. Install CAB to the HCU. 2. Install the pump connector to the CAB. 3. Install mounting bolts. Tighten to 2 Nm (16 in. lbs.). 4. Install the wiring harness connector to the CAB and push down on the release to secure the connector. 5. Install negative battery cable to the battery. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications ABS Assembly Mounting Bolts ............................................................................................................ .................................................... 15 Nm (11 ft. lbs.) ABS Assembly CAB Screws ............................. ..................................................................................................................................... 3.5 Nm (31 in. lbs.) ABS Assembly Brake Line Fittings ....................................................................................................................................................... 19 Nm (170 in. lbs.) Controller Mounting Screws ..................................................................................... ................................................................................. 6 Nm (53 in. lbs.) RWAL Module Mounting Bolts ..................................................................................................................................................... .......... 15 Nm (11 ft. lbs.) RWAL Valve Brake Line Fittings .......................................................................................................................................................... 19 Nm (170 in. lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) Hydraulic Control Assembly - Antilock Brakes: Description and Operation HCU (Hydraulic Control Unit) HYDRAULIC CONTROL UNIT DESCRIPTION The HCU consists of a valve body, pump motor, low pressure accumulators, inlet valves, outlet valves and noise attenuators. The HCU on the EBC 125 has an integral valve body for controlling the front and rear Brakes. The HCU on the EBC 325 has an integral valve body 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(s) is/are normally open, allowing unrestricted flow from the master cylinder to the wheels. When the CAB determines antilock intervention is required, the valve(s) close to isolate the master cylinder hydraulic circuit(s). Fluid is trapped in the circuit(s) and then prevented from reaching the wheels. The Dump Valve(s) is/are pulsed on and off by the CAB. The valve(s) 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 dump valve is off, fluid is allowed to the wheel. The Brake Return Check Valve allows the HCU to drain faster after the antilock activation, when the brake is released. The Reset Switch is used in the EBC 125 (RWAL) system only. The 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 antilock 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 DTC if incorrect pressure is detected on the EBC 125 (RWAL) antilock system when not in an ABS event. When the brakes are applied, fluid is forced from the master cylinder outlet port(s) to the HCU inlet ports(s). This pressure is transmitted through normally open isolation valve(s) inside the HCU, then through the outlet port(s) 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 wheel speed sensor(s) 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 action dumps any pressure that is trapped between the normally open valve and the brake back into an accumulator. Once the affected wheel 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, there is a pump/motor unit, two accumulators, three isolated valves, and three dump valves which are used to provide rapid response during the reapply sequence and to minimize pedal feedback due to the increased hydraulic circuits. OPERATION Accumulators in the valve body store extra fluid released to the system for ABS mode operation. The pump provides the fluid volume needed and is operated by a DC type motor. The motor is controlled by the CAB. The valves modulate brake pressure during antilock braking and are controlled by the CAB. 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. 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. NOTE: The three modes mentioned below do occur but not necessarily in the order listed everytime. During antilock braking, solenoid valve pressure modulation occurs in three stages, pressure increase, pressure hold, and pressure decrease. The valves are all contained in the valve body portion of the HCU. Pressure Decrease The outlet valve is opened and the inlet valve is closed 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 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. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) > Page 4156 Pressure Hold Both solenoid valves are closed in the pressure hold cycle but only the inlet valve is energized. 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 reapply the brakes. This cycle controls re-application of fluid apply pressure. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) > Page 4157 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Rear Wheel Antilock (RWAL) Valve DESCRIPTION Rear Wheel Antilock (RWAL) brake system is standard equipment on 1500 series vehicles. The RWAL brake system is designed to prevent rear wheel lock-up on virtually all types of road surfaces. RWAL braking is desirable because a vehicle, which is stopped without locking the rear wheels, will retain directional stability. This allows the driver to retain greater control of the vehicle during braking. The valve is located on the drivers side inner fender under the hood. The valve modulates hydraulic pressure to the rear brakes. The RWAL components include: RWAL Valve - Controller Antilock brake (CAB) - Rear Wheel Speed Sensor (WSS) OPERATION When the brakes are applied, hydraulic fluid is routed from the master cylinder's secondary circuit to the RWAL valve. From there hydraulic fluid is routed to the rear brakes. The Controller Antilock Brake (CAB) contains an Electronic Variable Brake Proportioning (EVBP) control algorithm, which proportions the applied braking force to the rear wheels during braking. The EVBP function of the RWAL system takes the place of a conventional hydraulic proportioning valve. The CAB monitors the rear wheel speed through the rear wheel speed sensor and calculates an estimated vehicle deceleration. When an established deceleration threshold is exceeded, an isolation valve is closed to hold the applied brake pressure to the rear brakes constant. Upon further increases in the estimated vehicle deceleration, the isolation valve is selectively opened to increase rear brake pressure in proportion to the front brake pressure. If impending rear wheel lock-up is sensed, the CAB signals the RWAL valve to modulate hydraulic brake pressure to the rear wheels to prevent lock-up. NORMAL BRAKING Since the RWAL valve also performs the EVBP or proportioning function, vehicle deceleration under normal braking may be sufficient to trigger the EVBP function of the RWAL system without full RWAL activity as would normally occur during an impending rear wheel lock-up. As previously mentioned, the isolation valve is selectively closed and opened to increase rear brake pressure in proportion to the front brake pressure under EVBP control. Slight brake pedal pulsations may be noticed as the isolation valve is opened. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > HCU (Hydraulic Control Unit) Hydraulic Control Assembly - Antilock Brakes: Service and Repair HCU (Hydraulic Control Unit) REMOVAL 1. Install a prop rod on the brake pedal to keep pressure on the brake system. 2. Disconnect the battery cables from the battery. 3. Remove the battery. 4. Disconnect the two electrical harness connectors. 5. Remove the five brake lines from the HCU. 6. Remove HCU/CAB mounting bolts and remove the HCU/CAB. INSTALLATION NOTE: If the CAB is being replaced with a new CAB is must be reprogrammed with the use of a DRB III. 1. Install HCU/CAB on the mounts and tighten the bolts to 15 Nm (11 ft. lbs.). 2. Install the five brake lines to the HCU and tighten to 19 Nm (170 in. lbs.). 3. Install the two electrical harness connectors to the HCU/CAB and push down on the release to secure the connectors. 4. Install the battery. 5. Install the battery cables to the battery. 6. Remove the prop rod on the brake pedal. 7. Bleed ABS brake system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > HCU (Hydraulic Control Unit) > Page 4160 Hydraulic Control Assembly - Antilock Brakes: Service and Repair RWAL Valve REMOVAL 1. Install a prop rod on the brake pedal to keep pressure on the brake system. 2. Disconnect the battery cables from the battery. 3. Remove the battery. 4. Disconnect the electrical harness connector. 5. Remove the brake lines from the RWAL valve. 6. Remove RWAL valve mounting nuts and remove the RWAL valve. INSTALLATION 1. Install RWAL valve and tighten the nuts to 15 Nm (11 ft. lbs.). 2. Install the brake lines to the RWAL valve and tighten to 19 Nm (170 in. lbs.). 3. Install the electrical harness connector to the RWAL valve and secure the connector. 4. Install the battery. 5. Install the battery cables to the battery. 6. Remove the prop rod on the brake pedal. 7. Bleed ABS brake system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Wheel Speed Sensors Front Sensor Bolt ................................................................................................................................................ 21 Nm (190 in. lbs.) Wheel Speed Sensors Bracket To Knuckle ............................................................................................................................................. 6.7 Nm (60 in. lbs.) Wheel Speed Sensors Rear Sensor Stud ............................................................................................................................................. 22.5 Nm (200 in. lbs.) Rear Wheel Speed Sensor Mounting Bolt .............................................................................................................................................. 24 Nm (200 in. lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 WHEEL SPEED SENSORS/TONE WHEELS Front Rear Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4166 Wheel Speed Sensor: Connector Locations Fig.25 Right Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4167 Fig.26 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4168 Fig.31 Left Side Engine Compartment and Hood Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4169 Fig.49 Rear Chassis Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 4170 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor (ABS) Rear Wheel Speed Sensor (ABS) Right Front Wheel Speed Sensor (ABS) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 4171 Wheel Speed Sensor: Description and Operation WHEEL SPEED SENSORS The EBC 125 (RWAL) system uses only one speed sensor mounted in the rear axle for the rear wheels. The EBC 325 (ABS) system uses one wheel speed sensor on each front wheel, and one 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 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 CAB takes control for antilock action through the HCU. Diagnostically, the coils of the wheel speed sensors have different amounts of resistance based upon the location. When measured across the connector two terminals, the resistance should be: Front sensor: 90 °C (194 °F) ..................................................................................................................................... ........................................... 2259 - 2761 Ohms 25 °C (77 °F) ............................................................. ..................................................................................................................... 1800 - 2200 Ohms -40 °C (-40 °F) ........................................................................................................................................... .................................... 1332 - 1628 Ohms Rear sensor: 90 °C (194 °F) ..................................................................................................................................... ........................................... 2900 - 3600 Ohms 25 °C (77 °F) ............................................................. ..................................................................................................................... 1600 - 2300 Ohms -40 °C (-40 °F) ........................................................................................................................................... ..................................... 1000 - 1400 Ohms NOTE:For all resistance ranges add 30% to the value for extreme heat, subtract 30% for extreme cold. On a EBC 325 (ABS) system each front wheel speed is monitored through the speed sensor mounted at the wheel end of the hub. On the EBC 125 (RWAL) and EBC 325 (ABS) systems the rear wheel speed is monitored through the speed sensor mounted in the rear axle assembly. The CAB will disable antilock control, illuminate the amber ABS warning indicator circuit via the PCI BUS, and store diagnostic 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 DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front hub/bearings. The third sensor is mounted on top of the rear axle differential housing. OPERATION The Wheel Speed Sensor consists of a magnet surrounded by windings from a single strand of wire. The sensor sends a small AC signal to the CAB. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) passes the stationary magnetic WSS. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 4172 When the ring gear is rotated, the exciter ring passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings. This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated. Each AC signal (positive to negative signal or sinewave) is interpreted by the CAB. It then compares the frequency of the sinewave to a time value to calculate vehicle speed. The CAB continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: Magnetic field strength; the stronger the magnetic field, the stronger the signal - Number of windings in the sensor; more windings provide a stronger signal - Exciter ring speed; the faster the exciter ring/ tone wheel rotates, the stronger the signal will be - Distance between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be The rear WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 inch. The assembly plant performs a "Rolls Test" on every vehicle that leaves the assembly plant. One of the test performed is a test of the WSS. To properly test the sensor, the assembly plant connects test equipment to the Data Link Connector (DLC). This connector is located to the right of the steering column and attached to the lower portion of the instrument panel. The rolls test terminal is spliced to the WSS circuit. The vehicle is then Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 4173 driven on a set of rollers and the WSS output is monitored for proper operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 4174 Wheel Speed Sensor: Testing and Inspection DIAGNOSIS AND TESTING - REAR WHEEL SPEED SENSOR Diagnosis of base brake conditions, which are mechanical in nature, should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The Antilock brake system performs several self tests every time the ignition switch is turned on and the vehicle is driven. The CAB monitors the system inputs and outputs circuits to verify the system is operating properly. If the CAB senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: The MDS or ORB 111 scan tool is used to diagnose the Antilock Brake system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front REMOVAL 1. Remove the front rotor. 2. Remove the wheel speed sensor mounting bolt from the hub. 3. Remove the wheel speed sensor from the hub. 4. Remove the wiring from the clips and disconnect the electrical connector. INSTALLATION 1. Install the wiring to the clips and Reconnect the electrical connector. 2. Install the wheel speed sensor to the hub. 3. Install the wheel speed sensor mounting bolt to the hub. Tighten the bolt to 21 Nm (190 in. lbs.). 4. Install the front rotor and brake caliper assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4177 Wheel Speed Sensor: Service and Repair Rear REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the brake line mounting nut and remove the brake line from the sensor stud. 3. Remove the mounting stud from the sensor and shield. 4. Remove the sensor and shield from the differential housing. 5. Disconnect the sensor wire harness and remove the sensor. INSTALLATION 1. Connect the harness to the sensor. Be sure the seal is securely in place between the sensor and the wiring connector. 2. Install the O-ring on the sensor (if removed). 3. Insert the sensor in the differential housing. 4. Install the sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (200 in. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding Brake Bleeding: Service and Repair Hydraulic Brake Booster Bleeding STANDARD PROCEDURE - BLEEDING The hydraulic booster is generally self-bleeding, this procedure will normally bleed the air from the booster. Normal driving and operation of the unit will remove any remaining trapped air. 1. Fill power steering pump reservoir. 2. Disconnect fuel shutdown relay and crank the engine for several seconds. 3. Check fluid level and add if necessary. 4. Connect fuel shutdown relay and start the engine. 5. Turn the steering wheel slowly from lock to lock twice. 6. Stop the engine and discharge the accumulator by depressing the brake pedal 5 times. 7. Start the engine and turn the steering wheel slowly from lock to lock twice. 8. Turn off the engine and check fluid level and add if necessary. NOTE: If fluid foaming occurs, wait for foam to dissipate and repeat steps 7 and 8. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding > Page 4182 Brake Bleeding: Service and Repair Master Cylinder Bleeding STANDARD PROCEDURE - MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports. Then position each tube end into 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding > Page 4183 Brake Bleeding: Service and Repair Base Brake System STANDARD PROCEDURE - MANUAL BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J 1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 1. Remove reservoir filler caps and fill reservoir. 2. If calipers, 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. 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. STANDARD PROCEDURE - PRESSURE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J 1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15 - 20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding > Page 4184 Brake Bleeding: Service and Repair Antilock Brake System STANDARD PROCEDURE - ABS BRAKE BLEEDING 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 ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Brake Pedal Assembly Bracket Nuts ........................................................................................................................................................ 28 Nm (21 ft. lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 4188 Brake Pedal Assy: Description and Operation DESCRIPTION NOTE: The brake pedal is serviced as a complete assembly including accelerator pedal and the bracket. A suspended-type brake pedal is used. The pedal is attached to the pedal support bracket with a pivot shaft pin and bushings. If the bushings become dry a spray lubricant can be used to eliminate noises. The booster push rod is attached to the pedal with a clip. The pedal, bushings, pivot pin and support bracket are not serviceable components. OPERATION The brake pedal is attached to the booster push rod. When the pedal is depressed, the primary booster push rod is depressed which move the booster secondary rod. The booster secondary rod depress the master cylinder piston. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 4189 Brake Pedal Assy: Service and Repair REMOVAL NOTE: The brake pedal is serviced as a complete assembly including accelerator pedal and the bracket. 1. Disconnect the negative battery cable. 2. Remove the steering column opening cover. 3. Remove the brake lamp switch and discard. 4. On vehicles equipped with adjustable pedals. Disconnect the adjuster cable to the pedal. 5. Remove the steering column. 6. Remove the brake booster. 7. Disconnect the electrical connectors. 8. Remove the module mounting bolts. 9. Disconnect the accelerator pedal cable. 10. Remove the pedal assembly mounting nuts/ fasteners. INSTALLATION 1. Install the pedal assembly to the vehicle. 2. Install the mounting bolts and tighten to 28 Nm (21 ft. lbs.). 3. Reconnect the accelerator cable to the pedal. 4. Install the module mounting bolts and tighten to 38 Nm (28 ft. lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 4190 5. Reconnect the electrical connectors. 6. Install the brake booster. 7. Install the steering column. 8. Install a new brake lamp switch. 9. On vehicles equipped with adjustable brake pedal. Reconnect the electrical connector to the motor and the adjuster cable at the pedal. 10. Install the steering column opening cover. 11. Reconnect the negative battery cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Service Precautions Brake Warning Indicator: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Service Precautions > Page 4194 Brake Warning Indicator: Description and Operation ABS WARNING INDICATOR AND RED BRAKE WARNING INDICATOR (EBC 125 AND EBC 325) The system is equipped with an amber ABS and a red Brake warning indicator to alert the driver of a malfunction it has detected. The CAB can signal the operation of both the amber ABS warning indicator and the red Brake warning indicator via PCI BUS. The CAB controls the ABS warning indicator by making it do one of three things: Light steady for 3.4 seconds during an initial test at the beginning of an ignition cycle to function as a bulb check. - Light steady when a system malfunction exists. - Flash if a vehicle tooth or tire parameter is faulty or missing. The Instrument Cluster controls the amber antilock brake system warning indicator. All Dodge Truck Instrument Clusters have direct control over the ABS warning indicator and Brake warning indicator. The Instrument Cluster transmits a message over the PCI BUS relating to diagnostics and current lamp status for the ABS and Brake indicator. The Instrument Cluster will expect a PCI BUS message back from the CAB indicating whether the indicator should be turned on or off. In the event that no signal is received from the CAB for a certain number of time, the Instrument Cluster will illuminate the ABS warning indicator. The indicator provides notice of ABS system-related problems and the need to take diagnostic action. The vehicle Instrument Cluster has a red Brake warning indicator to alert the driver to the following conditions: Brake fluid level low - Parking Brake applied - ABS system malfunction The Instrument Cluster controls the red Brake warning indicator. There is a parallel path to chassis ground that will illuminate the red Brake warning indicator: Through the parking Brake switch contacts - Through the Brake fluid level switch - Through the CAB via PCI BUS The CAB can control the operation of both the amber ABS warning indicator and the red Brake warning indicator: If the CAB is disconnected, the amber ABS warning indicator and red Brake warning indicator will be illuminated - If the axle type or tire size are not programmed properly, the amber indicator will blink - If any Foundation Brake system problem exists - If any ABS system DTC is set, both the amber and red indicators will be illuminated The ABS Enabling Strategy (FMVSS105) is for vehicles above 10,000-lbs. gross vehicle weight. This allows different operators to be alerted that an ABS fault existed in the last ignition cycle. When the ignition is cycled to the ON position the ABS system will be disabled if the vehicle speed was zero on the last ignition cycle. The disabled ABS system will illuminate the amber ABS and red BRAKE warning lamps until the vehicle speed reaches 7 km/h (4 mph)then the amber ABS and red BRAKE warning lamps will extinguish. If an ABS fault exists; the ABS is still disabled, the amber ABS and red BRAKE warning lamps will still be illuminated, and a CAB DTC is then set. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Service Precautions > Page 4195 Brake Warning Indicator: Testing and Inspection BRAKE INDICATOR The diagnosis found here addresses an inoperative brake indicator condition. If there are problems with several indicators in the instrument cluster, refer to Instrument Cluster Diagnosis And Testing. If no brake system problem is found, the following procedures will help to locate a shorted or open circuit, or a faulty park brake switch input. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Indicator Illuminates During Bulb Test, But Does Not When Park Brake Applied 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. Indicator Remains Illuminated - Brake System Checks Ok 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 4200 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 4201 Brake Caliper: Description and Operation DESCRIPTION The calipers are a single piston type in the rear and dual piston type in the front. The calipers are free to slide laterally, this allows continuous compensation for lining wear. OPERATION Disc Brake Caliper When the brakes are applied fluid pressure is exerted against the caliper piston. The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal. Fluid pressure applied to the piston is transmitted directly to the inboard brake pad. This forces the pad lining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bore forces the caliper to slide inward on the mounting bolts. This action brings the outboard brake pad lining into contact with the outer surface of the disc brake rotor. In summary, fluid pressure acting simultaneously on both piston and caliper, produces a strong clamping action. When sufficient force is applied, friction will attempt to stop the rotors from turning and bring the vehicle to a stop. Application and release of the brake pedal generates only a very slight movement of the caliper and piston. Upon release of the pedal, the caliper and piston return to a rest position. The brake pads do not retract an appreciable distance from the rotor. In fact, clearance is usually at, or close to zero. The reasons for this are to keep road debris from getting between the rotor and lining and in wiping the rotor surface clear each revolution. The caliper piston seal controls the amount of piston extension needed to compensate for normal lining wear. Fig. 2 Piston Seal Function During brake application, the seal is deflected outward by fluid pressure and piston movement. When the brakes (and fluid pressure) are released, the seal relaxes and retracts the piston. The amount of piston retraction is determined by the amount of seal deflection. Generally the amount is just enough to maintain contact between the piston and inboard brake pad. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper Brake Caliper: Service and Repair Disc Brake Caliper Front REMOVAL - FRONT CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose with result. Provide a suitable support to hang the caliper securely. 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Compress the disc brake caliper. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4204 4. Remove the banjo bolt and discard the copper washer. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4205 5. Remove the caliper slide pin bolts. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4206 6. Remove the disc brake caliper. INSTALLATION - FRONT NOTE: Install a new copper washers on the banjo bolt when installing 1. Install the disc brake caliper. CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. 2. Install the banjo bolt with new copper washers to the caliper. Tighten to 27 Nm (20 ft. lbs.) 3. Install the caliper slide pin bolts tighten to 32 Nm (24 ft. lbs.) 4. Bleed the base brake system. 5. Install the tire and wheel assembly. 6. Lower the vehicle. Rear REMOVAL - REAR 1. Raise and support vehicle. 2. Remove the wheel and tire assembly. 3. Compress the disc brake caliper using tool #C4212F. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4207 4. Remove the brake hose banjo bolt if replacing caliper. 5. Remove the caliper mounting slide pin bolts). 6. Remove the caliper from vehicle. INSTALLATION - REAR 1. Install caliper to the caliper adapter. 2. Coat the caliper mounting slide pin bolts with silicone grease. Then install and tighten the bolts to 30 Nm (22 ft. lbs.). 3. Install the brake hose banjo bolt if removed. 4. Install the brake hose to the caliper with new seal washers and tighten fitting bolt to 27 Nm (245 in. lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4208 CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. 5. Bleed the base brake system. 6. Install the wheel and tire assemblies. 7. Remove the supports and lower the vehicle. 8. Verify a firm pedal before moving the vehicle. 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4209 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. 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. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4210 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 in.). ASSEMBLY CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. 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. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4211 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 6. Seat dust boot in caliper with Handle C-4171 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 Mopar brake grease or Dow Corning 807 grease only. CAUTION: Use of alternative grease may cause damage to the boots seals. 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 grooves at either end of the bushing. 11. Install caliper bleed screw. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4212 Brake Caliper: Service and Repair Disc Brake Caliper Adapter Front REMOVAL - FRONT 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the disc brake caliper. 4. Remove the bolts securing the caliper adapter to the steering knuckle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4213 5. Remove the caliper adapter. INSTALLATION - FRONT 1. Install the caliper adapter to the steering knuckle . 2. Install the caliper adapter mounting bolts and tighten to 176 Nm (130 ft. lbs.). 3. Install the disc brake caliper. 4. Install the tire and wheel assembly. 5. Remove the support and lower the vehicle. Rear REMOVAL - REAR 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Drain a small amount of fluid from master cylinder brake reservoir with a clean suction gun. 4. Bottom the caliper pistons into the caliper by prying the caliper over. 5. Remove the caliper mounting bolts. 6. Remove the disc brake caliper from the mount. CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 7. Remove the inboard and outboard brake pads. 8. Remove the anti-rattle clips. 9. Remove the caliper adapter mounting bolts. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4214 10. Remove the caliper adapter. INSTALLATION - REAR 1. Install the caliper adapter mounting bolts. Tighten the mounting bolts to 135 Nm (100 ft. lbs.). 2. Install the anti-rattle clips. 3. Install the inboard and outboard pads. 4. Install the caliper mounting bolts. 5. Install the tire and wheel assembly Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4215 Brake Caliper: Service and Repair Disc Brake Caliper Adapter Mount REMOVAL - REAR 1. Remove wheel and tire assembly. 2. Remove the disc brake caliper. 3. Remove the caliper adapter. 4. Remove the rotor. 5. Remove the axle shaft. 6. Remove the park brake shoes. 7. Remove the parking brake cable from the brake lever. 8. Remove the bolts attaching the support plate to the axle and remove the support plate. 9. Remove the caliper adapter mount from the axle housing. INSTALLATION - REAR 1. Install the caliper adapter mount on the axle housing. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4216 2. Install support plate on axle flange. Tighten attaching bolts to 115 Nm (85 ft. lbs.). 3. Install parking brake cable in the brake lever. 4. Install the park brake shoes.. 5. Install axle shaft. 6. Adjust brake shoes to drum with brake gauge. 7. Install the rotor. 8. Install the caliper adapter. 9. Install the caliper. 10. Install wheel and tire assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair Brake Pad: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove the wheel and tire assemblies. 3. Compress the caliper. 4. Remove the caliper. 5. Remove the caliper by tilting the top up and off the caliper adapter. NOTE: Do not allow brake hose to support caliper assembly. 6. Support and hang the caliper. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Page 4220 7. Remove the inboard brake shoe from the caliper adapter. 8. Remove the outboard brake shoe from the caliper adapter. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Page 4221 Top Anti-Rattle Spring 9. Remove the anti-rattle springs from the caliper adapter. NOTE: Anti-rattle springs are not interchangeable. 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 mounting adapter and anti-rattle springs. 3. Lubricate anti-rattle springs with Mopar brake grease. 4. Install anti-rattle springs. NOTE: Anti-rattle springs are not interchangeable. 5. Install inboard brake shoe in adapter. 6. Install outboard brake shoe in adapter. 7. Tilt the top of the caliper over rotor and under adapter. Then push the bottom of the caliper down onto the adapter. 8. Install caliper. 9. Install wheel and tire assemblies and lower vehicle. 10. Apply brakes several times to seat caliper pistons and brake shoes and obtain firm pedal. 11. Top off master cylinder fluid level. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Base Brake Specifications Torque Specifications Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4225 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4226 Brake Rotor/Disc: Testing and Inspection ROTORS DIAGNOSIS AND TESTING DISC BRAKE ROTOR 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 with a disc brake lathe if surface scoring and wear are light. Replace the rotor for 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 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 Check rotor lateral runout with dial indicator C-3339 (1). Excessive lateral runout will cause brake pedal pulsation and rapid, uneven wear of the brake shoes. Position the dial indicator plunger approximately 25.4 mm (1 inch) inward from the rotor edge. NOTE: Be sure wheel bearing has zero end play before checking rotor runout. Maximum allowable rotor runout is 0.131 mm (0.005 inch) HD. Maximum allowable rotor runout is 0.050 mm (0.002 inch) LD. ROTOR THICKNESS VARIATION Variations in rotor thickness will cause pedal pulsation, noise and shudder. Measure rotor thickness at 6 to 12 points around the rotor face. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4227 Position the micrometer (1) approximately 25.4 mm (1 inch) from the rotor (2) outer circumference for each measurement. Thickness should not vary by more than 0.015 mm (0.0059 inch) from point-to-point on the rotor. Machine or replace the rotor if necessary. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Brake Rotor/Disc: Service and Repair Front Brake Rotor REMOVAL - FRONT 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the caliper from the steering knuckle and remove caliper adapter assembly. NOTE: Do not allow brake hose to support caliper adapter assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor > Page 4230 NOTE: Remove Hub Extension if equipped. Fig. 1 4. Remove the rotor from the hub/bearing wheel studs. INSTALLATION - FRONT 1. On models with all-wheel Antilock System (ABS), check condition of tone wheel on hub/bearing. If teeth on wheel are damaged, hub/bearing assembly will have to be replaced (tone wheel is not serviced separately). 2. Install the rotor onto the hub/bearing wheel studs. 3. Install the caliper adapter assembly and tighten adapter bolts to: 4. Install the wheel and tire assembly and lower the vehicle. 5. Apply the brakes several times to seat brake pads. Be sure to obtain firm pedal before moving vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor > Page 4231 Brake Rotor/Disc: Service and Repair Rear Brake Rotor Single Rear Wheels REMOVAL- REAR 1. Raise and support the vehicle 2. Remove the tire and wheel assembly. 3. Remove the disc brake caliper. 4. Remove the caliper adapter bolts. 5. Remove the retaining clips and rotor assembly. INSTALLATION- REAR 1. Install the rotor to the axle shaft. 2. Install the caliper adapter. 3. Install the caliper adapter bolts and tighten the mounting bolts to 135 Nm (100 ft. lbs.). 4. Install the disc brake caliper. 5. Install the tire and wheel assembly. 6. Lower the vehicle. Dual Rear Wheels ROTORS REMOVAL REAR DUAL WHEELS 1. Raise and support the vehicle 2. Remove the tire and wheel assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor > Page 4232 3. Remove the disc brake caliper. CALIPERS-DISC BRAKE REAR REMOVAL CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 1. Raise and support vehicle. 2. Remove the wheel and tire assembly. 3. Drain small amount of fluid from master cylinder brake reservoir with suction gun. 4. Remove the brake hose banjo bolt and discard the copper washers if replacing caliper. 5. Remove the caliper slide bolts (3). 6. Remove the caliper (6) from vehicle. 7. Remove the caliper adapter bolts. 8. Remove the rear axle shaft from the housing on dual rear wheels. 9. Remove the hub and rotor assembly (C3500 only). REAR - SRT-10 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor > Page 4233 1. Compress the disc brake caliper using tool #C4212F. 2. Remove the caliper pin bolts (3). 3. Remove the banjo bolt (6) and discard the copper washer. CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose with result. Provide a suitable support to hang the caliper securely. 4. Remove the rear disc brake caliper. INSTALLATION REAR DUAL WHEELS 1. Install the hub to the rotor. Tighten the bolts (1) to 128 Nm (95 ft. lbs.). 2. Install the hub and rotor assembly. 3. Install the rear axle shaft to the housing with dual wheels. 4. Install the caliper adapter bolts 197 Nm (145 ft. lbs.) LD. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor > Page 4234 5. Install the disc brake caliper. INSTALLATION REAR - SRT-10 NOTE: Install a new copper washers on the banjo bolt when installing 1. Install the rear disc brake caliper. 1. Ant-rattle clips 2. Disc Brake Caliper Adapter 3. Caliper slide Pin bolts 4. Caliper Adapter Bolts 5. Brake Hose 6. Banjo Bolt 2. Install the banjo bolt (6) with new copper washers to the caliper. tighten to 27 Nm (20 ft. lbs.). 3. Install the caliper pin bolts (3). tighten to 30 Nm (22 ft. lbs.). 4. Bleed the base brake system. 5. Install the tire and wheel assembly. See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement 6. Lower the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding Brake Bleeding: Service and Repair Hydraulic Brake Booster Bleeding STANDARD PROCEDURE - BLEEDING The hydraulic booster is generally self-bleeding, this procedure will normally bleed the air from the booster. Normal driving and operation of the unit will remove any remaining trapped air. 1. Fill power steering pump reservoir. 2. Disconnect fuel shutdown relay and crank the engine for several seconds. 3. Check fluid level and add if necessary. 4. Connect fuel shutdown relay and start the engine. 5. Turn the steering wheel slowly from lock to lock twice. 6. Stop the engine and discharge the accumulator by depressing the brake pedal 5 times. 7. Start the engine and turn the steering wheel slowly from lock to lock twice. 8. Turn off the engine and check fluid level and add if necessary. NOTE: If fluid foaming occurs, wait for foam to dissipate and repeat steps 7 and 8. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding > Page 4240 Brake Bleeding: Service and Repair Master Cylinder Bleeding STANDARD PROCEDURE - MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports. Then position each tube end into 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding > Page 4241 Brake Bleeding: Service and Repair Base Brake System STANDARD PROCEDURE - MANUAL BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J 1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 1. Remove reservoir filler caps and fill reservoir. 2. If calipers, 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. 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. STANDARD PROCEDURE - PRESSURE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J 1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15 - 20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Hydraulic Brake Booster Bleeding > Page 4242 Brake Bleeding: Service and Repair Antilock Brake System STANDARD PROCEDURE - ABS BRAKE BLEEDING 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 ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 4246 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 4247 Brake Caliper: Description and Operation DESCRIPTION The calipers are a single piston type in the rear and dual piston type in the front. The calipers are free to slide laterally, this allows continuous compensation for lining wear. OPERATION Disc Brake Caliper When the brakes are applied fluid pressure is exerted against the caliper piston. The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal. Fluid pressure applied to the piston is transmitted directly to the inboard brake pad. This forces the pad lining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bore forces the caliper to slide inward on the mounting bolts. This action brings the outboard brake pad lining into contact with the outer surface of the disc brake rotor. In summary, fluid pressure acting simultaneously on both piston and caliper, produces a strong clamping action. When sufficient force is applied, friction will attempt to stop the rotors from turning and bring the vehicle to a stop. Application and release of the brake pedal generates only a very slight movement of the caliper and piston. Upon release of the pedal, the caliper and piston return to a rest position. The brake pads do not retract an appreciable distance from the rotor. In fact, clearance is usually at, or close to zero. The reasons for this are to keep road debris from getting between the rotor and lining and in wiping the rotor surface clear each revolution. The caliper piston seal controls the amount of piston extension needed to compensate for normal lining wear. Fig. 2 Piston Seal Function During brake application, the seal is deflected outward by fluid pressure and piston movement. When the brakes (and fluid pressure) are released, the seal relaxes and retracts the piston. The amount of piston retraction is determined by the amount of seal deflection. Generally the amount is just enough to maintain contact between the piston and inboard brake pad. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper Brake Caliper: Service and Repair Disc Brake Caliper Front REMOVAL - FRONT CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose with result. Provide a suitable support to hang the caliper securely. 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Compress the disc brake caliper. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4250 4. Remove the banjo bolt and discard the copper washer. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4251 5. Remove the caliper slide pin bolts. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4252 6. Remove the disc brake caliper. INSTALLATION - FRONT NOTE: Install a new copper washers on the banjo bolt when installing 1. Install the disc brake caliper. CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. 2. Install the banjo bolt with new copper washers to the caliper. Tighten to 27 Nm (20 ft. lbs.) 3. Install the caliper slide pin bolts tighten to 32 Nm (24 ft. lbs.) 4. Bleed the base brake system. 5. Install the tire and wheel assembly. 6. Lower the vehicle. Rear REMOVAL - REAR 1. Raise and support vehicle. 2. Remove the wheel and tire assembly. 3. Compress the disc brake caliper using tool #C4212F. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4253 4. Remove the brake hose banjo bolt if replacing caliper. 5. Remove the caliper mounting slide pin bolts). 6. Remove the caliper from vehicle. INSTALLATION - REAR 1. Install caliper to the caliper adapter. 2. Coat the caliper mounting slide pin bolts with silicone grease. Then install and tighten the bolts to 30 Nm (22 ft. lbs.). 3. Install the brake hose banjo bolt if removed. 4. Install the brake hose to the caliper with new seal washers and tighten fitting bolt to 27 Nm (245 in. lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4254 CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. 5. Bleed the base brake system. 6. Install the wheel and tire assemblies. 7. Remove the supports and lower the vehicle. 8. Verify a firm pedal before moving the vehicle. 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4255 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. 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. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4256 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 in.). ASSEMBLY CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. 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. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4257 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 6. Seat dust boot in caliper with Handle C-4171 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 Mopar brake grease or Dow Corning 807 grease only. CAUTION: Use of alternative grease may cause damage to the boots seals. 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 grooves at either end of the bushing. 11. Install caliper bleed screw. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4258 Brake Caliper: Service and Repair Disc Brake Caliper Adapter Front REMOVAL - FRONT 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the disc brake caliper. 4. Remove the bolts securing the caliper adapter to the steering knuckle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4259 5. Remove the caliper adapter. INSTALLATION - FRONT 1. Install the caliper adapter to the steering knuckle . 2. Install the caliper adapter mounting bolts and tighten to 176 Nm (130 ft. lbs.). 3. Install the disc brake caliper. 4. Install the tire and wheel assembly. 5. Remove the support and lower the vehicle. Rear REMOVAL - REAR 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Drain a small amount of fluid from master cylinder brake reservoir with a clean suction gun. 4. Bottom the caliper pistons into the caliper by prying the caliper over. 5. Remove the caliper mounting bolts. 6. Remove the disc brake caliper from the mount. CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 7. Remove the inboard and outboard brake pads. 8. Remove the anti-rattle clips. 9. Remove the caliper adapter mounting bolts. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4260 10. Remove the caliper adapter. INSTALLATION - REAR 1. Install the caliper adapter mounting bolts. Tighten the mounting bolts to 135 Nm (100 ft. lbs.). 2. Install the anti-rattle clips. 3. Install the inboard and outboard pads. 4. Install the caliper mounting bolts. 5. Install the tire and wheel assembly Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4261 Brake Caliper: Service and Repair Disc Brake Caliper Adapter Mount REMOVAL - REAR 1. Remove wheel and tire assembly. 2. Remove the disc brake caliper. 3. Remove the caliper adapter. 4. Remove the rotor. 5. Remove the axle shaft. 6. Remove the park brake shoes. 7. Remove the parking brake cable from the brake lever. 8. Remove the bolts attaching the support plate to the axle and remove the support plate. 9. Remove the caliper adapter mount from the axle housing. INSTALLATION - REAR 1. Install the caliper adapter mount on the axle housing. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Disc Brake Caliper > Page 4262 2. Install support plate on axle flange. Tighten attaching bolts to 115 Nm (85 ft. lbs.). 3. Install parking brake cable in the brake lever. 4. Install the park brake shoes.. 5. Install axle shaft. 6. Adjust brake shoes to drum with brake gauge. 7. Install the rotor. 8. Install the caliper adapter. 9. Install the caliper. 10. Install wheel and tire assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Brake Fluid ............................................................................................................................................... Mopar DOT 3 and SAE J1703 should be used If DOT 3 brake fluid is not available, then DOT 4 or DOT 4+ is acceptable. Use only recommended brake fluids. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4266 Brake Fluid: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4267 Brake Fluid: Service and Repair STANDARD PROCEDURE - BRAKE FLUID LEVEL Always clean the master cylinder reservoir and caps before checking fluid level. If not cleaned, dirt could enter the fluid. The fluid fill level is indicated on the side of the master cylinder reservoir. The correct fluid level is to the MAX indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4271 Brake Fluid Level Switch Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4272 Brake Fluid Level Sensor/Switch: Description and Operation BRAKE FLUID LEVEL SWITCH CIRCUIT The switch signals the CAB for a hydraulic fluid problem. The antilock system uses input from the brake fluid level switch when activated. A low brake fluid condition in the master cylinder will close the switch circuit and read 0 volts. When the brake fluid level is at specifications, the switch will open and circuit sense voltage will read 5 volts. This signal tells the CAB if there is enough brake fluid in the master cylinder to have an antilock operation. The brake fluid level switch is located in the master cylinder with 10k resistor. The switch is a Hall effect design and uses a float to determine level. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Brake Line Fittings Master Cylinder ...................................................................................................................................................... 19 Nm (170 in. lbs.) Brake Line Fittings Junction Block ........................................................................................................................................................ 19 Nm (170 in. lbs.) Caliper Brake Line Banjo Bolt .................................................................................. ............................................................................... 27 Nm (20 ft. lbs.) Brake Hose Front Bolts To Frame ........................................................................................................................................................... 10 Nm (89 in. lbs.) Brake Hose Front Fitting ....................................................................................... ................................................................................. 19 Nm (170 in. lbs.) Brake Hose Rear Fitting .... .............................................................................................................................................................. ....... 19 Nm (170 in. lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tube Flaring Brake Hose/Line: Service and Repair Brake Tube Flaring STANDARD PROCEDURE - DOUBLE INVERTED FLARING A performed metal brake tube is recommended and preferred for all repairs. However, double-wall steel tube can be used for emergency repair when factory replacement parts are not readily available. 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 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. STANDARD PROCEDURE - ISO FLARING A reformed metal brake tube is recommended and preferred for all repairs. However, double-wall steel tube can be used for emergency repair when factory replacement parts are not readily available. To make a ISO flare use an ISO flaring tool kit. 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. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tube Flaring > Page 4278 4. Position the tube in the flaring tool flush with the top of the tool bar. Then tighten the tool bar on the tube. 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tube Flaring > Page 4279 Brake Hose/Line: Service and Repair Front Brake Hose REMOVAL - FRONT BRAKE HOSE 1. Install a prop rod on the brake pedal to keep pressure on the brake system. 2. Raise and support vehicle. 3. Remove the tire and wheel assembly. 4. Remove the brake hose from the brake line located at the frame. 5. Remove the brake hose banjo bolt at the caliper. 6. Remove the mounting bolt securing the brake hose to the frame and remove the wheel speed sensor wire from the brake hose. 7. Remove the hose. INSTALLATION - FRONT BRAKE HOSE 1. Install the hose. 2. Install the mounting bolt for the brake hose at the frame. 3. Install the brake hose banjo bolt at the caliper. 4. Reinstall the wheel speed sensor wire to the brake hose. 5. Remove the support and lower the vehicle. 6. Remove the prop rod from the brake pedal. 7. Bleed the brake system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tube Flaring > Page 4280 Brake Hose/Line: Service and Repair Rear Brake Hose REMOVAL - REAR BRAKE HOSE 1. Install prop rod on the brake pedal to keep pressure on the brake system. 2. Raise and support the vehicle. 3. Remove the brake line from the hose at the frame. 4. Remove the brake hose clip at the top of the hose located at the frame. 5. Remove the vent tube. 6. Remove the two brake lines at the bottom of the hose located at the axle. 7. Remove the mounting bolt for the brake hose at the axle. 8. Remove the hose. INSTALLATION - REAR BRAKE HOSE 1. Install the hose. 2. Install the mounting bolt for the brake hose at the axle. 3. Install the two brake lines at the bottom of the hose located at the axle. 4. Install the vent tube. 5. Install the brake hose clip at the top of the hose located at the frame. 6. Install the brake line to the hose at the frame. 7. Lower the vehicle and remove the support. 8. Remove the prop rod. 9. Bleed the brake system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tube Flaring > Page 4281 Brake Hose/Line: Service and Repair Rear Brake Lines REMOVAL - REAR TUBE / HOSE ASSEMBLY 1. Install prop rod on the brake pedal to keep pressure on the brake system. 2. Raise and support the vehicle. 3. Remove the brake line located at the axle. 4. Remove the mounting bolt for the brake hose at the axle. 5. Remove the banjo bolt at the caliper. 6. Remove the hose. INSTALLATION - REAR TUBE / HOSE ASSEMBLY 1. Install the hose. 2. Install the banjo bolt at the caliper. 3. Install the mounting bolt for the brake hose at the axle. 4. Install the brake line located at the axle. 5. Lower the vehicle and remove the support. 6. Remove the prop rod. 7. Bleed the brake system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 DESCRIPTION - ELECTRONIC VARIABLE BRAKE PROPORTIONING Vehicles equipped with ABS use Electronic Variable Brake Proportioning (EVBP) to balance front-to-rear braking. The EVBP is used in place of a rear proportioning valve. The EVBP system uses the ABS system to control the slip of the rear wheels in partial braking range. The braking force of the rear wheels is controlled electronically by using the inlet and outlet valves located in the Integrated Control Unit (ICU). OPERATION - ELECTRONIC VARIABLE BRAKE PROPORTIONING EVBP is able to decrease, hold and increase rear brake pressure without activating full ABS control. Upon entry into EVBP the inlet valve for the rear brake circuit is switched on so that the fluid supply from the master cylinder is shut off. In order to decrease the rear brake pressure, the outlet valve for the rear brake circuit is pulsed. This allows fluid to enter the Low Pressure Accumulator (LPA) in the Hydraulic Control Unit (HCU) resulting in a drop in fluid pressure to the rear brakes. In order to increase the rear brake pressure, the outlet valve is switched off and the inlet valve is pulsed. This increases the pressure to the rear brakes. The EVBP will remain functional during many ABS fault modes. If both the red BRAKE and amber ABS warning indicators are illuminated, the EVBP may not be functioning. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications ABS Assembly Mounting Bolts ............................................................................................................ .................................................... 15 Nm (11 ft. lbs.) ABS Assembly CAB Screws ............................. ..................................................................................................................................... 3.5 Nm (31 in. lbs.) ABS Assembly Brake Line Fittings ....................................................................................................................................................... 19 Nm (170 in. lbs.) Controller Mounting Screws ..................................................................................... ................................................................................. 6 Nm (53 in. lbs.) RWAL Module Mounting Bolts ..................................................................................................................................................... .......... 15 Nm (11 ft. lbs.) RWAL Valve Brake Line Fittings .......................................................................................................................................................... 19 Nm (170 in. lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) Hydraulic Control Assembly - Antilock Brakes: Description and Operation HCU (Hydraulic Control Unit) HYDRAULIC CONTROL UNIT DESCRIPTION The HCU consists of a valve body, pump motor, low pressure accumulators, inlet valves, outlet valves and noise attenuators. The HCU on the EBC 125 has an integral valve body for controlling the front and rear Brakes. The HCU on the EBC 325 has an integral valve body 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(s) is/are normally open, allowing unrestricted flow from the master cylinder to the wheels. When the CAB determines antilock intervention is required, the valve(s) close to isolate the master cylinder hydraulic circuit(s). Fluid is trapped in the circuit(s) and then prevented from reaching the wheels. The Dump Valve(s) is/are pulsed on and off by the CAB. The valve(s) 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 dump valve is off, fluid is allowed to the wheel. The Brake Return Check Valve allows the HCU to drain faster after the antilock activation, when the brake is released. The Reset Switch is used in the EBC 125 (RWAL) system only. The 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 antilock 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 DTC if incorrect pressure is detected on the EBC 125 (RWAL) antilock system when not in an ABS event. When the brakes are applied, fluid is forced from the master cylinder outlet port(s) to the HCU inlet ports(s). This pressure is transmitted through normally open isolation valve(s) inside the HCU, then through the outlet port(s) 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 wheel speed sensor(s) 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 action dumps any pressure that is trapped between the normally open valve and the brake back into an accumulator. Once the affected wheel 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, there is a pump/motor unit, two accumulators, three isolated valves, and three dump valves which are used to provide rapid response during the reapply sequence and to minimize pedal feedback due to the increased hydraulic circuits. OPERATION Accumulators in the valve body store extra fluid released to the system for ABS mode operation. The pump provides the fluid volume needed and is operated by a DC type motor. The motor is controlled by the CAB. The valves modulate brake pressure during antilock braking and are controlled by the CAB. 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. 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. NOTE: The three modes mentioned below do occur but not necessarily in the order listed everytime. During antilock braking, solenoid valve pressure modulation occurs in three stages, pressure increase, pressure hold, and pressure decrease. The valves are all contained in the valve body portion of the HCU. Pressure Decrease The outlet valve is opened and the inlet valve is closed 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 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. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) > Page 4290 Pressure Hold Both solenoid valves are closed in the pressure hold cycle but only the inlet valve is energized. 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 reapply the brakes. This cycle controls re-application of fluid apply pressure. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) > Page 4291 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Rear Wheel Antilock (RWAL) Valve DESCRIPTION Rear Wheel Antilock (RWAL) brake system is standard equipment on 1500 series vehicles. The RWAL brake system is designed to prevent rear wheel lock-up on virtually all types of road surfaces. RWAL braking is desirable because a vehicle, which is stopped without locking the rear wheels, will retain directional stability. This allows the driver to retain greater control of the vehicle during braking. The valve is located on the drivers side inner fender under the hood. The valve modulates hydraulic pressure to the rear brakes. The RWAL components include: RWAL Valve - Controller Antilock brake (CAB) - Rear Wheel Speed Sensor (WSS) OPERATION When the brakes are applied, hydraulic fluid is routed from the master cylinder's secondary circuit to the RWAL valve. From there hydraulic fluid is routed to the rear brakes. The Controller Antilock Brake (CAB) contains an Electronic Variable Brake Proportioning (EVBP) control algorithm, which proportions the applied braking force to the rear wheels during braking. The EVBP function of the RWAL system takes the place of a conventional hydraulic proportioning valve. The CAB monitors the rear wheel speed through the rear wheel speed sensor and calculates an estimated vehicle deceleration. When an established deceleration threshold is exceeded, an isolation valve is closed to hold the applied brake pressure to the rear brakes constant. Upon further increases in the estimated vehicle deceleration, the isolation valve is selectively opened to increase rear brake pressure in proportion to the front brake pressure. If impending rear wheel lock-up is sensed, the CAB signals the RWAL valve to modulate hydraulic brake pressure to the rear wheels to prevent lock-up. NORMAL BRAKING Since the RWAL valve also performs the EVBP or proportioning function, vehicle deceleration under normal braking may be sufficient to trigger the EVBP function of the RWAL system without full RWAL activity as would normally occur during an impending rear wheel lock-up. As previously mentioned, the isolation valve is selectively closed and opened to increase rear brake pressure in proportion to the front brake pressure under EVBP control. Slight brake pedal pulsations may be noticed as the isolation valve is opened. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > HCU (Hydraulic Control Unit) Hydraulic Control Assembly - Antilock Brakes: Service and Repair HCU (Hydraulic Control Unit) REMOVAL 1. Install a prop rod on the brake pedal to keep pressure on the brake system. 2. Disconnect the battery cables from the battery. 3. Remove the battery. 4. Disconnect the two electrical harness connectors. 5. Remove the five brake lines from the HCU. 6. Remove HCU/CAB mounting bolts and remove the HCU/CAB. INSTALLATION NOTE: If the CAB is being replaced with a new CAB is must be reprogrammed with the use of a DRB III. 1. Install HCU/CAB on the mounts and tighten the bolts to 15 Nm (11 ft. lbs.). 2. Install the five brake lines to the HCU and tighten to 19 Nm (170 in. lbs.). 3. Install the two electrical harness connectors to the HCU/CAB and push down on the release to secure the connectors. 4. Install the battery. 5. Install the battery cables to the battery. 6. Remove the prop rod on the brake pedal. 7. Bleed ABS brake system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > HCU (Hydraulic Control Unit) > Page 4294 Hydraulic Control Assembly - Antilock Brakes: Service and Repair RWAL Valve REMOVAL 1. Install a prop rod on the brake pedal to keep pressure on the brake system. 2. Disconnect the battery cables from the battery. 3. Remove the battery. 4. Disconnect the electrical harness connector. 5. Remove the brake lines from the RWAL valve. 6. Remove RWAL valve mounting nuts and remove the RWAL valve. INSTALLATION 1. Install RWAL valve and tighten the nuts to 15 Nm (11 ft. lbs.). 2. Install the brake lines to the RWAL valve and tighten to 19 Nm (170 in. lbs.). 3. Install the electrical harness connector to the RWAL valve and secure the connector. 4. Install the battery. 5. Install the battery cables to the battery. 6. Remove the prop rod on the brake pedal. 7. Bleed ABS brake system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic System Junction Block > Component Information > Specifications Hydraulic System Junction Block: Specifications Junction Block Bolts To Frame ............................................................................................................ ................................................... 10 Nm (7.5 ft. lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic System Junction Block > Component Information > Specifications > Page 4298 Hydraulic System Junction Block: Service and Repair BRAKE JUNCTION BLOCK REMOVAL 1. Remove the brake lines from the junction block . 2. Remove the junction block mounting bolt and remove the junction block from the bracket. INSTALLATION 1. Position the junction block on the bracket and install the mounting bolt. Tighten the mounting bolt to 23 Nm (210 in. lbs.) . 2. Install the brake lines into the junction block and tighten to 19 - 23 Nm (170 - 200 in. lbs.). 3. Bleed the base brake system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Master Cylinder Mounting Nuts ............................................................................................................................................................ 18 Nm (160 in. lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4302 Brake Master Cylinder: Description and Operation DESCRIPTION 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 stores reserve brake fluid for the hydraulic brake circuits and has a switch for indicating low fluid levels. 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. OPERATION The master cylinder bore contains a primary and secondary piston. The primary piston supplies hydraulic pressure to the front brakes. The secondary piston supplies hydraulic pressure to the rear brakes. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4303 Brake Master Cylinder: Testing and Inspection DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER 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 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. POWER BOOSTER VACUUM TEST 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. POWER BOOSTER CHECK VALVE TEST 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. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4304 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure Brake Master Cylinder: Service and Repair Master Cylinder Bleeding Procedure STANDARD PROCEDURE MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports (1). Then position each tube end into reservoir (2). 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 4307 Brake Master Cylinder: Service and Repair Master Cylinder Removal and Installation All Except Hydroboost REMOVAL - ALL EXCEPT HYDROBOOST 1. Remove the brake lines from the master cylinder. 2. Disconnect the electrical connector for the low fluid level. 3. Remove the mounting nuts from the master cylinder. 4. Remove the master cylinder. NOTE: Using care remove the master cylinder directly forward in order not to dislodge the output rod from its seat inside the booster. INSTALLATION - ALL EXCEPT HYDROBOOST NOTE: If master cylinder is replaced bleed cylinder before installation. NOTE: Make sure the output rod of the brake booster is in position before mounting of the master cylinder "This position will enable the output rod to enter inside of the master cylinder plunger sleeve during installation". Proper position is obtained when the output rod is centered perpendicular to Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 4308 the master cylinder mounting hole. NOTE: Before installing the master cylinder, pump the brake pedal several times with the engine off to remove vacuum from the booster. 1. Install the master cylinder on the booster mounting studs. 2. Install new mounting nuts and tighten to 25 Nm (221 in. lbs.) 3. Install the brake lines and tighten to 19 Nm (170 in. lbs.) 4. Reconnect the electrical connector for the low fluid level switch. 5. Fill and bleed the base brake system. Hydroboost REMOVAL- HYDROBOOST 1. Remove the brake lines from the master cylinder. 2. Disconnect the electrical connector for the low fluid level. 3. Remove the mounting nuts from the master cylinder. 4. Remove the master cylinder. NOTE: Using care remove the master cylinder directly forward in order not to dislodge the output rod from its seat inside the booster. INSTALLATION - HYDROBOOST NOTE: If master cylinder is replaced bleed cylinder before installation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 4309 NOTE: Make sure the output rod of the brake booster is in position before mounting of the master cylinder "This position will enable the output rod to enter inside of the master cylinder plunger sleeve during installation". Proper position is obtained when the output rod is centered perpendicular to the master cylinder mounting hole. 1. Install the master cylinder on the booster mounting studs. 2. Install new mounting nuts and tighten to 25 Nm (221 in. lbs.) 3. Install the brake lines and tighten to 19 Nm (170 in. lbs.) 4. Reconnect the electrical connector for the low fluid level switch. 5. Fill and bleed the base brake system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 4310 Brake Master Cylinder: Service and Repair Fluid Reservoir Removal and Installation REMOVAL 1. Install the prop rod on the brake pedal to keep pressure on the brake system. 2. Remove the reservoir cap and siphon fluid into a drain container . 3. Remove the electrical connector from the fluid level switch in the reservoir. 4. Remove the reservoir mounting bolt. 5. Remove the reservoir from the master cylinder by pulling upwards. 6. Remove old grommets from cylinder body. INSTALLATION CAUTION: Do not use any type of tool to install the grommets. Tools may cut, or tear the grommets creating a leak problem after installation. Install the grommets using finger pressure only. 1. Lubricate the new grommets with clean brake fluid and Install new grommets in cylinder body. Use finger pressure to install and seat grommets. 2. Start the reservoir in grommets. Then rock the reservoir back and forth while pressing downward to seat it into the grommets. 3. Install the mounting bolt for the reservoir to the master cylinder. 4. Reconnect the electrical connector to the fluid reservoir level switch. 5. Remove the prop rod from the vehicle. 6. Fill and bleed base brake system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable Parking Brake Cable: Service and Repair Front Parking Brake Cable REMOVAL - FRONT PARKING BRAKE CABLE 1. Raise and support vehicle. 2. Lockout the parking brake cable. 3. Loosen adjusting nut to create slack in front cable. 4. Remove the front cable from the cable connector. 5. Compress cable end fitting at underbody bracket and remove the cable from the bracket. 6. Lower vehicle. 7. Push ball end of cable out of pedal clevis with small screwdriver. 8. Compress cable end fitting at the pedal bracket and remove the cable. 9. Remove the left cowl trim and sill plate. 10. Pull up the carpet and remove the cable from the body clip. 11. Pull up on the cable and remove the cable with the body grommet. INSTALLATION - FRONT PARKING BRAKE CABLE 1. From inside the vehicle, insert the cable end fitting into the hole in the pedal assembly. 2. Seat the cable retainer in the pedal assembly. 3. Engage the cable ball end in clevis on the pedal assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable > Page 4316 4. Route the cable through the floor pan and install the body grommet. 5. Place the carpet down and install the left cowl trim and sill plate. 6. Raise and support the vehicle. 7. Route the cable through the underbody bracket and seat the cable end fitting in the bracket. 8. Connect the cable to the cable connector. 9. Perform the park brake adjustment procedure. 10. Lower the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable > Page 4317 Parking Brake Cable: Service and Repair Rear Parking Brake Cable Rear Park Brake Cable REMOVAL - REAR PARK BRAKE CABLE 1. Raise and support the vehicle. 2. Lockout the parking brake cable. 3. Loosen cable adjuster nut. 4. Remove the rear park brake cable from the intermediate park brake cable. 5. Compress tabs on cable end fitting on the rear park brake cable to the frame mount bracket. Then pull the cable through the bracket. 6. Disengage the park brake cable from behind the rotor assembly. 7. Compress cable tabs on each cable end fitting at the brake cable support plate. 8. Remove the cables from the brake cable support plates. INSTALLATION - REAR PARK BRAKE CABLE 1. Push each cable end through the brake cable support plate hole until the cable end fitting tabs lock into place. NOTE: Pull on the cable to ensure it is locked into place. 2. Push the cable through the frame bracket. 3. Lock the left cable end fitting tabs into the frame bracket hole. 4. Install the rear cables into the tensioner rod behind the rear of the brake assembly. 5. Install the cable to the intermediate cable connector. 6. Release and remove the lock out device. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable > Page 4318 7. Perform the park brake adjustment procedure. 8. Remove the supports and lower the vehicle. Left Rear Cable REMOVAL - LEFT REAR CABLE 1. Raise and support the vehicle. 2. Lockout the parking brake cable. 3. Loosen the brake cable at the equalizer and adjuster nut. 4. Remove the left brake cable from the equalizer. 5. Remove the brake cable from the frame bracket. 6. Remove the brake cable from the brake lever. INSTALLATION - LEFT REAR CABLE 1. Install the brake cable to the brake lever. 2. Install the brake cable to the frame bracket. 3. Install the left brake cable to the equalizer. 4. Adjust the brake cable at the equalizer and adjuster nut. Right Rear Cable REMOVAL - RIGHT REAR CABLE 1. Raise and support the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable > Page 4319 2. Lockout the parking brake cable. 3. Loosen the brake cable at the equalizer and adjuster nut. 4. Remove the right cable from the front cable. 5. Remove the right cable from the equalizer. 6. Remove the cable from the frame bracket. 7. Remove the cable from the axle bracket. 8. Remove the cable bracket from the shock bracket. 9. Remove the brake cable from the brake lever. INSTALLATION - RIGHT REAR CABLE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable > Page 4320 1. Install the brake cable to the brake lever. 2. Install the cable bracket to the shock bracket. 3. Install the cable to the axle bracket. 4. Install the cable to the frame bracket. 5. Install the right cable to the equalizer. 6. Install the right cable to the front cable. 7. Adjust the brake cable at the equalizer and using the adjuster nut. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair Parking Brake Lever: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Reach under the driver side outboard end of the instrument panel to access and unsnap the plastic retainer clip that secures the park brake release linkage rod to the park brake mechanism on the left cowl side inner panel. 3. Disengage the park brake release linkage rod end from the park brake mechanism. 4. Lift the park brake release handle to access and unsnap the plastic retainer clip that secures the park brake release linkage rod to the lever on the back of the park brake release handle. 5. Lower the park brake release handle and reach under the driver side outboard end of the instrument panel to disengage the park brake release linkage rod end from the lever on the back of the park brake release handle. 6. Lift the park brake release handle to access the handle mounting bracket. Park Brake Release Handle Remove/Install 7. Using a trim stick or another suitable wide flat-bladed tool, gently pry each of the park brake release handle mounting bracket latch tabs away from the retaining notches in the instrument panel receptacle. 8. With both of the park brake release handle mounting bracket latches released, slide the handle and bracket assembly down and out of the instrument panel receptacle. INSTALLATION 1. Position the park brake release handle to the instrument panel. 2. Slide the handle and bracket assembly up into the instrument panel receptacle until both of the park brake release handle mounting bracket latches are engaged with the notches in the instrument panel receptacle. 3. Lower the park brake release handle and reach under the driver side outboard end of the instrument panel to engage the park brake release linkage rod end with the lever on the back of the park brake release handle. 4. Lift the park brake release handle to access and snap the plastic retainer clip that secures the park brake release linkage rod to the lever on the back of the park brake release handle over the linkage rod. 5. Reach under the driver side outboard end of the instrument panel to access and engage the park brake release linkage rod end to the park brake mechanism. 6. Snap the plastic retainer clip that secures the park brake release linkage rod to the park brake mechanism on the left cowl side inner panel over the linkage rod. 7. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Specifications Parking Brake Pedal: Specifications Parking Brake Pedal Assembly ............................................................................................................................................. 19 Nm (14 ft. lbs., 250 in. lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Specifications > Page 4327 Parking Brake Pedal: Service and Repair REMOVAL 1. Release the parking brake. 2. Raise the vehicle. 3. Loosen the cable tensioner nut at the equalizer to create slack in the front cable. 4. Lower the vehicle. 5. Remove the knee bolster. 6. Disconnect the brake lamp wire from the switch on the pedal assembly. 7. Roll the carpet back, loosen the front cable grommet from the floor pan and the cable retainer. 8. Disengage the release rod from the arm on the pedal assembly. 9. Remove the bolts/nuts from the pedal assembly and remove the assembly. INSTALLATION 1. Position the replacement pedal assembly on the dash and cowl. 2. Install the bolts/nuts and tighten to 28 Nm (21 ft. lbs.). 3. Install the park brake release rod. 4. Connect the front cable to the arm on the pedal assembly. 5. Tighten the front cable grommet to the floor pan and the cable retainer, roll the carpet back. 6. Connect the wires to the brake lamp switch. 7. Install the knee bolster. 8. Raise the vehicle. 9. Adjust the parking brake cable tensioner. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments Parking Brake Shoe: Adjustments ADJUSTMENT- PARKING BRAKE SHOES CAUTION: Before adjusting the park brake shoes be sure that the park brake pedal is in the fully released position. If park brake pedal is not in the fully released position, the park brake shoes can not be accurately adjusted. 1. Raise vehicle. 2. Remove tire and wheel. 3. Remove disc brake caliper from caliper adapter. 4. Remove rotor from the axle shaft. NOTE: When measuring the brake drum diameter, the diameter should be measured in the center of the area in which the park brake shoes contact the surface of the brake drum. 5. Using Brake Shoe Gauge, Special Tool C-3919, or equivalent, accurately measure the inside diameter of the park brake drum portion of the rotor. 6. Using a ruler that reads in 64th of an inch, accurately read the measurement of the inside diameter of the park brake drum from the special tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 4331 7. Reduce the inside diameter measurement of the brake drum that was taken using Special Tool C-3919 by 1/64 of an inch. Reset Gauge, Brake Shoe, Special Tool C-3919 or the equivalent used, so that the outside measurement jaws are set to the reduced measurement. 8. Place Gauge, Brake Shoe, Special Tool C-3919, or equivalent over the park brake shoes. The special tool must be located diagonally across at the top of one shoe and bottom of opposite shoe (widest point) of the park brake shoes. 9. Using the star wheel adjuster, adjust the park brake shoes until the lining on the park brake shoes just touches the jaws on the special tool. 10. Repeat step 8 above and measure shoes in both directions. 11. Install brake rotor on the axle shaft. 12. Rotate rotor to verify that the park brake shoes are not dragging on the brake drum. If park brake shoes are dragging, remove rotor and back off star wheel adjuster one notch and recheck for brake shoe drag against drum. Continue with the previous step until brake shoes are not dragging on brake drum. 13. Install disc brake caliper on caliper adapter. 14. Install wheel and tire. 15. Tighten the wheel mounting nuts in the proper sequence until all nuts are torqued to half the specified torque. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 16. Lower vehicle. 17. Apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: Before moving vehicle, pump brake pedal several times to ensure the vehicle has a firm enough pedal to stop the vehicle. NOTE: On a new vehicle or after parking brake lining replacement, it is recommended that the parking brake system be conditioned prior to use. This is done, by making one stop from 25 mph on dry pavement or concrete using light to moderate force on the parking brake foot pedal. 18. Road test the vehicle to ensure proper function of the vehicle's brake system. ADJUSTMENT - WITH ADJUSTING TOOL Adjustment can be made with a standard brake gauge or with adjusting tool. Adjustment is performed with the complete brake assembly installed on the backing plate. 1. Be sure parking brake lever is fully released. 2. Raise vehicle so rear wheels can be rotated freely. 3. Remove plug from each access hole in brake support plates. 4. Loosen parking brake cable adjustment nut until there is slack in front cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 4332 5. Insert adjusting tool through support plate access hole and engage tool in teeth of adjusting screw star wheel. 6. Rotate adjuster screw star wheel (move tool handle upward) until slight drag can be felt when wheel is rotated. 7. Push and hold adjuster lever away from star wheel with thin screwdriver. 8. Back off adjuster screw star wheel until brake drag is eliminated. 9. Repeat adjustment at opposite wheel. Be sure adjustment is equal at both wheels. 10. Install support plate access hole plugs. 11. Adjust parking brake cable and lower vehicle. 12. Depress park brake pedal and make sure park brakes hold the vehicle stationary. 13. Release park brake pedal. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 4333 Parking Brake Shoe: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the disc brake caliper. 4. Remove the disc brake rotor. 5. Lockout the parking brake cable. 6. Disengage the park brake cable from behind the rotor assembly to allow easier disassembly of the park brake shoe. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 4334 7. Remove the axle shaft. 8. Disassemble the rear park brake shoes. CLEANING - REAR DRUM IN HAT BRAKE Clean the individual brake components, including the support plate exterior, with a water dampened cloth or with brake cleaner. Do not use any other cleaning agents. Remove light rust and scale from the brake shoe contact pads on the support plate with fine sandpaper. INSPECTION - REAR DRUM IN HAT BRAKE As a general rule, riveted brake shoes should be replaced when worn to within 0.78 mm (1/32 in.) of the rivet heads. Bonded lining should be replaced when worn to a thickness of 1.6 mm (1/16 in.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 4335 Examine the lining contact pattern to determine if the shoes are bent or the drum is tapered. The lining should exhibit contact across its entire width. Shoes exhibiting contact only on one side should be replaced and the drum checked for runout or taper. Inspect the adjuster screw assembly. Replace the assembly if the star wheel or threads are damaged, or the components are severely rusted or corroded. Discard the brake springs and retainer components if worn, distorted or collapsed. Also replace the springs if a brake drag condition had occurred. Overheating will distort and weaken the springs. Inspect the brake shoe contact pads on the support plate, replace the support plate if any of the pads are worn or rusted through. Also replace the plate if it is bent or distorted. INSTALLATION NOTE: On a new vehicle or after parking brake lining replacement, it is recommended that the parking brake system be conditioned prior to use. This is done, by making one stop from 25 mph on dry pavement or concrete using light to moderate force on the parking brake foot pedal. 1. Reassemble the rear park brake shoes. 2. Install the axle shaft. 3. Install the park brake cable to the lever behind the support plate. 4. Unlock the park brake cable. 5. Install the disc brake rotor. 6. Install the disc brake caliper. 7. Adjust the rear brake shoes. 8. Install the tire and wheel assembly. 9. Lower the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Adjustments Parking Brake Tensioner: Adjustments CABLE TENSIONER ADJUSTMENTS NOTE: Tensioner adjustment is only necessary when the tensioner, or a cable has been replaced or disconnected for service. When adjustment is necessary, perform adjustment only as described in the following procedure. This is necessary to avoid faulty park brake operation. 1. Raise the vehicle. 2. Back off the cable tensioner adjusting nut to create slack in the cables. 3. Remove the rear wheel/tire assemblies. Then remove the brake rotors. 4. Verify the brakes are in good condition and operating properly. 5. Verify the park brake cables operate freely and are not binding, or seized. 6. Check the rear brake shoe adjustment with standard brake gauge. 7. Install the rotors and verify that the rotors rotate freely without drag. 8. Install the wheel/tire assemblies. 9. Lower the vehicle enough for access to the park brake foot pedal. Then fully apply the park brakes. NOTE: Leave park brakes applied until adjustment is complete. 10. Raise the vehicle again. 11. Mark the tensioner rod 6.35 mm (1/4 in.) from edge of the tensioner. 12. Tighten the adjusting nut on the tensioner rod until the mark is no longer visible. CAUTION: Do not loosen, or tighten the tensioner adjusting nut for any reason after completing adjustment. 13. Lower the vehicle until the rear wheels are 15 - 20 cm (6 - 8 in.) off the shop floor. 14. Release the park brake foot pedal and verify that rear wheels rotate freely without drag. Then lower the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Service Precautions Parking Brake Warning Lamp: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Service Precautions > Page 4342 Parking Brake Warning Lamp: Description and Operation BRAKE/PARK BRAKE INDICATOR A brake indicator is standard equipment on all instrument clusters. The brake indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The brake indicator consists of stencil-like cutouts of the word "BRAKE" and the International Control and Display Symbol icon for "Brake Failure" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "BRAKE" text and the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The brake indicator is serviced as a unit with the instrument cluster. The brake indicator gives an indication to the vehicle operator when the parking brake is applied, when there are certain brake hydraulic system malfunctions as indicated by a low brake hydraulic fluid level condition, or when the brake fluid level switch is disconnected. The brake indicator can also give an indication when certain faults are detected in the Antilock Brake System (ABS). This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Programmable Communications Interface (PCI) data bus, and a hard wired input from the park brake switch. The brake indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (RUN/START) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the brake indicator for the following reasons: Bulb Test - Each time the ignition switch is turned to the On position the brake indicator is illuminated by the instrument cluster for about two seconds as a bulb test. - Brake Lamp-On Message - Each time the cluster receives a lamp-on message from the CAB, the brake indicator will be illuminated. The CAB can also send brake lamp-on messages as feedback during ABS diagnostic procedures. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB, or until the ignition switch is turned to the Off position, whichever occurs first. - Park Brake Switch Input - Each time the cluster detects ground on the park brake switch sense circuit (park brake switch closed = park brake applied or not fully released) while the ignition switch is in the On position, the brake indicator flashes on and off. The indicator continues to flash until the park brake switch sense input to the cluster is an open circuit (park brake switch open = park brake fully released), or until the ignition switch is turned to the Off position, whichever occurs first. Actuator Test - Each time the instrument cluster is put through the actuator test, the brake indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The park brake switch on the park brake pedal mechanism provides a hard wired ground input to the instrument cluster circuitry through the park brake switch sense circuit whenever the park brake is applied or not fully released. The CAB continually monitors the ABS system circuits and sensors, including the brake fluid level switch on the brake master cylinder reservoir, to decide whether the system is in good operating condition. The CAB then sends the proper lamp-on or lamp-off messages to the instrument cluster. If the CAB sends a lamp-on message after the bulb test, it indicates that the CAB has detected a brake hydraulic system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. For further diagnosis of the brake indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster Diagnosis and Testing. The park brake switch input to the instrument cluster can be diagnosed using conventional diagnostic tools and methods. For proper diagnosis of the brake fluid level switch, the ABS, the CAB, the PCI data bus, or the electronic message inputs to the instrument cluster that control the brake indicator, a DRBIII scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Service Precautions > Page 4343 Parking Brake Warning Lamp: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE/PARK BRAKE INDICATOR The diagnosis found here addresses an inoperative brake indicator condition. If there are problems with several indicators in the instrument cluster. If the brake indicator stays on with the ignition switch in the On position and the park brake released, or comes on while driving, the brake system must be diagnosed and repaired prior to performing the following tests. (Refer to BRAKES DIAGNOSIS AND TESTING). If no brake system problem is found, the following procedures will help to locate a shorted or open circuit, or a faulty park brake switch input. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Fig.26 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 4347 Fig.27 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 4348 Switch-Parking Brake Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 4349 Parking Brake Warning Switch: Description and Operation The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the EMIC processing of the park brake switch sense input requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 4350 Parking Brake Warning Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: If the brake indicator stays on with the ignition switch in the On position and the park brake released, or comes on while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or a faulty park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 4351 Parking Brake Warning Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. INSTALLATION 1. Reach under the left end of the instrument panel to position park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 N.m (24 in.lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 4352 5. Turn the ignition switch to the On position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Testing and Inspection Hydraulic Brake Booster: Testing and Inspection DIAGNOSIS AND TESTING - HYDRAULIC BOOSTER The hydraulic booster uses hydraulic pressure from the power steering pump. Before diagnosing a booster problem, first verify the power steering pump is operating properly. Perform the following checks. Check the power steering fluid level. - Check the brake fluid level. - Check all power steering hoses and lines for leaks and restrictions. - Check power steering pump pressure. NOISES The hydraulic booster unit will produce certain characteristic booster noises. The noises may occur when the brake pedal is used in a manner not associated with normal braking or driving habits. HISSING A hissing noise may be noticed when above normal brake pedal pressure is applied, 40 lbs. or above. The noise will be more noticeable if the vehicle is not moving. The noise will increase with the brake pedal pressure and an increase of system operating temperature. CLUNK-CHATTER-CLICKING A clunk-chatter-clicking may be noticed when the brake pedal is released quickly, after above normal brake pedal pressure is applied 50-100 lbs. BOOSTER FUNCTION TEST With the engine off depress the brake pedal several times to discharge the accumulator. Then depress the brake pedal using 40 lbs. of force and start the engine. The brake pedal should fall and then push back against your foot. This indicates the booster is operating properly. ACCUMULATOR LEAKDOWN 1. Start the engine, apply the brakes and turn the steering wheel from lock to lock. This will ensure the accumulator is charged. Turn off the engine and let the vehicle sit for one hour. After one hour there should be at least two power assisted brake application with the engine off. If the system does not retain a charge the booster must be replaced. 2. With the engine off depress the brake pedal several times to discharge the accumulator. Grasp the accumulator and see if it wobbles or turns. If it does the accumulator has lost a gas charge and the booster must be replaced. SEAL LEAKAGE If the booster leaks from any of the seals the booster assembly must be replaced. INPUT ROD SEAL: Fluid leakage from rear end of the booster. - PISTON SEAL: Fluid leakage from vent at front of booster. - HOUSING SEAL: Fluid leakage between housing and housing cover. - SPOOL VALVE SEAL: Fluid leakage near spool plug. - RETURN PORT FITTING SEAL: Fluid leakage from port fitting. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Testing and Inspection > Page 4357 HYDRAULIC BOOSTER DIAGNOSIS CHART Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Testing and Inspection > Page 4358 Hydraulic Brake Booster: Service and Repair REMOVAL NOTE: If the booster is being replaced because the power steering fluid is contaminated, flush the power steering system before replacing the booster. 1. With engine off depress the brake pedal 5 times to discharge the accumulator. 2. Remove brake lines from master cylinder. 3. Remove mounting nuts from the master cylinder. 4. Remove the bracket from the hydraulic booster lines and master cylinder mounting studs. 5. Remove the master cylinder. 6. Remove the return hose and the two pressure lines from the hydraulic booster. 7. Remove the booster push rod clip, washer and rod remove from the brake pedal. 8. Remove the mounting nuts from the hydraulic booster and remove the booster. INSTALLATION 1. Install the hydraulic booster and tighten the mounting nuts to 28 Nm (21 ft. lbs.). 2. Install the booster push rod, washer and clip onto the brake pedal. 3. Install the master cylinder on the mounting studs. and tighten the mounting nuts to 23 Nm (17 ft. lbs.). 4. Install the brake lines to the master cylinder and tighten to 19 - 200 Nm (170 - 200 in. lbs.). 5. Install the hydraulic booster line bracket onto the master cylinder mounting studs. 6. Install the master cylinder mounting nuts and tighten to 23 Nm (17 ft. lbs.). 7. Install the hydraulic booster pressure lines to the bracket and booster. 8. Tighten the pressure lines to 41 Nm (30 ft. lbs.). NOTE: Inspect O-rings on the pressure line fittings to insure they are in good condition before installation. Replace O-rings if necessary. 9. Install the return hose to the booster. 10. Bleed base brake system. 11. Fill the power steering pump with fluid. CAUTION: MOPAR (MS-9602) ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. 12. Bleed the hydraulic booster. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Brake Booster Mounting Nuts .............................................................................................................. .................................................... 33 Nm (28 ft. lbs.) Brake Booster Type (Gasoline Engines) ....................................................................................................................................... Vacuum Dual Diaphragm Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4362 Vacuum Brake Booster: Description and Operation DESCRIPTION All models use a tandem diaphragm, power brake booster. 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. OPERATION The booster unit consists of a single housing divided into two by a tandem diaphragm. 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 outlet connected to the engine intake manifold. Power assist is generated by utilizing a combination of vacuum and atmospheric pressure to boost brake assist. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4363 Vacuum Brake Booster: Testing and Inspection DIAGNOSIS AND TESTING MASTER CYLINDER/POWER BOOSTER 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 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. POWER BOOSTER VACUUM TEST 1. Connect vacuum gauge (6) to booster check valve (4) with short length of hose (3) and T-fitting (2). 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 (1) hose (7) shut between intake vacuum source (5) and check valve (4). 5. Stop engine and observe vacuum gauge (6). 6. If vacuum drops more than one inch HG (33 millibars) within 15 seconds, booster diaphragm or check valve is faulty. POWER BOOSTER CHECK VALVE TEST 1. Disconnect vacuum hose from check valve (1). 2. Remove check valve (1) and valve seal (2) from booster (3). 3. Use a hand operated vacuum pump for test. 4. Apply 15 - 20 inches vacuum at large end of check valve. 5. Plug off the small end to prevent vacuum leakage. 6. Vacuum should hold steady. If gauge on pump indicates vacuum loss, check valve is faulty and should be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4364 Vacuum Brake Booster: Service and Repair REMOVAL 1. Remove master cylinder. 2. Disconnect vacuum line at booster. 3. Remove clip securing booster push rod to brake pedal. 4. Remove the nuts from the booster mounting studs. 5. Remove the booster and gasket from front cowl panel. INSTALLATION 1. Guide the booster studs into the cowl panel holes and seat the booster on the panel. 2. Install and tighten new booster attaching nuts to 28 Nm (250 in. lbs.). 3. Install the booster push rod on brake pedal and install clip. 4. Install the booster check valve if removed and connect the vacuum hose to the check valve. 5. Install the master cylinder. 6. Fill and bleed the brake system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations EBC 125 (RWAL) EBC 325 (ABS) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4369 Electronic Brake Control Module: Diagrams Controller Antilock Brake C1 Controller Antilock Brake C2 (ABS) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4370 Electronic Brake Control Module: Description and Operation Fig.1 Hydraulic Control Unit CONTROLLER ANTILOCK BRAKE (CAB) The Controller Antilock Brake (CAB) is mounted to the Hydraulic Control Unit (HCU) and operates the ABS system. The CAB voltage source is through the ignition switch in the RUN position. 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 III 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 is being replaced with a new CAB is must be reprogrammed with the use of a DRB III. TRW EBC 125 CONTROLLER ANTILOCK BRAKE The CAB includes a microprocessor and two solenoids that control the valves that control brake pressure during RWAL braking and circuits that: Monitor the brake switch input to tell whether or not to prepare for possible antilock braking - Monitor the brake fluid level switch input to tell whether or not the state of the hydraulics has a problem - Monitor the wheel speed sensor input to determine when a rear wheel is tending to lock up - Operate the integral hydraulic control unit (HCU) during antilock braking based on comparing the speed sensor to information programmed in memory - Detect RWAL system related problems and take diagnostic action - Able to execute self-tests and output control commands TRW EBC 325 CONTROLLER ANTILOCK BRAKE The CAB 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 ABS braking - Monitor the brake fluid level switch input to tell whether or not the state of the hydraulics has a problem - Wheel speed sensors are monitored to determine when a wheel is tending to lock up. The CAB will operate the valves in the HCU to control braking pressure during ABS braking - Detect ABS system related problems and take diagnostic action - Able to execute self-tests and output control commands Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4371 Electronic Brake Control Module: Service and Repair REMOVAL 1. Remove the negative battery cable from the battery. 2. Pull up on the CAB harness connector release and remove connector. 3. Remove the CAB mounting bolts. 4. Remove the pump connector from the CAB. 5. Remove the CAB from the HCU. INSTALLATION NOTE: If the CAB is being replaced with a new CAB is must be reprogrammed with the use of a DRB III. 1. Install CAB to the HCU. 2. Install the pump connector to the CAB. 3. Install mounting bolts. Tighten to 2 Nm (16 in. lbs.). 4. Install the wiring harness connector to the CAB and push down on the release to secure the connector. 5. Install negative battery cable to the battery. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4376 Brake Fluid Level Switch Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4377 Brake Fluid Level Sensor/Switch: Description and Operation BRAKE FLUID LEVEL SWITCH CIRCUIT The switch signals the CAB for a hydraulic fluid problem. The antilock system uses input from the brake fluid level switch when activated. A low brake fluid condition in the master cylinder will close the switch circuit and read 0 volts. When the brake fluid level is at specifications, the switch will open and circuit sense voltage will read 5 volts. This signal tells the CAB if there is enough brake fluid in the master cylinder to have an antilock operation. The brake fluid level switch is located in the master cylinder with 10k resistor. The switch is a Hall effect design and uses a float to determine level. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations Braking Sensor/Switch: Locations Fig.26 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 4381 Fig.28 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 4382 Fig.31 Left Side Engine Compartment and Hood Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Fig.26 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 4386 Fig.27 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 4387 Switch-Parking Brake Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 4388 Parking Brake Warning Switch: Description and Operation The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the EMIC processing of the park brake switch sense input requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 4389 Parking Brake Warning Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: If the brake indicator stays on with the ignition switch in the On position and the park brake released, or comes on while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or a faulty park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 4390 Parking Brake Warning Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. INSTALLATION 1. Reach under the left end of the instrument panel to position park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 N.m (24 in.lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 4391 5. Turn the ignition switch to the On position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Wheel Speed Sensors Front Sensor Bolt ................................................................................................................................................ 21 Nm (190 in. lbs.) Wheel Speed Sensors Bracket To Knuckle ............................................................................................................................................. 6.7 Nm (60 in. lbs.) Wheel Speed Sensors Rear Sensor Stud ............................................................................................................................................. 22.5 Nm (200 in. lbs.) Rear Wheel Speed Sensor Mounting Bolt .............................................................................................................................................. 24 Nm (200 in. lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 WHEEL SPEED SENSORS/TONE WHEELS Front Rear Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4397 Wheel Speed Sensor: Connector Locations Fig.25 Right Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4398 Fig.26 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4399 Fig.31 Left Side Engine Compartment and Hood Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4400 Fig.49 Rear Chassis Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4401 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor (ABS) Rear Wheel Speed Sensor (ABS) Right Front Wheel Speed Sensor (ABS) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4402 Wheel Speed Sensor: Description and Operation WHEEL SPEED SENSORS The EBC 125 (RWAL) system uses only one speed sensor mounted in the rear axle for the rear wheels. The EBC 325 (ABS) system uses one wheel speed sensor on each front wheel, and one 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 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 CAB takes control for antilock action through the HCU. Diagnostically, the coils of the wheel speed sensors have different amounts of resistance based upon the location. When measured across the connector two terminals, the resistance should be: Front sensor: 90 °C (194 °F) ..................................................................................................................................... ........................................... 2259 - 2761 Ohms 25 °C (77 °F) ............................................................. ..................................................................................................................... 1800 - 2200 Ohms -40 °C (-40 °F) ........................................................................................................................................... .................................... 1332 - 1628 Ohms Rear sensor: 90 °C (194 °F) ..................................................................................................................................... ........................................... 2900 - 3600 Ohms 25 °C (77 °F) ............................................................. ..................................................................................................................... 1600 - 2300 Ohms -40 °C (-40 °F) ........................................................................................................................................... ..................................... 1000 - 1400 Ohms NOTE:For all resistance ranges add 30% to the value for extreme heat, subtract 30% for extreme cold. On a EBC 325 (ABS) system each front wheel speed is monitored through the speed sensor mounted at the wheel end of the hub. On the EBC 125 (RWAL) and EBC 325 (ABS) systems the rear wheel speed is monitored through the speed sensor mounted in the rear axle assembly. The CAB will disable antilock control, illuminate the amber ABS warning indicator circuit via the PCI BUS, and store diagnostic 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 DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front hub/bearings. The third sensor is mounted on top of the rear axle differential housing. OPERATION The Wheel Speed Sensor consists of a magnet surrounded by windings from a single strand of wire. The sensor sends a small AC signal to the CAB. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) passes the stationary magnetic WSS. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4403 When the ring gear is rotated, the exciter ring passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings. This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated. Each AC signal (positive to negative signal or sinewave) is interpreted by the CAB. It then compares the frequency of the sinewave to a time value to calculate vehicle speed. The CAB continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: Magnetic field strength; the stronger the magnetic field, the stronger the signal - Number of windings in the sensor; more windings provide a stronger signal - Exciter ring speed; the faster the exciter ring/ tone wheel rotates, the stronger the signal will be - Distance between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be The rear WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 inch. The assembly plant performs a "Rolls Test" on every vehicle that leaves the assembly plant. One of the test performed is a test of the WSS. To properly test the sensor, the assembly plant connects test equipment to the Data Link Connector (DLC). This connector is located to the right of the steering column and attached to the lower portion of the instrument panel. The rolls test terminal is spliced to the WSS circuit. The vehicle is then Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4404 driven on a set of rollers and the WSS output is monitored for proper operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4405 Wheel Speed Sensor: Testing and Inspection DIAGNOSIS AND TESTING - REAR WHEEL SPEED SENSOR Diagnosis of base brake conditions, which are mechanical in nature, should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The Antilock brake system performs several self tests every time the ignition switch is turned on and the vehicle is driven. The CAB monitors the system inputs and outputs circuits to verify the system is operating properly. If the CAB senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: The MDS or ORB 111 scan tool is used to diagnose the Antilock Brake system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front REMOVAL 1. Remove the front rotor. 2. Remove the wheel speed sensor mounting bolt from the hub. 3. Remove the wheel speed sensor from the hub. 4. Remove the wiring from the clips and disconnect the electrical connector. INSTALLATION 1. Install the wiring to the clips and Reconnect the electrical connector. 2. Install the wheel speed sensor to the hub. 3. Install the wheel speed sensor mounting bolt to the hub. Tighten the bolt to 21 Nm (190 in. lbs.). 4. Install the front rotor and brake caliper assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4408 Wheel Speed Sensor: Service and Repair Rear REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the brake line mounting nut and remove the brake line from the sensor stud. 3. Remove the mounting stud from the sensor and shield. 4. Remove the sensor and shield from the differential housing. 5. Disconnect the sensor wire harness and remove the sensor. INSTALLATION 1. Connect the harness to the sensor. Be sure the seal is securely in place between the sensor and the wiring connector. 2. Install the O-ring on the sensor (if removed). 3. Insert the sensor in the differential housing. 4. Install the sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (200 in. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 4415 Battery Temperature Sensor: Connector Locations Left Rear Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 4416 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 4417 Left Front Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 4418 Integrated Power Module And Fan Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4419 Sensor-Battery Temperature Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4420 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4421 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. 1. Remove battery. Refer to Battery for procedures. Battery Temperature Sensor Location 2. Pry sensor straight up from battery tray mounting hole to gain access to electrical connector. 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. 1. Pull electrical connector up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Refer to Battery for procedures. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection SWITCH CLUTCH PEDAL- SRT-10 1. Disconnect the connector on the clutch position switch (1) from the vehicle wiring harness. 2. Place a ohmmeter across the terminals of the switch connector. The switch should show no continuity with the clutch pedal in the released (clutch engaged) position. 3. Slowly push the clutch pedal to the floor (clutch disengaged). The ohmmeter should show continuity just before the pedal reaches the end of its travel. 4. If the clutch switch shows continuity with clutch pedal up or no continuity with clutch pedal down, the switch is defective. The switch has no serviceable parts and should be replaced as an assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection > Page 4425 Clutch Switch: Service and Repair SWITCH CLUTCH PEDAL POSITION REMOVAL 1. Disconnect the clutch pedal position switch connector. 2. Disconnect the clutch actuation rod from the clutch pedal. 3. Remove the clutch master cylinder from the toe box. 4. Remove the white clutch pedal position switch retaining clip (1). 5. Push the switch up (1) the rod (2) slightly. Then pull the bottom of the switch outward. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection > Page 4426 1. Install new switch (1) as shown. Be sure that the spring loaded plunger inside the switch is slightly compressed. The plunger inside the switch must go on the narrow section of the clutch master cylinder actuation rod. Place the top of the switch against the rod. Then push the switch up slightly. This will compress the plunger. Then push the bottom of the switch against the rod. Failure to install the switch as described or forcing the switch onto the rod will crack the switch. 2. Install new white plastic retaining clip. 3. Install the clutch master cylinder back into the vehicle. 4. Reconnect the clutch switch connector. 5. Check clutch position switch operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 IGNITION SWITCH DESCRIPTION The ignition switch (5) is located on the steering column (4). It is used as the main on/off switching device for most electrical components. The mechanical key cylinder is used to engage/disengage the electrical ignition switch. OPERATION Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the shift cable. This interlock device is used to lock the transmission shifter in the PARK position when the key cylinder is in any position and the brake pedal is not depressed. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4431 Ignition Switch Lock Cylinder: Service and Repair KEY CYLINDER REMOVAL The ignition key (1) must be in the key cylinder (2) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at side of key cylinder assembly (2). a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. INSTALLATION The ignition key (1) must be in the key cylinder (2) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (2) with the ignition switch. 2. Push the key cylinder (2) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Component Locations Starter Relay: Component Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Component Locations > Page 4437 Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4438 Starter Relay: Description and Operation The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted. If faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact. When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Starter Relay Starter Relay: Testing and Inspection Starter Relay Type 1 Relay The starter relay is located in Power Distribution Center (PDC). Refer to PDC cover for relay identification and location. For complete starter relay wiring circuit diagrams, refer to Wiring Diagrams. 1. Remove starter relay from PDC. 2. A relay in 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 faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace faulty relay. 4. Connect 12V 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, perform Relay Circuit Test that follows. If not OK, replace faulty relay. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 4441 Starter Relay: Testing and Inspection Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair open circuit to fuse in PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to common feed terminal (30) in the energized position. This terminal supplies battery voltage to starter solenoid field coils. There should be continuity between cavity for relay terminal 87 and starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair open circuit to starter solenoid as required. 4. The coil battery terminal (86) is connected to electromagnet in relay. It is energized when ignition switch is held in Start position. On vehicles with manual transmission, clutch pedal must be fully depressed for this test. Check for battery voltage at cavity for relay terminal 86 with ignition switch in Start position, and no voltage when ignition switch is released to On position. If OK, go to Step 5. If not OK with automatic transmission, check for open or short circuit to ignition switch and repair, if required. If circuit to ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. If not OK with a manual transmission, check circuit between relay and clutch pedal position switch for open or a short. If circuit is OK, refer to Clutch Pedal Position Switch in 6 , Clutch. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gearshift selector lever is in Park or Neutral positions. Check for continuity to ground at cavity for relay terminal 85. If not OK with manual transmission, repair circuit to ground as required. If not OK with automatic transmission, check for pen or short circuit to park/neutral position switch and repair, if required. If circuit to park/neutral position switch is OK, refer to Park/Neutral Position Switch in 21, Transmission. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Page 4442 Starter Relay: Service and Repair REMOVAL The starter relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Disconnect and isolate negative battery cable. 2. Remove cover from Power Distribution Center (PDC) for relay identification and location. 3. Remove starter relay from PDC. 4. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 5. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION 1. Push down firmly on starter relay until terminals are fully seated into PDC receptacle. 2. Install PDC cover. 3. Connect battery cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation Battery Cable: Description and Operation The battery cables are large gauge, stranded copper wires sheathed within a heavy plastic or synthetic rubber insulating jacket. The wire used in the battery cables combines excellent flexibility and reliability with high electrical current carrying capacity. Refer to Wiring for the location of the proper battery cable wire gauge information. The battery cables cannot be repaired and, if damaged or faulty they must be replaced. Both the battery positive and negative cables are available for service replacement only as a unit with the battery positive cable wire harness or the battery negative cable wire harness, which may include portions of the wiring circuits for the generator and other components on some models. Most models feature a stamped brass clamping type female battery terminal crimped onto one end of the battery cable wire and then solder-dipped. A pinch-bolt and hex nut are installed at the open end of the female battery terminal clamp. The battery positive cable also includes a red molded rubber protective cover for the female battery terminal clamp. Large eyelet type terminals are crimped onto the opposite end of the battery cable wire and then solder-dipped. The battery positive cable wires have a red insulating jacket to provide visual identification and feature a larger female battery terminal clamp to allow connection to the larger battery positive terminal post. The battery negative cable wires have a black insulating jacket and a smaller female battery terminal clamp. The battery cables connect the battery terminal posts to the vehicle electrical system. These cables also provide a return path for electrical current generated by the charging system for restoring the voltage potential of the battery. The female battery terminal clamps on the ends of the battery cable wires provide a strong and reliable connection of the battery cable to the battery terminal posts. The terminal pinch bolts allow the female terminal clamps to be tightened around the male terminal posts on the top of the battery. The eyelet terminals secured to the ends of the battery cable wires opposite the female battery terminal clamps provide secure and reliable connection of the battery to the vehicle electrical system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 4447 Battery Cable: Testing and Inspection A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cables. If excessive resistance is found in the battery cable connections, the connection point should be disassembled, cleaned of all corrosion or foreign material, then reassembled. Following reassembly, check the voltage drop for the battery cable connection and the battery cable again to confirm repair. When performing the voltage drop test, it is important to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached. EXAMPLE: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud. If you probe the battery positive terminal post and the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud, you are reading the combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and the battery positive cable. VOLTAGE DROP TEST WARNING: MODELS EQUIPPED WITH A DIESEL ENGINE HAVE AN AUTOMATIC SHUTDOWN (ASD)RELAY LOCATED IN THE POWER DISTRIBUTION CENTER (PDC). REMOVAL OF THE ASD RELAY MAY NOT PREVENT THE DIESEL ENGINE FROM STARTING. BE CERTAIN TO DISCONNECT THE FUEL SHUTDOWN SOLENOID WIRE HARNESS CONNECTOR TO PREVENT THE ENGINE FROM STARTING. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY. The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing this test, be certain that the following procedures are accomplished: - The battery is fully-charged and tested . - Fully engage the parking brake. - If the vehicle is equipped with an automatic transmission, place the gearshift selector lever in the Park position. If the vehicle is equipped with a manual transmission, place the gearshift selector lever in the Neutral position and block the clutch pedal in the fully depressed position. - Verify that all lamps and accessories are turned off. - To prevent a gasoline engine from starting, remove the Automatic Shut Down (ASD) relay. The ASD relay is located in the Integrated Power Module (IPM), in the engine compartment. See the fuse and relay layout label on the underside of the IPM cover for ASD relay identification and location. Test Battery Negative Connection Resistance - Typical 1. Connect the positive lead of the voltmeter to the battery negative terminal post. Connect the negative lead of the voltmeter to the battery negative cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery negative cable terminal clamp and the battery negative terminal post. NOTE: If the vehicle is equipped with two 12v batteries, step #1 must be performed twice, once for each battery. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 4448 Test Battery Positive Connection Resistance - Typical 2. Connect the positive lead of the voltmeter to the battery positive terminal post. Connect the negative lead of the voltmeter to the battery positive cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery positive cable terminal clamp and the battery positive terminal post. NOTE: If the vehicle is equipped with two 12v batteries, step #2 must be performed twice, once for each battery. Test Battery Positive Cable Resistance - Typical 3. Connect the voltmeter to measure between the battery positive cable terminal clamp and the starter solenoid B(+) terminal stud. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery positive cable eyelet terminal connection at the starter solenoid B(+) terminal stud. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery positive cable. NOTE: If the vehicle is equipped with two 12v batteries, step #3 must be performed twice, once for each battery. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 4449 Test Ground Circuit 4. Connect the voltmeter to measure between the battery negative cable terminal clamp and a good clean ground on the engine block. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable. NOTE: If the vehicle is equipped with two 12v batteries, step #4 must be performed twice, once for each battery. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 4450 Battery Cable: Service and Repair REMOVAL 1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. 2. Disconnect and isolate the remote battery negative cable terminal. 3. Remove the battery from the vehicle. 4. One at a time, trace the battery cable retaining pushpins, fasteners and routing clips until the cable is free from the vehicle. 5. Remove the battery cable from the engine compartment. INSTALLATION 1. Position the battery cable in the engine compartment. 2. One at a time, install the battery cable retaining pushpins, fasteners and routing clips until the cable is installed exactly where it was in the vehicle. Refer to Wiring for illustrations. 3. Install the battery in the vehicle. 4. Connect the battery negative cable terminal. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Component Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 4455 Battery Temperature Sensor: Connector Locations Left Rear Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 4456 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 4457 Left Front Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 4458 Integrated Power Module And Fan Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4459 Sensor-Battery Temperature Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4460 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4461 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. 1. Remove battery. Refer to Battery for procedures. Battery Temperature Sensor Location 2. Pry sensor straight up from battery tray mounting hole to gain access to electrical connector. 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. 1. Pull electrical connector up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Refer to Battery for procedures. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown Battery Tray: Service and Repair Battery Holddown REMOVAL 1. Loosen and remove the battery hold down retaining bolt. 2. Remove the battery hold down bracket from the battery case. INSTALLATION 1. Clean and inspect the battery hold down hardware. 2. Position the battery hold down bracket in the battery tray. Be certain that the hold down bracket is properly positioned in the battery tray before tightening the hold down hardware. 3. Install and tighten the battery hold down retaining bolt. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown > Page 4466 Battery Tray: Service and Repair Battery Tray Left Side REMOVAL 1. Remove the battery from the battery tray . 2. Remove the integrated power module. 3. Disconnect the wire harness retainers from the battery tray assembly. 4. Remove the anti-lock brake controller (if equipped) retaining bolts and support the brake controller with mechanics wire. It is not necessary to completely remove the anti-lock brake control unit. 5. Remove the left front wheelhouse splash shield. 6. Mark the location of the cruise servo (if equipped) and remove the retaining screws. Position the servo out of the way. 7. Remove the battery temperature sensor from the battery tray. 8. Disconnect the purge solenoid from its mounting bracket. 9. Disconnect the left front fender ground wire. Lower Battery Tray Retaining Bolts 10. Remove the remaining battery tray retaining bolts. 11. Remove the battery tray from the vehicle. INSTALLATION 1. Position the battery tray assembly and install the retaining bolts. 2. Connect the left front fender ground wire. 3. Install the purge solenoid on its mounting bracket. 4. Install the battery temperature sensor in the battery tray. 5. Install the cruise servo (if equipped) and retaining screws. 6. Install the left front wheelhouse splash shield. 7. Install the anti-lock brake controller (if equipped). 8. Connect the wire harness retainers on the battery tray assembly. 9. Install the integrated power module. 10. Install the battery. Right Side REMOVAL 1. Remove the battery from the battery tray. 2. Remove the right front wheelhouse splash shield. 3. Disconnect the right front fender ground wire. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown > Page 4467 4. Remove fasteners from grid heater relay bracket. 5. Remove air box. Right Side Battery Tray 6. Remove the remaining battery tray retaining bolts. 7. Remove the battery tray from the vehicle. INSTALLATION 1. Position the battery tray assembly and install the retaining bolts. 2. Connect the right front fender ground wire. 3. Install the air box. 4. Install the grid heater relay bracket. 5. Install the right front wheelhouse splash shield. 6. Install the battery. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Connector Views Alternator: Connector Views Generator (SRT) Generator (Diesel/3.7L/4.7L/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 4473 Alternator: Description and 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 be 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 stator winding connections deliver the induced alternating current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified direct current is delivered to the vehicle electrical system through the generator battery terminal. 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 section at the back 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 4474 Alternator: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove air cleaner assembly, refer to the Engine/ air Intake System for more information. 3. Remove the accessory drive belt, refer to the Cooling section for more information. 4. Disconnect the field connector. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 4475 5. Disconnect the battery positive cable from the generator first disconnect the B+ cap on the wiring harness side. 6. Remove the upper mounting bolt (1). 7. Remove the lower mounting bolt and nut (2). 8. Remove generator. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 4476 INSTALLATION 1. Install generator. 2. Install lower mounting bolt and nut. 3. Install upper mounting bolt. 4. Tighten bolts to 55 N.m (41 ft. lbs). 5. Connect battery positive cable to generator, and install B+ stud cap. 6. Connect field connector. 7. Install accessory drive belt, refer to Cooling section for more information. 8. Install air cleaner assembly, refer to Engine/air Intake System for more information. 9. Connect negative battery cable, tighten nut to 14.2 N.m (125 in.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Description and Operation Voltage Regulator: Description and Operation The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the PCM (Powertrain Control Module) (within the ECM for diesel engines). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. The amount of direct 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 (B+) and battery temperature (refer to Battery Temperature Sensor for more information). It then determines a target charging voltage. If sensed battery voltage is 0.5 volts or lower than the target voltage, the PCM grounds the field winding until sensed battery voltage is 0.5 volt above target voltage. A circuit in the PCM cycles the ground side of the generator field up to 100 times per second (100Hz), but has the capability to ground the field control wire 100% of the time (full field) to achieve the target voltage. If the charging rate cannot be monitored (limp-in), a duty cycle of 25% is used by the PCM in order to have some generator output. Also refer to Charging System Operation for additional information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection SWITCH CLUTCH PEDAL- SRT-10 1. Disconnect the connector on the clutch position switch (1) from the vehicle wiring harness. 2. Place a ohmmeter across the terminals of the switch connector. The switch should show no continuity with the clutch pedal in the released (clutch engaged) position. 3. Slowly push the clutch pedal to the floor (clutch disengaged). The ohmmeter should show continuity just before the pedal reaches the end of its travel. 4. If the clutch switch shows continuity with clutch pedal up or no continuity with clutch pedal down, the switch is defective. The switch has no serviceable parts and should be replaced as an assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Testing and Inspection > Page 4484 Clutch Switch: Service and Repair SWITCH CLUTCH PEDAL POSITION REMOVAL 1. Disconnect the clutch pedal position switch connector. 2. Disconnect the clutch actuation rod from the clutch pedal. 3. Remove the clutch master cylinder from the toe box. 4. Remove the white clutch pedal position switch retaining clip (1). 5. Push the switch up (1) the rod (2) slightly. Then pull the bottom of the switch outward. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Testing and Inspection > Page 4485 1. Install new switch (1) as shown. Be sure that the spring loaded plunger inside the switch is slightly compressed. The plunger inside the switch must go on the narrow section of the clutch master cylinder actuation rod. Place the top of the switch against the rod. Then push the switch up slightly. This will compress the plunger. Then push the bottom of the switch against the rod. Failure to install the switch as described or forcing the switch onto the rod will crack the switch. 2. Install new white plastic retaining clip. 3. Install the clutch master cylinder back into the vehicle. 4. Reconnect the clutch switch connector. 5. Check clutch position switch operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 IGNITION SWITCH DESCRIPTION The ignition switch (5) is located on the steering column (4). It is used as the main on/off switching device for most electrical components. The mechanical key cylinder is used to engage/disengage the electrical ignition switch. OPERATION Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the shift cable. This interlock device is used to lock the transmission shifter in the PARK position when the key cylinder is in any position and the brake pedal is not depressed. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4490 Ignition Switch Lock Cylinder: Service and Repair KEY CYLINDER REMOVAL The ignition key (1) must be in the key cylinder (2) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at side of key cylinder assembly (2). a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. INSTALLATION The ignition key (1) must be in the key cylinder (2) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (2) with the ignition switch. 2. Push the key cylinder (2) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams Starter-Eyelet (3.7L/4.7L/5.7L Off Road/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Starter Motor Starter Motor: Testing and Inspection Starter Motor Correct starter motor operation can be confirmed by performing the following free running bench test. This test can only be performed with starter motor removed from vehicle. Refer to Specifications for starter motor specifications. 1. Remove starter motor from vehicle. Refer to Starter Motor Removal and Installation. 2. Mount starter motor securely in a soft-jawed bench vise. The vise jaws should be clamped on the mounting flange of starter motor. Never clamp on starter motor by field frame. 3. Connect a suitable volt-ampere tester and a 12-volt battery to starter motor in series, and set ammeter to 100 ampere scale. See instructions provided by manufacturer of volt-ampere tester being used. 4. Install jumper wire from solenoid terminal to solenoid battery terminal. The starter motor should operate. If starter motor fails to operate, replace faulty starter motor assembly. 5. Adjust carbon pile load of tester to obtain free running test voltage. Refer to Specifications for starter motor free running test voltage specifications. 6. Note reading on ammeter and compare reading to free running test maximum amperage draw. Refer to Specifications for starter motor free running test maximum amperage draw specifications. 7. If ammeter reading exceeds maximum amperage draw specification, replace faulty starter motor assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Starter Motor > Page 4496 Starter Motor: Testing and Inspection Starter Solenoid This test can only be performed with starter motor removed from vehicle. 1. Remove starter motor from vehicle. Refer to Starter Motor Removal and Installation. 2. Disconnect wire from solenoid field coil terminal. 3. Check for continuity between solenoid terminal and solenoid field coil terminal with a continuity tester. There should be continuity. If OK, go to Step 4. If not OK, replace faulty starter motor assembly. 4. Check for continuity between solenoid terminal and solenoid case. There should be continuity. If not OK, replace faulty starter motor assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Page 4497 Starter Motor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Raise vehicle and support. 3. Disconnect the solenoid connector. 4. Remove the positive battery cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Page 4498 5. Remove the upper bolt. 6. Remove the lower bolt. 7. Remove the starter. INSTALLATION 1. Install starter. 2. Install lower bolt. 3. Install upper bolt. 4. Install positive battery cable. 5. Connect solenoid connector. 6. Lower vehicle. 7. Connect negative battery cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Component Locations Starter Relay: Component Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Component Locations > Page 4503 Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4504 Starter Relay: Description and Operation The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted. If faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact. When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Starter Relay Starter Relay: Testing and Inspection Starter Relay Type 1 Relay The starter relay is located in Power Distribution Center (PDC). Refer to PDC cover for relay identification and location. For complete starter relay wiring circuit diagrams, refer to Wiring Diagrams. 1. Remove starter relay from PDC. 2. A relay in 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 faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace faulty relay. 4. Connect 12V 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, perform Relay Circuit Test that follows. If not OK, replace faulty relay. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 4507 Starter Relay: Testing and Inspection Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair open circuit to fuse in PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to common feed terminal (30) in the energized position. This terminal supplies battery voltage to starter solenoid field coils. There should be continuity between cavity for relay terminal 87 and starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair open circuit to starter solenoid as required. 4. The coil battery terminal (86) is connected to electromagnet in relay. It is energized when ignition switch is held in Start position. On vehicles with manual transmission, clutch pedal must be fully depressed for this test. Check for battery voltage at cavity for relay terminal 86 with ignition switch in Start position, and no voltage when ignition switch is released to On position. If OK, go to Step 5. If not OK with automatic transmission, check for open or short circuit to ignition switch and repair, if required. If circuit to ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. If not OK with a manual transmission, check circuit between relay and clutch pedal position switch for open or a short. If circuit is OK, refer to Clutch Pedal Position Switch in 6 , Clutch. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gearshift selector lever is in Park or Neutral positions. Check for continuity to ground at cavity for relay terminal 85. If not OK with manual transmission, repair circuit to ground as required. If not OK with automatic transmission, check for pen or short circuit to park/neutral position switch and repair, if required. If circuit to park/neutral position switch is OK, refer to Park/Neutral Position Switch in 21, Transmission. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Page 4508 Starter Relay: Service and Repair REMOVAL The starter relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Disconnect and isolate negative battery cable. 2. Remove cover from Power Distribution Center (PDC) for relay identification and location. 3. Remove starter relay from PDC. 4. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 5. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION 1. Push down firmly on starter relay until terminals are fully seated into PDC receptacle. 2. Install PDC cover. 3. Connect battery cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations Left Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations > Page 4512 Starter Solenoid: Testing and Inspection This test can only be performed with starter motor removed from vehicle. 1. Remove starter motor from vehicle. 2. Disconnect wire from solenoid field coil terminal. 3. Check for continuity between solenoid terminal and solenoid field coil terminal with a continuity tester (1). There should be continuity If OK, go to Step 4. If not OK, replace faulty starter motor assembly. 4. Check for continuity (2) between solenoid terminal and solenoid case. There should be continuity. If not OK, replace faulty starter motor assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4518 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4519 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4520 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4521 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4522 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4523 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4524 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4525 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4526 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4527 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4528 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4529 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4530 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4531 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4532 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4533 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4534 Auxiliary Power Outlet: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4535 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4536 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4537 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4538 Auxiliary Power Outlet: Connector Views Power Outlet (SRT) Power Outlet-Console (Except Base) Power Outlet-Instrument Panel Power Outlet-Rear (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4539 Auxiliary Power Outlet: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-41-2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4540 8w-41-3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4541 8w-41-4 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Instrument Panel Auxiliary Power Outlet: Description and Operation Instrument Panel A cigar lighter outlet is installed to the left of the center stack area in the lower instrument panel. The cigar lighter outlet is secured by a snap fit within the bezel. The cigar lighter outlet, plastic cap and the knob and heating element unit are available for service replacement. These components cannot be repaired and, if inoperative or damaged, they must be replaced. The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or outlet 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 Integrated Power Module (IPM) when the ignition switch is in the Accessory or Run positions. The cigar lighter knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the outlet shell, the heating element resistor coil is grounded through its housing to the outlet shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the outlet shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the outlet 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 outlet shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Instrument Panel > Page 4544 Auxiliary Power Outlet: Description and Operation Console Two power outlets are utilized on this model. One in the instrument panel center lower bezel and the other in the center console. The power outlet bases are secured by a snap fit within the instrument panel or trim panel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. 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. 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 integrated power module 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. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Page 4545 Auxiliary Power Outlet: Testing and Inspection POWER OUTLET For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Check the fused B(+) fuse in the Integrated Power Module (IPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the inoperative fuse. 2. Turn the ignition switch to the Run position. Check for battery voltage at the fused B(+) fuse in the IPM. If OK, go to Step 3. If not OK, repair the open or short as required. 3. Remove the cigar lighter knob and element from the cigar lighter outlet shell. Check for continuity between the inside circumference of the cigar lighter outlet shell and a good ground. there should be continuity. If OK, go to Step 4. If not OK, go to Step 5. 4. Turn the ignition switch to the Run position. Check for battery voltage at the insulated contact located at the back of the cigar lighter outlet shell. If OK, replace the inoperative cigar lighter knob and element. If not OK, go to Step 5. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. 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 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Turn the ignition switch to the Accessory or Run positions. Check for battery voltage at the fused B(+) circuit cavity of the cigar lighter wire harness connector. If OK, replace the inoperative cigar lighter outlet. If not OK, repair the open fused B(+) circuit to the IPM fuse as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Page 4546 Auxiliary Power Outlet: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Pull the cigar lighter knob and element (1) out of the cigar lighter receptacle base (6), or unsnap the protective cap from the power outlet receptacle base (6). 3. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses (3) of the mount that secures the receptacle base to the panel (4). 4. Insert a pair of external snap ring pliers (5) into the cigar lighter or 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 the mount. 6. Pull the receptacle base away from the instrument panel far enough to access the instrument panel wire harness connector (2). 7. Disconnect the instrument panel wire harness connector (2) from the cigar lighter or power outlet receptacle base (6). 8. Remove the cigar lighter or power outlet mount from the instrument panel. INSTALLATION 1. Connect the instrument panel wire harness connector to the cigar lighter or power outlet receptacle base connector receptacle. 2. Install the cigar lighter or power outlet mount into the instrument panel. 3. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 4. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 5. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 6. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Positive Temperature Coefficients (PTC) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations Integrated Power Module Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 4553 Electrical Accessory Panel: Description and Operation The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 4554 Electrical Accessory Panel: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 4555 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 4556 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations Fuse: Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4560 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4561 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4562 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Connector Views Fuse Holder (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 4565 Fuse: Application and ID Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 4566 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 4567 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 4568 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 4572 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 4573 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 4574 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Module - Integrated Power (Rear View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4577 Fuse Block: Application and ID Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4578 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4579 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4580 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations Power Distribution Module: Locations Left Front Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4584 Battery Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4585 Integrated Power Module And Fan Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4586 Power Distribution Module: Diagrams 8w-13-12 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4587 Module-Integrated Power C1 Module-Integrated Power C2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4588 Module-Integrated Power C3 Module-Integrated Power C4 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4589 Module-Integrated Power C5 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4590 Module-Integrated Power C6 Module-Integrated Power C7 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 4593 Power Distribution Module: Description and Operation Front Control Module The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit. As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the FCM: - Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the FCM: - B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Data Bus Circuit Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 4594 Power Distribution Module: Testing and Inspection FRONT CONTROL MODULE The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus network and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any FCM related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool. The most reliable, efficient, and accurate means to diagnose the FCM requires the use of an appropriate scan tool and the proper Diagnostic Procedures. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 4597 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 4598 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 4599 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect and isolate the battery negative cable (3). 2. Partially remove the Integrated Power Module (IPM) (4) from the engine compartment. 3. Remove the Front Control Module (FCM) retaining screws. 4. Using both hands, separate the FCM from the IPM assembly disengaging the 49-way electrical connector and remove the FCM from the vehicle. INSTALLATION 1. Install the Front Control Module (FCM) onto the Integrated Power Module (IPM) (4) by pushing the 49-way electrical connector straight in. 2. Install the FCM retaining screws. Torque the screws to 7 in. lbs. 3. Install the IPM. 4. Connect the battery negative cable. 5. Verify normal vehicle operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Component Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Component Locations > Page 4604 Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 4605 Relay-Run-Accessory (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 4606 Power Distribution Relay: Description and Operation RELAY-TRAILER TOW All vehicles are equipped with two trailer tow relays, one for the trailer right turn and brake lamps and the other for the trailer left turn and brake lamps. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. A trailer tow relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The trailer tow relays are electromechanical switches that use a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a right or left trailer tow turn relay control circuit. The FCM controls trailer brake and turn lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the trailer lamps through a right or left trailer tow turn relay output circuit and provides battery voltage to the right or left trailer brake and turn lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The trailer tow relays can be diagnosed using conventional diagnostic tools and methods. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation Power Interrupt Connector/Switch: Description and Operation IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (1) that is disconnected within the Integrated Power Module (IPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the IPM as part of the preparation procedures performed just prior to new vehicle delivery. A laser printed fuse layout map is integral to the IPM cover to ensure proper fuse identification. The IOD fuse (1) is a 20 ampere mini blade-type fuse, located in fuse cavity # 51. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in the IPM cavity, and as a fuse holder that conveniently stores the fuse in the same cavity after it has been disconnected. CIRCUITS INCLUDED WITH IOD FUSE - Cluster (CCN) - Diagnostic Connector - Map Lamps - Glove Box Lamp - Courtesy Lamps Radio - Underhood Lamp The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Integrated Power Module (IPM) fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations Power Distribution Module: Locations Left Front Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4614 Battery Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4615 Integrated Power Module And Fan Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4616 Power Distribution Module: Diagrams 8w-13-12 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4617 Module-Integrated Power C1 Module-Integrated Power C2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4618 Module-Integrated Power C3 Module-Integrated Power C4 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4619 Module-Integrated Power C5 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4620 Module-Integrated Power C6 Module-Integrated Power C7 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 4623 Power Distribution Module: Description and Operation Front Control Module The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit. As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the FCM: - Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the FCM: - B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Data Bus Circuit Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 4624 Power Distribution Module: Testing and Inspection FRONT CONTROL MODULE The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus network and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any FCM related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool. The most reliable, efficient, and accurate means to diagnose the FCM requires the use of an appropriate scan tool and the proper Diagnostic Procedures. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 4627 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 4628 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 4629 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect and isolate the battery negative cable (3). 2. Partially remove the Integrated Power Module (IPM) (4) from the engine compartment. 3. Remove the Front Control Module (FCM) retaining screws. 4. Using both hands, separate the FCM from the IPM assembly disengaging the 49-way electrical connector and remove the FCM from the vehicle. INSTALLATION 1. Install the Front Control Module (FCM) onto the Integrated Power Module (IPM) (4) by pushing the 49-way electrical connector straight in. 2. Install the FCM retaining screws. Torque the screws to 7 in. lbs. 3. Install the IPM. 4. Connect the battery negative cable. 5. Verify normal vehicle operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Component Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Component Locations > Page 4634 Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 4635 Relay-Run-Accessory (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 4636 Power Distribution Relay: Description and Operation RELAY-TRAILER TOW All vehicles are equipped with two trailer tow relays, one for the trailer right turn and brake lamps and the other for the trailer left turn and brake lamps. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. A trailer tow relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The trailer tow relays are electromechanical switches that use a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a right or left trailer tow turn relay control circuit. The FCM controls trailer brake and turn lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the trailer lamps through a right or left trailer tow turn relay output circuit and provides battery voltage to the right or left trailer brake and turn lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The trailer tow relays can be diagnosed using conventional diagnostic tools and methods. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4640 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4641 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4642 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4643 Module - Integrated Power (Rear View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4644 Relay Box: Application and ID Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4645 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4646 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4647 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4651 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4652 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4653 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4654 Module - Integrated Power (Rear View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4655 Relay Box: Application and ID Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4656 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4657 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4658 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation Power Interrupt Connector/Switch: Description and Operation IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (1) that is disconnected within the Integrated Power Module (IPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the IPM as part of the preparation procedures performed just prior to new vehicle delivery. A laser printed fuse layout map is integral to the IPM cover to ensure proper fuse identification. The IOD fuse (1) is a 20 ampere mini blade-type fuse, located in fuse cavity # 51. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in the IPM cavity, and as a fuse holder that conveniently stores the fuse in the same cavity after it has been disconnected. CIRCUITS INCLUDED WITH IOD FUSE - Cluster (CCN) - Diagnostic Connector - Map Lamps - Glove Box Lamp - Courtesy Lamps Radio - Underhood Lamp The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Integrated Power Module (IPM) fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4668 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4669 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4670 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4671 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4672 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4673 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4674 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4675 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4676 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4677 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4678 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4679 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4680 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4681 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4682 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4683 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4684 Auxiliary Power Outlet: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4685 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4686 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4687 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4688 Auxiliary Power Outlet: Connector Views Power Outlet (SRT) Power Outlet-Console (Except Base) Power Outlet-Instrument Panel Power Outlet-Rear (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4689 Auxiliary Power Outlet: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-41-2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4690 8w-41-3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4691 8w-41-4 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Instrument Panel Auxiliary Power Outlet: Description and Operation Instrument Panel A cigar lighter outlet is installed to the left of the center stack area in the lower instrument panel. The cigar lighter outlet is secured by a snap fit within the bezel. The cigar lighter outlet, plastic cap and the knob and heating element unit are available for service replacement. These components cannot be repaired and, if inoperative or damaged, they must be replaced. The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or outlet 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 Integrated Power Module (IPM) when the ignition switch is in the Accessory or Run positions. The cigar lighter knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the outlet shell, the heating element resistor coil is grounded through its housing to the outlet shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the outlet shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the outlet 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 outlet shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Instrument Panel > Page 4694 Auxiliary Power Outlet: Description and Operation Console Two power outlets are utilized on this model. One in the instrument panel center lower bezel and the other in the center console. The power outlet bases are secured by a snap fit within the instrument panel or trim panel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. 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. 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 integrated power module 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. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Page 4695 Auxiliary Power Outlet: Testing and Inspection POWER OUTLET For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Check the fused B(+) fuse in the Integrated Power Module (IPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the inoperative fuse. 2. Turn the ignition switch to the Run position. Check for battery voltage at the fused B(+) fuse in the IPM. If OK, go to Step 3. If not OK, repair the open or short as required. 3. Remove the cigar lighter knob and element from the cigar lighter outlet shell. Check for continuity between the inside circumference of the cigar lighter outlet shell and a good ground. there should be continuity. If OK, go to Step 4. If not OK, go to Step 5. 4. Turn the ignition switch to the Run position. Check for battery voltage at the insulated contact located at the back of the cigar lighter outlet shell. If OK, replace the inoperative cigar lighter knob and element. If not OK, go to Step 5. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. 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 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Turn the ignition switch to the Accessory or Run positions. Check for battery voltage at the fused B(+) circuit cavity of the cigar lighter wire harness connector. If OK, replace the inoperative cigar lighter outlet. If not OK, repair the open fused B(+) circuit to the IPM fuse as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Page 4696 Auxiliary Power Outlet: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Pull the cigar lighter knob and element (1) out of the cigar lighter receptacle base (6), or unsnap the protective cap from the power outlet receptacle base (6). 3. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses (3) of the mount that secures the receptacle base to the panel (4). 4. Insert a pair of external snap ring pliers (5) into the cigar lighter or 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 the mount. 6. Pull the receptacle base away from the instrument panel far enough to access the instrument panel wire harness connector (2). 7. Disconnect the instrument panel wire harness connector (2) from the cigar lighter or power outlet receptacle base (6). 8. Remove the cigar lighter or power outlet mount from the instrument panel. INSTALLATION 1. Connect the instrument panel wire harness connector to the cigar lighter or power outlet receptacle base connector receptacle. 2. Install the cigar lighter or power outlet mount into the instrument panel. 3. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 4. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 5. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 6. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Positive Temperature Coefficients (PTC) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations Integrated Power Module Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 4703 Electrical Accessory Panel: Description and Operation The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 4704 Electrical Accessory Panel: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 4705 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 4706 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations Fuse: Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4710 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4711 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4712 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Connector Views Fuse Holder (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 4715 Fuse: Application and ID Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 4716 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 4717 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 4718 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 4722 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 4723 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 4724 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Module - Integrated Power (Rear View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4727 Fuse Block: Application and ID Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4728 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4729 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4730 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations Power Distribution Module: Locations Left Front Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4734 Battery Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4735 Integrated Power Module And Fan Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4736 Power Distribution Module: Diagrams 8w-13-12 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4737 Module-Integrated Power C1 Module-Integrated Power C2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4738 Module-Integrated Power C3 Module-Integrated Power C4 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4739 Module-Integrated Power C5 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4740 Module-Integrated Power C6 Module-Integrated Power C7 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 4743 Power Distribution Module: Description and Operation Front Control Module The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit. As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the FCM: - Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the FCM: - B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Data Bus Circuit Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 4744 Power Distribution Module: Testing and Inspection FRONT CONTROL MODULE The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus network and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any FCM related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool. The most reliable, efficient, and accurate means to diagnose the FCM requires the use of an appropriate scan tool and the proper Diagnostic Procedures. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 4747 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 4748 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 4749 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect and isolate the battery negative cable (3). 2. Partially remove the Integrated Power Module (IPM) (4) from the engine compartment. 3. Remove the Front Control Module (FCM) retaining screws. 4. Using both hands, separate the FCM from the IPM assembly disengaging the 49-way electrical connector and remove the FCM from the vehicle. INSTALLATION 1. Install the Front Control Module (FCM) onto the Integrated Power Module (IPM) (4) by pushing the 49-way electrical connector straight in. 2. Install the FCM retaining screws. Torque the screws to 7 in. lbs. 3. Install the IPM. 4. Connect the battery negative cable. 5. Verify normal vehicle operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Component Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Component Locations > Page 4754 Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 4755 Relay-Run-Accessory (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 4756 Power Distribution Relay: Description and Operation RELAY-TRAILER TOW All vehicles are equipped with two trailer tow relays, one for the trailer right turn and brake lamps and the other for the trailer left turn and brake lamps. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. A trailer tow relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The trailer tow relays are electromechanical switches that use a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a right or left trailer tow turn relay control circuit. The FCM controls trailer brake and turn lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the trailer lamps through a right or left trailer tow turn relay output circuit and provides battery voltage to the right or left trailer brake and turn lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The trailer tow relays can be diagnosed using conventional diagnostic tools and methods. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation Power Interrupt Connector/Switch: Description and Operation IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (1) that is disconnected within the Integrated Power Module (IPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the IPM as part of the preparation procedures performed just prior to new vehicle delivery. A laser printed fuse layout map is integral to the IPM cover to ensure proper fuse identification. The IOD fuse (1) is a 20 ampere mini blade-type fuse, located in fuse cavity # 51. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in the IPM cavity, and as a fuse holder that conveniently stores the fuse in the same cavity after it has been disconnected. CIRCUITS INCLUDED WITH IOD FUSE - Cluster (CCN) - Diagnostic Connector - Map Lamps - Glove Box Lamp - Courtesy Lamps Radio - Underhood Lamp The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Integrated Power Module (IPM) fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations Power Distribution Module: Locations Left Front Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4764 Battery Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4765 Integrated Power Module And Fan Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4766 Power Distribution Module: Diagrams 8w-13-12 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4767 Module-Integrated Power C1 Module-Integrated Power C2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4768 Module-Integrated Power C3 Module-Integrated Power C4 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4769 Module-Integrated Power C5 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 4770 Module-Integrated Power C6 Module-Integrated Power C7 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 4773 Power Distribution Module: Description and Operation Front Control Module The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit. As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the FCM: - Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the FCM: - B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Data Bus Circuit Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 4774 Power Distribution Module: Testing and Inspection FRONT CONTROL MODULE The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus network and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any FCM related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool. The most reliable, efficient, and accurate means to diagnose the FCM requires the use of an appropriate scan tool and the proper Diagnostic Procedures. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 4777 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 4778 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 4779 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect and isolate the battery negative cable (3). 2. Partially remove the Integrated Power Module (IPM) (4) from the engine compartment. 3. Remove the Front Control Module (FCM) retaining screws. 4. Using both hands, separate the FCM from the IPM assembly disengaging the 49-way electrical connector and remove the FCM from the vehicle. INSTALLATION 1. Install the Front Control Module (FCM) onto the Integrated Power Module (IPM) (4) by pushing the 49-way electrical connector straight in. 2. Install the FCM retaining screws. Torque the screws to 7 in. lbs. 3. Install the IPM. 4. Connect the battery negative cable. 5. Verify normal vehicle operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Component Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Component Locations > Page 4784 Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 4785 Relay-Run-Accessory (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 4786 Power Distribution Relay: Description and Operation RELAY-TRAILER TOW All vehicles are equipped with two trailer tow relays, one for the trailer right turn and brake lamps and the other for the trailer left turn and brake lamps. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. A trailer tow relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The trailer tow relays are electromechanical switches that use a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a right or left trailer tow turn relay control circuit. The FCM controls trailer brake and turn lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the trailer lamps through a right or left trailer tow turn relay output circuit and provides battery voltage to the right or left trailer brake and turn lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The trailer tow relays can be diagnosed using conventional diagnostic tools and methods. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4790 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4791 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4792 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4793 Module - Integrated Power (Rear View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4794 Relay Box: Application and ID Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4795 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4796 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4797 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4801 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4802 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4803 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4804 Module - Integrated Power (Rear View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4805 Relay Box: Application and ID Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4806 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4807 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4808 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation Power Interrupt Connector/Switch: Description and Operation IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (1) that is disconnected within the Integrated Power Module (IPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the IPM as part of the preparation procedures performed just prior to new vehicle delivery. A laser printed fuse layout map is integral to the IPM cover to ensure proper fuse identification. The IOD fuse (1) is a 20 ampere mini blade-type fuse, located in fuse cavity # 51. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in the IPM cavity, and as a fuse holder that conveniently stores the fuse in the same cavity after it has been disconnected. CIRCUITS INCLUDED WITH IOD FUSE - Cluster (CCN) - Diagnostic Connector - Map Lamps - Glove Box Lamp - Courtesy Lamps Radio - Underhood Lamp The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Integrated Power Module (IPM) fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications Alignment: Specifications Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4817 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4818 Alignment: Description and Operation WHEEL ALIGNMENT DESCRIPTION NOTE: Suspension components with rubber/urethane bushings should be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur. Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. CAUTION: Never attempt to modify suspension or steering components by heating or bending. OPERATION - CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides less positive caster. Tilting the top of the knuckle rearward provides more positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns - CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire - TOE is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause's unstable steering, uneven tire wear and steering wheel off- center. The wheel toe position is the final front wheel alignment adjustment - THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4819 Alignment: Testing and Inspection PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart for additional information. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. 6. On 4x4 vehicles check suspension height (LD only). 7. Road test the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4820 Alignment: Service and Repair STANDARD PROCEDURE - CAMBER,CASTER AND TOE ADJUSTMENT NOTE: 4X4 (LD) SUSPENSION HEIGHT MEASUREMENT MUST BE PERFORMED BEFORE AN ALIGNMENT. Fig. 3 Camber and caster angle adjustments involve changing the position of the upper control arm with the slots in the frame brackets using special tool 8876 to move the upper control arm outwards for proper adjustment. NOTE: When the upper control arm pivot bolts are loosened the upper control arm will normally go inwards toward the frame automatically with the weight of the vehicle. CASTER Moving the front or rear position of the upper control arm in or out, will change the caster angle and camber angle significantly. To maintain the camber angle while adjusting caster, move one pivot bolt of the upper control arm in or out. Then move the other pivot bolt of the upper control arm in the opposite direction. Install special tool 8876 between the top of the upper control arm bracket and the upper control arm (on 1500 series 4X2 & 4X4). Install special tool 8876 between the bottom of the upper control arm bracket pressing the tool against the frame and the upper control arm (on 2500/3500 series 4X2) in order to move the upper control arm outwards for proper adjustment with the vehicle at normal ride height. To increase positive caster angle, move the rear position of the upper control arm inward (toward the engine). Move the front of the upper control arm outward (away from the engine) slightly until the original camber angle is obtained using special tool 8876 to move the upper control arm for proper adjustment. CAMBER Move both pivot bolts of the upper control arm together in or out. This will change the camber angle significantly and little effect on the caster angle using special tool 8876 to move the upper control arm for proper adjustment. After adjustment is made tighten the upper control arm nuts to proper torque specification. TOE ADJUSTMENT The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts. NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4821 Fig. 4 3. Adjust the wheel toe position by turning the inner tie rod as necessary. 4. Tighten the tie rod jam nut to 75 Nm (55 ft. lbs.). 5. Verify the specifications 6. Turn off engine. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4822 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation KNUCKLE DESCRIPTION The knuckle (1) is a single casting with legs machined for the upper and lower ball joints. The knuckle also has machined mounting locations for the front brake calipers (4) and hub bearing (5). OPERATION The steering knuckle pivot between the upper and lower ball joint. Steering linkage attached to the knuckle allows the vehicle to be steered. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation > Page 4827 Front Steering Knuckle: Service and Repair KNUCKLE REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, rotor, shield and ABS wheel speed sensor if equipped. 4. Remove the front halfshaft nut (if equipped). 5. Remove the tie rod end nut. Separate the tie rod from the knuckle with Remover 8677. CAUTION: When installing Remover 8677 to separate the ball joint, be careful not to damage the ball joint seal. 6. Remove the lower ball joint nut. Separate the ball joint from the knuckle with Remover 8677 and remove the knuckle. 7. Remove the upper ball joint nut. Separate the ball joint from the knuckle (1) with Remover 8677 (2) 8. Remove the hub/bearing from the steering knuckle. INSTALLATION CAUTION: The ball joint stud tapers must be CLEAN and DRY before installing the knuckle. Clean the stud tapers with mineral spirits to remove dirt and grease. NOTE: When installing hub/bearing with ABS brakes, position the speed sensor opening towards the front of the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation > Page 4828 1. Install the hub/bearing to the steering knuckle (1) and tighten the bolts to 163 Nm (120 ft. lbs.) (LD) or 176 Nm (130 ft. lbs.) (HD 4X2). 2. Install the knuckle (1) onto the upper and lower ball joints. 3. Install the upper and lower ball joint nuts (3). Tighten the upper ball joint nut to 54 Nm (40 ft. lbs.) (on 1500 series only an additional 90° turn is required) and the lower ball joint nut (3) to 52 Nm (38 ft. lbs.) (on 1500 series only an additional 90° turn is required) (LD) or 135 Nm (100 ft. lbs.) (HD 4X2). 4. Remove the hydraulic jack from the lower suspension arm. 5. Install the tie rod end and tighten the nut to 61 Nm (45 ft. lbs.). 6. Install the front halfshaft into the hub/bearing (if equipped). 7. Install the the halfshaft nut and tighten to 251 Nm (185 ft. lbs.) (if equipped). 8. Install the ABS wheel speed sensor if equipped and brake shield, rotor and caliper. 9. Install the wheel and tire assembly. 10. Remove the support and lower the vehicle. 11. Perform a wheel alignment. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Power Steering - Additive Prohibition Power Steering Fluid: Technical Service Bulletins Power Steering - Additive Prohibition NUMBER: 19-010-04 GROUP: Steering DATE: November 29, 2004 SUBJECT: Power Steering Fluid Contamination MODELS: 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR/DH) Ram Truck 2004 - 2005 (HB) Durango 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004 - 2005 (KJ) Liberty 2004 - 2005 (LX) 300/Magnum 2004 - 2005 (PL) Neon/SRT4 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2004 - 2005 (ST) Sebring Coupe/Stratus Coupe 2004 - 2005 (TJ) Wrangler 2004 - 2005 (ZB) Viper DISCUSSION: Do not use fluids or supplements that contain Teflon as they will cause a restriction at the filter in the power steering fluid reservoir, causing severe damage to the steering system. The power steering fluid used in Chrysler Group vehicles is an engineered product, the addition of ANY unapproved fluids or supplements can interfere with the proper function of the fluid and cause damage to the steering system. To ensure the performance and durability of Chrysler Group steering systems, use only Mopar Power Steering Fluid +4, ATF+4 Automatic Transmission Fluid, or equivalent (MS-9602), in the power steering system. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Power Steering - Additive Prohibition > Page 4834 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Power Steering - Additive Prohibition > Page 4835 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Power Steering - Additive Prohibition > Page 4836 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Power Steering - Additive Prohibition > Page 4837 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Power steering fluid capacities are dependent on engine/chassis options as well as steering gear/cooler options. Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these capacities may vary. Chrysler does not provide a capacity specification for this vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 4840 Power Steering Fluid: Fluid Type Specifications Power Steering Fluid Type ....................................................................................................................... Mopar ATF+4 Automatic Transmission Fluid Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Page 4841 Power Steering Fluid: Description and Operation FLUID NOTE: It is normal that some pressure will build up inside the reservoir, especially, with a warm vehicle. A slight popping noise upon removal of the cap is normal. The fluid level should read between the ADD and the FULL COLD marks. When the fluid is hot it should read between ADD and FULL HOT marks. Only add fluid when the vehicle is cold. The recommended fluid for the power steering system is Mopar(R) ATF +4. Mopar(R) ATF+4, when new is red in color. The ATF+4 is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition, As the vehicle is driven, the ATF+4 will begin to look darker in color and may eventually become brown. THIS IS NORMAL. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Page 4842 Power Steering Fluid: Testing and Inspection POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION: MOPAR(R) ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. The power steering fluid level can be viewed on the dipstick attached to the filler cap. There are two ranges listed on the dipstick, COLD and HOT. Before opening power steering system, wipe the reservoir filler cap free of dirt and debris. Remove the cap and check the fluid level on its dipstick. When the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the fluid level should read between the minimum and maximum area of the cold range. When the fluid is hot, fluid level is allowed to read up to the highest end of the HOT range. Only add fluid when the vehicle is cold. Use only Mopar(R) ATF+4 Do not overfill the power steering system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair Power Steering Fluid Cooler: Service and Repair FLUID COOLER REMOVAL 1. Drain and siphon the power steering fluid. 2. Remove the underneath splash shield. 3. Remove the two bolts (2) from the air deflector (40 between the bumper (3) and A/C condenser (1). 4. Disconnect the return and supply hoses connected to the power steering fluid cooler using special tool 8875. 5. Disconnect the hose mounting bracket (3). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Page 4846 6. Remove the mounting bracket bolts (1) securing the fluid cooler (3) to the brace. 7. Remove the fluid cooler (1) from the vehicle. NOTE: If needed disconnect the power steering fluid cooler hoses (3) from the fluid cooler (1) using special tool 8875 (2). INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Page 4847 1. Install the fluid cooler (1) to the vehicle. 2. Install the mounting bracket bolts (1) securing the fluid cooler (3) to the brace. 3. Reconnect the quick connect fitting (1) to the return and supply hoses to the power steering fluid cooler. 4. Install the hose retaining bracket (3). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Page 4848 5. Install the air deflector shield (4). 6. Install the lower front air deflector. 7. Refill the power steering fluid. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair Power Steering Fluid Reservoir: Service and Repair RESERVOIR REMOVAL 1. Remove power steering pump from vehicle. 2. Clean exterior of pump. 3. Clamp pump body in a soft jaw vice. NOTE: Use new retaining clips for installation. 4. Pry up tab and slide each retaining clip (2) off pump (1). Discard clips (2). 5. Remove fluid reservoir (1) from pump housing. Remove and discard o-ring seal. INSTALLATION 1. Lubricate new o-ring Seal with clean ATF+4 fluid or equivalent. 2. Install o-ring seal in housing. 3. Install reservoir (1) onto housing. 4. Slide and tap in NEW reservoir retainer clips (2) making sure each tab locks into place on housing. 5. Install power steering pump on vehicle. 6. Fill power steering pump reservoir to correct fluid level. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting Power Steering Line/Hose: Service and Repair Fluid Cooler Line Quick Connect Fitting STANDARD PROCEDURE - FLUID COOLER LINE QUICK CONNECT FITTING DISASSEMBLY 1. Remove dust cap (2) by pulling it straight back off of quick connect fitting (1). 2. Place disconnect tool (Special Tool 8875) (4) onto fluid cooler line with the fingers of the tool facing the quick connect fitting (1). 3. Slide disconnect tool down the line (3) and engage the fingers of the tool into the retaining clip. When properly engaged in the clip, the tool will fit flush against the quick connect fitting (1). 4. Rotate the disconnect tool 60° to expand the retaining clip. 5. While holding the disconnect tool (4) against the quick connect fitting (1), pull back on the oil cooler line to remove. ASSEMBLY Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 4856 1. Align fluid cooler line (3) with quick connect fitting (1) while pushing straight into the fitting. 2. Push in on oil cooler line until a "click" is heard or felt. 3. Slide dust cap (4) down the oil cooler line and snap it over the quick connect fitting until it is fully seated and rotates freely. Dust cap (4) will only snap over quick connect fitting when the cooler line is properly installed. NOTE: If dust cap will not snap into place, repeat assembly step #2. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 4857 Power Steering Line/Hose: Service and Repair Fluid Cooler Tube FLUID COOLER TUBE REMOVAL 1. Drain and siphon the power steering fluid. 2. Remove the underneath splash shield. 3. Disconnect the quick connect power steering fluid cooler tubes (3) from the fluid cooler (1) using special tool 8875 (2). 4. Disconnect the quick connect (1) return and supply tubes connected to the power steering fluid cooler using special tool 8875. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 4858 5. Remove the tube retaining bracket (4) and then the fluid cooler tubes (2). INSTALLATION 1. Reconnect the quick connect fitting (2) to the return and supply tubes (3) to the power steering fluid cooler (1). 2. Reconnect the quick connect fitting (2) to the return and supply tubes to the power steering fluid hoses. 3. Install the Tube retaining bracket (4). 4. Install the lower front air deflector. 5. Refill the power steering fluid. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 4859 Power Steering Line/Hose: Service and Repair Pressure Hose - Pump to Fan PRESSURE HOSE - PUMP TO FAN REMOVAL NOTE: Review all Warnings and Cautions. CAUTION: Cap all open ends of power steering hoses, power steering pump fittings and steering gear ports when disconnected. This will prevent the entry of foreign material into the components during servicing. 1. Siphon power steering fluid from fluid reservoir. 2. Unthread power steering pressure hose quick-connect (10) from power steering pump pressure fitting. Drain excess power steering fluid from line. 3. Unthread power steering pressure hose quick-connect (8) from hydraulic fan (6). Drain excess power steering fluid from line. 4. Remove power steering pressure hose (7) from routing clip on cooling module (5) . Remove hose. INSTALLATION NOTE: Before installing power steering hose, replace used o-rings as necessary. Clean hose ends and open ports with a lint-free cloth. Lubricate o-rings with clean power steering fluid. 1. If pressure hose is separate from quick-connect fittings: a. Thread quick-connect fitting (8) into cooling fan port. Tighten fitting to 28 Nm (21 ft. lbs.) torque. b. Slide fan end of pressure hose tube into quick-connect fitting until it locks into place. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 4860 2. If pressure hose has quick-connect fittings installed on ends, thread fan end quick-connect fitting into fan port. Tighten hose fitting to 28 Nm (21 ft. lbs.) torque. 3. Install power steering pressure hose into routing clip (7) on cooling module (5). 4. If pressure hose is separate from quick-connect fittings: a. Thread quick-connect fitting into power steering pump pressure fitting (10). Tighten hose fitting to 28 Nm (21 ft. lbs.) torque. b. Slide pump end of pressure hose tube into quick-connect fitting until it locks into place. 5. If pressure hose has quick-connect fittings installed on ends, thread pump end quick-connect fitting into power steering pump pressure fitting. Tighten fitting to 28 Nm (21 ft. lbs.) torque. 6. Fill power steering pump reservoir to correct fluid level. 7. Perform Power Steering Pump Initial Operation procedure. 8. Check for leaks at all hose connections. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 4861 Power Steering Line/Hose: Service and Repair Pressure Hose - Fan to Gear PRESSURE HOSE - FAN TO GEAR REMOVAL NOTE: Review all Warnings and Cautions. CAUTION: Cap all open ends of power steering hoses, power steering pump fittings and steering gear ports when disconnected. This will prevent the entry of foreign material into the components during servicing. 1. Siphon power steering fluid from fluid reservoir. 2. Unthread power steering pressure hose quick-connect (6) from hydraulic fan (1). Drain excess power steering fluid from line. 3. Unthread power steering pressure hose tube nut from power steering gear port. Drain excess power steering fluid from line. 4. Remove power steering pressure hose. INSTALLATION NOTE: Before installing power steering hose, replace used o-rings as necessary. Clean hose ends and open ports with a lint-free cloth. Lubricate o-rings with clean power steering fluid. 1. Thread power steering pressure hose tube nut on end of hose into power steering gear port. Tighten tube nut to 28 Nm (21 ft. lbs.) torque. 2. If fan end of pressure hose is separate from quickconnect fitting: a. Thread quick-connect fitting (6) into cooling fan port (1). Tighten fitting to 28 Nm (21 ft. lbs.) torque. b. Slide fan end of pressure hose tube into quickconnect fitting until it locks into place. 3. If fan end of pressure hose has quick-connect fitting installed, thread fan end quick-connect fitting into fan port. Tighten fitting to 28 Nm (21 ft. lbs.) torque. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 4862 4. Fill power steering pump reservoir to correct fluid level. 5. Perform Power Steering Pump Initial Operation procedure. 6. Check for leaks at all hose connections. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 4863 Power Steering Line/Hose: Service and Repair Fluid Cooler Line Quick Connect Fitting STANDARD PROCEDURE - FLUID COOLER LINE QUICK CONNECT FITTING DISASSEMBLY 1. Remove dust cap (2) by pulling it straight back off of quick connect fitting (1). 2. Place disconnect tool (Special Tool 8875) (4) onto fluid cooler line with the fingers of the tool facing the quick connect fitting (1). 3. Slide disconnect tool down the line (3) and engage the fingers of the tool into the retaining clip. When properly engaged in the clip, the tool will fit flush against the quick connect fitting (1). 4. Rotate the disconnect tool 60° to expand the retaining clip. 5. While holding the disconnect tool (4) against the quick connect fitting (1), pull back on the oil cooler line to remove. ASSEMBLY Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 4864 1. Align fluid cooler line (3) with quick connect fitting (1) while pushing straight into the fitting. 2. Push in on oil cooler line until a "click" is heard or felt. 3. Slide dust cap (4) down the oil cooler line and snap it over the quick connect fitting until it is fully seated and rotates freely. Dust cap (4) will only snap over quick connect fitting when the cooler line is properly installed. NOTE: If dust cap will not snap into place, repeat assembly step #2. Fluid Cooler Tube FLUID COOLER TUBE REMOVAL 1. Drain and siphon the power steering fluid. 2. Remove the underneath splash shield. 3. Disconnect the quick connect power steering fluid cooler tubes (3) from the fluid cooler (1) using special tool 8875 (2). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 4865 4. Disconnect the quick connect (1) return and supply tubes connected to the power steering fluid cooler using special tool 8875. 5. Remove the tube retaining bracket (4) and then the fluid cooler tubes (2). INSTALLATION 1. Reconnect the quick connect fitting (2) to the return and supply tubes (3) to the power steering fluid cooler (1). 2. Reconnect the quick connect fitting (2) to the return and supply tubes to the power steering fluid hoses. 3. Install the Tube retaining bracket (4). 4. Install the lower front air deflector. 5. Refill the power steering fluid. Pressure Hose - Pump to Fan Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 4866 PRESSURE HOSE - PUMP TO FAN REMOVAL NOTE: Review all Warnings and Cautions. CAUTION: Cap all open ends of power steering hoses, power steering pump fittings and steering gear ports when disconnected. This will prevent the entry of foreign material into the components during servicing. 1. Siphon power steering fluid from fluid reservoir. 2. Unthread power steering pressure hose quick-connect (10) from power steering pump pressure fitting. Drain excess power steering fluid from line. 3. Unthread power steering pressure hose quick-connect (8) from hydraulic fan (6). Drain excess power steering fluid from line. 4. Remove power steering pressure hose (7) from routing clip on cooling module (5) . Remove hose. INSTALLATION NOTE: Before installing power steering hose, replace used o-rings as necessary. Clean hose ends and open ports with a lint-free cloth. Lubricate o-rings with clean power steering fluid. 1. If pressure hose is separate from quick-connect fittings: a. Thread quick-connect fitting (8) into cooling fan port. Tighten fitting to 28 Nm (21 ft. lbs.) torque. b. Slide fan end of pressure hose tube into quick-connect fitting until it locks into place. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 4867 2. If pressure hose has quick-connect fittings installed on ends, thread fan end quick-connect fitting into fan port. Tighten hose fitting to 28 Nm (21 ft. lbs.) torque. 3. Install power steering pressure hose into routing clip (7) on cooling module (5). 4. If pressure hose is separate from quick-connect fittings: a. Thread quick-connect fitting into power steering pump pressure fitting (10). Tighten hose fitting to 28 Nm (21 ft. lbs.) torque. b. Slide pump end of pressure hose tube into quick-connect fitting until it locks into place. 5. If pressure hose has quick-connect fittings installed on ends, thread pump end quick-connect fitting into power steering pump pressure fitting. Tighten fitting to 28 Nm (21 ft. lbs.) torque. 6. Fill power steering pump reservoir to correct fluid level. 7. Perform Power Steering Pump Initial Operation procedure. 8. Check for leaks at all hose connections. Pressure Hose - Fan to Gear PRESSURE HOSE - FAN TO GEAR REMOVAL NOTE: Review all Warnings and Cautions. CAUTION: Cap all open ends of power steering hoses, power steering pump fittings and steering gear ports when disconnected. This will prevent the entry of foreign material into the components during servicing. 1. Siphon power steering fluid from fluid reservoir. 2. Unthread power steering pressure hose quick-connect (6) from hydraulic fan (1). Drain excess power steering fluid from line. 3. Unthread power steering pressure hose tube nut from power steering gear port. Drain excess power steering fluid from line. 4. Remove power steering pressure hose. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 4868 INSTALLATION NOTE: Before installing power steering hose, replace used o-rings as necessary. Clean hose ends and open ports with a lint-free cloth. Lubricate o-rings with clean power steering fluid. 1. Thread power steering pressure hose tube nut on end of hose into power steering gear port. Tighten tube nut to 28 Nm (21 ft. lbs.) torque. 2. If fan end of pressure hose is separate from quickconnect fitting: a. Thread quick-connect fitting (6) into cooling fan port (1). Tighten fitting to 28 Nm (21 ft. lbs.) torque. b. Slide fan end of pressure hose tube into quickconnect fitting until it locks into place. 3. If fan end of pressure hose has quick-connect fitting installed, thread fan end quick-connect fitting into fan port. Tighten fitting to 28 Nm (21 ft. lbs.) torque. 4. Fill power steering pump reservoir to correct fluid level. 5. Perform Power Steering Pump Initial Operation procedure. 6. Check for leaks at all hose connections. Return Hose - Fan to Pump RETURN HOSE - FAN TO PUMP REMOVAL NOTE: Review all Warnings and Cautions. CAUTION: Cap all open ends of power steering hoses, power steering pump fittings and steering gear ports when disconnected. This will prevent the entry of foreign material into the components during servicing. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 4869 1. Siphon power steering fluid from fluid reservoir. 2. Remove clamp, then return hose at reservoir (9). 3. Remove clamp, then return hose at fan (9). 4. Remove hose. INSTALLATION NOTE: Before installing power steering hose, clean open power steering hose ends and fittings with a lint-free towel. 1. Slide hose clamps onto ends of return hose far enough to clear molded fitting on pump reservoir and fan fitting once hose is installed. 2. Slide fan end of return hose (9) onto fan fluid fitting. Expand hose clamp and slide it into position on hose past bead formed into fitting. 3. Install power steering pressure hose into routing clip (7) on cooling module (5). 4. Slide pump end of return hose (9) onto molded fitting on pump reservoir (3). Expand hose clamp and slide it into position on hose past bead formed into reservoir fitting. 5. Fill power steering pump reservoir to correct fluid level. 6. Perform Power Steering Pump Initial Operation procedure. 7. Check for leaks at all hose connections. Return Hose - Gear to Cooler RETURN HOSE - GEAR TO COOLER REMOVAL NOTE: Review all Warnings and Cautions. CAUTION: Cap all open ends of power steering hoses, power steering pump fittings and steering gear ports when disconnected. This will prevent the entry of foreign material into the components during servicing. 1. Siphon power steering fluid from fluid reservoir. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 4870 2. Unthread power steering return hose tube nut from power steering gear port (1). Pull tube out of gear port and drain excess power steering fluid from line. 3. Raise vehicle. 4. Remove front splash shield 5. Disconnect the quick connect fittings (1) on the cooler hose going to the cooler using special tool 8875. INSTALLATION NOTE: Before installing power steering hose, replace used o-rings as necessary. Clean hose ends, fittings and open ports with a lint-free cloth. Lubricate o-rings with clean power steering fluid. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 4871 1. Install return hose into engine compartment using reverse of how it was removed. 2. Install hose at fluid cooler to the quick connect (1). 3. Install front air deflector. 4. Lower vehicle. 5. Thread return hose tube nut on gear end of hose into power steering gear port. Tighten tube nut to 28 Nm (21 ft. lbs.) torque. 6. Fill power steering pump reservoir to correct fluid level. 7. Perform Power Steering Pump Initial Operation procedure. 8. Check for leaks at all hose connections. Return Hose - Cooler to Pump RETURN HOSE - COOLER TO PUMP REMOVAL NOTE: Review all Warnings and Cautions. CAUTION: Cap all open ends of power steering hoses, power steering pump fittings and steering gear ports when disconnected. This will prevent the entry of foreign material into the components during servicing. 1. Siphon power steering fluid from fluid reservoir. 2. Remove clamp, then return hose at reservoir. 3. Raise vehicle. 4. Remove front air deflector. 5. Disconnect the quick connect filling (6) at the return hose from the metal line at the cooler using special tool 8875. INSTALLATION NOTE: Before installing power steering hose, replace used o-rings as necessary. Clean hose ends, fittings and open ports with a lint-free cloth. Lubricate o-rings with clean power steering fluid. 1. Install hose into engine compartment using reverse of how it was removed. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Fluid Cooler Line Quick Connect Fitting > Page 4872 2. Reconnect the quick connect fitting (6) of the hose at fluid cooler (5). 3. Install front air deflector. 4. Lower vehicle. 5. Slide pump end of return hose onto molded fitting of pump reservoir. Expand hose clamp and slide it into position on hose past bead formed into reservoir fitting. 6. Fill power steering pump reservoir to correct fluid level. 7. Perform Power Steering Pump Initial Operation procedure. 8. Check for leaks at all hose connections. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4877 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4878 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4879 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Page 4880 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Pump Leakage Power Steering Pump: Testing and Inspection Pump Leakage PUMP LEAKAGE The pump is serviced as an assembly and should not be disassembled. The plastic pump reservoir and the reservoir o-rings can be replaced. Check for leaks in the following areas: Pump shaft seal behind the pulley - Pump to reservoir o-ring - Reservoir cap - Pressure and return lines - Flow control valve fitting Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Pump Leakage > Page 4883 Power Steering Pump: Testing and Inspection Hydraulic Flow and Pressure HYDRAULIC FLOW AND PRESSURE The following procedures are used to test the operation of the power steering and hydraulic fan systems on this vehicle. These tests will provide the Gallons Per Minute (GPM) or flow rate of the power steering pump along with the maximum relief pressure at given points in the system. Perform the first test anytime a power steering system problem is present and the second as necessary once the first test is completed. These tests will determine if the power steering pump, hydraulic fan, or power steering gear is not functioning properly. They will also determine if the flow coming out of the hydraulic fan motor is sufficient for the power steering gear. The following pressure and flow tests are performed using the Power Steering Analyzer kit 6815 (with appropriate hoses) and Adapter kit 9091. FLOW AND PRESSURE TEST - AT POWER STEERING PUMP 1. Check power steering belt to ensure it is in good condition and adjusted properly. 2. Assemble Power Steering Analyzer as follows: a. Gauge end (inlet) of Flow Meter And Gauge 6800 - Hose 6905, Hose 6713, Adapter Tube 9091-1 b. Valve end (outlet) of Flow Meter And Gauge 6800 - Hose 6959, Adapter Fitting 9091-3 3. Unthread pressure hose quick-connect fitting from power steering pump. 4. Connect Adapter Tube 9091-1 to pressure fitting on power steering pump. 5. Connect power steering pressure hose to Adapter Fitting 9091-3. 6. Open Analyzer test valve completely. 7. Start engine and allow to idle long enough to circulate power steering fluid through Analyzer flow meter and hoses. 8. Shut off engine and check fluid level; add fluid as necessary. Repeat Step 7 and Step 8 until air is bled from system. 9. Start engine and allow to idle. 10. Check Analyzer gauge pressure. Initial pressure reading should be 483 - 690 kPa (70 - 100 psi). If pressure is higher, inspect hoses for restrictions and repair as necessary. 11. Increase engine speed to 1100 rpm and read Analyzer Flow Meter. The reading should be 2.6 GPM minimum. If flow reading is below specification, replace power steering pump. FLOW AND PRESSURE TEST - AT POWER STEERING GEAR NOTE: This test should only be done if necessary after completing the Pump Flow And Pressure Test 1. Remove Analyzer from pump and pressure hose to fan. Reattach pressure hose to pump. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Pump Leakage > Page 4884 2. Assemble Power Steering Analyzer as follows: a. Gauge end (inlet) of Flow Meter And Gauge 6800 - Hose 6959, Adapter Fitting 9091-4 b. Valve end (outlet) of Flow Meter And Gauge 6800 - Hose 6905, Hose 6713, Adapter Tube 9091-2 3. Unthread pressure hose tube nut from power steering gear. 4. Connect power steering pressure hose to Adapter Fitting 9091-4. 5. Connect Adapter Tube 9091-2 to power steering gear. 6. Open Analyzer test valve completely. 7. Start engine and allow to idle long enough to circulate power steering fluid through Analyzer flow meter and hoses. 8. Shut off engine and check fluid level; add fluid as necessary. Repeat Step 7 and Step 8 until air is bled from system. 9. Start engine and allow to idle. 10. Check Analyzer gauge pressure. Initial pressure reading should be 345 - 552 kPa (50 - 80 psi). If pressure is higher, inspect hoses for restrictions and repair as necessary. 11. Increase engine speed to 1500 RPM and read Analyzer Flow Meter. The reading should be 2.4 - 2.8 GPM. If flow reading is below specification, replace hydraulic fan. CAUTION: This next step involves testing maximum fan motor steering relief pressure. Do not leave the valve closed for more than three seconds. 12. Close Analyzer valve fully three times for three seconds each time and record highest pressure indicated on Analyzer gauge each time. All three readings must be within fan motor steering relief pressure specifications. 13. Completely open test valve and turn steering wheel to the extreme left and right positions against stops. Record the highest pressure readings at each position. If pressure readings are not within 50 psi from each other, the gear is leaking internally and must be replaced. PUMP OUTLET SPECIFICATIONS GEAR INLET SPECIFICATIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Standard Procedure-Flushing Power Steering System Power Steering Pump: Service and Repair Standard Procedure-Flushing Power Steering System FLUSHING POWER STEERING SYSTEM Flushing is required when the power steering/hydraulic booster system fluid has become contaminated. Contaminated fluid in the steering/booster system can cause seal deterioration and affect steering gear/booster spool valve operation. 1. Raise the front end of the vehicle off the ground until the wheels are free to turn. 2. Remove the return line from the pump. NOTE: If vehicle is equipped with a hydraulic booster remove both return lines from the pump. 3. Plug the return line port/ports at the pump. 4. Position the return line/lines into a large container to catch the fluid. 5. While an assistant is filling the pump reservoir start the engine. 6. With the engine running at idle turn the wheel back and forth. NOTE: Do not contact or hold the wheel against the steering stops. 7. Run a quart of fluid through the system then stop the engine and install the return line/lines. 8. Fill the system with fluid and perform Steering Pump Initial Operation. 9. Start the engine and run it for fifteen minutes then stop the engine. 10. Remove the return line/lines from the pump and plug the pump port/ports. 11. Pour fresh fluid into the reservoir and check the draining fluid for contamination. If the fluid is still contaminated, then flush the system again. 12. Install the return line/lines and perform Steering Pump Initial Operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Standard Procedure-Flushing Power Steering System > Page 4887 Power Steering Pump: Service and Repair Power Steering Pump - Initial Operation INITIAL OPERATION WARNING: THE FLUID LEVEL SHOULD BE CHECKED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING COMPONENTS. NOTE: Remove as much of the old fluid out of the system as possible with a suction tool or by removing a hose, When a component has failed. Then refill it with fresh fluid until it is clean. This may have to be done more than once. CAUTION: MOPAR(R) ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. Wipe filler cap clean, then check the fluid level. The dipstick should indicate COLD when the fluid is at normal ambient temperature. 1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two 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 use the DRB III to activate the hydraulic fan on full fan operation. 8. Turn the steering wheel slowly from lock to lock. 9. Stop the engine, check the fluid level and refill as required and repeat the process CAUTION: Do not run a vehicle with foamy fluid for an extended period. This may cause pump damage. 10. If the fluid is extremely foamy or milky looking, allow the vehicle to stand a few minutes and repeat the procedure. 11. While the vehicle is in park, use the DRB III to activate the hydraulic fan to full fan operation and briefly rev the engine up to 3000 rpm to fully engage the hydraulic fan. 12. Check the fluid level add if necessary. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Standard Procedure-Flushing Power Steering System > Page 4888 Power Steering Pump: Service and Repair Removal and Installation PUMP REMOVAL NOTE: Review all Warnings and Cautions. CAUTION: Cap all open ends of power steering hoses, power steering pump fittings and steering gear ports when disconnected. This will prevent the entry of foreign material into the components during servicing. 1. Disconnect negative (-) cable from battery and isolate cable. 2. Siphon power steering fluid from fluid reservoir. 3. Remove the coolant recovery container. 4. Remove the air cleaner housing lid and tube assembly. 5. Remove accessory drive belt from tensioner pulley and power steering pump drive pulley. 6. Unthread quick-connect fitting and remove power steering pressure hose from power steering pump pressure fitting. Drain excess power steering fluid from line. 7. Disconnect A/C clutch coil wire connector (2). 8. Remove return hose from radiator fan at power steering pump reservoir. 9. Remove return hose from fluid cooler at Dower steering pump reservoir. 10. Remove three bolts mounting power steering pump (5) to engine. 11. Remove power steering pump. 12. If required, transfer necessary parts from removed power steering pump to replacement power steering pump. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Standard Procedure-Flushing Power Steering System > Page 4889 1. Install power steering pump (1) in reverse order of removal. 2. Install three power steering pump mounting bolts. Tighten mounting bolts to 23 Nm (200 inch lbs.) torque. 3. Install return hose from fluid cooler on fitting of power steering pump reservoir. Install hose clamp on return hose past upset bead on power steering reservoir fitting. 4. Install return hose from radiator fan on fitting of power steering pump reservoir. Install hose clamp on return hose past upset bead on power steering reservoir fitting. 5. Install power steering pressure hose in power steering pump pressure fitting. Tighten pressure hose quick-connect fitting to 28 Nm (21 ft. lbs.) torque. 6. Connect A/C clutch coil wire connector (2). 7. Install accessory drive belt. 8. Install the air cleaner housing lid and tube assembly. 9. Install the coolant recovery container. 10. Connect the battery negative (-) cable to battery negative battery terminal. 11. Fill power steering pump reservoir to correct fluid level. 12. Perform Power Steering Pump Initial Operation procedure. 13. Check for leaks at all hose connections. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Standard Procedure-Flushing Power Steering System > Page 4890 Power Steering Pump: Service and Repair Pulley PULLEY REMOVAL 1. Remove the power steering pump assembly (1). 2. Remove the pulley (2) from the pump using NOTCH 7185) power steering pulley removal tool or equivalent (3). INSTALLATION 1. Replace pulley (1) if bent, cracked, or loose. 2. Install pulley (1) on pump with Installer C-4063-B (2) 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 minutes) 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Page 4891 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING 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 disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation KEY-IN IGNITION SWITCH DESCRIPTION The key-in ignition switch is integral to the ignition switch, which is mounted on the left side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition key cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition key cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 19-003-05 > May > 05 > Steering - Movement Felt in Column Steering Column Bearing: Customer Interest Steering - Movement Felt in Column NUMBER: 19-003-05 GROUP: Steering DATE: May 03, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-012-04, DATED DECEMBER 13, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CLARIFICATION OF THE SYMPTOM AND DIAGNOSIS. SUBJECT: In And Out Movement In Steering Column OVERVIEW: This bulletin involves replacing the steering column upper bearing retainer. MODELS: 2003 - 2005 (DR) Ram Truck 2004 - 2005 (HB) Durango 2005 ((ND) Dakota NOTE: This bulletin applies to vehicles built after December 1, 2003 (MDH 1201XX) SYMPTOM/CONDITION: **The vehicle operator may describe a small amount of movement in the steering column when pulling the steering wheel toward you while seated in the driver's seat** DIAGNOSIS: **While seated in the driver's seat, attempt to push and pull the steering wheel in and out. If the steering column exhibits any in and out movement, perform the Repair Procedure.** PARTS REQUIRED: REPAIR PROCEDURE: WARNING: The steering column bearing retainer is spring loaded and could fly off the shaft during this repair. Safety glasses should be worn at all times. 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. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE. 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. 1. Disconnect and isolate the negative battery terminal. Wait at least two minutes for the airbag system capacitor to discharge prior to disassembling the steering column. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 19-003-05 > May > 05 > Steering - Movement Felt in Column > Page 4907 NOTE: If you are not familiar with steering column and air bag repair procedures, refer section 19 of the appropriate Service Manual for detailed procedures and safety precautions. 2. Remove the drivers air bag, steering wheel, steering column shroud, clock spring and multifunction switch. 3. Inspect the wave spring under existing retainer (Fig. 1). If spring is fully compressed, stop this procedure and replace column. If the spring is not fully compressed, proceed to step 4. 4. With the ignition key removed, rotate steering wheel until it locks (you may have to reinstall wheel in order to rotate shaft) 5. Remove bearing retainer from shaft if possible by hand, with pliers, or by placing a screwdriver underneath retainer and prying upward (Fig. 2). If the retainer can be removed, proceed to step 7. If the retainer will not come off the shaft, continue with step 6. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 19-003-05 > May > 05 > Steering - Movement Felt in Column > Page 4908 6. Use a sharp 1/4" chisel to score the retainer as shown (Fig. 3). Be careful not to damage any of the surrounding components with chisel. Only apply enough force to score the retainer. Do not attempt to break completely through the retainer with the chisel, this excessive force will damage the bearings. Remove any material particles that might fall into the bearing pocket. 7. Insert a screwdriver under retainer (near score mark) and pry the retainer upward until it breaks. If unsuccessful, re-score the retainer again and try again. 8. Discard old retainer and wave spring. Make sure shaft is pulled upward (toward driver) as far as possible and the bearing race and wedge are sitting tightly inside of bearing. 9. Install the new wave spring and retainer on wedge on shaft. 10. Check steering column shaft threads by hand tightening installation tool bolt provided in the kit into shaft approximately 1/2" and removing. If bolt threads easily into shaft proceed to step 9. If bolt does not thread easily into shaft, re-tap the hole using an M10 x 1.5 tap. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 19-003-05 > May > 05 > Steering - Movement Felt in Column > Page 4909 11. Place bearing installation tool onto shaft until it contacts retainer (Fig. 4). 12. Insert the bolt into steering column shaft. Hand tighten until threads are fully engaged. Tighten bolt down with 15 mm socket wrench until the tool bottoms out on bearing. You may hear a clicking noise as the retainer is being pressed down onto the shaft, this is normal. 13. Remove bolt and tool. Inspect retainer and spring (Fig. 1). The spring should be centered under the retainer and compressed as shown. If the spring is not centered under retainer it may be pushed towards the shaft using a screwdriver (do not damage spring). If spring needs adjusting, repeat step 12 to ensure the retainer is in the correct position. 14. Install the multifunction switch, clock spring, steering column shroud, steering wheel and drivers air bag. 15. Connect the negative battery cable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 19-003-05 > May > 05 > Steering Movement Felt in Column Steering Column Bearing: All Technical Service Bulletins Steering - Movement Felt in Column NUMBER: 19-003-05 GROUP: Steering DATE: May 03, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-012-04, DATED DECEMBER 13, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CLARIFICATION OF THE SYMPTOM AND DIAGNOSIS. SUBJECT: In And Out Movement In Steering Column OVERVIEW: This bulletin involves replacing the steering column upper bearing retainer. MODELS: 2003 - 2005 (DR) Ram Truck 2004 - 2005 (HB) Durango 2005 ((ND) Dakota NOTE: This bulletin applies to vehicles built after December 1, 2003 (MDH 1201XX) SYMPTOM/CONDITION: **The vehicle operator may describe a small amount of movement in the steering column when pulling the steering wheel toward you while seated in the driver's seat** DIAGNOSIS: **While seated in the driver's seat, attempt to push and pull the steering wheel in and out. If the steering column exhibits any in and out movement, perform the Repair Procedure.** PARTS REQUIRED: REPAIR PROCEDURE: WARNING: The steering column bearing retainer is spring loaded and could fly off the shaft during this repair. Safety glasses should be worn at all times. 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. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE. 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. 1. Disconnect and isolate the negative battery terminal. Wait at least two minutes for the airbag system capacitor to discharge prior to disassembling the steering column. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 19-003-05 > May > 05 > Steering Movement Felt in Column > Page 4915 NOTE: If you are not familiar with steering column and air bag repair procedures, refer section 19 of the appropriate Service Manual for detailed procedures and safety precautions. 2. Remove the drivers air bag, steering wheel, steering column shroud, clock spring and multifunction switch. 3. Inspect the wave spring under existing retainer (Fig. 1). If spring is fully compressed, stop this procedure and replace column. If the spring is not fully compressed, proceed to step 4. 4. With the ignition key removed, rotate steering wheel until it locks (you may have to reinstall wheel in order to rotate shaft) 5. Remove bearing retainer from shaft if possible by hand, with pliers, or by placing a screwdriver underneath retainer and prying upward (Fig. 2). If the retainer can be removed, proceed to step 7. If the retainer will not come off the shaft, continue with step 6. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 19-003-05 > May > 05 > Steering Movement Felt in Column > Page 4916 6. Use a sharp 1/4" chisel to score the retainer as shown (Fig. 3). Be careful not to damage any of the surrounding components with chisel. Only apply enough force to score the retainer. Do not attempt to break completely through the retainer with the chisel, this excessive force will damage the bearings. Remove any material particles that might fall into the bearing pocket. 7. Insert a screwdriver under retainer (near score mark) and pry the retainer upward until it breaks. If unsuccessful, re-score the retainer again and try again. 8. Discard old retainer and wave spring. Make sure shaft is pulled upward (toward driver) as far as possible and the bearing race and wedge are sitting tightly inside of bearing. 9. Install the new wave spring and retainer on wedge on shaft. 10. Check steering column shaft threads by hand tightening installation tool bolt provided in the kit into shaft approximately 1/2" and removing. If bolt threads easily into shaft proceed to step 9. If bolt does not thread easily into shaft, re-tap the hole using an M10 x 1.5 tap. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 19-003-05 > May > 05 > Steering Movement Felt in Column > Page 4917 11. Place bearing installation tool onto shaft until it contacts retainer (Fig. 4). 12. Insert the bolt into steering column shaft. Hand tighten until threads are fully engaged. Tighten bolt down with 15 mm socket wrench until the tool bottoms out on bearing. You may hear a clicking noise as the retainer is being pressed down onto the shaft, this is normal. 13. Remove bolt and tool. Inspect retainer and spring (Fig. 1). The spring should be centered under the retainer and compressed as shown. If the spring is not centered under retainer it may be pushed towards the shaft using a screwdriver (do not damage spring). If spring needs adjusting, repeat step 12 to ensure the retainer is in the correct position. 14. Install the multifunction switch, clock spring, steering column shroud, steering wheel and drivers air bag. 15. Connect the negative battery cable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Column Bearing: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Clutch Control Solenoid Valve: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Opening Cover Steering Column Cover: Service and Repair Steering Column Opening Cover REMOVAL 1. Remove the two screws (1) that secure the bottom of the steering column opening cover (2) to the instrument panel. 2. Using a trim stick C-4755 or equivalent, release the two retainer clips that secure the top of the steering column opening cover to the instrument panel and remove the cover. INSTALLATION 1. Position the steering column opening cover (2) to the instrument panel and fully engage the two upper retainer clips to the instrument panel. 2. Install the two screws (1) that secure the steering column opening cover to the instrument panel. Tighten the screws to 2.2 N.m (20 in.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Opening Cover > Page 4932 Steering Column Cover: Service and Repair Steering Column Opening Support Bracket REMOVAL 1. Remove the steering column opening cover from the instrument panel (1). 2. Remove the hood release handle from the steering column opening support bracket (2). 3. Disengage the retaining tabs that secure the data link connector (3) to the steering column opening support bracket and remove the data link connector from the bracket. 4. Remove the two screws (4) that secure the steering column opening support bracket (3) to the instrument panel (2). 5. Slide the steering column opening support bracket upward to disengage the two locating tabs (1) and remove the bracket. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Opening Cover > Page 4933 1. Position the steering column opening bracket (3) onto the instrument panel (2) and engage to the two locating tabs (1). 2. Install the two screws (4) that secure the steering column opening bracket to the instrument panel. Tighten the screws to 2.2 N.m (20 in.lbs.). 3. Position the data link connector (3) into the opening in the steering column opening bracket (2) and fully engage the retaining tabs that secure the connector to the bracket. 4. Install the hood release handle. 5. Install the steering column opening cover onto the instrument panel (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Handle > Component Information > Service and Repair Tilt Wheel Handle: Service and Repair TILT LEVER KNOB RELEASE REMOVAL 1. Remove the tilt lever handle. 2. Remove the steering column opening cover. 3. Remove the lower shroud. NOTE: Use special care not to pry on the clockspring electrical connector when removing or installing the mounting screw located next to the clockspring. 4. Remove the two mounting screws (3) from the tilt lever knob release bracket (1). 5. Disconnect the electrical harness plastic mounting tab (2) from the the bracket (1). 6. Unsnap the cable (2) from the bracket (1). 7. Remove the end of the cable (2) from the tilt lever knob release bracket (1). INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Handle > Component Information > Service and Repair > Page 4937 1. Route the cable (2) into the tilt lever release knob bracket (1). 2. Snap the cable end (2) into the bracket (1). NOTE: Use special care not to pry on the clockspring electrical connector when removing or installing the mounting screw located next to the clockspring. NOTE: New screws should be used when installing the tilt lever release knob bracket to the column. 3. Install the tilt lever release knob bracket (1) to the column and install the two new mounting screws (3) Tighten the two new screws to 4.5 Nm (40 inch lbs.). 4. Install the electrical harness plastic mounting tab (2) to the bracket (1). 5. Install the lower shroud. 6. Install the steering column opening cover. 7. Install the tilt lever handle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4941 Steering Gear: Description and Operation GEAR- INDEPENDENT FRONT SUSPENSION DESCRIPTION A rack and pinion steering gear is made up of two main components, the pinion shaft and the rack. The gear cannot be adjusted or internally serviced. If a malfunction or a fluid leak occurs, the gear must be replaced as an assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation Steering Gear: Service and Repair Removal and Installation GEAR - INDEPENDENT FRONT SUSPENSION REMOVAL NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative methods of locking the steering wheel for service will have to be used. 1. Lock the steering wheel. 2. Drain and siphon the power steering fluid from the reservoir. 3. Raise the vehicle. 4. Remove and discard the steering coupler pinch bolt. 5. Remove the power steering hoses from the rack & pinion. 6. Remove the tire and wheel assembly. 7. Remove the tie rod end nuts and separate tie rod ends from the knuckles with Special tool 8677. 8. Remove the skid plate. 9. Remove the rack & pinion mounting bolts (1). 10. Remove the rack & pinion (2) from the vehicle. INSTALLATION NOTE: Before installing gear inspect bushings and replace if worn or damaged. NOTE: In the frame there is two holes for the mounting of the steering gear one is slotted and one is round, When tightening the gear to specifications make sure to tighten the mounting bolt with the hole first to avoid movement of the steering gear. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 4944 1. Install the gear on the front crossmember and tighten the mounting bolts (2) to 319 Nm (235 ft. lbs.) LD torque specification. Or tighten the mounting bolts to 251 Nm (185 ft. lbs.) 4X2 HD torque specification &. 2. Slide the shaft coupler onto the gear. Install new pinch bolt and tighten to 49 Nm (36 ft. lbs.). 3. Clean and dry the tie rod end studs and the knuckle tapers. 4. Install the tie rod ends into the steering knuckles and tighten the nuts to 61 Nm (45 ft. lbs.) then an additional 90°. 5. Install the pressure power steering hose to the steering gear and tighten to 32 Nm (23 ft. lbs.). 6. Install the return power steering hose to the steering gear and tighten to 71 Nm (52 ft. lbs.) LD torque specification. Or tighten the mounting bolts to 54 Nm (40 ft. lbs.) 4X2 HD torque specification. 7. Install the front skid plate. 8. Install the tire and wheel assembly. 9. Remove the support and lower the vehicle. 10. Fill the system with fluid. 11. Adjust the toe position. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 4945 Steering Gear: Service and Repair Bushing BUSHING REMOVAL 1. Remove the steering gear. CAUTION: Do not overtighten the vise on the gear case. 2. Mount the steering gear in a soft jawed vise. NOTE: If the bushings are seized a brass punch can be used to remove the bushings from the gear using care not to strike the gear. 3. Remove the front mounting bushings. 4. Remove the rear mounting bushings. 5. Remove the steering gear from the vise and place it on the bench. INSTALLATION NOTE: Coat all bushings with a thin rubber lubricate oil prior to installation. NOTE: A rubber mallet can be used to assist in the installation of the bushings once lubricated. 1. Coat the rear bushings with a thin rubber lubricate oil then install the rear bushings using a rubber mallet to seat the bushings in the gear. 2. Coat the front bushings with a thin rubber lubricate oil then install the front bushings using a rubber mallet to seat the bushings in the gear. 3. Install the steering gear. 4. Adjust the toe position (if necessary). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair > Upper Steering Coupling Steering Shaft Coupler: Service and Repair Upper Steering Coupling UPPER STEERING COUPLING REMOVAL REMOVAL 1. Disconnect the negative battery cable. NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative methods of locking the steering wheel for service will have to be used. 2. Lock the steering wheel with the tire in the straight position. 3. Remove and discard the lower pinch bolt. 4. Lower the steering coupler shaft from the column. 5. Remove the upper steering coupling shaft (2) seal by pushing in the four tags (1) securing it to the panel. 6. Remove and discard the lower coupler pinch bolt (1) from the lower steering coupling shaft (1). 7. Remove the upper steering coupling shaft (3) from the vehicle. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair > Upper Steering Coupling > Page 4950 1. Install the upper steering coupling shaft (3) to the vehicle. 2. Install the upper steering coupling shaft seal (2) by pushing it in securing the four tangs (1) to the panel. NOTE: Note: A new steering coupling shaft pinch bolt for the upper and lower shafts must be used. 3. Install the steering coupler shaft (1) to the column. 4. Install the upper pinch bolt (3) use new bolt and tighten to 57 Nm (42 ft. lbs.). 5. Install the shaft to the lower coupler (1). 6. Install the lower pinch bolt (1) use new bolt and tighten to 57 Nm (42 ft. lbs.). 7. Unlock the steering wheel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair > Upper Steering Coupling > Page 4951 8. Reconnect the negative battery cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair > Upper Steering Coupling > Page 4952 Steering Shaft Coupler: Service and Repair Lower Steering Coupling LOWER STEERING COUPLING REMOVAL ALL LD & HD EXCEPT 4X4 HD 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative methods of locking the steering wheel for service will have to be used. 3. Lock the steering wheel with the tire in the straight position. 4. Remove the left front tire and wheel assembly. 5. Mark both coupler connections for proper installation. 6. Remove and discard the upper coupler pinch bolt. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair > Upper Steering Coupling > Page 4953 7. Remove and discard the lower coupler pinch bolt. INSTALLATION 1. Install the coupler to the steering rack & pinion using the marks made in the removal process. 2. Install the coupler to the intermediate shaft using the marks made in the removal process. NOTE: New pinch bolts must be used for reinstallation. 3. Install the lower pinch bolt and tighten to 57 Nm (42 ft. lbs.). 4. Install the upper pinch bolt and tighten to 57 Nm (42 ft. lbs.). 5. Install the left front tire and wheel assembly. 6. Lower the vehicle. 7. Reconnect the negative battery cable. 8. Unlock the steering wheel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair Steering Wheel: Service and Repair STEERING WHEEL REMOVAL 1. Disable and remove the driver's side airbag. 2. Partially remove the steering wheel bolt (1) and leave the bolt in the column. 3. Install puller CJ98-1 (2) or equivalent using the top of the bolt to push on. 4. Remove and discard the steering wheel bolt. 5. Remove the steering wheel (1). INSTALLATION NOTE: Do not reuse the old steering wheel bolt (a new bolt must be used) 1. Install steering wheel to the column NOTE: Be certain that the steering wheel mounting bolt is tightened to the proper torque specification to ensure proper clockspring operation. 2. Install the new steering wheel bolt. Tighten the bolt to 61 Nm (45 ft. lbs.). 3. Install the driver's side air bag. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection Tie Rod End: Testing and Inspection OUTER TIE ROD END NOTE: If the outer tie rod end is equipped with a lubrication fitting, grease the joint then road test the vehicle before performing test. 1. Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight. 2. Remove the front tires. 3. Mount a dial indicator solidly to the vehicle steering knuckle and then zero the dial indicator. 4. Position indicator plunger on the top side of the outer tie rod end. NOTE: The dial indicator plunger must be perpendicular to the machined surface of the outer tie rod end. 5. Position a pry bar in order to pry downwards on the outer tie rod end. 6. If the travel exceeds 0.5 mm (0.020 inch), replace the outer tie rod end. 7. If the outer tie rod end is within specs reinstall the front tires. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection > Page 4961 Tie Rod End: Service and Repair OUTER TIE ROD END REMOVAL NOTE: Do not twist the boot anytime during removal or installation. 1. Loosen the jam nut. 2. Remove the outer tie rod end nut from the ball stud (1). 3. Separate the tie rod ball stud (1) from the knuckle with Remover 8677 (2). 4. Unthread the outer tie rod end (1) from the inner tie rod. INSTALLATION NOTE: Do not twist the boot at anytime during removal or installation. 1. Thread the outer tie rod end (3) onto the inner tie rod (2), to it's original position. 2. Install the outer tie rod end (3) into the steering knuckle. 3. Tighten the ball stud nut on the ball stud to 61 Nm (45 ft. lbs.) then an additional 90°. 4. Set wheel toe pattern. 5. Tighten jam nut (1) to 75 Nm (55 ft. lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Wear limit Independent front suspension Upper and lower .................................................................................................................................. ....................................................... 0.5 mm (0.02 in.) Link/coil suspension Lower ................................................................................................................................................... .................................................. 2.29 mm (0.090 in.) Upper ................................................................ ....................................................................................................................................... 1.52 mm (0.060 in) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 LOWER BALL JOINT 1. Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight. 2. Mount a dial indicator solidly to the top side of the lower control arm and then zero the dial indicator. 3. Position the indicator plunger against the bottom surface of the steering knuckle. NOTE: The dial indicator plunger must be perpendicular to the machined surface of the steering knuckle. 4. Position a pry bar under the tire assembly. Pry upwards on the tire assembly. 5. If the travel exceeds 0.5 mm (0.020 inch), replace the lower ball joint. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint > Page 4968 Ball Joint: Testing and Inspection Upper Ball Joint UPPER BALL JOINT 1. Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight. 2. Remove the front tires. 3. Mount a dial indicator (1) solidly to the frame and then zero the dial indicator (1). 4. Position dial indicator plunger (1) on the top side of the upper ball joint. NOTE: The dial indicator plunger must be perpendicular to the machined surface of the ball joint. NOTE: Use care not to pry or tear the ball joint boot (5), when checking the free play. 5. Position a pry bar (3) between the steering knuckle (4) and the upper control arm (2). Pry upwards on the upper control arm. 6. If the travel exceeds 0.5 mm (0.020 inch), replace the upper control arm since the upper ball joint is integral to the arm. 7. If the upper ball joint is within specs reinstall the front tires. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Ball Joint: Service and Repair Lower Ball Joint LOWER BALL JOINT REMOVAL 1. Remove the tire and wheel assembly. 2. Remove the brake caliper and rotor. 3. Disconnect the tie rod from the steering knuckle. 4. Remove the lower ball joint nut and separate the lower ball joint from the steering knuckle (1) using special tool 8677 (2). 5. Move the halfshaft to the side and support the halfshaft out of the way (If Equipped). 6. Remove the snap ring, from the lower control arm (HD 4X2 only) NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. 7. Press the ball joint (3) from the lower control arm using special tools C-4212-F (PRESS) (1), 8698-2 (RECEIVER) (4) and 8698-3 (DRIVER) (2). INSTALLATION NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint > Page 4971 1. Install the ball joint (3) into the control arm (4) and press in using special tools C-4212-F (press) (1), 8698-1 (driver) (2) and 8698-3 (receiver) (5). 2. Install the ball joint boot. 3. Stake the ball joint flange in four evenly spaced places around the ball joint flange, using a chisel and hammer (LD only). 4. Replace the snap ring (HD 4X2 only) 5. Remove the support for the halfshaft and install into position (If Equipped). 6. Install the steering knuckle. 7. Install the tie rod end into the steering knuckle. 8. Install and tighten the halfshaft nut to 251 Nm (185 ft. lbs.). (If Equipped). 9. Install the brake caliper and rotor. 10. Install the tire and wheel assembly. 11. Check the vehicle ride height. 12. Perform a wheel alignment. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint > Page 4972 Ball Joint: Service and Repair Upper Ball Joint Chrysler does not provide a procedure to replace the upper ball joint separately of the upper control arm. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair Control Arm Bushing: Service and Repair LOWER CONTROL ARM BUSHINGS - 2WD (LD) NOTE: HD 4X2 bushings are not serviceable. 1. Remove the lower control arm. 2. Secure the control arm in a vise. NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. LARGE BUSHING 1. Install bushing remover tools 8836-2 (receiver) (4), 8836-4 (spacer) (1) and 8836-5 (driver) (2) with the threaded rod 8839 (3) and the bearing as shown for replacement of the large bushing. SMALL BUSHING 1. Install the bushing tool 8836-6 (driver) (2), 8836-3 (spacer) (3) and 8836-2 (receiver) (4) with the threaded rod 8839 (1) and the bearing as shown for the replacement of the small bushing INSTALLATION NOTE: HD 4X2 bushings are not serviceable. LARGE BUSHING NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Page 4977 1. Install the new bushing into the lower control arm using special tools 8836-2 (receiver) (3), 8836-1 (driver) (1), 8836-4 (spacer) (4) with the bearing and the threaded rod (8839) (2). SMALL BUSHING 1. Install the small bushings into the lower control arm using tools 8836-7 (driver) (4), 8836-2 (receiver) (1), 8836-3 (spacer) (3) and the bearing with the threaded rod (8839) (2). 1. Remove the control arm from the vise. 2. Install the lower control arm. 3. Reset the vehicle ride height. 4. Perform a wheel alignment. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair Front Cross-Member: Service and Repair TRANSMISSION CROSSMEMBER REMOVAL 1. Raise and support the vehicle. 2. Remove the transfer case skid plate (3-if equipped). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Page 4982 3. Support the transmission (1) with a transmission jack (2) or suitable lifting device. 4. 2WD Vehicles-Remove the transmission mount nuts (3). 5. Remove the bolts and remove the crossmember (2). 6. 4WD Vehicles-Remove the transmission mount nuts (5). 7. Remove the bolts (3) and remove the crossmember (4). INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Page 4983 1. On Light Duty Vehicles, install the crossmember (2) and the bolts (4). Tighten the bolts to 102 N.m (75 ft.lbs.). 2. Install the transmission mount nuts and tighten to 54 N.m (40 ft.lbs.). 3. On Heavy Duty Vehicles, install the crossmember (4) and the bolts (3). Tighten the bolts to 115 N.m (85 ft.lbs.). 4. Install the transmission mount nuts and tighten to 54 N.m (40 ft.lbs.). 5. Remove the transmission support (2). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Page 4984 6. Install the transfer case skid plate (3-if equipped). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation KNUCKLE DESCRIPTION The knuckle (1) is a single casting with legs machined for the upper and lower ball joints. The knuckle also has machined mounting locations for the front brake calipers (4) and hub bearing (5). OPERATION The steering knuckle pivot between the upper and lower ball joint. Steering linkage attached to the knuckle allows the vehicle to be steered. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation > Page 4988 Front Steering Knuckle: Service and Repair KNUCKLE REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, rotor, shield and ABS wheel speed sensor if equipped. 4. Remove the front halfshaft nut (if equipped). 5. Remove the tie rod end nut. Separate the tie rod from the knuckle with Remover 8677. CAUTION: When installing Remover 8677 to separate the ball joint, be careful not to damage the ball joint seal. 6. Remove the lower ball joint nut. Separate the ball joint from the knuckle with Remover 8677 and remove the knuckle. 7. Remove the upper ball joint nut. Separate the ball joint from the knuckle (1) with Remover 8677 (2) 8. Remove the hub/bearing from the steering knuckle. INSTALLATION CAUTION: The ball joint stud tapers must be CLEAN and DRY before installing the knuckle. Clean the stud tapers with mineral spirits to remove dirt and grease. NOTE: When installing hub/bearing with ABS brakes, position the speed sensor opening towards the front of the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation > Page 4989 1. Install the hub/bearing to the steering knuckle (1) and tighten the bolts to 163 Nm (120 ft. lbs.) (LD) or 176 Nm (130 ft. lbs.) (HD 4X2). 2. Install the knuckle (1) onto the upper and lower ball joints. 3. Install the upper and lower ball joint nuts (3). Tighten the upper ball joint nut to 54 Nm (40 ft. lbs.) (on 1500 series only an additional 90° turn is required) and the lower ball joint nut (3) to 52 Nm (38 ft. lbs.) (on 1500 series only an additional 90° turn is required) (LD) or 135 Nm (100 ft. lbs.) (HD 4X2). 4. Remove the hydraulic jack from the lower suspension arm. 5. Install the tie rod end and tighten the nut to 61 Nm (45 ft. lbs.). 6. Install the front halfshaft into the hub/bearing (if equipped). 7. Install the the halfshaft nut and tighten to 251 Nm (185 ft. lbs.) (if equipped). 8. Install the ABS wheel speed sensor if equipped and brake shield, rotor and caliper. 9. Install the wheel and tire assembly. 10. Remove the support and lower the vehicle. 11. Perform a wheel alignment. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Locations Left Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Locations > Page 4994 Switch-Disconnecting Stabilizer Bar (Smart Bar) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front-Independent Front Suspension Stabilizer Link: Service and Repair Front-Independent Front Suspension STABILIZER LINK - 4X2 REMOVAL 1. Raise and support the vehicle. 2. Remove the lower nut. 3. Remove the upper nut, retainer and grommets. 4. Remove the stabilizer link (1) from the vehicle. INSTALLATION 1. Install the stabilizer link (1) to the vehicle. 2. Install the lower nut and Tighten to 102 Nm (75 ft. lbs.). 3. Install the retainers, grommets and upper nut and Tighten to 27 Nm (20 ft. lbs.). 4. Remove the support and lower the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front-Independent Front Suspension > Page 4997 Stabilizer Link: Service and Repair Rear STABILIZER LINK- SRT-10 REMOVAL 1. Raise and support the vehicle. 2. Remove the rear tire. 3. Support the rear axle with a jack. 4. Remove the upper link nut and bolt (1) at the frame. 5. Remove the lower link nut (4) at the stabilizer bar (3). 6. Remove stabilizer link (2). INSTALLATION 1. Install the upper bolt and nut (1) for the stabilizer link (2) to the frame. Tighten to 1021 Nm (75 ft. lbs.). 2. Install the stabilizer link (2) to the stabilizer bar (3). 3. Install the nut and tighten to 111 Nm (82 ft. lbs.). 4. Remove the jack and lower the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation Suspension Spring ( Coil / Leaf ): Description and Operation LEAF SPRING - SRT-10 DESCRIPTION The rear suspension system uses multi-leaf springs with an added leaf spring (limiter Spring) (3) to act as a traction bar designed into the spring to limit the amount of travel in the spring on hard accelerations. The forward end of the springs are mounted to the body rail hangers through rubber bushings (2). The rearward end of the springs are attached to the body by the use of shackles. The spring and shackles use rubber bushings (1). OPERATION The springs control ride quality and maintain vehicle ride height. The shackles allow the springs to change their length as the vehicle moves over various road conditions. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front-Independent Front Suspension Suspension Spring ( Coil / Leaf ): Service and Repair Front-Independent Front Suspension SPRING REMOVAL 1. Raise and support vehicle. 2. Remove the front wheel and tire assembly. 3. Support the lower control arm at the outboard side of the lower control arm to support vehicle weight. 4. Remove the shock absorber. 5. Install Spring Compressor DD-1278 (1) up through the lower suspension arm, coil spring and shock hole in the frame. The bell-shaped adapter (2) goes against the lower suspension arm. Install the nut on top of the tool at the shock hole. 6. Tighten the spring compressor nut against bell shaped adapter finger tight then loosen 1/2 turn. NOTE: This will hold the spring in place until the lower suspension arm is separated from the steering knuckle. 7. Remove the stabilizer link. 8. Remove the lower ball joint nut at the steering knuckle. 9. Install Ball Joint Remover tool 8677 on the lower ball joint and separate the ball joint from the knuckle. NOTE: Do not allow the upper control arm and steering knuckle to rebound downwards they must be supported. 10. Support the upper control arm and steering knuckle out of the way. 11. Remove the lower control arm support. 12. Tighten the spring compressor tool to allow clearance for the lower ball joint to be removed out of the knuckle. NOTE: It may necessary to loosen the control arm pivot bolt to allow downward swing. 13. Loosen the tension on the spring compressor tool slowly allowing the lower suspension arm to pivot downward. 14. Remove the spring compressor tool. 15. Remove coil spring and isolator pad from the vehicle. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5003 1. Tape the isolator pad to the top of the coil spring. Position the spring in the lower suspension arm well. Be sure that the coil spring is seated in the well. 2. Install Spring Compressor DD-1278 (1) up through the lower suspension arm, coil spring and shock hole in the frame. 3. Tighten the tool nut to compress the coil spring. 4. Remove the support from the upper control arm and steering knuckle. 5. Position the lower ball joint into the steering knuckle. 6. Install the retaining nut on the lower ball joint and tighten to 52 Nm (38 ft. lbs.) (on 1500 series only an additional 90° turn is required) or 135 Nm (100 ft. lbs.) (HD 4X2 only). 7. Remove the spring compressor tool. 8. Support the lower control arm at the outboard side of the lower control arm to support vehicle weight. 9. Install the shock absorber. 10. Install the stabilizer link. 11. Remove the lower control arm support. 12. Install the wheel and tire assembly and lower the vehicle. 13. Lower the vehicle to the floor with vehicle weight and Tighten the front and rear control arm pivot bolts if loosened to 204 Nm (150 ft. lbs.) (LD) or 285 Nm (210 ft. lbs.) (HD 4X2 only). 14. Perform a wheel alignment. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5004 Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Bushing BUSHINGS REMOVAL NOTE: When removing the LD front eye bushing be sure to note the orientation of the "voids" or holes. The voids need to be in line with the main leaf when installing the new bushing or vehicle ride will degrade. 1. Remove the spring from the vehicle. 2. Make small relief cuts in the flared up end of the bushing metal being careful not to cut the spring. Use a punch to bend the flared bushing metal down for push out. 3. Position the spring eye in a press. 4. Press the bushing out with an appropriate size driver. INSTALLATION NOTE: When installing the LD front eye bushing be sure to note the orientation of the "voids" or holes. The voids need to be in line with the main leaf when installing the new bushing or vehicle ride will degrade. 1. Press new bushing into the spring eye with an appropriate size driver. The bushing should be centered in the spring eye. 2. Stake the outer metal of the bushing in a minimum of six points to retain the bushing. 3. Install the spring on the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5005 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Leaf Spring LEAF SPRING - SRT-10 REMOVAL 1. Raise and support the vehicle. 2. Support the axle with a suitable holding fixture. 3. Remove the nuts (2), spring clamp bolts (1) and the plate that attach the spring to the axle. 4. Remove the nuts and bolts from the spring front and rear shackle (1). 5. Remove the spring (2) from the vehicle. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5006 1. Position spring on axle shaft tube so spring center bolt is inserted into the locating hole in the axle tube (2). 2. Align the front of the spring with the bolt hole in the front bracket. Install the eye pivot bolt and nut. 3. Align the rear of the spring into the shackle and install the bolt and nut (1). 4. Tighten the spring front and rear eye pivot bolt snug do not torque. 5. Install the spring clamp bolts (1), plate and the retaining nuts (2). 6. Remove the holding fixture for the rear axle. 7. Remove the supports and lower the vehicle so that the weight is being supported by the tires. 8. Tighten the spring clamp retaining nuts (2) to 149 Nm (110 ft. lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5007 9. Tighten the spring front and rear pivot bolt nuts to 163 Nm (120 ft. lbs.) (1). Spring Tip Inserts SPRING TIP INSERTS REMOVAL 1. Raise and support the vehicle. 2. Remove both rear tire and wheel assemblies. 3. Position a large C-Clamp (3) adjacent to the spring clinch clip (1) and clamp the leaves of the spring together CAUTION: When working on the front leaf spring clinch clamps finish the front before starting on the rear to prevent personal injury. 4. Use an appropriate pry bar (2) to bend open the spring clinch clip (1). If necessary, remove the existing spring clinch clip isolators. 5. Use the pry bar (2) to spread apart the leaf (1). The clearance between the leaves should be enough to remove the old liner (if necessary) and Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5008 install the replacement liner. 6. If necessary, remove the old spring tip liner (1). INSTALLATION 1. With the prybar still inserted between the leaves, install a new spring tip liner onto the leaf. 2. Firmly seat the spring tip liner onto the leaf. A C-Clamp (1) can be used to compress the adjacent leaves together 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. 3. Apply a small amount of lubricant oil onto the tip liner wear pad. 4. Install all the spring tip liners. 5. Place one spring clinch clip isolator (1) onto the outboard side of the spring clinch clip and one isolator on the inboard side of the spring clinch clip. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5009 6. Using large adjustable pliers (2), close the spring clinch clip (1) until the isolator contacts the leaf spring. CAUTION: DO NOT USE A HAMMER TO CLOSE THE SPRING CLINCH CLIP. DAMAGE TO THE ISOLATOR MAY RESULT. 7. Use an appropriate pry bar to bend open the spring clinch clip. If necessary, remove the existing spring clinch clip isolators. 8. Repeat procedure for the other side of the vehicle. 9. Install the tire wheel assemblies. 10. Lower the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection Suspension Strut / Shock Absorber: Testing and Inspection SHOCK A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching components. These noises can usually be stopped by tightening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attaching components. Repair as necessary if any of these conditions exist. A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermittent. This condition is not repairable and the shock absorber must be replaced. The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, hold it in an upright position and force the piston in and out of the cylinder four or five times. The action throughout each stroke should be smooth and even. The shock absorber bushings do not require any type of lubrication. Do not attempt to stop bushing noise by lubricating them. Grease and mineral oil-base lubricants will deteriorate the bushing. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front-Independent Front Suspension Suspension Strut / Shock Absorber: Service and Repair Front-Independent Front Suspension SHOCK - 4X2 REMOVAL 1. Raise and support vehicle. 2. Support the lower control arm outboard end. 3. Remove the upper shock absorber nut (1), retainer (2) and grommet (3). 4. Remove the lower nuts and remove the shock absorber. INSTALLATION NOTE: Upper shock nut must be replaced or use Mopar Lock N' Seal or Loctite (R) 242 on existing nut. 1. Install the lower retainer and grommet on the shock absorber stud. Insert the shock absorber (4) through the frame bracket hole. 2. Install the lower nuts and tighten the nuts to 35 Nm (25 ft. lbs.). 3. Install the upper grommet (3), retainer (2) and new nut (1) or use Mopar Lock N' Seal or Loctite(R) 242 on existing nut, on the shock absorber stud. Tighten nut to 54 Nm (40 ft. lbs.). 4. Remove the support from the lower control arm outboard end. 5. Lower the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5015 Suspension Strut / Shock Absorber: Service and Repair Rear Shock SHOCK REMOVAL 1. Raise vehicle and support the axle. NOTE: The rear upper shock attachment uses a flag nut. Do not use an air tool to remove the bolt, the flag may rotate into the bottom of the bed and cause damage. Use a wrench to hold the nut when loosening. 2. Remove the upper shock bolt and nut (1). 3. Remove the lower shock bolt and nut. 4. Remove the rear shock absorber (3) from the vehicle. INSTALLATION 1. Position the shock absorber (3) in the brackets. 2. Install the bolts through the brackets and the shock. Install the flag nut (1) on the top bolt and nut on lower bolt. 3. Tighten the upper and lower bolt/nuts Tighten to 135 Nm (100 ft. lbs.). 4. Remove the support and lower the vehicle. Power Hop Damper- SRT-10 POWER HOP DAMPER- SRT-10 REMOVAL 1. Raise and support the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5016 2. Remove the damper nut and bolt (3) at the axle. 3. Remove the damper nut and bolt (2) at the axle. 4. Remove the damper bracket (1) from the differential cover (4) if necessary. 5. Remove the from the vehicle. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5017 1. Install the damper bracket (1) to the rear differential cover (4) if removed. Tighten the bolts (5) to 41 Nm (30 ft. lbs.). 2. Compress the damper for easier installation. 3. Install the damper to the mounting brackets (1). 4. Install the damper nut and bolt to the axle. Tighten the bolts to 102 Nm (75 ft. lbs.). 5. Decompress the damper (1). 6. Install the damper nut and bolt (2) to the frame (3). Tighten the bolts to 102 Nm (75 ft. lbs.). 7. Lower the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair Suspension Travel Bumper: Service and Repair JOUNCE BUMPER REMOVAL 1. Remove the two bolts (1) securing the jounce bumper (2) to the bracket. 2. Remove the jounce bumper (2). INSTALLATION 1. Install the jounce bumper (2). 2. Install the two bolts (1) securing the jounce bumper (2) to the bracket. Tighten the bolts to 40 Nm (30 ft. lbs.) (LD) or Tighten the bolts to 61 Nm (45 ft. lbs.) (HD). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel Bearing Grease ...................................................................................................... Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 5024 Wheel Bearing: Service and Repair HUB/BEARING - 4X2 REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped (4). 5. Remove the three hub/bearing mounting bolts (5) from the steering knuckle (3). 6. Slide the hub/bearing (1) out of the steering knuckle (3). NOTE: The next step excludes SAT-10. (SAT-10 does not have a dust shield) 7. Remove the brake dust shield (2). INSTALLATION 1. Install the brake dust shield (2). SRT-10 Excluded in this step. 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts (5) to 163 Nm (120 ft. lbs.) 4X2 LD. Or tighten the bolts (5) to 176 Nm (130 ft. lbs.) 4X2 HD.. 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped (4). 5. Install the wheel and tire assembly. 6. Remove the support and lower vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Independent front suspension Halfshaft nut ........................................................................................ ................................................................................................. 251 Nm (185 ft. lbs.) Link/coil suspension Axle nut step 1 .................................................................................................... ................................................................................................ 179 Nm (132 ft. lbs.) step 2 ................ .............................................................................................................................................................. ...................... 356 Nm (263 ft. lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > System Information > Description and Operation Tire Monitoring System: Description and Operation Chrysler provides no information on a Tire Pressure Monitoring System for this vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation DESCRIPTION SPARE / TEMPORARY TIRE The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 50 M.P.H. when using the temporary spare tire. Refer to Owner's Manual for complete details. FULL SIZE, SPARE WHEEL WITH MATCHING TIRE The spare is a full usage wheel with a matching tire. It can be used within the (posted legal) speed limits or distance limitations as of the rest of the vehicles four tires. Refer to Owner's Manual for complete details. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels Wheels: Technical Service Bulletins Wheels - Caring for Chrome Wheels NUMBER: 22-001-05 GROUP: Wheels and Tires DATE: December 1, 2005 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-004-03, DATED SEPTEMBER 26, 2003 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS AND CLEANER SUGGESTIONS. SUBJECT: Chrome Wheel Care MODELS: 2000 - 2003 (AB) Ram Van/Wagon 2002 - 2004 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2004 - **2006** (CS) Pacifica 2002 - 2003 (DN) Durango 2002 - **2006 (DR/DH) Ram Truck** 2004 - **2006** (HB) Durango 2001 - **2006** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 - **2006** (KJ) Liberty 1998 - 2004 (LH) Concorde/Intrepid/LHS/300M 2005 - **2006 (LX/LE) 300/Charger/Magnum** **2005 - 2006 (ND) Dakota** 1998 - 2000 (NS) Town & Country 2002 - **2005** (PL) Neon 1999 - 2002 (PR) Prowler 2001 - **2006** (PT) PT Cruiser 2001 - **2006** (RS) Town & Country/Caravan 2001 - **2005** (ST) Sebring/Stratus Coupe 2002 - **2006** (TJ) Wrangler **2002 - 2006 (VA) Sprinter** 2001 - 2004 (WJ) Grand Cherokee **2005 - 2006 (WK/WH) Grand Cherokee** **2006 (XK) Commander** 2003 - **2006 (ZB) Viper/Viper Coupe** Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels > Page 5041 2004 - **2006 (ZH) Crossfire/Crossfire Convertible/SRT6** DISCUSSION: Chrome wheels should be cleaned regularly with **good quality car wash such as MOPAR Car Wash Concentrate p/n 04796236AB,** and water to maintain their luster and prevent corrosion. Wash them with the same soap solution as the body of the vehicle. Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to wheels. MOPAR Tire and Wheel Cleaner, p/n 05066247AB - 22 oz. or 05066248AB - 5 gal. **or MOPAR Wheel Cleaner, p/n 04796239AB,** is recommended to remove normal brake dust, dirt, grease and grime. NOTE: To clean extremely dirty wheels, MOPAR Chrome Cleaner, pin 04318013, is recommended. Any of the "DO NOT USE" items listed below can damage or stain wheels and wheel trim. DO NOT USE: ^ Wheel cleaners that contain hydroflouric acid, biflouride compounds, sulfuric acid, or phosphoric acid. ^ Any abrasive type cleaner ^ Any abrasive cleaning pad (such as steel wool) or abrasive brush ^ Any oven cleaner. ^ A car wash that has carbide tipped wheel-cleaning brushes. CAUTION: Many commercial wheel cleaners contain acids that may harm the wheel surface. Avoid all "wheel acid" type cleaners. CAUTION: Any facility found using acid based wheel cleaners will void all wheel warranties, and all damage to customer wheels will be the facility's responsibility. Refer to Global Warranty Bulletin D-01-22 for further information. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5042 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5043 Wheels: Description and Operation WHEELS DESCRIPTION Original equipment wheels are designed for the specified Maximum Vehicle Capacity. All models use steel or aluminum drop center wheels. Aluminum wheels require special balance weights and alignment equipment. 1. On vehicles equipped with dual rear wheels, The rim is an eight stud hole pattern wheel. The wheels have a flat mounting surface (1). 2. The slots (1) in the wheel must be aligned to provide access to the valve stem. WHEEL DESIGN The rim size is on the vehicle safety certification label located on the drivers door shut face. The size of the rim is determined by the drivetrain package. Original equipment wheels/rims are designed for operation up to the specified maximum vehicle capacity. All models use stamped steel, cast aluminum or forged aluminum wheels. Every wheel has raised sections between the rim flanges (1) and rim drop well (3) called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5044 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5045 Wheels: Testing and Inspection WHEEL INSPECTION Inspect wheels for: Excessive run out - Dents or cracks - Damaged wheel lug nut holes - Air Leaks from any area or surface of the rim NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged an original equipment replacement wheel should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: FAILURE TO USE EQUIVALENT REPLACEMENT WHEELS MAY ADVERSELY AFFECT THE SAFETY AND HANDLING OF THE VEHICLE. USED WHEELS ARE NOT RECOMMENDED. THE SERVICE HISTORY OF THE WHEEL MAY HAVE INCLUDED SEVERE TREATMENT OR VERY HIGH MILEAGE. THE RIM COULD FAIL WITHOUT WARNING. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel Bearing Grease ...................................................................................................... Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 5049 Wheel Bearing: Service and Repair HUB/BEARING - 4X2 REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped (4). 5. Remove the three hub/bearing mounting bolts (5) from the steering knuckle (3). 6. Slide the hub/bearing (1) out of the steering knuckle (3). NOTE: The next step excludes SAT-10. (SAT-10 does not have a dust shield) 7. Remove the brake dust shield (2). INSTALLATION 1. Install the brake dust shield (2). SRT-10 Excluded in this step. 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts (5) to 163 Nm (120 ft. lbs.) 4X2 LD. Or tighten the bolts (5) to 176 Nm (130 ft. lbs.) 4X2 HD.. 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped (4). 5. Install the wheel and tire assembly. 6. Remove the support and lower vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair Wheel Cover: Service and Repair WHEEL COVER REMOVAL NOTE: The hub caps must be removed before raising the vehicle off the ground. NOTE: You must use the flat end of the hub/cap remover/installer combination tool to pry off the wheel skins. Insert the flat tip completely and using a back and forth motion, loosen the wheel skin. repeat this procedure around the tire until the wheel skin pops off. 1. On 2500/3500 single rear wheel (SRW) models, insert a hub/cap remover/installer combination tool using the blade on the end of the tool to pry the cap off in a back and forth motion. 2. On 3500 models with Dual Rear Wheels (DRW), you must first remove the hub caps. The hub/cap remover/installer combination tool must be inserted in the pry off notch of the rear hub caps. 3. Position the hub/cap remover/installer combination tool and pull out on the tool firmly. The cap should come off. 4. The wheel skins can now be removed from the wheel. 5. On 3500 models front hub caps use the hub/cap remover/installer combination tool to pry off the cap in a back and forth motion. The wheel skins can now be removed. INSTALLATION REAR 1. Install one 1 1/2 inch valve stem extension on each rear inner wheel. NOTE: A 3/8 inch drive 10mm deep wheel socket with a 10 inch or greater extension can be used to remove the existing valve stem cap and install the extension. 2. Install one 1 inch valve stem extension on each outer wheel. 3. Align the cooling windows of the wheel skin with the cooling windows of the wheel. Seat one side of the wheel skin's retainer onto the wheel. Using a rubber mallet, strike the wheel skin on the outer circumference. Strike at several locations around the circumference until the skin is fully seated. NOTE: The wheel skin and the hub cap are fully seated when there is a consistent gap between the skin/cap and the wheel. 4. Tug on the hub/cap wheel skin to ensure that they are properly installed. FRONT 1. Align the valve stem with the notch in the wheel skin. 2. Seat on side of the wheel skin's wire retainer on to the wheel. 3. Using a rubber mallet, strike the opposite side of the wheel skin until the skin is properly seated. NOTE: The wheel skin and the hub cap are fully seated when there is a consistent gap between the skin/cap and the wheel. 4. Tug on the hub cap/wheel skin to ensure that they are properly installed. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Independent front suspension Halfshaft nut ........................................................................................ ................................................................................................. 251 Nm (185 ft. lbs.) Link/coil suspension Axle nut step 1 .................................................................................................... ................................................................................................ 179 Nm (132 ft. lbs.) step 2 ................ .............................................................................................................................................................. ...................... 356 Nm (263 ft. lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 5060 Wheel Fastener: Service and Repair STUDS REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, caliper adapter and rotor. 4. Remove the wheel speed sensor from the hub. 5. Press the stud from the hub using special tool C-4150A (1). 6. Remove the stud (2) from the hub (1) through the backing plate access hole (3). INSTALLATION 1. Install the new stud (2) into the hub flange (1). 2. Install three proper sized washers onto the stud, then install lug nut with the flat side of the nut against the washers. 3. Tighten the lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. 4. Remove the lug nut and washers. 5. Install the brake rotor, caliper adapter, and caliper. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 5061 6. Install the wheel speed sensor. 7. Install the wheel and tire assembly, use new lug nut on the stud or studs that were replaced. 8. Remove the support and lower the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation Accumulator HVAC: Description and Operation Accumulator - Typical The accumulator is mounted in the engine compartment between the evaporator outlet and the compressor suction port. An integral mounting bracket is used to secure the accumulator to the dash panel. The accumulator cannot be repaired and, if faulty or damaged, it must be replaced. The rubber O-rings are available for service replacement. Refrigerant enters the accumulator canister as a low pressure vapor through the inlet tube. Any liquid, oil-laden refrigerant falls to the bottom of the canister, which acts as a separator. A desiccant bag is mounted inside the accumulator canister to absorb any moisture which may have entered and become trapped within the refrigerant system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation > Page 5066 Accumulator HVAC: Service and Repair REMOVAL WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Remove the air filter housing cover to gain access to the accumulator. A/C Accumulator - Typical 4. Remove the secondary retaining clip from the spring-lock coupler that secures the suction line to the accumulator outlet tube. 5. Using the proper A/C line disconnect tool, disconnect the suction line from the accumulator outlet tube. 6. Remove the O-ring seal from the accumulator outlet tube fitting and discard. 7. Install plugs in, or tape over the opened suction line and the accumulator outlet tube fitting. 8. Loosen the bolts that secure the accumulator to the bracket located on the dash panel. 9. Remove the secondary retaining clip from the spring-lock coupler that secures the accumulator to the evaporator outlet tube. 10. Using the proper A/C line disconnect tool, disconnect the accumulator inlet tube fitting from the evaporator outlet tube. 11. Remove the O-ring seal from the accumulator inlet tube fitting and discard. 12. Install plugs in, or tape over the opened accumulator inlet tube fitting and the evaporator outlet tube. 13. Remove the accumulator from the engine compartment. INSTALLATION NOTE: If the accumulator is being 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. 1. Position the accumulator onto the dash panel bracket in the engine compartment. Do not tighten the bolts at this time. 2. Remove the tape or plugs from the accumulator inlet tube fitting and the evaporator outlet tube. 3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the accumulator inlet tube fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the accumulator inlet tube fitting to the evaporator outlet tube. 5. Install the secondary retaining clip onto the spring-lock coupler that secures the accumulator inlet tube fitting to the evaporator outlet tube. 6. Tighten the accumulator bracket bolts to 4.5 Nm (40 in. lbs.). 7. Remove the tape or plugs from the suction line fitting and the accumulator outlet tube. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation > Page 5067 8. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the accumulator outlet tube fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 9. Connect the suction line to the accumulator outlet tube. 10. Install the secondary retaining clip onto the spring-lock coupler that secures the suction line to the accumulator outlet tube. 11. Install the air filter housing cover to gain access to the accumulator. 12. Reconnect the battery negative cable. 13. Evacuate the refrigerant system. 14. Charge the refrigerant system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 5072 Air Door Actuator / Motor: Diagrams Actuator-Blend Door (Single Zone) Actuator Blend Door - Driver (Dual Zone) Actuator Blend Door - Passenger (Dual Zone) Actuator - Mode Door 1 (Panel To Floor) Actuator - Mode Door 2 (Defrost To Floor) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 5073 Actuator - Recirculation Door Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator Air Door Actuator / Motor: Description and Operation Blend Door Actuator The blend door actuators are reversible, 12-volt Direct Current (DC), servo motors. Models with the single zone heater and air conditioner system have a single blend door, which is controlled by a single blend door actuator. Models with the optional dual zone front heater and air conditioner system have dual blend doors, which are controlled by two blend door actuators. The single zone blend door actuator is located on the driver side end of the HVAC housing, close to the dash panel. In the dual zone system, the same blend door actuator used for the single zone system becomes the driver side blend door actuator, and is mechanically connected to only the driver side blend door. In the dual zone system, a second separate blend door actuator is also located on the top of the HVAC housing and is mechanically connected to only the passenger side blend door. The blend door actuators are interchangeable with each other, as well as with the actuators for the mode door, defrost door and the recirculation door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Integral mounting tabs allow the actuator to be secured with three screws to the HVAC housing. Each actuator also has an identical output shaft with splines that connects it to the linkage that drives the proper door. The blend door actuators do not require mechanical indexing to the blend door linkage, as they are electronically calibrated by the heater-A/C control module. The blend door actuators cannot be adjusted or repaired and, if damaged or faulty, they must be replaced. Each blend door actuator is connected to the A/C heater control through the vehicle electrical system by a dedicated two-wire lead and connector from the HVAC wire harness. The blend door actuator can move the blend-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the blend-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the blend-air door moves in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the blend-air door stops and will not move. The motor connections also provide a feedback signal to the A/C-heater control. This feedback signal allows the A/C-heater control to monitor the operation and relative positions of the blend door actuator and the blend-air door. The A/C-heater control learns the blend door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the blend door actuator circuits. The blend door actuator can be diagnosed using a DRBIII(R) scan tool. Refer to Body Diagnostic Procedures for more information. The blend door actuators cannot be adjusted or repaired and, if damaged or faulty, they must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator > Page 5076 Air Door Actuator / Motor: Description and Operation Defrost Door Actuator The defrost door actuator is a reversible, 12-volt Direct Current (DC), servo motor. The defrost door actuator is located on the driver side end of the HVAC housing, underneath the instrument panel and is mechanically connected to the defroster door. The defrost door actuator is interchangeable with the actuators for the mode door, blend door(s) and the recirculation door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Integral mounting tabs allow the actuator to be secured with three screws to the HVAC housing. Each actuator also has an identical output shaft with splines that connects it to the linkage that drives the proper door. The defrost door actuator does not require mechanical indexing to the defrost door, as it is electronically calibrated by the heater-A/C control module. The defrost door actuator cannot be adjusted or repaired and, if damaged or faulty, it must be replaced. The defrost door actuator is connected to the heater-A/C control module through the vehicle electrical system by a dedicated two-wire lead and connector from the HVAC wire harness. The defrost door actuator can move the defrost door in two directions. When the heater-A/C control module pulls the voltage on one side of the motor connection high and the other connection low, the defrost door will move in one direction. When the module reverses the polarity of the voltage to the motor, the defrost door moves in the opposite direction. When the module makes the voltage to both connections high or both connections low, the defrost door stops and will not move. These same motor connections also provide a feedback signal to the heater-A/C control module. This feedback signal allows the module to monitor the operation and relative positions of the defrost door actuator and the defrost door. The heater-A/C control module learns the defrost door stop positions during the calibration procedure and will store a Diagnostic Trouble Code (DTC) for any problems it detects in the defrost door actuator circuits. The defrost door actuator can be diagnosed using a DRBIII(R) scan tool. Refer to Body Diagnostic Procedures. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator > Page 5077 Air Door Actuator / Motor: Description and Operation Mode Door Actuator The mode door actuator is a reversible 12-volt Direct Current (DC) servo motor. The mode door actuator is located on the HVAC housing, behind the instrument panel and is mechanically connected to the mode door. The mode door actuator is interchangeable with the actuators for the blend door(s), defrost door and the recirculation door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Integral mounting tabs allow the actuator to be secured with three screws to the HVAC housing. Each actuator also has an identical output shaft with splines that connects it to the linkage that drives the proper door. The mode door actuator does not require mechanical indexing to the mode door linkage, as it is electronically calibrated by the heater-A/C control module. The mode door actuator cannot be adjusted or repaired and, if damaged or faulty, it must be replaced. The mode door actuator is connected to the A/Cheater control through the vehicle electrical system by a dedicated two-wire lead and connector from the HVAC wire harness. The mode door actuator can move the mode door in two directions. When the A/Cheater control pulls the voltage on one side of the motor connection high and the other connection low, the mode door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the mode door moves in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the mode door stops and will not move. These same motor connections also provide a feedback signal to the A/C-heater control. This feedback signal allows the A/C-heater control to monitor the operation and relative position of the mode door actuator and the mode door. The A/C-heater control learns the mode door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the mode door actuator circuits. The mode door actuator can be diagnosed using a DRBIII(R) scan tool. Refer to Body Diagnostic Procedures for more information. The mode door actuator cannot be adjusted or repaired and, if damaged or faulty, it must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator > Page 5078 Air Door Actuator / Motor: Description and Operation Recirculation Door Actuator The recirculation door actuator is a reversible 12-volt Direct Current (DC) servo motor. The single recirculation door actuator is located on the passenger side end of the HVAC housing, on the top of the air inlet housing. The recirculation door actuator is mechanically connected to the recirculation air door. The recirculation door actuator is interchangeable with the actuators for the blend door(s), defrost door and the mode door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Integral mounting tabs allow the actuator to be secured with three screws to air inlet housing. Each actuator also has an identical output shaft with splines that connects it to the linkage that drives the proper door. The recirculation door actuator does not require mechanical indexing to the recirculation door linkage, as it is electronically calibrated by the heater-A/C control module. The recirculation door actuator cannot be adjusted or repaired and, if damaged or faulty, it must be replaced. The recirculation door actuator is connected to the heater-A/C control module through the vehicle electrical system by a dedicated two-wire lead and connector of the HVAC wire harness. The recirculation door actuator can move the recirculation door in two directions. When the heater-A/C control module pulls the voltage on one side of the motor connection high and the other connection low, the recirculation air door will move in one direction. When the module reverses the polarity of the voltage to the motor, the recirculation air door moves in the opposite direction. When the module makes the voltage to both connections high or both connections low, the recirculation air door stops and will not move. These same motor connections also provide a feedback signal to the heater-A/C control module. This feedback signal allows the module to monitor the operation and relative position of the recirculation door actuator and the recirculation air door. The heater-A/C control module learns the recirculation air door stop positions during the calibration procedure and will store a Diagnostic Trouble Code (DTC) for any problems it detects in the recirculation door actuator circuits. The recirculation door actuator can be diagnosed using a DRBIII(R) scan tool. Refer to Body Diagnostic Procedures for more information. The recirculation door actuator cannot be adjusted or repaired and, if damaged or faulty, it must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: The single zone heating and air conditioning system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend air door and one for the passenger side blend air door. The same service procedures can be used for each of these actuators. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. 3. Disconnect the wire harness connector from the blend door actuator(s). HVAC Housing - Dual Zone Shown, Single Zone Typical 4. Remove the screws that secure the blend door actuator(s) to the HVAC housing. 5. Remove the blend door actuator(s) from the HVAC housing. INSTALLATION 1. Position the blend door actuator(s) into the HVAC housing. If necessary, rotate the actuator(s) slightly to align the splines on the actuator output sleeve(s) with those on the blend door linkage. 2. Install and tighten the screws that secure the blend door actuator(s) to the HVAC housing. Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the HVAC wire harness connector to the blend door actuator(s). 4. Install the instrument panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5081 5. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5082 Air Door Actuator / Motor: Service and Repair Defrost Door Actuator Replacement REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. HVAC Housing - Dual Zone Shown, Single Zone Typical 3. Disconnect the wire harness connector from the defrost door actuator. 4. Remove the screws that secure the defrost door actuator to the HVAC housing. 5. Remove the defrost door actuator from the HVAC housing. INSTALLATION 1. Position the defrost door actuator into the HVAC housing. If necessary, rotate the actuator slightly to align the splines on the actuator output sleeve with those on the defrost door linkage. 2. Install and tighten the screws that secure the defrost door actuator to the HVAC housing. Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the HVAC wire harness connector to the defrost door actuator. 4. Install the instrument panel. 5. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5083 Air Door Actuator / Motor: Service and Repair Mode Door Actuator Replacement REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. HVAC Housing - Dual Zone Shown, Single Zone Typical 3. Disconnect the wire harness connector from the mode door actuator. 4. Remove the screws that secure the mode door actuator to the HVAC housing. 5. Remove the mode door actuator from the HVAC housing. INSTALLATION 1. Position the mode door actuator onto the HVAC housing. If necessary, rotate the actuator slightly to align the splines on the actuator output sleeve with those on the mode door linkage. 2. Install and tighten the screws that secure the mode door actuator to the HVAC housing. Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the HVAC wire harness connector to the mode door actuator. 4. Install the instrument panel. 5. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5084 Air Door Actuator / Motor: Service and Repair Recirculation Door Actuator Replacement REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle . HVAC Housing - Dual Zone Shown, Single Zone Typical 3. Disconnect the wire harness connector from the recirculation door actuator. 4. Remove the screws that secure the recirculation door actuator to the air inlet housing. 5. Remove the recirculation door actuator from the air inlet housing. INSTALLATION 1. Position the recirculation door actuator onto the air inlet housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the recirculation air door. 2. Install and tighten the screws that secure the recirculation door actuator to the air inlet housing. Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the HVAC wire harness connector to the recirculation door actuator. 4. Install the instrument panel. 5. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Description and Operation Air Duct: Description and Operation AIR OUTLETS There are four panel outlets in the instrument panel, one located near each outboard end of the instrument panel facing the rear of the vehicle, and two located near the top of the instrument panel center bezel. The air outlets can be removed individually for service replacement. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement Air Duct: Service and Repair Air Outlets Replacement REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: The instrument panel air outlets are retained into the outlet housings by a light snap fit. Instrument Panel Air Outlets 1. Using a trim stick or another suitable wide flat-bladed tool, gently pry the panel air outlet(s) out of the panel outlet housing(s) as required. INSTALLATION 1. Position the air outlet(s) onto the outlet housing(s). 2. Gently push the air outlet into the housing until it snaps into position. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement > Page 5090 Air Duct: Service and Repair Defroster Ducts Replacement REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the instrument panel from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair Defroster Duct 2. Disconnect the wire harness connector from the center radio speaker. 3. Position the speaker wire harness connector out of the way. 4. Remove the screw that secures the defroster duct adapter to the instrument panel support. 5. Remove the defroster duct adapter from the defroster duct. 6. Remove the six screws that secure the defroster duct to the instrument panel. 7. Remove the defroster duct from the instrument panel. INSTALLATION 1. Install the defroster duct into the instrument panel. 2. Install the six screws that secure the defroster duct to the instrument panel. Tighten the screws to 2.2 Nm (20 in.lbs.). 3. Install the defroster duct adapter onto the defroster duct. 4. Install the screw that secures the defroster duct adapter to the instrument panel support. Tighten the screw to 2.2 Nm (20 in.lbs.). 5. Connect the wire harness connector to the center radio speaker. 6. Install the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement > Page 5091 Air Duct: Service and Repair Floor Distribution Ducts Replacement REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the HVAC housing from the vehicle . 2. Remove the screws that secure the floor distribution duct to the bottom of the HVAC housing. 3. Remove the floor distribution duct from the HVAC housing. Floor Distribution Duct INSTALLATION 1. Install the floor distribution duct onto the bottom of the HVAC housing. 2. Install the five screws that secure the floor distribution duct to the HVAC housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Install the HVAC housing. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement > Page 5092 Air Duct: Service and Repair Instrument Panel Demister Ducts Replacement REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the defroster ducts. 2. Remove the two screws that secure the center distribution duct to the instrument panel support. 3. Remove the center distribution duct from instrument panel support, panel ducts and demister ducts. Instrument Panel Demister Ducts 4. Remove the right side panel duct adapter. 5. Remove the right side intermediate demister duct. 6. Remove the left side intermediate demister duct. 7. Remove the left side panel duct adapter. 8. Remove the instrument panel cover. 9. Remove the screws that secure the left and right side panel ducts to the instrument panel. 10. Remove the left and right side panel ducts from the instrument panel. INSTALLATION 1. Install the left and right side ducts to the instrument panel. 2. Install the screws that secure the left and right side ducts to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Install the instrument panel top cover. 4. Install the left side panel duct adapter. 5. Install the left side intermediate demister duct. 6. Install the right side intermediate demister duct. 7. Install the right side panel duct adapter. 8. Install the center distribution duct to the instrument panel support. 9. Install the two screws that secure the center distribution duct to the instrument panel support. Tighten the screws to 2.2 Nm (20 in. lbs.). 10. Install the defroster ducts. 11. Install the two screws that secure the center distribution duct to the instrument panel support. Tighten the screws to 2.2 Nm(20 in. lbs.) 12. Install the defroster ducts. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Outlets Replacement > Page 5093 Air Duct: Service and Repair Instrument Panel Ducts Replacement REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the defroster ducts. 2. Remove the two screws that secure the center distribution duct to the instrument panel support. 3. Remove the center distribution duct from instrument panel support, panel ducts and demister ducts. Insturment Panel Ducts 4. Remove the right side panel duct adapter. 5. Remove the right side intermediate demister duct. 6. Remove the left side intermediate demister duct. 7. Remove the left side panel duct adapter. 8. Remove the instrument panel cover. 9. Remove the screws that secure the left and right side panel ducts to the instrument panel. 10. Remove the left and right side panel ducts from the instrument panel. INSTALLATION 1. Install the left and right side panel ducts to the instrument panel. 2. Install the screws that secure the left and right side panel ducts to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Install the instrument panel top cover. 4. Install the left side panel duct adapter. 5. Install the left side intermediate demister duct. 6. Install the right side intermediate demister duct . 7. Install the right side panel duct adapter 8. Install the center distribution duct to the instrument panel support. 9. Install the two screws that secure the center distribution duct to the instrument panel support. Tighten the screws to 2.2 Nm (20.in.lbs). 10. Install the demister ducts. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Left Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5097 Left Side Engine Compartment And Hood Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5098 Sensor-Ambient Air Temperature Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5099 Ambient Temperature Sensor / Switch HVAC: Description and Operation The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the left side of the radiator yoke, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent by the Front Control Module (FCM). The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the FCM. Based upon the resistance in the sensor, the FCM senses a specific voltage on the temperature sensor signal circuit. The FCM then translates the voltage into a temperature reading that it sent over the Programmable Communications Interface (PCI) data bus circuit to other modules utilizing temperature information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5100 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection The temperature function is supported by the ambient temperature sensor, a wiring circuit, and Front Control Module (FCM). If any portion of the ambient temperature sensor circuit fails or if Programmable Communications Interface (PCI) Data Bus information is missing, a (- -) will appear in the display in place of the temperature. When the sensor is exposed to temperatures above 55° C (130° F), or if the sensor circuit is shorted, 55° C (130° F) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below - 40° C (- 40° F) or if the sensor circuit is open, - 40° C (- 40° F) will appear in the display. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, test the compass mini-trip computer. SENSOR TEST 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is 336 kilohms. At 55° C (130° F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, refer to Sensor Circuit Test. If not OK, replace the inoperative ambient temperature sensor. SENSOR CIRCUIT TEST For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connectors from the ambient temperature sensor and the FCM. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the FCM harness connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Check for continuity between the ambient temperature sensor signal circuit cavity of the FCM harness connector and a good ground. There should be no continuity. If OK, test the compass mini-trip computer operation. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5101 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Open the hood. 2. Disconnect and isolate the battery negative cable. 3. Working on the underside of the hood, remove screw holding sensor to hood panel. 4. Disconnect the sensor electrical connector and remove sensor from vehicle. INSTALLATION 1. Connect the sensor electrical connector. 2. Working on the underside of the hood, install screw holding sensor to hood panel. 3. Connect the battery negative cable. 4. Close the hood. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Connector Views Motor-Blower Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5107 Blower Motor: Description and Operation The blower motor and blower wheel are located in the passenger side end of the HVAC housing, below the glove box. The blower motor controls the velocity of air flowing through the HVAC housing by spinning a squirrel cage-type blower wheel within the housing at the selected speed. The blower motor and wheel can be removed from the housing inside the vehicle without removing the instrument panel or HVAC housing. The blower motor will only operate with the ignition switch in the On position and the A/C-heater mode control switch in any position, except Off. The blower motor receives a fused battery feed circuit through a fuse in the Power Distribution Center (PDC) whenever the ignition switch is in the On position. Blower motor speed is controlled by regulating the ground path through or around the blower motor resistor block and through the A/C-heater blower motor switch. The blower motor and blower motor wheel are serviced only as a unit and cannot be repaired and, if faulty or damaged, must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5108 Blower Motor: Testing and Inspection BLOWER MOTOR INOPERATIVE WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. For circuit descriptions and diagrams, refer to the appropriate wiring information. The wiring information includes wiring, diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. BLOWER MOTOR ELECTRICAL DIAGNOSIS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5109 Blower Motor Electrical Diagnosis Refer to the Blower Motor Electrical Diagnosis chart for basic checks of the blower motor circuit. BLOWER MOTOR NOISE OR VIBRATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5110 Blower Motor Noise/Vibration Diagnosis Refer to the Blower Motor Noise/Vibration Diagnosis chart for basic checks of the blower motor when a vibration or noise is present. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5111 Blower Motor: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: The blower motor is located on the passenger side of the vehicle under the instrument panel. The blower motor can be removed from the vehicle without having to remove the HVAC housing. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the wire harness connector from the blower motor. HVAC Blower Motor - Typical 3. Remove the three screws that secure the blower motor to the HVAC housing. 4. Remove the blower motor from the HVAC housing by rotating and tilting the blower motor as needed for clearance. INSTALLATION 1. Align and install the blower motor into the HVAC housing. 2. Install the three screws that secure the blower motor to the HVAC housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Connect the wire harness connector to the blower motor. 4. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams Resistor Block-Blower Motor Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Page 5118 Blower Motor Resistor: Description and Operation The blower motor resistor is mounted to the bottom side of the HVAC housing near the blower motor. It can be accessed for service from underneath the instrument panel. The resistor has multiple resistor wires, each of which will reduce the current flow to the blower motor to change the blower motor speed by changing the resistance in the blower motor ground path. The blower motor switch directs the ground path through the correct resistor wire to obtain the selected 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. The blower motor resistor cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Page 5119 Blower Motor Resistor: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. For circuit descriptions and diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector from the blower motor resistor block. 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 blower motor resistor or blower motor as required. If not OK, replace the faulty blower motor resistor block. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Page 5120 Blower Motor Resistor: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. CAUTION: Stay clear of the blower motor resistor block heat sink (Hot). Do not operate the blower motor with the resistor block removed. Blower Motor Resistor Block 1. Disconnect and isolate the negative battery cable. 2. Reach under the instrument panel near the blower motor and disconnect the wire harness connector from the blower motor resistor block. 3. Remove the two screws that secure the blower motor resistor block to the HVAC housing. 4. Remove the resistor block from the HVAC housing. INSTALLATION 1. Position the blower motor resistor block into the HVAC housing. 2. Install the two screws that secure the resistor block to the HVAC housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Connect the wire harness connector to the resistor block. 4. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation A/C-Heater Control - Single Zone Shown, Dual Zone Typical The blower motor is controlled by a rotary-type blower motor switch, mounted in the A/C-heater control. The switch allows the selection of one of four different blower motor speeds and includes an Off position. The blower motor switch provides a blower motor ground path through the A/C-heater mode control switch. The blower motor switch directs this ground path through or around the blower motor resistor wires, as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, the entire A/C-heater control must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and Operation > Page 5124 Blower Motor Switch: Testing and Inspection For circuit descriptions and diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check for battery voltage at the fuse in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the A/C-heater control from the instrument panel. Check for continuity between the ground circuit cavity of the A/C-heater control wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 3. With the A/C-heater control wire harness connector disconnected, place the A/C-heater mode control switch 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 A/C-heater control as you move the blower motor switch 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 A/C-heater control connector and the blower motor resistor as required. If not OK, replace the faulty A/C-heater control. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations Cabin Air Filter: Locations Chrysler provides no information on a Cabin Air Filter for this vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair BODY VENT REMOVAL 1. Remove the rear cab trim panel, Refer to Trim Panel. 2. Disengage the retaining tabs (1) that secure the body vent (3) to the cab back panel (2). 3. Remove the vent through the opening in the cab back panel. INSTALLATION 1. Position the body vent (3) into the opening of the cab back panel (2). 2. Install the body vent into the cab back panel and fully engage the retaining tabs (1). 3. Install the rear cab trim panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams Clutch - A/C Compressor Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 5135 Compressor Clutch: Description and Operation The A/C compressor clutch assembly consists of a stationary electromagnetic A/C clutch field coil (4), pulley bearing and pulley assembly (3), clutch plate (2) and shims (7). These components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt. The A/C clutch field coil and the pulley bearing and pulley assembly are both retained on the nose of the A/C compressor with snap rings (5 and 6). The clutch plate is splined to the compressor shaft and secured with a bolt (1). The A/C compressor clutch components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt. When the electromagnetic A/C clutch field coil is energized, it magnetically draws the clutch plate into contact with the clutch 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 assembly. A/C compressor clutch engagement is controlled by the powertrain control module (PCM) or the engine control module (ECM), depending on engine application. The A/C compressor clutch components cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Compressor Clutch: Initial Inspection and Diagnostic Overview NOTE: The A/C clutch can be serviced in the vehicle. The refrigerant system can remain fully-charged during compressor clutch, pulley and bearing assembly, or coil replacement. Examine the friction surfaces of the pulley and the clutch plate (2) for wear. The pulley and clutch 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 A/C compressor (1) for refrigerant oil. If refrigerant oil is found, the compressor shaft seal is leaking and the A/C compressor must be replaced. Check the pulley bearing for roughness or excessive leakage of grease. Replace the pulley and bearing assembly, if required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5138 Compressor Clutch: Component Tests and General Diagnostics After a new A/C compressor clutch has been installed, cycle the compressor clutch approximately twenty times (five seconds on, then five seconds off). During this procedure, set the A/C-heater controls to the A/C Recirculation Mode, the blower motor 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Sanden A/C Compressor Compressor Clutch: Service and Repair Sanden A/C Compressor REMOVAL NOTE: The A/C compressor clutch can be serviced in the vehicle. The refrigerant system can remain fully-charged during compressor clutch, pulley and bearing assembly, or coil replacement. 1. Disconnect and isolate the negative battery cable. 2. Remove the accessory drive belt. 3. Disconnect the engine wire harness connector for the A/C compressor clutch coil from the clutch field coil wire harness connector on the top of the A/C compressor. 4. Remove the bolts that secure the A/C compressor to the mounting bracket and support the A/C compressor. 5. Insert the two pins of the spanner wrench (Special Tool C-4489 or equivalent) (2) into the holes of the clutch plate (1). Hold the clutch plate stationary and remove the nut. 6. Remove the clutch plate and shims. 7. Using snap ring pliers (Special Tool C-4574 or equivalent) (2), remove the snap ring that secures the pulley and bearing assembly (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Sanden A/C Compressor > Page 5141 8. Install the lip of the pulley and bearing puller (Special Tool C-6141-1 or equivalent) (1) into the snap ring groove of the pulley and bearing assembly and install the shaft protector (Special Tool C-6141-2 or equivalent) (2). CAUTION: Do not apply excessive force to the end of the compressor shaft with the puller center bolt or damage to the shaft may occur. 9. Install the puller through-bolts (Special Tool C-6461 or equivalent) through the puller flange (2) and into the puller jaws (1). Turn the puller center bolt clockwise until the pulley and bearing assembly is free. 10. Remove the screw and retainer (3) from the wire harness lead (2) of the clutch field coil (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Sanden A/C Compressor > Page 5142 11. Using snap ring pliers (Special Tool C-4574 or equivalent) (2), remove the snap ring that secures the clutch field coil (1) and remove the field coil. INSTALLATION CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the clutch field coil to the A/C compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or to the left of the clutch field coil dowel pin location on the A/C compressor. 1. Install the clutch field coil (1) and using snap ring pliers (Special Tool C-4574 or equivalent) (2), install the snap ring that secures the field coil to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove. 2. Install the retainer and screw (3) over the wire harness lead (2) of the clutch field coil (1) and onto the A/C compressor. Tighten the screw to 2.2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Sanden A/C Compressor > Page 5143 N.m (20 in.lbs.). 3. Position the pulley and bearing assembly (1) squarely onto the front of the A/C compressor. NOTE: Thread the installer fully onto the compressor shaft. Turn the installer nut until the pulley and bearing assembly is fully seated. 4. Using installer (Special Tool C-6871 or equivalent) (2), install the pulley and bearing assembly. CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the pulley and bearing assembly to the A/C compressor. The bevel side of the snap ring must face outward. 5. Using snap ring pliers (Special Tool C-4574 or equivalent) (2), install the snap ring that secures the pulley and bearing assembly (1) onto the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Sanden A/C Compressor > Page 5144 6. If the original clutch plate (1) and pulley and bearing assembly are to be reused, reinstall the original shim(s) onto the compressor shaft. If a new clutch plate and/or pulley and bearing assembly are being used, install a 1.0, 0.50, and 0.13 millimeter (0.040, 0.020, and 0.005 inch) shims from the new clutch hardware package that is provided with the new clutch. 7. Install the clutch plate onto the compressor shaft. 8. Insert the two pins of the spanner wrench (Special Tool C-4489 or equivalent) (2) into the holes of the clutch plate (1). Hold the clutch plate stationary and install the nut that secures the clutch plate. Tighten the nut to 20 N.m (15 ft.lbs.). NOTE: The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is correct. Spin the pulley before performing a final check of the air gap. 9. With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate and the pulley and bearing assembly faces with a feeler gauge. The air gap should be between specifications. If the proper air gap is not obtained, add or subtract shims as needed until the desired air gap is obtained. 10. Install the bolts that secure the A/C compressor to the mounting bracket. 11. Connect the engine wire harness connector to the A/C compressor clutch coil. 12. Install the accessory drive belt. 13. Reconnect the negative battery cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Sanden A/C Compressor > Page 5145 Compressor Clutch: Service and Repair Denso A/C Compressor REMOVAL NOTE: The A/C compressor clutch can be serviced in the vehicle. The refrigerant system can remain fully-charged during compressor clutch, pulley and bearing assembly, or coil replacement. 1. Disconnect and isolate the negative battery cable. 2. Remove the accessory drive belt. 3. Disconnect the engine wire harness connector for the A/C compressor clutch coil from the clutch field coil wire harness connector on the top of the A/C compressor. 4. Remove the bolts that secure the A/C compressor to the engine and support the A/C compressor. 5. Remove the compressor shaft bolt (1). A band-type oil filter wrench or a strap wrench may be used to secure the clutch plate (2) during bolt removal. CAUTION: Do not pry between the clutch plate and the pulley and bearing assembly to remove the clutch plate from the compressor shaft as this may damage the clutch plate. NOTE: Use care not to lose any clutch shim(s) during removal of the clutch plate, as they may be reused during the clutch plate installation Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Sanden A/C Compressor > Page 5146 process. 6. Tap the clutch plate (2) lightly with a plastic mallet to release it from the splines on the compressor shaft (1). Remove the clutch plate and shim(s) (3) from the compressor shaft. 7. Using snap ring pliers (Special Tool C-4574 or equivalent) (2), remove the external snap ring (1) that secures the pulley and bearing assembly (3) to the front cover of the A/C compressor, then slide the pulley and bearing assembly off of the A/C compressor. 8. Remove the screw that secures the clutch coil pigtail wire connector bracket and ground clip to the top of the compressor housing (3). 9. Using snap ring pliers (Special Tool C-4574 or equivalent) (1), remove the external snap ring (4) that secures the clutch field coil (2) to the front cover of the compressor housing, then slide the clutch field coil off of the A/C compressor. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Sanden A/C Compressor > Page 5147 1. Align the dowel pin on the back of the clutch field coil (2) with the hole in the compressor front cover (3) and position the clutch field coil onto the A/C compressor. Be certain that the clutch coil wire harness is properly oriented and routed so that it is not pinched between the compressor front cover and the clutch field coil. CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the clutch field coil to the A/C compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or to the left of the clutch field coil dowel pin location on the A/C compressor. 2. Using snap ring pliers (Special Tool C-4574 or equivalent) (1), install the external snap ring (4) that secures the clutch field coil to the front cover of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove and oriented correctly 3. Install the screw that secures the clutch field coil wire harness connector bracket and ground clip to the top of the compressor housing. Tighten the screw securely. CAUTION: When installing the pulley and bearing assembly, DO NOT mar the friction surfaces of the pulley or premature failure of the clutch will result. 4. Install the pulley and bearing assembly (1) onto the front cover of the A/C compressor. If necessary, tap the pulley gently with a block of wood (2) placed on the pulley friction surface. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Sanden A/C Compressor > Page 5148 CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the pulley and bearing assembly to the A/C compressor. The bevel side of the snap ring must face outward. 5. Using snap ring pliers (Special Tool C-4574 or equivalent) (2), install the external snap ring (1) that secures the pulley and bearing assembly (3) to the front cover of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove. 6. If the original clutch plate (2) and pulley and bearing assembly are to be reused, reinstall the original shim(s) (3) on the compressor shaft (1) against the shoulder. If a new clutch plate and/or pulley and bearing assembly are being used, install a trial stack of shims 2.54 mm (0.010 in.) thick on the compressor shaft against the shoulder. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Sanden A/C Compressor > Page 5149 7. Install the clutch plate (2) onto the compressor shaft. 8. Install the compressor shaft bolt (1). Tighten the bolt to 17.5 N.m (155 in.lbs.). NOTE: The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is correct. Spin the pulley before performing a final check of the air gap. 9. With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate and the pulley and bearing assembly faces with a feeler gauge. The air gap should be between specifications. If the proper air gap is not obtained, add or subtract shims as needed until the desired air gap is obtained. 10. Install the bolts that secure the A/C compressor to the engine. 11. Connect the engine wire harness connector to the A/C compressor clutch coil. 12. Install the accessory drive belt. 13. Reconnect the negative battery cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Description and Operation Compressor Clutch Coil: Description and Operation Compressor Clutch - Typical The compressor dutch assembly consists of a stationary electromagnetic coil, a pulley bearing and pulley assembly, and a clutch plate. The electromagnetic coil and the pulley bearing and pulley assembly are each retained on the nose of the compressor front housing with snap rings. The clutch plate is keyed to 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. The A/C compressor clutch provides the means to engage and disengage the A/C 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 pulley bearing, which is part of the pulley assembly. The compressor clutch and coil are the only serviced parts on the compressor. A/C compressor clutch engagement is controlled by several components: the A/C-heater control, A/C pressure transducer, A/C compressor clutch relay, evaporator temperature sensor and the powertrain control module (PCM). The PCM may delay compressor clutch engagement for up to thirty seconds. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Description and Operation > Page 5153 Compressor Clutch Coil: Testing and Inspection For circuit descriptions and diagrams. The battery must be fully-charged before performing the following tests. Refer to 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 A/C-heater controls 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 0.2 volt of the battery voltage. If there is voltage at the clutch coil, but the reading is not within 0.2 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 DRBIII (R) scan tool and testing of the compressor clutch circuit and PCM control. 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 (PDC) - A/C-heater control - A/C compressor clutch relay - A/C pressure transducer - Evaporator temperature sensor - Powertrain control module (PCM) 4. The compressor clutch coil is acceptable if the current draw measured at the clutch coil is within specifications with the electrical system voltage at 11.5 to 12.5 volts. This should only be checked with the work area temperature at 21° C (70° 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 above specifications, 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. INSPECTION Examine the friction surfaces of the dutch pulley and the clutch plate for wear. The pulley and dutch 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 A/C compressor for oil. Remove the felt from the front cover. If the felt is saturated with oil, the shaft seal is leaking and the A/C compressor must be replaced. Check the pulley bearing for roughness or excessive leakage of grease. Replace the pulley and clutch plate, if required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Description and Operation > Page 5154 Compressor Clutch Coil: Service and Repair A/C COMPRESSOR 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 A/C-heater control to the Recirculation Mode, 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. REMOVAL The refrigerant system can remain fully-charged during compressor clutch, rotor, or coil replacement. The compressor clutch can be serviced in the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Remove the serpentine drive belt. 3. Disconnect the compressor clutch coil wire harness connector. 4. Remove the bolts that secure the compressor to the mounting bracket. 5. Remove the compressor from the mounting bracket. Support the compressor in the engine compartment while servicing the clutch. Clutch Nut Remove - Typical 6. Insert the two pins of the spanner wrench (Special Tool C-4489 or equivalent) into the holes of the dutch plate. Hold the dutch plate stationary and remove the hex nut. 7. Remove the dutch plate. 8. Remove the compressor dutch shims. External Snap Ring Remove - Typical Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Description and Operation > Page 5155 9. Remove the external front housing snap ring with snap ring pliers. Shaft Protector And Puller - Typical 10. Install the lip of the rotor puller (Special Tool C-6141-1 or equivalent) into the snap ring groove exposed in the previous step, and install the shaft protector (Special Tool C-6141-2 or equivalent). Install Puller Plate - Typical 11. Install the puller through-bolts (Special Tool C-6461 or equivalent) through the puller flange and into the jaws of the rotor puller and tighten. Turn the puller center bolt clockwise until the rotor is free. CAUTION: DO NOT APPLY FORCE TO THE END OF THE COMPRESSOR SHAFT. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Description and Operation > Page 5156 Clutch Coil Lead Wire Harness - Typical 12. Remove the screw and retainer from the dutch coil lead wire harness on the compressor front housing. Clutch Field Coil Snap Ring Remove - Typical 13. Remove the snap ring from the compressor hub and remove the dutch field coil. Slide the dutch field coil off of the compressor hub. INSTALLATION 1. Install the clutch field coil and snap ring. 2. Install the screw and retainer on the clutch coil lead wire harness on the compressor front housing. Tighten screw to 2.2 Nm (20 in. lbs.). 3. Align the rotor assembly squarely on the front compressor housing hub. 4. Install the rotor bearing assembly with the installer (Special Tool C-6871 or equivalent). Thread the installer on the shaft, then turn the nut until the rotor assembly is seated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Description and Operation > Page 5157 Clutch Pulley Install - Typical 5. Install the external front housing 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. 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. 6. Install the original clutch shims on the compressor shaft. 7. Install the clutch plate. Install the shaft hex nut and tighten to 15-20 Nm (11-15 ft. lbs.). 8. Check the clutch air gap with a feeler gauge. If the air gap does not meet specifications, add or subtract shims as required. Check Clutch Air Gap - Typical NOTE: The air gap is determined by the spacer shims. When installing an original, or a new clutch assembly, try the original shims first. When installing a new clutch onto a compressor that previously did not have a clutch, use a 1.0, 0.50, and 0.13 millimeter (0.040, 0.020, and 0.005 inch) shims from the new clutch hardware package that is provided with the new clutch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Diode HVAC > Component Information > Service and Repair Compressor Clutch Diode HVAC: Service and Repair NOTE: If the vehicle is equipped with dual batteries (diesel engine), be sure to disconnect the negative battery cable from both batteries. 1. Disconnect and isolate the negative battery cable(s). 2. Remove the diode from the wire harness. Note the direction of current flow (1). The band located on the end of the diode (2) indicates current flow through the diode. 3. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 4. Install the new diode in the wire harness, making sure current flow is correct. If necessary refer to the appropriate wiring diagram for current flow. Diode as shown in the wiring diagram (3). CAUTION: Do not use acid core solder when installing a new diode. Acid core solder will corrode the diode connections within the harness, which can cause A/C compressor clutch failure. 5. Solder the connections together using rosin core type solder only. 6. Tape the new diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 7. Reconnect the negative battery cable(s). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5164 Compressor Clutch Relay: Description and Operation A/C Compressor Clutch Micro-Relay The A/C compressor clutch relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The A/C compressor clutch relay is located in the integrated power module (IPM) in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the IPM cover for A/C compressor clutch relay identification and location. The black, molded plastic case is the most visible component of the A/C compressor clutch relay. Five male spade-type terminals extend from the bottom of the base to connect the relay to the vehicle electrical system, and the ISO designation for each terminal is molded into the base adjacent to each terminal. The ISO terminal designations are as follows: - 30 (Common Feed) - This terminal is connected to the movable contact point of the relay. - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The A/C compressor clutch relay is an electromechanical switch that uses a low current input from the powertrain control module (PCM) or engine control module (ECM) depending on engine application, to control the high current output to the compressor clutch electromagnetic coil. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. The resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The A/C compressor clutch relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the A/C compressor clutch relay include: - The common feed terminal (30) receives a battery current input from a fuse in the IPM through a fused B(+) circuit at all times. - The coil ground terminal (86) receives a ground input from the PCM/ECM through the A/C compressor clutch relay control circuit only when the PCM/ ECM electronically pulls the control circuit to ground. - The coil battery terminal (85) receives a battery current input from PTC 1 in the IPM through a fused ignition switch output (run) circuit only when the ignition switch is in the On position. - The normally open terminal (87) provides a battery current output to the compressor clutch coil through the A/C compressor clutch relay output circuit only when the A/C compressor clutch relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the A/C compressor clutch relay coil is de-energized. Refer to the appropriate wiring information for diagnosis and testing of the micro-relay and for complete HVAC wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5165 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. Integrated Power Module (IPM) 2. Remove the cover from the integrated power module (IPM). 3. Refer to the fuse and relay layout label on the IPM cover for compressor clutch relay identification and location. 4. Remove the A/C compressor clutch relay from the IPM. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the IPM cover for A/C compressor clutch relay location. 2. Position the A/C compressor clutch relay in the proper receptacle in the IPM. 3. Align the A/C compressor clutch relay terminals with the terminal cavities in the IPM receptacle. 4. Push down firmly on the A/C compressor clutch relay until the terminals are fully seated in the terminal cavities in the IPM receptacle. 5. Install the cover onto the IPM. 6. Reconnect the negative battery cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation Condenser HVAC: Description and Operation The A/C condenser is located in the front of the engine compartment behind the grille. The A/C condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the A/C compressor to give up its heat to the air passing over the condenser fins, which causes the refrigerant to cool and change to a liquid state. When air passes through the fins of the A/C condenser, the high-pressure refrigerant gas within the A/C condenser gives up its heat. The refrigerant then condenses as it leaves the A/C condenser and becomes a high-pressure liquid. The volume of air flowing over the condenser fins is critical to the proper cooling performance of the A/C system. Therefore, it is important that there are no objects placed in front of the radiator grille openings at 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 A/C condenser service. The A/C condenser cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 5169 Condenser HVAC: Service and Repair REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Disconnect the A/C discharge line and the A/C liquid line from the A/C condenser. 4. Remove the two bolts (1) that secure the A/C condenser and shroud assembly (4) to the upper radiator support (2). 5. Carefully lift the A/C condenser and shroud assembly off of the front bumper support (3) and remove the assembly from the engine compartment. 6. If required, place the A/C condenser and shroud assembly on a workbench and remove the six bolts (3) that secure the condenser shroud (2) to the A/C condenser (1) and separate the shroud from the A/C condenser. INSTALLATION NOTE: - If the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. - Be certain that each of the radiator and condenser air seals are reinstalled in their proper locations. These air seals are required for the A/C and engine cooling systems to perform as designed. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 5170 1. If removed, install the condenser shroud (2) onto the A/C condenser (1). 2. Install the six bolts (3) that secure the condenser shroud to the A/C condenser. Tighten the bolts to 2.2 N.m (20 in.lbs.). 3. Position the A/C condenser and shroud assembly (4) into the engine compartment. 4. Install the A/C condenser and shroud assembly onto the front bumper support (3). 5. Install the two bolts (1) that secure the A/C condenser and shroud assembly to the upper radiator support (2). Tighten the bolts to 10.5 N.m (95 in.lbs.). 6. Connect the A/C discharge line and the A/C liquid line onto the A/C condenser. 7. Reconnect the negative battery cable. 8. Evacuate the refrigerant system. 9. Charge the refrigerant system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Condenser Fan Motor > Component Information > Locations Condenser Fan Motor: Locations Left Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Condenser Fan Motor > Component Information > Locations > Page 5175 Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations Control Assembly: Locations Center Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 5182 Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 5183 Center Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Connector Views Control Assembly: Connector Views Control - A/C-Heater C1 Control - A/C-Heater C2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 5186 Control Assembly: Description and Operation A/C HEATER CONTROL The heater and air conditioning systems use electrical controls. These controls provide the vehicle operator with a number of setting options to help control the climate and comfort within the vehicle. Single Zone HVAC Control Dual Zone A/C Control The A/C-heater control for the Single Zone system or Dual Zone system is located to the right of the instrument cluster on the instrument panel. The Single Zone control panel contains a rotary-type temperature control switch, a rotary-type mode control switch and a rotary-type blower motor speed switch. The A/C-heater control also has a push button to activate the optional heated side view mirror defroster elements and to turn the A/C on. The Dual Zone control panel contains a pair of slider-type temperature control switches, a rotary-type mode control switch and a rotary-type blower motor speed switch. The control also has buttons to activate the optional heated side view mirror defroster elements, turn the A/C on and set the system to Max A/C. The A/C-heater control panel cannot be repaired. If faulty or damaged, the entire unit must be replaced. The illumination lamps are available for service replacement. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 5187 Control Assembly: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the center bezel from the instrument panel. A/C-Heater Control - Typical, Rear View 3. Remove the screws that secure the A/C-heater control to the instrument panel. INSTALLATION 1. Position the A/C-heater control onto the instrument panel center bezel and install the retaining screws. Tighten the screws to 2.2 Nm (20 in. lbs.). 2. Install the instrument panel center bezel. 3. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Coolant Temperature Sensor / Switch HVAC > Component Information > Locations Left Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Description and Operation A/C Coupler O-ring: Description and Operation The spring-lock coupler is held together by a garter spring inside a circular cage on the male half of the fitting. When the two coupler halves are connected, the flared end of the female fitting slips behind the garter spring inside the cage on the male fitting. The garter spring and cage prevent the flared end of the female fitting from pulling out of the cage. Spring-Lock Coupler - Typical Two O-rings on the male half of the fitting are used to seal the connection. These O-rings are compatible with -134a refrigerant and must be replaced with O-rings made of the same material. Secondary clips are installed over the two connected coupler halves at the factory for added protection. In addition, some models have a plastic ring that is used at the factory as a visual indicator to confirm that these couplers are connected. After the coupler is connected, the plastic indicator ring is no longer required; however, it will remain on the refrigerant line near the coupler cage. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Description and Operation > Page 5195 A/C Coupler O-ring: Service and Repair REMOVAL 1. Recover the refrigerant from the refrigerant system . 2. Remove the secondary retaining clip from the spring-lock coupler. 3. Fit the proper size A/C line disconnect tool (Special Tool Kit 7193 or equivalent) over the spring-lock coupler cage. Refrigerant Line Spring-Lock Coupler Disconnect 4. Close the two halves of the A/C line disconnect tool around the spring-lock coupler. NOTE: The garter spring may not release if the A/C line disconnect tool is cocked while pushing it into the coupler cage opening. 5. Push the A/C line disconnect tool into the open side of the coupler cage to expand the garter spring. Once the garter spring is expanded and while still pushing the disconnect tool into the open side of the coupler cage, pull on the refrigerant line attached to the female half of the coupler fitting until the flange on the female fitting is separated from the garter spring and cage on the male fitting within the disconnect tool. 6. Open and remove the A/C line disconnect tool from the disconnected spring-lock coupler. 7. Complete the separation of the two halves of the coupler fitting. Inspect the O-ring seals and mating areas for damage. INSTALLATION 1. Check to make sure that the garter spring is located within the cage of the male coupler fitting, and that the garter spring is not damaged. a. If the garter spring is missing, install a new spring by pushing it into the coupler cage opening. b. If the garter spring is damaged, remove it from the coupler cage with a small wire hook (DO NOT use a screwdriver) and install a new garter spring. 2. Clean any dirt or foreign material from both halves of the coupler fitting. CAUTION: Use only the specified O-rings as they are made of a special material for the -134a system. The use of any other O-rings may allow the connection to leak intermittently during vehicle operation. 3. Install new O-rings on the male half of the coupler fitting. 4. Lubricate the male fitting and O-rings, and the inside of the female fitting with clean -134a refrigerant oil. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 5. Fit the female half of the coupler fitting over the male half of the fitting. 6. Push together firmly on the two halves of the coupler fitting until the garter spring in the cage on the male half of the fitting snaps over the flanged end on the female half of the fitting. 7. Make sure that the spring-lock coupler is fully engaged by trying to separate the two coupler halves. This is done by pulling the refrigerant lines on either side of the coupler away from each other. 8. Install the secondary retaining clip over the spring-lock coupler cage. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5204 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5205 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5206 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5207 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5208 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5209 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5210 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5211 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5212 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5213 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5214 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5215 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5221 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5222 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5223 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5224 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5225 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5226 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5227 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5228 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5229 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5230 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5231 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 5232 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5233 Evaporator Core: Description and Operation The A/C evaporator is located in the HVAC housing, behind the instrument panel. The evaporator is positioned in the HVAC housing so that all air that enters the housing must pass over the fins of the evaporator coils before it is distributed through the system ducts and outlets. However, air passing over the evaporator fins will only be conditioned when the compressor is engaged and circulating refrigerant through the evaporator tubes. Refrigerant enters the A/C evaporator from the fixed orifice tube as a low-temperature, low-pressure mixture of liquid and gas. As air flows over the fins of the A/C 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 low-pressure gas before it leaves the A/C evaporator. The A/C evaporator cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5234 Evaporator Core: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the HVAC housing. Refer to Housing Assembly HVAC/ Service and Repair/ Procedures. 2. Disassemble the HVAC housing to access the A/C evaporator. Refer to Housing Assembly HVAC/ Service and Repair/ Procedures. 3. Remove the evaporator temperature sensor probe from the A/C evaporator. A/C Evaporator - Typical 4. Lift the A/C evaporator out of the HVAC housing. INSTALLATION NOTE: If the A/C evaporator is being 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. 1. Install the A/C evaporator into the HVAC housing. Make sure that the evaporator drain is clean and unrestricted and that the evaporator deflector shield is installed. 2. Install the evaporator temperature sensor probe into the A/C evaporator. 3. Assemble the HVAC housing. Refer to Housing Assembly HVAC/ Service and Repair/ Procedures. 4. Install the HVAC housing. Refer to Housing Assembly HVAC/ Service and Repair/ Procedures. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5238 Sensor-Evaporator Temperature Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5239 Evaporator Temperature Sensor / Switch: Description and Operation The evaporator temperature sensor is a two-wire temperature sensing element located at the coldest point on the face of the evaporator. The sensor is attached to the evaporator coil fins. The evaporator temperature sensor prevents condensation on the evaporator coil from freezing and obstructing A/C system air flow. The evaporator temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The evaporator temperature sensor monitors the temperature of the evaporator. The sensor will change its internal resistance in response to the temperatures it monitors. The A/C-heater control module is connected to the sensor through a sensor ground circuit and a sensor signal circuit. As the evaporator temperature increases, the resistance of the sensor decreases and the voltage monitored by the module decreases. The module uses this monitored voltage reading to an indication of the evaporator temperature. The A/C-heater control module is programmed to respond to this input by cycling the air conditioning compressor clutch as necessary to optimize air conditioning system performance and to protect the system from evaporator freezing. The external location of the sensor allows the sensor to be removed or installed without disturbing the refrigerant in the system. The evaporator temperature sensor is diagnosed using a DRBIII(R) scan tool. Refer to Body Diagnostic Procedures. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5240 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the HVAC housing from the vehicle . Evaporator Temperature Sensor Wire Connector 3. Disconnect the HVAC wire harness connector from the evaporator temperature sensor. 4. Disassemble the HVAC housing to gain access to the evaporator coil. Evaporator Temperature Sensor Probe 5. Remove the evaporator temperature sensor probe from the evaporator coil. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5241 INSTALLATION 1. Install the evaporator probe into the evaporator coil. 2. Assemble the HVAC housing. 3. Connect the HVAC wire harness connector to the evaporator temperature sensor. 4. Install the HVAC housing . 5. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation Expansion Block/Orifice Tube: Description and Operation Fixed A/C Orifice Tube - Typical The fixed A/C orifice tube is installed in the liquid line between the outlet of the condenser and the inlet of the evaporator. The A/C orifice tube is only serviced as an part of the liquid line. The fixed A/C orifice tube is used to meter the flow of liquid refrigerant into the evaporator coil. The high-pressure liquid refrigerant from the condenser expands into a low-pressure liquid as it passes through the metering orifice and diffuser screen of the A/C orifice tube. The A/C orifice tube is not serviceable. The A/C orifice tube cannot be repaired and, if faulty or plugged, it must be replaced as part of the liquid line. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Page 5245 Expansion Block/Orifice Tube: Testing and Inspection A/C ORIFICE TUBE WARNING: THE LIQUID LINE BETWEEN THE CONDENSER OUTLET AND THE A/C ORIFICE TUBE CAN BECOME HOT ENOUGH TO BURN THE SKIN. USE EXTREME CAUTION WHEN PERFORMING THE FOLLOWING TEST. NOTE: The A/C orifice tube can be checked for proper operation using the following procedure. However, the A/C orifice tube is only serviced as a part of the liquid line. If the results of this test indicate that the A/C orifice tube is obstructed or missing, the liquid line must be replaced. 1. Confirm that the refrigerant system is properly charged. 2. Start the engine. Turn on the air conditioning system and confirm that the compressor clutch is engaged. 3. Allow the air conditioning system to operate for five minutes. 4. Lightly and cautiously touch the liquid line near the condenser outlet at the front of the engine compartment. The liquid line should be hot to the touch. 5. Touch the liquid line near the evaporator inlet at the rear of the engine compartment. The liquid line should be cold to the touch. 6. If there is a distinct temperature differential between the two ends of the liquid line, the A/C orifice tube is in good condition. If there is little or no detectable temperature differential between the two ends of the liquid line, the A/C orifice tube is obstructed or missing and the liquid line must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation Heater Core: Description and Operation The heater core is located in the HVAC housing, behind the instrument panel. It is a heat exchanger made of rows of tubes and fins. Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows through the heater core, heat is removed from the engine and is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The blend door allows control of the heater output air temperature by regulating the amount of air flowing through the heater core within the HVAC housing. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Page 5249 Heater Core: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Disassembly of the HVAC housing is not required to remove heater core. 1. Remove the HVAC housing. Refer to Housing Assembly HVAC/ Service and Repair/ Procedures. 2. Remove the foam seal from the heater core tubes. Heated Core - Dual Zone Shown, Single Zone Typical 3. If equipped with the Dual Zone system, remove the linkage rod from the actuator levers to gain access to the heater core. 4. Remove the two screws that secure the heater core tube bracket to the HVAC housing. 5. Remove the heater core tube bracket. 6. Pull the heater core out of the HVAC housing. 7. Inspect all foam seals and repair or replace them as required. INSTALLATION 1. Install the heater core into the HVAC housing. 2. Position the heater core tube bracket onto the HVAC housing. 3. Install the two screws that secure the heater core bracket to the HVAC housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 4. If equipped with the Dual Zone system, install the linkage rod onto the actuator levers. 5. Install the foam seal onto the heater core tubes. 6. Install the HVAC housing. Refer to Housing Assembly HVAC/ Service and Repair/ Procedures. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement Heater Hose: Service and Repair Heater Inlet Hose Replacement REMOVAL The heater inlet hose is constructed from rubber hoses and plastic hose connectors. The ends are secured to the heater core, engine and engine coolant reservoir (depending on engine application) by spring tension clamps. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Drain the engine cooling system. Heated Hoses - Typical 2. Remove the heater hose retaining brackets as required (depending on engine application). 3. Using spring tension clamp pliers, compress and slide the clamps off of each end of the hose being removed. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes/heater core, causing an engine coolant leak. 4. Disconnect each hose end by carefully twisting the hose back and forth on the tube, while gently pulling it away from the end of the tube. 5. If necessary, carefully cut the hose end and peel the hose off of the tube. NOTE: Replacement of the heater inlet hose will be required if the hose ends are cut for removal. 6. Remove the heater inlet hose from the engine compartment. 7. Separate the heater hoses from each other as required (depending on engine application). INSTALLATION 1. If separated, reconnect the heater hoses to each other as required (depending on engine application). 2. Position the heater inlet hose into the engine compartment. 3. Using spring tension clamp pliers, compress and slide each clamp away from the end of the hose being installed. 4. Install each hose by carefully twisting the hose back and forth while gently pushing it onto the tube end. 5. Using spring tension clamp pliers, compress and slide the clamps onto each end of the hose being installed. 6. Install the heater hose retaining brackets as required (depending on engine application). 7. Refill the engine cooling system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement > Page 5254 Heater Hose: Service and Repair Heater Return Hose Replacement REMOVAL The heater return hose is constructed from rubber hoses and plastic hose connectors. The ends are secured to the heater core, engine and engine coolant reservoir (depending on engine application) by spring tension clamps. WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Drain the engine cooling system. Heated Hoses - Typical 2. Remove the heater hose retaining brackets as required (depending on engine application). 3. Using spring tension clamp pliers, compress and slide the clamps off of each end of the hose being removed. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes/heater core, causing an engine coolant leak. 4. Disconnect each hose end by carefully twisting the hose back and forth on the tube, while gently pulling it away from the end of the tube. 5. If necessary, carefully cut the hose end and peel the hose off of the tube. NOTE: Replacement of the heater return hose will be required if the hose ends are cut for removal. 6. Remove the heater return hose from the engine compartment. 7. Separate the heater hoses from each other as required (depending on engine application). INSTALLATION 1. If separated, reconnect the heater hoses to each other as required (depending on engine application). 2. Position the heater return hose into the engine compartment. 3. Using spring tension clamp pliers, compress and slide each clamp away from the end of the hose being installed. 4. Install each hose by carefully twisting the hose back and forth while gently pushing it onto the tube end. 5. Using spring tension clamp pliers, compress and slide the clamps onto each end of the hose being installed. 6. Install the heater hose retaining brackets as required (depending on engine application). 7. Refill the engine cooling system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 A high pressure relief valve is located on the compressor cylinder head, which is on the rear of the compressor. 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 when 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 that the valve is faulty. The high pressure relief valve is a factory-calibrated unit. The valve cannot be adjusted or repaired, and must not be removed or otherwise disturbed. The valve is only serviced as a part of the compressor assembly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service Precautions Hose/Line HVAC: Service Precautions ENGINE COOLING SYSTEM WARNING: - THE ENGINE COOLING SYSTEM IS DESIGNED TO DEVELOP INTERNAL PRESSURES OF 97 TO 123 KILOPASCALS (14 TO 18 POUNDS PER SQUARE INCH). DO NOT REMOVE OR LOOSEN THE COOLANT PRESSURE CAP, CYLINDER BLOCK DRAIN PLUGS, RADIATOR DRAIN, RADIATOR HOSES, HEATER HOSES, OR HOSE CLAMPS WHILE THE ENGINE COOLING SYSTEM IS HOT AND UNDER PRESSURE. FAILURE TO OBSERVE THIS WARNING CAN RESULT IN SERIOUS BURNS FROM THE HEATED ENGINE COOLANT. ALLOW THE VEHICLE TO COOL FOR A MINIMUM OF 15 minutes BEFORE OPENING THE COOLING SYSTEM FOR SERVICE. A/C SYSTEM WARNING: - THE AIR CONDITIONING SYSTEM CONTAINS REFRIGERANT UNDER HIGH PRESSURE. SEVERE PERSONAL INJURY MAY RESULT FROM IMPROPER SERVICE PROCEDURES. REPAIRS SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL.AVOID BREATHING THE REFRIGERANT AND REFRIGERANT OIL VAPOR OR MIST. EXPOSURE MAY IRRITATE THE EYES, NOSE, AND/OR THROAT. WEAR EYE PROTECTION WHEN SERVICING THE AIR CONDITIONING REFRIGERANT SYSTEM. SERIOUS EYE INJURY CAN RESULT FROM DIRECT CONTACT WITH THE REFRIGERANT. IF EYE CONTACT OCCURS, SEEK MEDICAL ATTENTION IMMEDIATELY. - DO NOT EXPOSE THE REFRIGERANT TO OPEN FLAME. POISONOUS GAS IS CREATED WHEN REFRIGERANT IS BURNED. AN ELECTRONIC LEAK DETECTOR IS RECOMMENDED. - IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE THE WORK AREA BEFORE RESUMING SERVICE. LARGE AMOUNTS OF REFRIGERANT RELEASED IN A CLOSED WORK AREA WILL DISPLACE THE OXYGEN AND CAUSE SUFFOCATION. THE EVAPORATION RATE OF R-134a REFRIGERANT AT AVERAGE TEMPERATURE AND ALTITUDE IS EXTREMELY HIGH. AS A RESULT, ANYTHING THAT COMES IN CONTACT WITH THE REFRIGERANT WILL FREEZE. ALWAYS PROTECT THE SKIN OR DELICATE OBJECTS FROM DIRECT CONTACT WITH THE REFRIGERANT. - THE R-134a SERVICE EQUIPMENT OR THE VEHICLE REFRIGERANT SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. SOME MIXTURES OF AIR AND R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS, AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE. CAUTION: - Liquid refrigerant is corrosive to metal surfaces. Follow the operating instructions supplied with the service equipment being used. - Never add R-12 to a refrigerant system designed to use R-134a and do not use R-12 equipment or parts on the R-134a system. Damage to the system will result. - R-12 refrigerant oil must not be mixed with R-134a refrigerant oil. They are not compatible and damage to the system will result. - Do not overcharge the refrigerant system. Overcharging will cause excessive compressor head pressure and can cause noise and system failure. Recover the refrigerant before opening any fitting or connection. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. - If equipped, do not remove the secondary retention clip from any spring-lock coupler connection while the refrigerant system is under pressure. Recover the refrigerant before removing the secondary retention clip. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. - Do not open the refrigerant system or uncap a replacement component until you are ready to service the system. This will prevent contamination in the system. Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system. Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap or plug. - Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a container of refrigerant oil until you are ready to use it. Replace the cap on the oil container immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free container. - Keep service tools and the work area clean. Contamination of the refrigerant system must be avoided. - The use of A/C system sealers may result in damage to A/C refrigerant recovery/evacuation/recharging equipment and/or A/C systems. - Many federal, state/provincial and local regulations prohibit the recharge of A/C systems with known leaks. DaimlerChrysler recommends the detection of A/C system leaks through the use of approved leak detectors and fluorescent leak detection dyes. Vehicles found with A/C system sealers should be treated as contaminated and replacement of the entire A/C refrigerant system is recommended. A/C systems found to be contaminated with A/C system sealers, A/C stop-leak products or seal conditioners voids the warranty for the A/C system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line Hose/Line HVAC: Description and Operation A/C Discharge Hose/Line The A/C discharge line is the refrigerant line that goes from the A/C compressor to the A/C condenser. The A/C discharge line for the 5.9L Diesel engine is serviced as an assembly with the suction line. The A/C discharge line has no serviceable parts except the rubber O-ring seals. CAUTION: Use only O-ring seals specified for the vehicle. Failure to use correct O-ring seal will cause the refrigerant system connection to leak. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C discharge line is removed and installed. If the A/C discharge line is found to be leaking or is damaged, it must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 5263 Hose/Line HVAC: Description and Operation A/C Liquid Hose/Line The liquid line is the refrigerant line that carries refrigerant from the A/C condenser to the evaporator. The liquid line for this model consist of two separate lines that connect to each other. The liquid lines are made from light-weight aluminum or steel, and use braze-less fittings. The front half of the liquid line contains the fixed orifice tube. The liquid lines are only serviced as an assembly, except for the rubber O-ring seals used on the end fittings. The liquid lines cannot be adjusted or repaired and, if found to be leaking or damaged, they must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 5264 Hose/Line HVAC: Description and Operation A/C Suction Hose/Line The suction line is the refrigerant line that goes from the evaporator outlet tube to the compressor inlet port. The suction line for the 5.9L Diesel engine is only serviced as an assembly with the discharge line. The suction line has no serviceable parts except the rubber O-rings. If the suction line is found to be leaking or is damaged, it must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Hose/Line > Page 5265 Hose/Line HVAC: Description and Operation Refrigerant Lines 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, which is sandwiched between rubber layers, is used for the R-134a air conditioning system on this vehicle. This nylon tube 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 or steel, and commonly use braze-less fittings. Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from an 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 are coupled with other components of the HVAC system with either O-rings or dual plane seals. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Page 5266 Hose/Line HVAC: Testing and Inspection REFRIGERANT SYSTEM LEAKS WARNING: R-134a SERVICE EQUIPMENT OR VEHICLE A/C SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. MIXTURE OF AIR and R-134a CAN BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE. AVOID BREATHING A/C REFRIGERANT AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY IRRITATE EYES, NOSE AND THROAT. USE ONLY APPROVED SERVICE EQUIPMENT MEETING SAE REQUIREMENTS TO DISCHARGE R-134a SYSTEM. IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE WORK AREA BEFORE RESUMING SERVICE. NOTE: The refrigerant system does come from the factory with a yellow tracer dye already installed to aid in detection of leaks. If the A/C system is not cooling properly, determine if the refrigerant system is fully charged with R-134a. This is accomplished by performing a system Charge Level-Check or Fill. If while performing this test A/C liquid line pressure is less than 345 kPa (50 psi) proceed to System Empty procedure. If liquid line pressure is greater than 345 kPa (50 psi) proceed to System Low procedure. If the refrigerant system is empty or low in refrigerant charge, a leak at any line fitting or component seal is likely. A review of the fittings, lines and components for oily residue is an indication of the leak location. To detect a leak in the refrigerant system, perform one of the following procedures as indicated by the symptoms. SYSTEM EMPTY 1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approx. 28 in Hg.). Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level, proceed with this procedure. 2. Prepare a 0.284 Kg. (10 oz.) refrigerant charge to be injected into the system. 3. Connect and dispense 0.284 Kg. (10 oz.) of refrigerant into the evacuated refrigerant system. 4. Proceed to Step 2 of System Low procedure. SYSTEM LOW 1. Determine if there is any (R-134a) refrigerant in the system. 2. Position the vehicle in a wind free work area. This will aid in detecting small leaks. 3. Bring the refrigerant system up to operating temperature and pressure. This is done by allowing the engine to run for five minutes with the system set to the following: Transmission in Park or Neutral with parking brake set - Engine idling at 700 rpm - A/C controls set in 100 percent outside air - Blower switch in the high A/C position - A/C in the ON position - Open all windows CAUTION: A leak detector designed for R-12 refrigerant (only) will not detect leaks in a R-134a refrigerant system. 4. Shut off the vehicle and wait 2 to 7 minutes. Then use an Electronic Leak Detector that is designed to detect R-134a type refrigerant and search for leaks. Fittings, lines, or components that appear to be oily usually indicates a refrigerant leak. To inspect the evaporator core for leaks, insert the leak detector probe into the drain tube opening or a heat duct. A R-134a dye is available to aid in leak detection, use only DaimlerChrysler approved refrigerant dye. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Liquid Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement REMOVAL WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Disconnect and isolate the battery negative cable. 2. If equipped with the diesel engine, remove the passenger side battery. 3. If equipped with the diesel engine, remove the passenger side battery tray. 4. Recover the refrigerant from the refrigerant system. 5. Remove the plastic cover from the condenser outlet stud. A/C Liquid Line - Typical 6. Remove the nut that secures the liquid line fitting to the condenser outlet. 7. Disconnect the liquid line from the condenser. 8. Remove the seal from the liquid line fitting and discard. 9. Install plugs in, or tape over the liquid line fitting and condenser outlet port. 10. Disengage the liquid lines from the body retaining clips. 11. Remove the secondary retaining clip from the spring-lock coupler that secures the front section of the liquid line to the rear section of the liquid line. 12. Using the proper A/C line disconnect tool, disconnect the front section of the liquid line from the rear section of the liquid line. 13. Remove the O-ring seal from the liquid line fitting and discard. 14. Install plugs in, or tape over the opened front liquid line fitting and rear liquid line tube. 15. Remove the secondary retaining clip from the spring-lock coupler that secures the liquid line to the evaporator inlet tube. 16. Using the proper A/C line disconnect tool, disconnect the liquid line from the evaporator inlet tube. 17. Remove the O-ring seal from the liquid line fitting and discard. 18. Install plugs in, or tape over the opened liquid line fitting and evaporator inlet tube. 19. Remove both sections of the liquid line from the engine compartment. INSTALLATION 1. Position both sections of the liquid line into the engine compartment. 2. Remove the tape or plugs from the rear liquid line fitting and the evaporator inlet tube. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Liquid Hose/Line Replacement > Page 5269 3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the rear liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the liquid line fitting to the evaporator inlet tube. 5. Install the secondary retaining clip onto the spring-lock coupler that secures the liquid line fitting to the evaporator inlet tube. 6. Remove the tape or plugs from the front liquid line fitting and the rear liquid line tube. 7. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the front liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the front liquid line fitting to the rear liquid line tube. 9. Install the secondary retaining clip onto the spring-lock coupler that secures the front liquid line fitting to the rear liquid line tube. 10. Engage the liquid lines to the body retaining clips. 11. Remove the tape or plugs from the liquid line fitting and condenser outlet port. 12. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 13. Connect the liquid line to the condenser outlet port. 14. Install and tighten the nut that secures the liquid line fitting to the condenser. Tighten the nut to 20 Nm (180 in. lbs.). 15. Install the plastic cover onto the condenser outlet stud. 16. If equipped with the diesel engine, install the passenger side battery tray. 17. If equipped with the diesel engine, install the passenger side battery. 18. Reconnect the battery negative cables. 19. Evacuate the refrigerant system. 20. Charge the refrigerant system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Liquid Hose/Line Replacement > Page 5270 Hose/Line HVAC: Service and Repair Diode Replacement 1. Disconnect and isolate the battery negative cable. If the vehicle has dual batteries, remove the negative cable from both batteries. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness. Note the direction of current flow. 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. If necessary refer to the appropriate wiring diagram for current flow. 6. Solder the connections together using rosin core type solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 8. Reconnect the battery negative cable(s) and test the affected systems. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Liquid Hose/Line Replacement > Page 5271 Hose/Line HVAC: Service and Repair Handling Tubing and Fittings CAUTION: The system must be completely empty before opening any fitting or connection in the refrigeration system. Open fittings with caution even after the system has been emptied. If any pressure is noticed as a fitting is loosened, retighten fitting and evacuate the system again. A good rule for the flexible hose lines is to keep the radius of all bends at least 10 times the diameter of the hose. Sharper bends will reduce the flow of refrigerant. The flexible hose lines should be routed so they are at least 3 inches (80 mm) from the exhaust manifold. Inspect all flexible hose lines to make sure they are in good condition and properly routed. The use of correct wrenches when making connections is very important. Improper wrenches or improper use of wrenches can damage the fittings. The internal parts of the A/C system will remain stable as long as moisture-free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system. When opening a refrigeration system, have everything you will need to repair the system ready. This will minimize the amount of time the system must be opened. Cap or plug all lines and fittings as soon as they are opened. This will help prevent the entrance of dirt and moisture. All new lines and components should be capped or sealed until they are ready to be used. Before connecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system. All tools, including the refrigerant dispensing manifold, the manifold gauge set, and test hoses should be kept clean and dry. Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and moisture can enter the system when it is opened for repair or replacement of lines or components. The refrigerant oil will absorb moisture readily out of the air. This moisture will convert into acids within a closed system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Description and Operation Housing Assembly HVAC: Description and Operation All models are equipped with a common HVAC housing assembly that combines A/C and heating capabilities into a single unit mounted within the passenger compartment. The HVAC housing assembly consists of the following: - HVAC housing - The HVAC housing consists of an upper housing (7) and a lower housing (10) that are attached together by screws and is mounted to the dash panel behind the instrument panel. The HVAC housing contains the heater core (9), A/C evaporator (15), blend-air and modeair doors, and has mounting provisions for the air-door actuators (3, 5, 6 and 8), floor distribution duct (4), blower motor (13), blower motor resistor, foam seals (12, 14 and 16) and the HVAC wire harness (11). - Air inlet housing - The air inlet housing (1) is mounted to the right end of the HVAC housing and contains the recirculation-air door and has mounting provisions for the recirculation door actuator (2). The heating-A/C system is a blend-air type system. The blend-air doors control the amount of conditioned air that is allowed to flow through, or around, the heater core. The dual zone heating A/C system uses two blend door actuators while the single zone system uses only one blend door actuator. The A/C system is designed for the use of a non-CFC, R-134a refrigerant and uses an A/C evaporator to cool and dehumidify the incoming air prior to blending it with the heated air. A temperature control determines the discharge air temperature by operating the blend door actuator(s), which moves the blend-air door(s). This allows an almost immediate control of the output air temperature of the system. The mode door actuator operates the mode-air doors which direct the flow of the conditioned air out the various air outlets, depending on the mode selected. The recirculation door actuator operates the recirculation-air door which closes off the fresh air intake and recirculates the air already inside the vehicle. The electric door actuators are connected to the vehicle electrical system by the HVAC wire harness. The blower motor controls the velocity of air flowing through the HVAC housing assembly by spinning the blower wheel within the HVAC housings at the selected speed by use of the blower motor resistor. The HVAC housing must be removed from the vehicle and disassembled for service of the heater core, A/C evaporator, evaporator temperature sensor, blend-air and mode-air doors. The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement Housing Assembly HVAC: Removal and Replacement Air Inlet Housing Removal and Installation REMOVAL WARNING: - REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. 1. Remove the HVAC housing assembly. 2. Remove the recirculation door actuator (1) from the air inlet housing (2) and disconnect the HVAC wire harness (4) from the actuator. 3. Remove the two screws (3) that secure the rear of the air inlet housing to the top of the HVAC housing (5). 4. Release the two retaining clips (1) that secure the front of the air inlet housing (2) to the top of the HVAC housing (3) and remove the air inlet housing. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5277 NOTE: If the foam seal on the air inlet housing is deformed or damaged, it must be replaced. 5. If required, disassemble the air inlet housing. INSTALLATION NOTE: - The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. - If the foam seal on the air inlet housing is deformed or damaged, it must be replaced. 1. Position the air inlet housing (2) onto the top of the HVAC housing (3). 2. Engage the two retaining clips (1) that secure the front of the air inlet housing to the HVAC housing. 3. Install the two screws (3) that secure the rear of the air inlet housing (2) to the top of the HVAC housing (5). Tighten the screws to 2.2 N.m (20 in.lbs.). 4. Install the recirculation door actuator (1) onto the air inlet housing. 5. Connect the HVAC wire harness (4) to the recirculation door actuator. 6. Install the HVAC housing assembly. HVAC Housing - Removal and Installation REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5278 WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: The HVAC housing must be removed from the vehicle and the two halves of the housing separated for service access of the heater core, evaporator coil, defrost door, blend door(s) and the recirculation door. 1. Disconnect and isolate the battery negative cable. 2. Drain the engine cooling system . 3. Recover the refrigerant from the refrigerant system. 4. Disconnect the liquid refrigerant line fitting from the evaporator inlet tube. Discard the O-ring seal and install plugs in, or tape over the opened liquid refrigerant line fitting and evaporator inlet tube. 5. Remove the accumulator. Discard the O-ring seals and install plugs in, or tape over the opened refrigerant line fittings and evaporator outlet tube. 6. Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes. 7. Remove the powertrain control module (PCM) from the engine compartment to gain access to the HVAC housing retaining nuts. 8. Remove the two nuts from the HVAC housing mounting studs in the engine compartment. 9. Remove the instrument panel from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair HVAC Housing - Dual Zone Shown, Single Zone Typical 10. Remove the bolt that secures the HVAC housing to the floor bracket located in the center of the vehicle. 11. Remove the two nuts from the HVAC housing mounting studs in the passenger compartment. 12. Remove the HVAC housing from inside the vehicle. Take care not to allow any remaining coolant to drain onto the vehicles interior. INSTALLATION WARNING: IF THE VEHICLE IS EQUIPPED WITH AIR CONDITIONING, REVIEW THE WARNINGS AND CAUTIONS IN Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5279 PLUMBING BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Position the HVAC housing into the vehicle. Be certain that the evaporator condensate drain tube and the housing mounting studs are inserted into their correct locations. 2. Install the two nuts that secure the HVAC housing to the mounting studs in the passenger compartment. Tighten the nuts to 6.2 Nm (55 in. lbs.). 3. Install the bolt that secures the HVAC housing to the floor bracket in the passenger compartment. Tighten the bolt to 6.2 Nm (55 in. lbs.). 4. Install the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 5. Install the two nuts that secure the HVAC housing to the mounting studs in the engine compartment. Tighten the nuts to 6.2 Nm (55 in. lbs.). 6. Install the powertrain control module (PCM). 7. Unplug or remove the tape from the heater core tubes and connect the heater hoses to the heater core tubes. 8. Unplug or remove the tape from the opened refrigerant line fittings and the evaporator outlet tube and install the accumulator. 9. Unplug or remove the tape from the liquid line and the evaporator inlet tube fittings. Connect the liquid line coupler to the evaporator inlet tube. 10. Evacuate the refrigerant system. 11. Charge the refrigerant system . 12. Fill the engine cooling system. 13. Connect the battery negative cable. 14. Start the engine and check for proper operation of the heating and air conditioning systems. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5280 Housing Assembly HVAC: Overhaul Air Inlet Housing DISASSEMBLY NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. 1. Remove the air inlet housing (1) from the HVAC housing and place it on a workbench. 2. Remove the two foam insulators (2) from the air inlet housing. 3. To remove the recirculation-air door (1) from the air inlet housing (2), first carefully release the retaining tabs of actuator coupler (3) located on the inside surface of the air inlet housing and pull the actuator coupler out of the pivot shaft of the recirculation-air door. NOTE: If the seals on the air door is deformed or damaged, the air door must be replaced. 4. Remove the recirculation-air door from the air inlet housing. ASSEMBLY NOTE: - The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. - If the seals on the air door is deformed or damaged, the air door must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5281 1. Position the recirculation-air door (1) into the air inlet housing (2). CAUTION: Make sure that the recirculation-air door pivot shaft is properly seated in the pivot seat located in the air inlet housing. 2. Align the actuator coupler (3) with the recirculation-air door pivot shaft and install the coupler until the coupler retaining tabs are fully engaged to the air inlet housing. Be sure to install the coupler with the coupler arm located between the two stop tabs on the air inlet housing. 3. Install the two foam insulators (2) into the air inlet housing (1). 4. Install the air inlet housing onto the HVAC housing. HVAC Housing DISASSEMBLY 1. Remove the HVAC housing from the vehicle and place it on the workbench. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5282 HVAC Housing - Diassembled 2. Disconnect the electrical connectors from the blower motor, blower motor resistor block, evaporator temperature sensor and each actuator. 3. Remove the HVAC wiring harness from the HVAC housing. 4. If necessary, remove the blower motor from the HVAC housing . 5. If necessary, remove the blower motor resistor block from the HVAC housing. 6. Carefully remove the foam seals from the heater core and evaporator coil tube mounting flange of the HVAC housing. If the either seal is deformed or damaged, it must be replaced. 7. Remove the screws that secure the heater core in the HVAC housing and carefully remove the heater core from the housing. 8. Use a screwdriver to pry off the four snap clips that help secure the upper and lower HVAC housing halves together. 9. Remove the screws that secure the upper and lower HVAC housing halves to each other and those that secure the recirculation housing to the upper HVAC housing. 10. Carefully separate the recirculation housing and the upper HVAC housing from the lower housing. ASSEMBLY 1. Position the upper HVAC housing to the lower housing. During assembly, be certain of the following: a. That each of the door pivot shaft ends are properly engaged in there pivot holes. b. That the evaporator drain opening is clean and the drain foam seal is properly installed. 2. Install the screws and snap clips that secure the upper and lower HVAC housing halves to each other and those that secure the recirculation housing to the upper HVAC housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Install the foam seals on the heater core and evaporator coil tubes. 4. If removed, install the blower motor resistor block. 5. If removed, install the blower motor. 6. Install the HVAC wire harness. Make sure the wires are routed through all wiring retainers. 7. Connect the wire harness to the blower motor, blower motor resistor block, evaporator temperature sensor and each actuator. 8. Install the HVAC housing. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications REFRIGERANT CAPACITY Refer to the A/C Underhood Specification Label located in the engine compartment. 2004 Ram Gas ...................................................................................................................................................... .................................. 0.728kg (1.604 lbs.) 2004 Ram Diesel ............................................................. ....................................................................................................................... 0.850kg (1.873 lbs.) 2005 Ram Gas .................................................................................................................................... .................................................... 0.728kg (1.604 lbs.) 2005 Ram Diesel ........................................... ......................................................................................................................................... 0.850kg (1.873 lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 5287 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ...................................................................... R-134a Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 5288 Refrigerant: Description and 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery Refrigerant: Service and Repair Refrigerant System - Recovery WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT BEFORE PERFORMING THE FOLLOWING OPERATION. A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to recover the refrigerant from an R-134a refrigerant system. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 5291 Refrigerant: Service and Repair Refrigerant System - Evacuate NOTE: - Special effort must be used to prevent moisture from entering the A/C system oil. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. - If a compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended period of time. It is recommended that the refrigerant oil be drained and replaced with new oil or a new compressor be used. This will eliminate the possibility of contaminating the refrigerant system. - If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be filled. Moisture and air mixed with the refrigerant will raise the compressor head pressure above acceptable operating levels. This will reduce the performance of the air conditioner and damage the compressor. Moisture will boil at near room temperature when exposed to vacuum. To evacuate the refrigerant system: - When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection. 1. Recover the refrigerant system. 2. Connect a suitable charging station, refrigerant recovery machine or a manifold gauge set with vacuum pump and refrigerant recovery equipment. 3. Open the suction and discharge valves and start the vacuum pump. The vacuum pump should run a minimum of 45 minutes prior to charge to eliminate all moisture in system. When the suction gauge reads -88 kPa (- 26 in. Hg) vacuum or greater for 30 minutes, close all valves and turn off vacuum pump. If the system fails to reach specified vacuum, the refrigerant system likely has a leak that must be corrected. If the refrigerant system maintains specified vacuum for at least 30 minutes, start the vacuum pump, open the suction and discharge valves. Then allow the system to evacuate an additional 10 minutes. 4. Close all valves. Turn off and disconnect the vacuum pump. 5. Charge the refrigerant system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 5292 Refrigerant: Service and Repair Refrigerant System - Charge WARNING: - REVIEW SAFETY PRECAUTIONS AND WARNINGS BEFORE CHARGING THE REFRIGERANT SYSTEM. - AVOID BREATHING A/C REFRIGERANT AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY IRRITATE EYES, NOSE AND THROAT. USE ONLY APPROVED SERVICE EQUIPMENT MEETING SAE REQUIREMENTS TO DISCHARGE R-134a SYSTEM. IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE WORK AREA BEFORE RESUMING SERVICE. - R-134a SERVICE EQUIPMENT OR VEHICLE A/C SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. MIXTURE OF AIR and R-134a CAN BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE. CAUTION: - Do not overcharge refrigerant system, as excessive compressor head pressure can cause noise and system failure. - A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process. Refer the equipment manufacturer instructions for more information. The procedure below should be used to fill the refrigerant charge in the air conditioning system. This A/C system does not have or use a sight glass to check or charge the system. After the system has been tested for leaks and evacuated, a refrigerant (R-134a) charge can be injected into the system. NOTE: When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection. 1. If using a separate vacuum pump close all valves before disconnecting pump. Connect manifold gauge set to the A/C service ports. NOTE: Always refer to the underhood HVAC Specification label for the refrigerant fill level of the vehicle being serviced. 2. Measure refrigerant. Refer to the instructions provided with the equipment being used. 3. Verify engine is shut off. Open the suction and discharge valves. Open the charge valve to allow the refrigerant to flow into the system. When the transfer of refrigerant has stopped, close the suction and discharge valve. 4. If all of the charge did not transfer from the dispensing device, put vehicle controls into the following mode: - Automatic transmission in park or manual transmission in neutral - Engine at idle - A/C mode control set to outside air - A/C mode control set to panel mode - A/C temperature control set to full cool - Blower motor control set on highest speed - Vehicle windows closed If the A/C compressor does not engage, test the compressor clutch control circuit and correct any failure. 5. Open the suction valve to allow the remaining refrigerant to transfer to the system. WARNING: TAKE CARE NOT TO OPEN THE DISCHARGE (HIGH-PRESSURE) VALVE AT THIS TIME. 6. Close all valves and test the A/C system performance. 7. Disconnect the charging station or manifold gauge set. Install the service port caps. REFRIGERANT CHARGE CAPACITY 2004 Ram Gas .................................................................................................................................... .................................................... 0.728kg (1.604 lbs.) 2004 Ram Diesel ........................................... ......................................................................................................................................... 0.850kg (1.873 lbs.) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Total System Fill .................................................................................................................................. ............................................................ 6 oz (180 ml) Accumulator ......................................................................................................................................... ............................................................... 2 oz (60 ml) Condenser ........................................................................................................................................... ................................................................. 1 oz (30 ml) Evaporator ........................................................................................................................................... ................................................................ 2 oz (60 ml) Compressor ..................................................................................................................................... Drain and measure the oil from the old compressor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 5297 Refrigerant Oil: Fluid Type Specifications Denso 10S17 Compressor .................................................................................................................. ........................................................... ND-8 PAG Oil Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 5298 Refrigerant Oil: Description and Operation The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, PolyAlkylene Glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to an R-134a refrigerant system. There are different PAG oils available, and each contains a different additive package. Two different type of A/C compressors are used in this vehicle depending on engine application. Both compressors are designed to use a PAG refrigerant oil. However, the PAG oil type differs between the two compressor designs. Use only refrigerant oil of the same type as recommended to service the refrigerant system (always refer to the specification tag included with the replacement A/C compressor or the under-hood A/C system specification tag). After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause compressor damage, and too much can reduce air conditioning system performance. PAG refrigerant oil is much more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair > Refrigerant Oil Level Refrigerant Oil: Service and Repair Refrigerant Oil Level STANDARD PROCEDURE - REFRIGERANT OIL LEVEL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. CAUTION: The refrigerant oil in the R-134a A/C system is unique depending on the A/C compressor used. Use only PAG oils that are designed to work with R-134a refrigerant and the A/C compressor in the vehicle. Always refer to the underhood A/C System Specification Label for the correct oil designation. It is important to have the correct amount of lubricant in the A/C refrigerant system to ensure proper lubrication of the A/C compressor. Too little lubricant will result in damage to the compressor. Too much lubricant will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. The lubricant used in the compressor is polyalkalene glycol PAG lubricant. Only the refrigerant lubricant approved for use with this vehicle should be used to service the system. Do not use any other lubricant. The lubricant container should be kept tightly capped until it is ready for use. Refrigerant lubricant will quickly absorb any moisture it comes in contact with. It will not be necessary to check the oil level in the A/C compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to component replacement, or a rupture or leak from a refrigerant line, connector fitting, component or component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of the recommended 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. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair > Refrigerant Oil Level > Page 5301 Refrigerant Oil: Service and Repair Component Refrigerant Oil Level Check A/C Component Referigerant Oil Capacities When an air conditioning system is first assembled at the factory, all components (except the A/C compressor) are refrigerant oil free. After the refrigerant system has been charged with (R-134a) refrigerant and operated, the oil in the A/C compressor is dispersed through the lines and components. The A/C evaporator, A/C condenser, and accumulator will retain a significant amount of oil. Refer to the A/C Component Refrigerant Oil Capacities table. When a component is replaced, the specified amount of refrigerant oil must be added. When a new A/C compressor is being installed, drain the lubricant from the used compressor, measure the amount drained and discard the used lubricant. Drain the lubricant from the new A/C compressor into a clean container. Return the amount of lubricant measured from the used compressor, plus the amount reclaimed from the system back into the new A/C compressor. When a line or component has ruptured and oil has escaped, the accumulator must be replaced along with the ruptured component. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair > Refrigerant Oil Level > Page 5302 Refrigerant Oil: Service and Repair Compressor Refrigerant Oil Level Check NOTE: Most reclaim/recycling equipment will measure the lubricant being removed during recovery. This amount of lubricant should be added back into the system. Refer to the reclaim/recycling equipment manufacturers instructions. 1. Recover the refrigerant from the system. 2. Disconnect the refrigerant lines from the A/C compressor. Cap open lines to prevent moisture from entering the system. 3. Remove the A/C compressor from the vehicle. 4. From the suction and discharge ports on the A/C compressor, drain the lubricant from the old A/C compressor into a clean container. 5. From the suction and discharge ports on the A/C compressor, drain the lubricant from the new A/C compressor into a clean container. 6. Install new lubricant back into the new A/C compressor in the amount measured from the used compressor, plus adding any amount of lubricant lost when the refrigerant system was reclaimed. 7. Install the A/C compressor and connect the refrigerant lines. Then evacuate and charge refrigerant system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams Transducer-A/C Pressure (Diesel/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 5306 Refrigerant Pressure Sensor / Switch: Description and Operation The A/C pressure transducer is a switch that is installed on a fitting located on the refrigerant discharge line between the compressor and the condenser in the front corner of the engine compartment. An internally threaded hex fitting on the transducer connects it to the externally threaded Schrader-type fitting on the discharge line. A rubber O-ring seals the connection between the transducer and the discharge line fitting. Three terminals within a molded plastic connector receptacle on the top of the transducer connect it to the vehicle electrical system through a wire lead and connector of the headlamp and dash wire harness. The A/C pressure transducer cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the discharge line. The transducer will change its internal resistance in response to the pressures it monitors. The Powertrain Control Module (PCM) or the Engine Control Module (ECM) depending on engine application, provides a five volt reference signal and a sensor ground to the transducer, then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure. The PCM/ ECM is programmed to respond to this and other sensor inputs by controlling the operation of the air conditioning compressor clutch and the radiator cooling fan to help optimize air conditioning system performance and to protect the system components from damage. The A/C pressure transducer input to the PCM/ECM will also prevent the air conditioning compressor clutch from engaging when ambient temperatures are below about 10° C (50° F) due to the pressure/temperature relationship of the refrigerant. The Schrader-type valve in the discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the system. The A/C pressure transducer is diagnosed using a DRBIII(R) scan tool. Refer to the appropriate diagnostic information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 5307 Refrigerant Pressure Sensor / Switch: Testing and Inspection The A/C pressure transducer is tested using a DRBIII(R) scan tool. Refer to the appropriate diagnostic information. Before testing the A/C pressure transducer, be certain that the transducer wire harness connection is clean of corrosion and properly connected. For the air conditioning system to operate, an A/C pressure transducer voltage reading between 0.451 and 4.519 volts is required. Voltages outside this range indicate a low or high refrigerant system pressure condition to the Powertrain Control Module (PCM) or Engine Control Module (ECM) depending on engine application. The PCM/ECM is programmed to respond to a low or high refrigerant system pressure by suppressing operation of the compressor. Refer to the A/C Pressure Transducer Voltage chart for the possible conditions indicated by the transducer voltage reading. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 5308 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the wire harness connector from the A/C pressure transducer. A/C Pressure Transducer - 3.7L Shown 3. Remove the A/C pressure transducer from the fitting on the discharge line. 4. Remove the O-ring seal from the A/C pressure transducer fitting and discard. INSTALLATION NOTE: Replace the O-ring seal before installing the A/C pressure transducer. 1. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the A/C pressure transducer fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 2. Install and tighten the A/C pressure transducer onto the discharge line fitting. The transducer should be hand-tightened securely onto the discharge line fitting. 3. Connect the wire harness connector to the A/C pressure transducer. 4. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5316 Compressor Clutch Relay: Description and Operation A/C Compressor Clutch Micro-Relay The A/C compressor clutch relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The A/C compressor clutch relay is located in the integrated power module (IPM) in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the IPM cover for A/C compressor clutch relay identification and location. The black, molded plastic case is the most visible component of the A/C compressor clutch relay. Five male spade-type terminals extend from the bottom of the base to connect the relay to the vehicle electrical system, and the ISO designation for each terminal is molded into the base adjacent to each terminal. The ISO terminal designations are as follows: - 30 (Common Feed) - This terminal is connected to the movable contact point of the relay. - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The A/C compressor clutch relay is an electromechanical switch that uses a low current input from the powertrain control module (PCM) or engine control module (ECM) depending on engine application, to control the high current output to the compressor clutch electromagnetic coil. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. The resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The A/C compressor clutch relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the A/C compressor clutch relay include: - The common feed terminal (30) receives a battery current input from a fuse in the IPM through a fused B(+) circuit at all times. - The coil ground terminal (86) receives a ground input from the PCM/ECM through the A/C compressor clutch relay control circuit only when the PCM/ ECM electronically pulls the control circuit to ground. - The coil battery terminal (85) receives a battery current input from PTC 1 in the IPM through a fused ignition switch output (run) circuit only when the ignition switch is in the On position. - The normally open terminal (87) provides a battery current output to the compressor clutch coil through the A/C compressor clutch relay output circuit only when the A/C compressor clutch relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the A/C compressor clutch relay coil is de-energized. Refer to the appropriate wiring information for diagnosis and testing of the micro-relay and for complete HVAC wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5317 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. Integrated Power Module (IPM) 2. Remove the cover from the integrated power module (IPM). 3. Refer to the fuse and relay layout label on the IPM cover for compressor clutch relay identification and location. 4. Remove the A/C compressor clutch relay from the IPM. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the IPM cover for A/C compressor clutch relay location. 2. Position the A/C compressor clutch relay in the proper receptacle in the IPM. 3. Align the A/C compressor clutch relay terminals with the terminal cavities in the IPM receptacle. 4. Push down firmly on the A/C compressor clutch relay until the terminals are fully seated in the terminal cavities in the IPM receptacle. 5. Install the cover onto the IPM. 6. Reconnect the negative battery cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Left Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5325 Left Side Engine Compartment And Hood Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5326 Sensor-Ambient Air Temperature Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5327 Ambient Temperature Sensor / Switch HVAC: Description and Operation The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the left side of the radiator yoke, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent by the Front Control Module (FCM). The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the FCM. Based upon the resistance in the sensor, the FCM senses a specific voltage on the temperature sensor signal circuit. The FCM then translates the voltage into a temperature reading that it sent over the Programmable Communications Interface (PCI) data bus circuit to other modules utilizing temperature information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5328 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection The temperature function is supported by the ambient temperature sensor, a wiring circuit, and Front Control Module (FCM). If any portion of the ambient temperature sensor circuit fails or if Programmable Communications Interface (PCI) Data Bus information is missing, a (- -) will appear in the display in place of the temperature. When the sensor is exposed to temperatures above 55° C (130° F), or if the sensor circuit is shorted, 55° C (130° F) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below - 40° C (- 40° F) or if the sensor circuit is open, - 40° C (- 40° F) will appear in the display. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, test the compass mini-trip computer. SENSOR TEST 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is 336 kilohms. At 55° C (130° F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, refer to Sensor Circuit Test. If not OK, replace the inoperative ambient temperature sensor. SENSOR CIRCUIT TEST For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connectors from the ambient temperature sensor and the FCM. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the FCM harness connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Check for continuity between the ambient temperature sensor signal circuit cavity of the FCM harness connector and a good ground. There should be no continuity. If OK, test the compass mini-trip computer operation. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5329 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Open the hood. 2. Disconnect and isolate the battery negative cable. 3. Working on the underside of the hood, remove screw holding sensor to hood panel. 4. Disconnect the sensor electrical connector and remove sensor from vehicle. INSTALLATION 1. Connect the sensor electrical connector. 2. Working on the underside of the hood, install screw holding sensor to hood panel. 3. Connect the battery negative cable. 4. Close the hood. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 A/C-Heater Control - Single Zone Shown, Dual Zone Typical The blower motor is controlled by a rotary-type blower motor switch, mounted in the A/C-heater control. The switch allows the selection of one of four different blower motor speeds and includes an Off position. The blower motor switch provides a blower motor ground path through the A/C-heater mode control switch. The blower motor switch directs this ground path through or around the blower motor resistor wires, as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, the entire A/C-heater control must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation > Page 5333 Blower Motor Switch: Testing and Inspection For circuit descriptions and diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check for battery voltage at the fuse in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the A/C-heater control from the instrument panel. Check for continuity between the ground circuit cavity of the A/C-heater control wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 3. With the A/C-heater control wire harness connector disconnected, place the A/C-heater mode control switch 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 A/C-heater control as you move the blower motor switch 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 A/C-heater control connector and the blower motor resistor as required. If not OK, replace the faulty A/C-heater control. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Coolant Temperature Sensor / Switch HVAC > Component Information > Locations Left Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5340 Sensor-Evaporator Temperature Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5341 Evaporator Temperature Sensor / Switch: Description and Operation The evaporator temperature sensor is a two-wire temperature sensing element located at the coldest point on the face of the evaporator. The sensor is attached to the evaporator coil fins. The evaporator temperature sensor prevents condensation on the evaporator coil from freezing and obstructing A/C system air flow. The evaporator temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The evaporator temperature sensor monitors the temperature of the evaporator. The sensor will change its internal resistance in response to the temperatures it monitors. The A/C-heater control module is connected to the sensor through a sensor ground circuit and a sensor signal circuit. As the evaporator temperature increases, the resistance of the sensor decreases and the voltage monitored by the module decreases. The module uses this monitored voltage reading to an indication of the evaporator temperature. The A/C-heater control module is programmed to respond to this input by cycling the air conditioning compressor clutch as necessary to optimize air conditioning system performance and to protect the system from evaporator freezing. The external location of the sensor allows the sensor to be removed or installed without disturbing the refrigerant in the system. The evaporator temperature sensor is diagnosed using a DRBIII(R) scan tool. Refer to Body Diagnostic Procedures. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5342 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the HVAC housing from the vehicle . Evaporator Temperature Sensor Wire Connector 3. Disconnect the HVAC wire harness connector from the evaporator temperature sensor. 4. Disassemble the HVAC housing to gain access to the evaporator coil. Evaporator Temperature Sensor Probe 5. Remove the evaporator temperature sensor probe from the evaporator coil. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5343 INSTALLATION 1. Install the evaporator probe into the evaporator coil. 2. Assemble the HVAC housing. 3. Connect the HVAC wire harness connector to the evaporator temperature sensor. 4. Install the HVAC housing . 5. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams Transducer-A/C Pressure (Diesel/SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 5347 Refrigerant Pressure Sensor / Switch: Description and Operation The A/C pressure transducer is a switch that is installed on a fitting located on the refrigerant discharge line between the compressor and the condenser in the front corner of the engine compartment. An internally threaded hex fitting on the transducer connects it to the externally threaded Schrader-type fitting on the discharge line. A rubber O-ring seals the connection between the transducer and the discharge line fitting. Three terminals within a molded plastic connector receptacle on the top of the transducer connect it to the vehicle electrical system through a wire lead and connector of the headlamp and dash wire harness. The A/C pressure transducer cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the discharge line. The transducer will change its internal resistance in response to the pressures it monitors. The Powertrain Control Module (PCM) or the Engine Control Module (ECM) depending on engine application, provides a five volt reference signal and a sensor ground to the transducer, then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure. The PCM/ ECM is programmed to respond to this and other sensor inputs by controlling the operation of the air conditioning compressor clutch and the radiator cooling fan to help optimize air conditioning system performance and to protect the system components from damage. The A/C pressure transducer input to the PCM/ECM will also prevent the air conditioning compressor clutch from engaging when ambient temperatures are below about 10° C (50° F) due to the pressure/temperature relationship of the refrigerant. The Schrader-type valve in the discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the system. The A/C pressure transducer is diagnosed using a DRBIII(R) scan tool. Refer to the appropriate diagnostic information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 5348 Refrigerant Pressure Sensor / Switch: Testing and Inspection The A/C pressure transducer is tested using a DRBIII(R) scan tool. Refer to the appropriate diagnostic information. Before testing the A/C pressure transducer, be certain that the transducer wire harness connection is clean of corrosion and properly connected. For the air conditioning system to operate, an A/C pressure transducer voltage reading between 0.451 and 4.519 volts is required. Voltages outside this range indicate a low or high refrigerant system pressure condition to the Powertrain Control Module (PCM) or Engine Control Module (ECM) depending on engine application. The PCM/ECM is programmed to respond to a low or high refrigerant system pressure by suppressing operation of the compressor. Refer to the A/C Pressure Transducer Voltage chart for the possible conditions indicated by the transducer voltage reading. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 5349 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the wire harness connector from the A/C pressure transducer. A/C Pressure Transducer - 3.7L Shown 3. Remove the A/C pressure transducer from the fitting on the discharge line. 4. Remove the O-ring seal from the A/C pressure transducer fitting and discard. INSTALLATION NOTE: Replace the O-ring seal before installing the A/C pressure transducer. 1. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the A/C pressure transducer fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 2. Install and tighten the A/C pressure transducer onto the discharge line fitting. The transducer should be hand-tightened securely onto the discharge line fitting. 3. Connect the wire harness connector to the A/C pressure transducer. 4. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation A/C SERVICE PORT VALVE CORES The A/C service port valve cores are serviceable items. The A/C pressure transducer is mounted on the high side service port which is located on the discharge line near the A/C compressor. The low side service port is located on the suction line near the accumulator outlet tube. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation > Page 5353 Service Port HVAC: Service and Repair A/C SERVICE PORT VALVE CORES REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Remove the protective cap from the low side service port as necessary. 2. Remove the A/C pressure transducer from the high side service port as necessary . 3. Recover the refrigerant from the refrigerant system . 4. Using a standard Schrader-type valve core tool, remove the valve core from the service ports as required. 5. Install a plug in or tape over the opened service port(s). INSTALLATION 1. Lubricate the A/C service port valve core with clean refrigerant oil prior to installation. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 2. Remove the tape or plug from the A/C service port. CAUTION: A valve core that is not fully seated in the A/C service port can result in damage to the valve during refrigerant system evacuation and charge. Such damage may result in a loss of system refrigerant while uncoupling the charge adapters. 3. Using a standard Schrader-type valve core tool, install and tighten the replacement valve core into the A/C service ports as required. 4. Evacuate the refrigerant system. 5. Charge the refrigerant system. 6. Install the A/C pressure transducer to the high side service port as necessary . 7. Install the protective cap onto the A/C service ports as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System SERVICE AFTER AN AIRBAG DEPLOYMENT Any vehicle which is to be returned to use following an airbag deployment, must have both airbags, the driver airbag trim cover, the clockspring, and the steering column assembly replaced. These components are not intended for reuse and will be damaged or weakened as a result of an airbag deployment, which may or may not be obvious during a visual inspection. Other vehicle components should be closely inspected, but are to be replaced only as required by the extent of the visible damage incurred. CLEAN UP PROCEDURE Following an airbag deployment, the vehicle interior will contain a powdery residue. This residue consists primarily of harmless particulate by-products of the small pyrotechnic charge used to initiate the propellant used to deploy the airbags. However, this residue may also contain traces of sodium hydroxide powder, a chemical by-product of the propellant material that is used to generate the nitrogen gas that inflates the airbag. Since sodium hydroxide powder can irritate the skin, eyes, nose, or throat, be sure to wear safety glasses, rubber gloves, and a long-sleeved shirt during cleanup (Wear Safety Glasses and Rubber Gloves - Typical). WARNING: IF YOU EXPERIENCE SKIN IRRITATION DURING CLEANUP, RUN COOL WATER OVER THE AFFECTED AREA. ALSO, IF YOU EXPERIENCE IRRITATION OF THE NOSE OR THROAT, EXIT THE VEHICLE FOR FRESH AIR UNTIL THE IRRITATION CEASES. IF IRRITATION CONTINUES, SEE A PHYSICIAN. Begin the cleanup by removing both airbags from the vehicle. CAUTION: All damaged, faulty, or non-deployed supplemental restraints which are replaced on vehicles are to be handled and disposed of properly. If an airbag unit is faulty or damaged and non-deployed, refer to the Hazardous Substance Control System for proper disposal. Be certain to dispose of all non-deployed and deployed supplemental restraints in a manner consistent with state, provincial, local and federal regulations. Next, use a vacuum cleaner to remove any residual powder from the vehicle interior. Clean from outside the vehicle and work your way inside, so that you avoid kneeling or sitting on a non-cleaned area. Be certain to vacuum the heater and air conditioning outlets as well (Vacuum Heater and A/C Outlets - Typical). Run the heater and air conditioner blower on the lowest speed setting and vacuum any powder expelled from the outlets. You may need to vacuum the interior of the vehicle a second time to recover all of the powder. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 5359 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION RESTRAINT SYSTEM After a impact where an airbag has been deployed due to a collision, the following MUST be replaced: 1. Front Seat Belts and Retractors (driver and passenger) with integral Tensioners. 2. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. WARNING: WHEN THE FRONT AIRBAG IS DEPLOYED, THE TENSIONER WILL HAVE DEPLOYED ALSO AND MUST BE REPLACED. 3. Do not reuse the bolts attaching the seat belt retractor to the seat frame. Failure to follow proper installation procedure may result in the seat track latch pins not being synchronized. 4. Inspect the condition of the shoulder/lap belt. replace the retractor if the belt is cut, frayed, torn, or damaged in any way. The rear seat back retaining nut also serves as the center seat belt anchor. Be certain to torque this nut. 5. All seat belts should be closely inspected for cuts, tears, fraying, or damage in any way following any frontal impact or airbag deployment. The seat belts are to be replaced when visible damage is incurred. Inspect the Lower Anchors and Tether for Children (LATCH) child restraint anchors for damage after an impact event and replace as needed. 6. During, and following, any child restraint anchor service, due to impact event or vehicle repair, carefully inspect all mounting hardware, tether straps and anchors for proper installation, operation, or damage. if a child restraint anchor is found damaged in any way, the anchor must be replaced with the seat assembly. failure to do so could result in occupant personal injury or death. NOTE: Never attempt to repair a seat belt component. always replace damaged or faulty seat belt components with the correct, new and unused replacement parts. VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS) If any of the Occupant Classification System (OCS) components of the passenger side front seat cushion require replacement, they are serviced only as a factory-calibrated, assembled, and tamper-evident service replacement package. This package includes the assembled frame, springs, pad, seat weight bladder and pressure sensor, foam, wiring and a calibrated OCM. When installing this package, always replace all of the existing components with the new components as a unit. Do not attempt to separate or disconnect any of the new OCS components contained in the service replacement package from each other, and do not attempt to reuse any of the replaced components in this or any other vehicle. CAUTION: Never replace both the Airbag Control Module (ACM) and the Occupant Classification Module (OCM) at the same time. If both require replacement, replace one. Then perform the supplemental restraint verification test before replacing the other. Both the ACM and the OCM store OCS calibration data, which they transfer to one another when one of them is replaced. If both are replaced at the same time, an irreversible fault will be set in both modules. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING 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 disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Harness: > 23-004-04 > Feb > 04 > Interior - Cup Holder Sticking/Binding Air Bag Harness: Customer Interest Interior - Cup Holder Sticking/Binding NUMBER: 23-004-04 GROUP: Body DATE: February 10, 2004 SUBJECT: Cup Holder Bind Or Sticks OVERVIEW: This bulletin involves adjusting the instrument panel trim to provide clearance for the cup holder. MODELS: 2004 (DR) Ram Truck SYMPTOM/CONDITION: DIAGNOSIS: Operate the cup holder. If the cup holder binds or will not open or only opens partially, perform the Repair Procedure. REPAIR PROCEDURE: 1. Using a plastic trim stick, or suitable tool, gently pry on each side of the Airbag Control Module (ACM) cover located under the cup holder and remove the ACM cover. 2. Operated the cup holder with the ACM cover removed. If the cup holder now operates freely, there is an interference between the ACM cover and bottom of the cup holder. If the cup holder binds with the ACM cover removed, proceed to Step 6. 3. Install the ACM cover and inspect the area where the cup holder and the ACM cover come together (Fig. 1). There must be a gap between the ACM cover and the bottom of the cup holder. If the ACM cover is in contact with cup holder, try realigning the cover by pushing the bottom of the cover towards the front. if this provides a gap and the cup holder now operates freely, the repair is complete. If the gap cannot be achieved by adjusting the ACM cover proceed to the next step. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Harness: > 23-004-04 > Feb > 04 > Interior - Cup Holder Sticking/Binding > Page 5373 4. The ACM wire harness runs rearward along the left side of the tunnel under the carpet. (Fig. 2). Rub your hand along the carpet in the area of the bottom of the ACM cover and feel for the harness. If the harness can be felt, it may be pushing the ACM cover upward and into the cup holder. If this is happening it may be necessary to reroute the harness or remove carpet padding from the area. 5. Roll the carpet back and make sure that there are no plastic retainers in the area that could cause the interference. If a retainer is present remove it. Make sure that the harness is not sitting on a raised portion of the floor. If it is, reroute the harness to a lower area on the floor. Remove the any carpet padding from the area where the harness contacts the carpet to gain additional clearance. This should provide the clearance needed. and complete the repair. 6. Remove the cup holder. 7. Operate the cup holder out of the vehicle. If the cup holder still binds it must be replaced. If it operates freely, inspect the metal bracket where the cup holder fasteners attach as shown. (Fig. 3). If the bracket is bent, it could cause the cup holder to twist or distort when the screws are installed. Straighten the bracket and install the cup holder. If the cup holder operates freely the repair is complete. if the cup holder still binds, it must be replaced. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Harness: > 23-004-04 > Feb > 04 > Interior - Cup Holder Sticking/Binding > Page 5374 TIME ALLOWANCE: FAILURE CODE: Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 23-004-04 > Feb > 04 > Interior - Cup Holder Sticking/Binding Air Bag Harness: All Technical Service Bulletins Interior - Cup Holder Sticking/Binding NUMBER: 23-004-04 GROUP: Body DATE: February 10, 2004 SUBJECT: Cup Holder Bind Or Sticks OVERVIEW: This bulletin involves adjusting the instrument panel trim to provide clearance for the cup holder. MODELS: 2004 (DR) Ram Truck SYMPTOM/CONDITION: DIAGNOSIS: Operate the cup holder. If the cup holder binds or will not open or only opens partially, perform the Repair Procedure. REPAIR PROCEDURE: 1. Using a plastic trim stick, or suitable tool, gently pry on each side of the Airbag Control Module (ACM) cover located under the cup holder and remove the ACM cover. 2. Operated the cup holder with the ACM cover removed. If the cup holder now operates freely, there is an interference between the ACM cover and bottom of the cup holder. If the cup holder binds with the ACM cover removed, proceed to Step 6. 3. Install the ACM cover and inspect the area where the cup holder and the ACM cover come together (Fig. 1). There must be a gap between the ACM cover and the bottom of the cup holder. If the ACM cover is in contact with cup holder, try realigning the cover by pushing the bottom of the cover towards the front. if this provides a gap and the cup holder now operates freely, the repair is complete. If the gap cannot be achieved by adjusting the ACM cover proceed to the next step. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 23-004-04 > Feb > 04 > Interior - Cup Holder Sticking/Binding > Page 5380 4. The ACM wire harness runs rearward along the left side of the tunnel under the carpet. (Fig. 2). Rub your hand along the carpet in the area of the bottom of the ACM cover and feel for the harness. If the harness can be felt, it may be pushing the ACM cover upward and into the cup holder. If this is happening it may be necessary to reroute the harness or remove carpet padding from the area. 5. Roll the carpet back and make sure that there are no plastic retainers in the area that could cause the interference. If a retainer is present remove it. Make sure that the harness is not sitting on a raised portion of the floor. If it is, reroute the harness to a lower area on the floor. Remove the any carpet padding from the area where the harness contacts the carpet to gain additional clearance. This should provide the clearance needed. and complete the repair. 6. Remove the cup holder. 7. Operate the cup holder out of the vehicle. If the cup holder still binds it must be replaced. If it operates freely, inspect the metal bracket where the cup holder fasteners attach as shown. (Fig. 3). If the bracket is bent, it could cause the cup holder to twist or distort when the screws are installed. Straighten the bracket and install the cup holder. If the cup holder operates freely the repair is complete. if the cup holder still binds, it must be replaced. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 23-004-04 > Feb > 04 > Interior - Cup Holder Sticking/Binding > Page 5381 TIME ALLOWANCE: FAILURE CODE: Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Fig.37 Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5385 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5386 Air Bag Control Module: Diagrams Module-Occupant Restraint Controller C1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5387 Module-Occupant Restraint Controller C2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5388 Air Bag Control Module: Description and Operation The Airbag Control Module (ACM) (1) is also sometimes referred to as the Occupant Restraint Controller (ORC). The ACM is located below the instrument panel center stack in the passenger compartment of the vehicle, where it is secured by three screws to a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel just forward of the instrument panel center support bracket. Concealed within a hollow in the center of the die cast aluminum ACM housing is the electronic circuitry of the ACM which includes a microprocessor, an electronic impact sensor, an electronic sating sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ACM housing with four screws to enclose and protect the internal electronic circuitry and components. An arrow (2) printed on the label (3) on the top of the ACM housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ACM housing has integral mounting flanges on three corners. The mounting flange to the left of the connector receptacle has an integral locating pin on its lower surface. Both left side flanges have round mounting holes, while the flange on the right side has a slotted mounting hole. A molded plastic electrical connector (4) with two receptacles, one containing twenty-four terminal pins and the other containing thirty-two terminal pins, exits the rearward facing side of the ACM housing. These terminal pins connect the ACM to the vehicle electrical system through two dedicated take outs and connectors of the instrument panel wire harness. The impact sensor and sating sensor internal to the ACM are calibrated for the specific vehicle, and are only serviced as a unit with the ACM. In addition, there are unique versions of the ACM for light and heavy-duty models, and for vehicles with or without the optional side curtain airbags. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The microprocessor in the Airbag Control Module (ACM) contains the supplemental restraint system logic circuits and controls all of the supplemental restraint system components. The ACM uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Programmable Communications Interface (PCI) data bus network. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and for supplemental restraint system diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. The ACM microprocessor continuously monitors all of the supplemental restraint system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the PCI data bus to turn on the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ACM. For some DTCs, if a fault does not recur for a number of ignition cycles, the ACM will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. In standard cab models, the ACM also monitors a resistor multiplexed input from the passenger airbag on/off switch and provides a control output for the Off indicator in the switch through a passenger airbag indicator driver circuit. If the passenger airbag on/off switch is set to the Off position, the ACM turns on the passenger airbag on/off switch Off indicator and will internally disable the passenger airbag from being deployed. The ACM also turns on the on/off switch Off indicator for about seven seconds each time the ignition switch is turned to the On position as a bulb test. Following the bulb test, the ACM controls the status of the Off indicator based upon the resistance of the input from the on/off switch. The ACM will also set and/or store a DTC for faults it detects in the passenger airbag on/off switch circuits, and will turn on the airbag indicator in the EMIC if a fault has been detected. The ACM receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Integrated Power Module (IPM), and a fused ignition switch output (run-start) circuit through a second fuse in the IPM. The ACM receives ground through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector that is secured by a ground screw to the instrument panel structural support. These connections allow the ACM to be operational whenever the ignition switch is in the Start or On positions. The ACM also contains an energy-storage capacitor. When the ignition switch is in the Start or On positions, this capacitor is continually being charged with enough electrical energy to deploy the supplemental restraint components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup supplemental restraint system protection in case there is a loss of battery current supply to the ACM during an impact. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5389 Two sensors are contained within the ACM, an electronic impact sensor and a safing sensor. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provide verification of the direction and severity of an impact. On models equipped with optional side curtain airbags, the ACM also monitors inputs from two remote side impact sensors located within both the left and right B-pillars to control deployment of the side curtain airbag units. The safing sensor is an electronic accelerometer sensor within the ACM that provides an additional logic input to the ACM microprocessor. The safing sensor is used to verify the need for a supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. Vehicles equipped with optional side curtain airbags feature a second safing sensor within the ACM to provide confirmation to the ACM microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ACM microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require supplemental restraint system protection and, based upon the severity of the monitored impact and the status of the passenger airbag on/off switch input, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ACM sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and, if the vehicle is so equipped, either side curtain airbag unit. For vehicles equipped with the passenger airbag on/off switch, the passenger front airbag and seat belt tensioner will be deployed by the ACM only if enabled by the switch (passenger airbag on/off switch indicator Off) at the time of the impact. The hard wired inputs and outputs for the ACM may be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ACM, the PCI data bus network, or the electronic message inputs to and outputs from the ACM. The most reliable, efficient, and accurate means to diagnose the ACM, the PCI data bus, and the electronic message inputs to and outputs from the ACM requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Module Air Bag Control Module: Service and Repair Module WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE SUPPLEMENTAL RESTRAINTS. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. On models with a manual transmission, remove the floor console from the top of the floor panel transmission tunnel. 3. On models with an automatic transmission, remove the ACM cover from the instrument panel. 4. Reach through the rearward facing opening below the instrument panel center stack support bracket on the top of the floor panel transmission tunnel to access and disconnect the two wire harness connectors (3 & 4) for the Airbag Control Module (ACM) (1) from the ACM connector receptacles located on the rearward facing side of the module. To disconnect the wire harness connectors from the ACM, depress the release tab and lift the lever arm on each connector. 5. From the left side of the floor panel transmission tunnel, reach behind the module to access and loosen the screw (2) that secures the right side of the ACM to the bracket (5) on the floor panel transmission tunnel. Loosen the screw about 7 millimeters (0.25 inch). 6. From the left side of the floor panel transmission tunnel, remove the two screws that secure the left side of the ACM to the bracket on the floor panel transmission tunnel. 7. Still working from the left side of the floor panel transmission tunnel, lift the ACM upward far enough to disengage the locating pin on the bottom of the ACM mounting flange from the locating hole in the mounting bracket, then slide the ACM toward the left far enough to disengage the slotted hole in the right ACM mounting flange from under the head of the previously loosened right mounting screw. 8. Remove the ACM from the left side of the floor panel transmission tunnel. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Module > Page 5392 1. Position the Airbag Control Module (ACM) (1) to the left side of the floor panel transmission tunnel near the ACM bracket (5). When the ACM is correctly positioned, the arrow on the ACM label will be pointed forward in the vehicle. 2. From the left side of the floor panel transmission tunnel, slide the ACM toward the right far enough to engage the slotted hole in the right ACM mounting flange under the head of the previously loosened right mounting screw (2), then engage the locating pin on the bottom of the left ACM mounting flange into the locating hole in the bracket. 3. Still working from the left side of the floor panel transmission tunnel, install and tighten the two screws that secure the left ACM mounting flanges to the bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 12 N.m (9 ft.lbs.). 4. From the left side of the floor panel transmission tunnel, reach behind the module to access and tighten the screw that secures the right side of the ACM to the bracket on the floor panel transmission tunnel. Tighten the screw to 12 N.m (9 ft.lbs.). 5. Reach through the rearward facing opening below the instrument panel center stack support bracket on the top of the floor panel transmission tunnel to access and reconnect the two wire harness connectors (3 & 4) for the ACM to the ACM connector receptacle located on the rearward facing side of the module. Be certain that the latches on the connectors are each fully engaged. 6. On models with an automatic transmission, reinstall the ACM cover onto the instrument panel. 7. On models with a manual transmission, reinstall the floor console onto the top of the floor panel transmission tunnel. 8. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Module > Page 5393 Air Bag Control Module: Service and Repair Cover WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: The Airbag Control Module (ACM) cover is used only on models with an automatic transmission. Models with a manual transmission require that the floor console be removed to access the ACM for service. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry each side of the ACM cover (2) away from the instrument panel at each side of the center bracket on the floor panel transmission tunnel far enough to disengage the two snap clip retainers from the instrument panel receptacles (1). 3. Remove the ACM cover from the instrument panel. INSTALLATION 1. Position the ACM cover (2) to the instrument panel. 2. Align the snap clip retainer on each side of the ACM cover with the instrument panel receptacle (1) at each side of the center bracket on the floor panel transmission tunnel. 3. Using hand pressure, press firmly and evenly on the outside of the ACM cover over each snap clip retainer location until each retainer is fully engaged in its instrument panel receptacle. 4. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations Air Bag Deactivation Switch: Locations Rear Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 5397 Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 5398 Left Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 5399 Right Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 5400 Switch-Passenger Airbag On/Off Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 5401 Air Bag Deactivation Switch: Description and Operation The passenger airbag on/off switch (1) is standard equipment on all standard cab versions of this model when they are equipped with the dual front airbag system. This switch is a two-position, resistor multiplexed switch with a single integral red Light-Emitting Diode (LED), and a non-coded key cylinder-type actuator. The switch is located in the lower right corner of instrument panel center bezel, near the center of instrument panel to make the Off indicator (3) visible to all front seat occupants. When the switch is in its installed position, the only components visible through the dedicated opening of the cluster bezel are the switch face plate (2) and nomenclature, and the key cylinder actuator (4). The "Off" position of the switch is illuminated when this switch position is selected, while the "On" position of the switch is designated by text imprinted upon the face plate of the switch, but is not illuminated. The remainder of the switch is concealed behind the switch face plate and the instrument panel center bezel. The passenger airbag on/off switch housing is constructed of molded plastic and has three integral mounting tabs. These mounting tabs are used to secure the switch to the back of the molded plastic switch face plate with three small screws. The molded plastic face plate also has three integral mounting tabs that are used to secure the switch and face plate unit to the instrument panel center bezel with three additional screws. A molded plastic connector receptacle on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The molded plastic harness connector insulator is keyed and latched to ensure proper and secure switch electrical connections. The passenger airbag on/off switch cannot be adjusted or repaired and, if faulty or damaged, the switch must be replaced. The passenger airbag on/off switch allows the customer to turn the passenger airbag function On or Off to accommodate certain uses of the right front seating position where airbag protection may not be desired. See the vehicle glove box for specific recommendations on when to enable or disable the passenger airbag. The Off indicator of the switch will be illuminated whenever the switch is turned to the Off position and the ignition switch is in the On position. The ignition key is the only key or object that should ever be inserted into the key cylinder actuator of the switch. The on/off switch requires only a partial key insertion to fully depress a spring-loaded locking plunger. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. To actuate the passenger airbag on/off switch, insert the ignition key into the switch key actuator far enough to fully depress the plunger, then rotate the actuator to the desired switch position. When the switch key actuator is rotated to its clockwise stop (the key actuator slot will be aligned with the Off indicator), the Off indicator is illuminated and the passenger airbag is disabled. When the switch is rotated to its counterclockwise stop (the key actuator slot will be in a vertical position), the Off indicator will be extinguished and the passenger airbag is enabled. The passenger airbag on/off switch connects one of two internal resistors in series between the passenger airbag mux switch sense and passenger airbag mux switch return circuits of the Airbag Control Module (ACM). The ACM continually monitors the resistance in these circuits to determine the switch position that has been selected. When the switch is in the Off position, the ACM provides a ground input to the switch through the passenger airbag indicator driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the Off indicator of the switch. The ACM will also illuminate the Off indicator of the switch for about seven seconds each time the ignition switch is turned to the On position as a bulb test. The ACM will store a Diagnostic Trouble Code (DTC) for any fault it detects in the passenger airbag on/off switch or Off indicator circuits, and will illuminate the airbag indicator in the instrument cluster if a fault is detected. For proper diagnosis of the passenger airbag on/off switch or the ACM, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 5402 Air Bag Deactivation Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the center bezel (1) from the instrument panel. 3. From the back of the center bezel, remove the three screws (2) that secure the passenger airbag on/off switch and face plate unit (3) to the back of the bezel. 4. Remove the passenger airbag on/off switch and face plate from the center bezel as a unit. INSTALLATION 1. Position the passenger airbag on/off switch and face plate unit (3) to the back of the center bezel (1). 2. Install and tighten the three screws (2) that secure the passenger airbag on/off switch face plate to the back of the center bezel. Tighten the screws to 2 N.m (17 in.lbs.). 3. Reinstall the center bezel onto the instrument panel. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Clockspring Assembly / Spiral Cable: Diagrams Clockspring C1 Clockspring C2 Clockspring C3 Clockspring C4 (Premium) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 5406 Clockspring Assembly / Spiral Cable: Description and Operation The clockspring assembly is secured with two screws onto the multi-function switch mounting housing near the top of the steering column behind the steering wheel. The clockspring consists of a flat, round molded plastic case (8) with a stubby tail that hangs below the steering column. The tail contains two connector receptacles that face toward the instrument panel. Within the plastic case is a spool-like molded plastic rotor (10) with a large exposed hub. The upper surface of the rotor hub has a large center hole, two large flats, an engagement dowel with a yellow rubber boot (7), two short pigtail wires with connectors (1), and two connector receptacles (5) that face toward the steering wheel. The lower surface of the rotor hub has a molded plastic turn signal cancel cam (3) with two lobes that is keyed to the rotor and is secured there with four integral snap features. Within the plastic case and wound around the rotor spool is a long ribbon-like tape that consists of several thin copper wire leads sandwiched between two thin plastic membranes. The outer end of the tape terminates at the connector receptacles (4) that face the instrument panel, while the inner end of the tape terminates at the pigtail wires and connector receptacles on the hub of the clockspring rotor that face the steering wheel. Service replacement clocksprings are shipped pre-centered and with a molded plastic locking pin (1) that snaps into a receptacle on the rotor and is engaged between two tabs on the upper surface of the rotor case. The locking pin secures the centered clockspring rotor to the clockspring case during shipment and handling, but must be removed from the clockspring after it is installed on the steering column. The clockspring cannot be repaired. If the clockspring is faulty, damaged, or if the driver airbag has been deployed, the clockspring must be replaced. The clockspring is a mechanical electrical circuit component that is used to provide continuous electrical continuity between the fixed instrument panel wire harness and the electrical components mounted on or in the rotating steering wheel. On this model the rotating electrical components include the driver airbag, the horn switch, the speed control switches, and the remote radio switches, if the vehicle is so equipped. The clockspring case is positioned and secured to the multi-function switch mounting housing near the top of the steering column. The connector receptacles on the tail of the fixed clockspring case connect the clockspring to the vehicle electrical system through two take outs with connectors from the instrument panel wire harness. The clockspring rotor is movable and is keyed by an engagement dowel that is molded onto the rotor hub between two fins that are cast into the lower surface of the steering wheel armature. A yellow rubber boot is installed over the engagement dowel to eliminate contact noise between the dowel and the steering wheel. The two lobes on the turn signal cancel cam on the lower surface of the clockspring rotor hub contact a turn signal cancel actuator of the multi-function switch to provide automatic turn signal cancellation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 5407 Two short, yellow-sleeved pigtail wires on the upper surface of the clockspring rotor connect the clockspring to the driver airbag, while a steering wheel wire harness connects the two connector receptacles on the upper surface of the clockspring rotor to the horn switch feed pigtail wire connector and, if the vehicle is so equipped, to the optional speed control and remote radio switches on the steering wheel. Like the clockspring in a timepiece, the clockspring tape has travel limits and can be damaged by being wound too tightly during full stop-to-stop steering wheel rotation. To prevent this from occurring, the clockspring is centered when it is installed on the steering column. Centering the clockspring indexes the clockspring tape to the movable steering components so that the tape can operate within its designed travel limits. However, if the clockspring is removed from the steering column or if the steering shaft is disconnected from the steering gear, the clockspring spool can change position relative to the movable steering components. The clockspring must be re-centered following completion of this service or the tape may be damaged. Service replacement clocksprings are shipped pre-centered and with a plastic locking pin installed. This locking pin should not be removed until the clockspring has been installed on the steering column. If the locking pin is removed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Clockspring Centering Clockspring Assembly / Spiral Cable: Service and Repair Clockspring Centering WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position. 1. Place the front wheels in the straight-ahead position. 2. Remove the clockspring from the steering column. 3. Rotate the clockspring rotor (10) clockwise to the end of its travel. Do not apply excessive torque. 4. From the end of the clockwise travel, rotate the rotor about two and one-half turns counterclockwise. The engagement dowel and yellow rubber boot (7) should end up at the bottom, and the arrows on the clockspring rotor and case (9) should be in alignment. 5. The clockspring is now centered. Secure the clock-spring rotor to the clockspring case to maintain clockspring centering until it is reinstalled on the steering column. 6. The front wheels should still be in the straight-ahead position. Reinstall the clockspring onto the steering column. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Clockspring Centering > Page 5410 Clockspring Assembly / Spiral Cable: Service and Repair Removal and Installation WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position. 1. Place the front wheels in the straight ahead position. 2. Disconnect and isolate the battery negative cable. 3. Remove the driver airbag from the steering wheel. 4. Disconnect the steering wheel wire harness connectors from the upper clockspring connector receptacles. CAUTION: Be certain that the screws that secure the steering wheel puller to the steering wheel are fully engaged in the steering wheel armature without passing through the steering wheel and damaging the clockspring. 5. Remove the steering wheel from the steering column. 6. Remove the steering column opening cover from the instrument panel. 7. Grasp the tilt steering column knob (2) firmly and pull it straight rearward to remove it from the tilt adjuster lever (1) on the left side of the column. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Clockspring Centering > Page 5411 8. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 9. Using hand pressure, push gently inward on both sides of the upper shroud near the parting line between the upper and lower shrouds to release the snap features that secure it to the lower shroud. 10. Remove the upper shroud from the lower shroud and the steering column. 11. Remove the one center screw that secures the lower shroud to the steering column (4). 12. Remove the lower shroud from the steering column. 13. Disconnect the two instrument panel wire harness connectors from the two connector receptacles located below the steering column on the back of the clockspring housing. 14. Remove the two screws (3) that secure the clock-spring to the multi-function switch mounting housing. 15. Remove the clockspring from the multi-function switch mounting housing. The clockspring cannot be repaired. It must be replaced if faulty or damaged, or if the driver airbag has been deployed. 16. If the removed clockspring is to be reused, be certain to secure the clockspring rotor to the clockspring case to maintain clockspring centering until it is reinstalled on the steering column. If clockspring centering is not maintained, the clock-spring must be centered again before it is reinstalled. INSTALLATION CAUTION: If the clockspring is not properly centered in relation to the steering wheel, steering shaft and steering gear, it may be damaged. Service replacement clocksprings are shipped pre-centered and with a locking pin installed. This locking pin should not be removed until the clockspring has been installed on the steering column. If the locking pin is removed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Clockspring Centering > Page 5412 NOTE: Before starting this procedure, be certain that the front wheels are still in the straight-ahead position. 1. While holding the centered clockspring rotor and case stationary in relation to each other, carefully slide the clockspring down over the steering column upper shaft. 2. Align and seat the hole in the locating tab (2) on the clockspring case over the locating pin on the multi-function switch mounting housing. 3. Install and tighten the two screws (3) that secure the clockspring to the multi-function switch mounting housing. Tighten the screws to 2 N.m (20 in.lbs.). 4. Reconnect the two instrument panel wire harness connectors to the two connector receptacles located below the steering column on the back of the clockspring housing. 5. Position the lower shroud (3) onto the steering column (4). 6. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column lock housing. Tighten the screw to 2 N.m (20 in.lbs.). 7. Position the upper shroud (1) onto the steering column over the lower shroud. If the vehicle is equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the openings in the right side of the upper and lower shroud halves. 8. Align the snap features on the upper shroud with the receptacles on the lower shroud and apply hand pressure to snap them together. 9. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Clockspring Centering > Page 5413 10. Align the tilt steering column knob (2) with the tilt adjuster lever (1) on the left side of the steering column and use hand pressure to snap it back into place. 11. Reinstall the steering column opening cover onto the instrument panel. 12. If a new clockspring has been installed, remove the plastic locking pin that is securing the clock-spring rotor to the clockspring case to maintain clockspring centering. NOTE: When reinstalling the steering wheel, be certain to index the yellow rubber booted engagement dowel on the upper surface of the clock-spring rotor between the two fins cast into the lower surface of the steering wheel armature hub. 13. Reinstall the steering wheel onto the steering column. 14. Reconnect the steering wheel wire harness connectors to the upper clockspring connector receptacles. Be certain that the steering wheel wire harness is routed between the steering wheel back trim cover and the steering wheel armature. 15. Reinstall the driver airbag onto the steering wheel. 16. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 5417 Impact Sensor: Diagrams Sensor-Side Impact-Left 1 Sensor-Side Impact-Right 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 5418 Impact Sensor: Description and Operation Two side impact sensors (1) are used on this model when it is equipped with the optional side curtain air-bags, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the bi-directional safing sensor that is internal to the Air-bag Control Module (ACM). Each side impact sensor is secured with a nut within the right or left B-pillar just above the front seat belt retractors and behind the lower B-pillar trim within the passenger compartment. The sensor housing has an integral connector receptacle (2), an integral mounting stud (3), and an integral anti-rotation pin. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The side impact sensors cannot be repaired or adjusted and, if damaged or faulty, they must be replaced. The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Airbag Control Module (ACM). The ACM microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ACM. The impact sensors and the ACM communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the side impact sensors and the ACM may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ACM, the impact sensors, or the electronic message inputs to or outputs from the impact sensors. The most reliable, efficient, and accurate means to diagnose the impact sensors, the ACM, and the electronic message communication between the sensors and the ACM requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab Impact Sensor: Service and Repair Standard Cab WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE SIDE IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE SIDE IMPACT SENSOR ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. IF AN IMPACT SENSOR IS ACCIDENTALLY DROPPED DURING SERVICE, THE SENSOR MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Adjust the driver or passenger side front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the front outboard seat belt and retractor from the inside of the B-pillar. 4. Remove the nut (4) that secures the stud of the side impact sensor (1) to the inner B-pillar. 5. Reach through the retractor mounting hole (3) in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 6. Pull the side impact sensor out of the B-pillar far enough to access and disconnect the body wire harness connector (2) from the sensor connector receptacle. 7. Remove the sensor from the B-pillar. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab > Page 5421 1. Position the side impact sensor (1) to the retractor mounting hole (3) in the inner B-pillar. 2. Reconnect the body wire harness connector (2) to the sensor connector receptacle. 3. Reach through the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (4) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in.lbs.). 5. Reinstall the front outboard seat belt and retractor to the inside of the B-pillar. 6. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab > Page 5422 Impact Sensor: Service and Repair Quad Cab WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE SIDE IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE SIDE IMPACT SENSOR ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. IF AN IMPACT SENSOR IS ACCIDENTALLY DROPPED DURING SERVICE, THE SENSOR MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (2) to the inner B-pillar (1). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (4) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab > Page 5423 1. Position the side impact sensor (2) to the large hole above the retractor mounting hole in the inner B-pillar (1). 2. Reconnect the body wire harness connector (4) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in.lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation Malfunction Lamp / Indicator: Description and Operation An airbag indicator is standard equipment on all instrument clusters. However, the instrument cluster can be programmed to disable this indicator on vehicles that are not equipped with the airbag system, which is not available in some markets. The airbag indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The airbag indicator consists of a stencil-like cutout of the words "AIR BAG" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "AIR BAG" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The airbag indicator is serviced as a unit with the instrument cluster. The airbag indicator gives an indication to the vehicle operator when the airbag system is faulty or inoperative. The airbag indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Airbag Control Module (ACM) over the Programmable Communications Interface (PCI) data bus. The airbag indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the airbag indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the airbag indicator is illuminated for about six seconds. The entire bulb test is a function of the ACM. - ACM Lamp-On Message - Each time the cluster receives a lamp-on message from the ACM, the airbag indicator will be illuminated. The indicator remains illuminated for about twelve seconds or until the cluster receives a lamp-off message from the ACM, whichever is longer. - Communication Error - If the cluster receives no airbag messages for three consecutive seconds, the airbag indicator is illuminated. The indicator remains illuminated until the cluster receives a single lamp-off message from the ACM. - Actuator Test - Each time the cluster is put through the actuator test, the airbag indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The actuator test illumination of the airbag indicator is a function of the instrument cluster. 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 lamp-on or lamp-off messages to the instrument cluster. If the ACM sends a lamp-on message after the bulb test, it indicates that the ACM has detected a system malfunction and/or that the airbags and seat belt tensioners may not deploy when required, or may deploy when not required. The ACM will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the airbag indicator fails to illuminate due to an open or short in the cluster airbag indicator circuit, the cluster sends a message notifying the ACM of the condition, the instrument cluster and the ACM will each store a DTC, and the cluster will flash the seatbelt indicator on and off as a backup to notify the vehicle operator. For proper diagnosis of the airbag system, the ACM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the airbag indicator, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Fig.37 Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5431 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5432 Air Bag Control Module: Diagrams Module-Occupant Restraint Controller C1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5433 Module-Occupant Restraint Controller C2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5434 Air Bag Control Module: Description and Operation The Airbag Control Module (ACM) (1) is also sometimes referred to as the Occupant Restraint Controller (ORC). The ACM is located below the instrument panel center stack in the passenger compartment of the vehicle, where it is secured by three screws to a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel just forward of the instrument panel center support bracket. Concealed within a hollow in the center of the die cast aluminum ACM housing is the electronic circuitry of the ACM which includes a microprocessor, an electronic impact sensor, an electronic sating sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ACM housing with four screws to enclose and protect the internal electronic circuitry and components. An arrow (2) printed on the label (3) on the top of the ACM housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ACM housing has integral mounting flanges on three corners. The mounting flange to the left of the connector receptacle has an integral locating pin on its lower surface. Both left side flanges have round mounting holes, while the flange on the right side has a slotted mounting hole. A molded plastic electrical connector (4) with two receptacles, one containing twenty-four terminal pins and the other containing thirty-two terminal pins, exits the rearward facing side of the ACM housing. These terminal pins connect the ACM to the vehicle electrical system through two dedicated take outs and connectors of the instrument panel wire harness. The impact sensor and sating sensor internal to the ACM are calibrated for the specific vehicle, and are only serviced as a unit with the ACM. In addition, there are unique versions of the ACM for light and heavy-duty models, and for vehicles with or without the optional side curtain airbags. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The microprocessor in the Airbag Control Module (ACM) contains the supplemental restraint system logic circuits and controls all of the supplemental restraint system components. The ACM uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Programmable Communications Interface (PCI) data bus network. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and for supplemental restraint system diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. The ACM microprocessor continuously monitors all of the supplemental restraint system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the PCI data bus to turn on the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ACM. For some DTCs, if a fault does not recur for a number of ignition cycles, the ACM will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. In standard cab models, the ACM also monitors a resistor multiplexed input from the passenger airbag on/off switch and provides a control output for the Off indicator in the switch through a passenger airbag indicator driver circuit. If the passenger airbag on/off switch is set to the Off position, the ACM turns on the passenger airbag on/off switch Off indicator and will internally disable the passenger airbag from being deployed. The ACM also turns on the on/off switch Off indicator for about seven seconds each time the ignition switch is turned to the On position as a bulb test. Following the bulb test, the ACM controls the status of the Off indicator based upon the resistance of the input from the on/off switch. The ACM will also set and/or store a DTC for faults it detects in the passenger airbag on/off switch circuits, and will turn on the airbag indicator in the EMIC if a fault has been detected. The ACM receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Integrated Power Module (IPM), and a fused ignition switch output (run-start) circuit through a second fuse in the IPM. The ACM receives ground through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector that is secured by a ground screw to the instrument panel structural support. These connections allow the ACM to be operational whenever the ignition switch is in the Start or On positions. The ACM also contains an energy-storage capacitor. When the ignition switch is in the Start or On positions, this capacitor is continually being charged with enough electrical energy to deploy the supplemental restraint components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup supplemental restraint system protection in case there is a loss of battery current supply to the ACM during an impact. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5435 Two sensors are contained within the ACM, an electronic impact sensor and a safing sensor. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provide verification of the direction and severity of an impact. On models equipped with optional side curtain airbags, the ACM also monitors inputs from two remote side impact sensors located within both the left and right B-pillars to control deployment of the side curtain airbag units. The safing sensor is an electronic accelerometer sensor within the ACM that provides an additional logic input to the ACM microprocessor. The safing sensor is used to verify the need for a supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. Vehicles equipped with optional side curtain airbags feature a second safing sensor within the ACM to provide confirmation to the ACM microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ACM microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require supplemental restraint system protection and, based upon the severity of the monitored impact and the status of the passenger airbag on/off switch input, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ACM sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and, if the vehicle is so equipped, either side curtain airbag unit. For vehicles equipped with the passenger airbag on/off switch, the passenger front airbag and seat belt tensioner will be deployed by the ACM only if enabled by the switch (passenger airbag on/off switch indicator Off) at the time of the impact. The hard wired inputs and outputs for the ACM may be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ACM, the PCI data bus network, or the electronic message inputs to and outputs from the ACM. The most reliable, efficient, and accurate means to diagnose the ACM, the PCI data bus, and the electronic message inputs to and outputs from the ACM requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Module Air Bag Control Module: Service and Repair Module WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE SUPPLEMENTAL RESTRAINTS. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. On models with a manual transmission, remove the floor console from the top of the floor panel transmission tunnel. 3. On models with an automatic transmission, remove the ACM cover from the instrument panel. 4. Reach through the rearward facing opening below the instrument panel center stack support bracket on the top of the floor panel transmission tunnel to access and disconnect the two wire harness connectors (3 & 4) for the Airbag Control Module (ACM) (1) from the ACM connector receptacles located on the rearward facing side of the module. To disconnect the wire harness connectors from the ACM, depress the release tab and lift the lever arm on each connector. 5. From the left side of the floor panel transmission tunnel, reach behind the module to access and loosen the screw (2) that secures the right side of the ACM to the bracket (5) on the floor panel transmission tunnel. Loosen the screw about 7 millimeters (0.25 inch). 6. From the left side of the floor panel transmission tunnel, remove the two screws that secure the left side of the ACM to the bracket on the floor panel transmission tunnel. 7. Still working from the left side of the floor panel transmission tunnel, lift the ACM upward far enough to disengage the locating pin on the bottom of the ACM mounting flange from the locating hole in the mounting bracket, then slide the ACM toward the left far enough to disengage the slotted hole in the right ACM mounting flange from under the head of the previously loosened right mounting screw. 8. Remove the ACM from the left side of the floor panel transmission tunnel. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Module > Page 5438 1. Position the Airbag Control Module (ACM) (1) to the left side of the floor panel transmission tunnel near the ACM bracket (5). When the ACM is correctly positioned, the arrow on the ACM label will be pointed forward in the vehicle. 2. From the left side of the floor panel transmission tunnel, slide the ACM toward the right far enough to engage the slotted hole in the right ACM mounting flange under the head of the previously loosened right mounting screw (2), then engage the locating pin on the bottom of the left ACM mounting flange into the locating hole in the bracket. 3. Still working from the left side of the floor panel transmission tunnel, install and tighten the two screws that secure the left ACM mounting flanges to the bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 12 N.m (9 ft.lbs.). 4. From the left side of the floor panel transmission tunnel, reach behind the module to access and tighten the screw that secures the right side of the ACM to the bracket on the floor panel transmission tunnel. Tighten the screw to 12 N.m (9 ft.lbs.). 5. Reach through the rearward facing opening below the instrument panel center stack support bracket on the top of the floor panel transmission tunnel to access and reconnect the two wire harness connectors (3 & 4) for the ACM to the ACM connector receptacle located on the rearward facing side of the module. Be certain that the latches on the connectors are each fully engaged. 6. On models with an automatic transmission, reinstall the ACM cover onto the instrument panel. 7. On models with a manual transmission, reinstall the floor console onto the top of the floor panel transmission tunnel. 8. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Module > Page 5439 Air Bag Control Module: Service and Repair Cover WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: The Airbag Control Module (ACM) cover is used only on models with an automatic transmission. Models with a manual transmission require that the floor console be removed to access the ACM for service. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry each side of the ACM cover (2) away from the instrument panel at each side of the center bracket on the floor panel transmission tunnel far enough to disengage the two snap clip retainers from the instrument panel receptacles (1). 3. Remove the ACM cover from the instrument panel. INSTALLATION 1. Position the ACM cover (2) to the instrument panel. 2. Align the snap clip retainer on each side of the ACM cover with the instrument panel receptacle (1) at each side of the center bracket on the floor panel transmission tunnel. 3. Using hand pressure, press firmly and evenly on the outside of the ACM cover over each snap clip retainer location until each retainer is fully engaged in its instrument panel receptacle. 4. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING 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 disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation Child Seat Tether Attachment: Description and Operation This model is equipped with a Lower Anchors and Tether for Children, or LATCH child restraint anchorage system. The LATCH system provides for the installation of suitable child restraints in certain seating positions without using the standard equipment seat belt provided for that seating position. Standard cab models are equipped with a fixed-position child restraint upper tether anchor for the front center and outboard seating positions (2), and child restraint lower anchors for the front outboard seating position (1). Quad cab models are equipped with a fixed-position child restraint upper tether anchor strap for the rear center and both rear outboard seating positions (2), and child restraint lower anchors for both rear outboard seating positions (1). All front seat child restraint anchors are deleted on quad cab models. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Page 5448 The two upper tether anchors (3) for standard cab models are integral to the upper cab back panel reinforcement and are concealed behind individual trim cover and bezel units (1) that are integral to the cab back trim panel (2). These upper tether anchors cannot be adjusted or repaired and, if faulty or damaged, they must be replaced as a unit with the upper cab back panel reinforcement. The upper tether anchor trim covers and bezels are serviced as a unit with the cab back trim panel. The three upper tether anchor straps (1) for quad cab models are secured to the upper cab back panel (2) reinforcement with screws (3). These anchor straps are concealed behind the upright rear seat back. The upper tether anchor straps are available for individual service replacement. The lower anchors (2) for all models are integral to their respective front or rear seat cushion frame. Round markers (3) with an imprinted child seat icon on the standard cab front seat back trim cover helps identify the anchor locations for that application because they may be otherwise difficult to see with the seat back in the upright position. These lower anchors are each constructed from round steel bar stock that is formed into a U-shape, then securely welded at each end to the seat cushion frame. They are each accessed from the front of their respective seats, at each side where the seat back meets the Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Page 5449 seat cushion. These lower anchors cannot be adjusted or repaired and, if faulty or damaged, they must be replaced as a unit with the seat cushion frame. On quad cab models, if the rear seat lower anchors (2) have been bent or broken as a result of a vehicle collision, the latch for the affected rear seat cushion frame unit must also be replaced. WARNING: DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. See owner's manual in the vehicle glove box for more information on the proper use of all of the factory-installed child restraint anchors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Page 5450 Child Seat Tether Attachment: Service and Repair TETHER STRAP WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: The following procedure applies only to the rear seat upper child tether straps used on quad cab models. The child restraint anchors used in other models and locations are integral to other components and cannot be serviced separately. REMOVAL 1. Remove the rear seat from the vehicle. 2. Remove the screw (3) that secures the child tether strap (1) to the upper cab back panel (2) reinforcement. 3. Remove the child tether strap from the upper cab back panel reinforcement. INSTALLATION 1. Position the child tether strap (1) onto the cab back panel (2) upper reinforcement. 2. Install and tighten the screw (3) that secures the child tether strap to the upper cab back panel reinforcement. Tighten the screw to 14 N.m (10 ft.lbs.). 3. Reinstall the rear seat into the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Description and Operation Seat Belt: Description and Operation AUTOMATIC LOCKING RETRACTOR The seat belt retractors used in all seating positions include an inertia-type, emergency locking mechanism (7) as standard equipment. However, the retractor locking mechanism for the passenger side front seating position is mechanically switchable from an emergency locking retractor to an automatic locking retractor. The primary function of this feature is to securely accommodate a child seat in the passenger side front seating position of the vehicle without the need for a self-cinching seat belt tip half latch plate unit or another supplemental device that would be required to prevent the seat belt webbing from unwinding freely from the retractor spool of an inertia-type emergency locking retractor mechanism. The automatic locking mechanism is integral to the passenger side front seat belt and retractor unit and is concealed beneath a molded plastic cover located on the same side of the retractor spool as the seat belt tensioner housing. The retractor is secured to the inner B-pillar on the right side of the vehicle and is concealed beneath the molded plastic inner B-pillar trim. The automatic locking mechanism cannot be adjusted or repaired and, if faulty or damaged, the entire passenger side front seat belt and retractor unit must be replaced. The automatic locking mode of the retractor is engaged and the retractor is switched from operating as a standard inertia-type emergency locking retractor by first buckling the combination lap and shoulder belt buckle. Then grasp the shoulder belt and pull all of the webbing out of the retractor. Once all of the belt webbing is extracted from the spool, the retractor will automatically become engaged in the pre-locked automatic locking mode and will make an audible clicking or ratcheting sound as the shoulder belt is allowed to retract to confirm that the automatic locking mode is now engaged. Once the automatic locking mode is engaged, the retractor will remain locked and the belt will remain tight around whatever it is restraining. The retractor is returned to standard emergency locking mode by unbuckling the combination lap and shoulder belt buckle and allowing the belt webbing to be almost fully retracted onto the retractor spool. The emergency locking mode is confirmed by the absence of the audible clicking or ratcheting sound as the belt webbing retracts. This mode will allow the belt to unwind from and wind onto the retractor spool freely unless and until a predetermined inertia load is sensed, or until the retractor is again switched to the automatic locking mode. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt Seat Belt: Service and Repair Seat Belt FRONT CENTER WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: A fixed position front center seat belt buckle is located on the left side of the front center seat section (20 percent) used on all models. Standard cab models also have a unique fixed position black, keyed front center seat belt lower anchor buckle for the three-point center seat belt lower anchor located on the right side of the front center seat section. The following procedure also applies to the fixed position front center seat lap belt located on the right side of the front center seat section of all quad cab models. The three-point front center seat belt and retractor unit is only used on standard cab models. REMOVAL 1. Move the adjacent right or left front outboard seat section (40 percent) to its most forward position for easiest access to the front center seat belt buckle, lap belt lower anchor, or unique black, keyed front center seat belt lower anchor buckle (1). 2. From behind the front seat, remove the screw (5) that secures the front center seat belt buckle, lap belt lower anchor, or unique black, keyed front center seat belt lower anchor buckle to the center seat support bracket (3). 3. From the front of the front seat, reach between the center seat cushion (6) and the adjacent right or left front outboard seat cushion to access and remove the front center seat belt buckle, lap belt unit, or unique black, keyed front center seat belt lower anchor buckle through the elastic strap (2) on the side of the center seat cushion. 4. Remove the front center seat belt buckle, lap belt unit, or unique black, keyed front center seat belt lower anchor buckle from the front seat. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 5456 1. From the front of the front seat, position the front center seat belt buckle, lap belt unit, or unique black, keyed front center seat belt lower anchor buckle (1) between the center seat cushion (6) and the adjacent right or left front outboard seat cushion. 2. From the front of the front seat, reach between the center seat cushion and the adjacent right or left front outboard seat cushion to route the front center seat belt buckle, lap belt unit lower anchor, or unique black, keyed front center seat belt lower anchor buckle through the elastic strap (2) on the side of the center seat cushion. 3. From behind the front seat, position the front center seat belt buckle, lap belt lower anchor, or unique black, keyed front center seat belt lower anchor buckle to the center seat support bracket (3). Be certain to engage the anti-rotation tab on the buckle or belt anchor into the corresponding hole in the center seat support bracket. 4. Install and tighten the screw (5) that secures the front center seat belt buckle, lap belt lower anchor, or unique black, keyed front center seat belt lower anchor buckle to the center seat support bracket. Tighten the screw to 40 N.m (29 ft.lbs.). 5. Move the adjacent right or left front outboard seat section (40 percent) back to its rearward position. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 5457 Seat Belt: Service and Repair Seat Belt & Retractor Front Center WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: A front center seat belt and retractor is used only on standard cab models. Quad cab models have a lap belt in the front center seating position. REMOVAL 1. Reach between the center of the front seat cushion and front seat back to access and unbuckle the front center seat belt lower anchor latch plate from the unique black, keyed lower anchor buckle. Use an ignition key or a small screwdriver to depress the small white release button on the anchor buckle. 2. Move the front seat to its most forward position for easiest access to the front center seat belt and retractor unit. 3. Remove the stowage tray from the rear floor panel behind the seat. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry at each side of the front center seat belt bezel (5) on the cab back trim panel (1) to release the snap features that secure the bezel to the panel. 5. Remove the bezel from the webbing of the front center seat belt (4). 6. Remove the trim from the cab back panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 5458 7. Remove the two screws (3) that secure the belt bracket (2) of the front center seat belt (7) to the body bracket (1) on the upper cab back panel (8) reinforcement. 8. Remove the belt bracket of the front center seat belt from the body bracket on the upper cab back panel reinforcement. 9. Remove the two screws (4) that secure the front center seat belt retractor bracket (5) to the floor panel (6) near the base of the cab back panel. 10. Remove the front center seat belt and retractor unit from the floor panel. INSTALLATION 1. Position the front center seat belt and retractor unit (5) to the floor panel (6) at the base of the cab back panel (8) to the right of center. 2. Install and tighten the two screws (4) that secure the front center seat belt retractor bracket to the floor panel near the base of the cab back panel. Tighten the screws to 40 N.m (29 ft.lbs.). 3. Position the belt bracket (2) of the front center seat belt (7) to the body bracket (1) on the upper cab back panel reinforcement. 4. Install and tighten the two screws (3) that secure the belt bracket of the front center seat belt to the body bracket on the upper cab back panel reinforcement. Tighten the screws to 20 N.m (15 ft.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 5459 5. Reinstall the trim (1) onto the cab back panel. 6. Route the webbing of the front center seat belt (4) through the bezel (5) and position the bezel to the belt opening near the top of the cab back trim panel. 7. Using hand pressure, press firmly and evenly on each side of the front center seat belt bezel until it snaps into place on the cab back trim panel. 8. Reinstall the stowage tray onto the rear floor panel behind the seat. 9. Move the front seat back to its rearward position. 10. Reach between the center of the front seat cushion and front seat back to access and buckle the front center seat belt lower anchor latch plate to the unique black, keyed lower anchor buckle. Front Outboard - Standard Cab The seat belt retractor on the driver's side of standard cab models only includes a tension reducer. The seat belt retractor on the passenger's side of all models includes a switchable automatic locking mechanism. WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: - The following procedure is for replacement of a faulty or damaged front outboard seat belt and retractor unit, which includes a seat belt tensioner for this model. The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. - If the seat belt or retractor is faulty or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the front outboard seat belt and retractor from the vehicle. REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 5460 1. Move the front seat to its most forward position for easiest access to the lower seat belt anchor (7) and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the stowage tray from the rear floor panel behind the seat. 4. Remove the screw (8) that secures the lower seat belt anchor to the lower inner B-pillar (14). 5. Remove the lower seat belt anchor from the lower inner B-pillar. 6. Unsnap and remove the trim cover (5) from the front outboard seat belt turning loop (3) to access the screw (4) that secures the turning loop to the height adjuster (1) on the upper inner B-pillar. Discard the removed turning loop trim cover as it is not intended for reuse. 7. Remove the screw that secures the seat belt turning loop to the height adjuster. 8. Remove the seat belt turning loop from the height adjuster. 9. Remove the upper (2) and lower (6) trim from the inner B-pillar. 10. Remove the screw (12) that secures the seat belt web guide (13) to the inner B-pillar near the belt line. 11. Remove the seat belt web guide from the inner B-pillar. 12. On the driver side only, disconnect the body wire harness take out and white connector from the connector receptacle for the seat belt tension reducer located near the bottom of the retractor (10). 13. Disengage the seat belt tensioner pigtail wire retainer from the hole in the inner B-pillar sheet metal. 14. Disconnect the yellow seat belt tensioner pigtail wire connector from the body wire harness take out and connector (11) for the tensioner. 15. Remove the screw (9) that secures the lower retractor bracket to the lower inner B-pillar below the retractor mounting hole. 16. Disengage the hooks on the upper retractor bracket from the slots in the lower inner B-pillar above the retractor mounting hole. 17. Remove the front outboard seat belt and retractor from the retractor mounting hole in the lower inner B-pillar. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 5461 1. Position the front outboard seat belt and retractor (10) to the retractor mounting hole in the lower inner B-pillar (14). 2. Engage the hooks on the upper retractor bracket into the slots in the lower inner B-pillar above the retractor mounting hole. 3. Install and tighten the screw (9) that secures the lower retractor bracket to the lower inner B-pillar below the retractor mounting hole. Tighten the screw to 40 N.m (29 ft.lbs.). 4. Reconnect the yellow seat belt tensioner pigtail wire connector to the body wire harness take out and connector (11) for the tensioner. 5. Engage the seat belt tensioner pigtail wire retainer into the hole in the inner B-pillar sheet metal. 6. On the driver side only, reconnect the body wire harness take out and white connector to the seat belt tension reducer connector receptacle near the bottom of the retractor. 7. Position the seat belt web guide (13) to its mounting location on the inner B-pillar near the belt line. 8. Install and tighten the screw (12) that secures the seat belt web guide to the inner B-pillar. Tighten the screw to 2 N.m (20 in.lbs.). 9. Reinstall the upper (2) and lower (6) trim onto the inner B-pillar. 10. Position the seat belt turning loop (3) onto the height adjuster (1) on the upper inner B-pillar. 11. Install and tighten the screw (4) that secures the seat belt turning loop to the height adjuster. Tighten the screw to 40 N.m (29 ft.lbs.). 12. Engage the lower snap features of the new trim cover (5) over the front outboard seat belt turning loop and, using hand pressure, press firmly and evenly on the top of the trim cover until it snaps into place. 13. Position the lower seat belt anchor (7) to the lower inner B-pillar. 14. Install and tighten the screw (8) that secures the lower seat belt anchor to the B-pillar. Tighten the screw to 40 N.m (29 ft.lbs.). 15. Reinstall the stowage tray onto the rear floor panel behind the seat. 16. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. 17. Move the front seat back to its rearward position. Front Outboard - Quad Cab The seat belt retractor on the passenger's side of all models includes a switchable automatic locking mechanism. WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 5462 IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: - The following procedure is for replacement of a faulty or damaged front outboard seat belt and retractor unit, which includes a seat belt tensioner for this model.The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. - If the seat belt or retractor is faulty or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the front outboard seat belt and retractor from the vehicle. REMOVAL 1. Move the front seat to its most forward position for easiest access to the lower seat belt anchor (10) and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the screw (9) that secures the lower seat belt anchor to the floor panel near the base of the inner B-pillar (3). 4. Remove the lower seat belt anchor from the floor panel near the base of the inner B-pillar. 5. Unsnap and remove the trim cover (6) from the front outboard seat belt turning loop (4) to access the screw (5) that secures the turning loop to the height adjuster (1) on the upper inner B-pillar. Discard the removed turning loop trim cover as it is not intended for reuse. 6. Remove the screw that secures the seat belt turning loop to the height adjuster. 7. Remove the seat belt turning loop from the height adjuster. 8. Remove the upper (2) and lower (8) trim from the inner B-pillar. 9. Remove the screw (14) that secures the seat belt web guide (15) to the inner B-pillar near the belt line. 10. Remove the seat belt web guide from the inner B-pillar. 11. Disengage the seat belt tensioner pigtail wire retainer from the hole in the inner B-pillar sheet metal. 12. Disconnect the yellow seat belt tensioner pigtail wire connector from the body wire harness take out and connector (13) for the tensioner. 13. Remove the screw (11) that secures the lower retractor (12) bracket to the lower inner B-pillar below the retractor mounting hole. 14. Disengage the hooks on the upper retractor bracket from the slots in the lower inner B-pillar above the retractor mounting hole. 15. Remove the front outboard seat belt and retractor from the retractor mounting hole in the lower inner B-pillar. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 5463 1. Position the front outboard seat belt and retractor (12) to the retractor mounting hole in the lower inner B-pillar (3). 2. Engage the hooks on the upper retractor bracket into the slots in the lower inner B-pillar above the retractor mounting hole. 3. Install and tighten the screw (11) that secures the lower retractor bracket to the lower inner B-pillar below the retractor mounting hole. Tighten the screw to 40 N.m (29 ft.lbs.). 4. Reconnect the yellow seat belt tensioner pigtail wire connector to the body wire harness take out and connector (13) for the tensioner. 5. Engage the seat belt tensioner pigtail wire retainer into the hole in the inner B-pillar sheet metal. 6. Position the seat belt web guide (15) to its mounting location on the inner B-pillar near the belt line. 7. Install and tighten the screw (14) that secures the seat belt web guide to the inner B-pillar. Tighten the screw to 2 N.m (20 in.lbs.). 8. Reinstall the upper (2) and lower (8) trim onto the inner B-pillar. 9. Position the seat belt turning loop (4) onto the height adjuster (1) on the upper inner B-pillar. 10. Install and tighten the screw (5) that secures the seat belt turning loop to the height adjuster. Tighten the screw to 40 N.m (29 ft.lbs.). 11. Engage the lower snap features of the new trim cover (6) over the front outboard seat belt turning loop and, using hand pressure, press firmly and evenly on the top of the trim cover until it snaps into place. 12. Position the lower seat belt anchor (10) to the floor panel near the base of the inner B-pillar. 13. Install and tighten the screw (9) that secures the lower seat belt anchor to the floor panel near the base of the inner B-pillar. Tighten the screw to 40 N.m (29 ft.lbs.). 14. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. 15. Move the front seat back to its rearward position. Rear Center WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: The rear center seat belt retractor is secured with a single screw to a mounting bracket that includes the unique black, keyed center seat belt lower anchor buckle and the right outboard occupant buckle, but can be removed from the mounting bracket and is serviced separately from the two buckles. The center anchor buckle and the right outboard occupant buckle are serviced as a unit with their mounting bracket. REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 5464 1. Reach between the rear seat cushion and the rear seat back to access and unbuckle the center seat belt lower anchor latch plate (12) from the unique black, keyed center lower anchor buckle (10). Use an ignition key or a small screwdriver to depress the small white release button on the anchor buckle. 2. Remove the rear seat from the vehicle. On models with the optional 60/40 split rear bench, only the 60 percent section (right side) of the rear seat must be removed. 3. Lift upward on the forward edge of the rear center seat belt bezel (3) at the top of the cab back panel (1) to release the snap features that secure the bezel to the belt bracket (5). 4. Remove the bezel from the webbing of the rear center seat belt (2). 5. Lift the rear center seat belt cover (4) off of the belt bracket at the top of the cab back panel and remove the cover from the webbing of the rear center seat belt. 6. Remove the two screws (6) that secure the belt bracket of the rear center seat belt to the body bracket (7) on the upper cab back panel reinforcement. 7. Remove the belt bracket of the rear center seat belt from the body bracket. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 5465 8. Remove the screw (6) that secures the rear center seat belt retractor (3) to the center anchor (5) and right outboard occupant (1) buckles and mounting bracket (4) unit on the rear floor panel near the cab back panel. 9. Remove the rear center seat belt retractor from the center anchor and right outboard occupant buckles and mounting bracket unit. 10. Remove the rear center seat belt and retractor unit from the vehicle. INSTALLATION 1. Position the rear center seat belt and retractor unit (3) onto the center anchor (5) and right outboard occupant (1) buckles and mounting bracket (4) unit on the rear floor panel near the base of the cab back panel. 2. Install and tighten the screw (6) that secures the rear center seat belt retractor bracket to the center anchor and right outboard occupant buckles and mounting bracket unit. Tighten the screw to 40 N.m (29 ft.lbs.). 3. Position the belt bracket (5) of the rear center seat belt (2) onto the body bracket (7) on the upper cab back panel (1) reinforcement. 4. Install and tighten the two screws (6) that secure the belt bracket of the rear center seat belt to the body bracket. Tighten the screws to 20 N.m (15 ft.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 5466 5. Lift the webbing of the rear center seat belt and slide the cover (4) over the belt bracket at the top of the cab back panel until it is fully seated. 6. Route the rear center seat belt bezel (3) over the webbing of the rear center seat belt. 7. Position the rear center seat belt bezel over the cover and belt bracket at the top of the cab back panel and engage the rearward snap features of the bezel with the belt bracket. Using hand pressure, press firmly and evenly downward on the front of the bezel until it snaps into place over the cover and belt bracket. 8. Reinstall the rear seat into the vehicle. On models with the optional 60/40 split rear bench, only the 60 percent section (right side) of the rear seat must be reinstalled. 9. Reach between the rear seat cushion and the rear seat back to buckle the rear center seat belt lower anchor latch plate (12) to the unique black, keyed center lower anchor buckle. Rear Outboard WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. REMOVAL 1. Remove the rear seat from the vehicle. 2. Remove the screw (9) that secures the lower seat belt anchor (8) to the base of the inner C-pillar (1). 3. Remove the lower seat belt anchor from the base of the inner C-pillar. 4. Unsnap and remove the trim cover (5) from the rear outboard seat belt turning loop (3) to access the screw (4) that secures the turning loop to the upper inner C-pillar. Discard the removed turning loop trim cover as it is not intended for reuse. 5. Remove the screw that secures the seat belt turning loop to the C-pillar. 6. Remove the seat belt turning loop from the upper inner C-pillar. 7. Remove the upper and lower trim (2) from the inner C-pillar. 8. Remove the screw (7) that secures the seat belt web guide (12) to the inner C-pillar near the belt line. 9. Remove the seat belt web guide from the inner C-pillar. 10. Remove the screw (10) that secures the lower retractor bracket (11) to the lower inner C-pillar below the retractor mounting hole. 11. Disengage the hook on the upper retractor bracket from the slot in the lower inner C-pillar above the retractor mounting hole. 12. Remove the rear outboard seat belt and retractor from the retractor mounting hole in the lower inner C-pillar. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 5467 INSTALLATION 1. Position the rear outboard seat belt and retractor (11) to the retractor mounting hole in the lower inner C-pillar (1). 2. Engage the hook on the upper retractor bracket into the slot in the lower inner C-pillar above the retractor mounting hole. 3. Install and tighten the screw (10) that secures the lower retractor bracket to the lower inner C-pillar below the retractor mounting hole. Tighten the screw to 40 N.m (29 ft.lbs.). 4. Position the seat belt web guide (12) to the inner C-pillar near the belt line. 5. Install and tighten the screw (7) that secures the seat belt web guide to the inner C-pillar. Tighten the screw to 2 N.m (20 in.lbs.). 6. Reinstall the upper and lower trim (2) onto the inner C-pillar. 7. Position the seat belt turning loop (3) onto the upper inner C-pillar. 8. Install and tighten the screw (4) that secures the seat belt turning loop to the C-pillar. Tighten the screw to 40 N.m (29 ft.lbs.). 9. Engage the lower snap features of the new trim cover (5) over the rear outboard seat belt turning loop and, using hand pressure, press firmly and evenly on the top of the trim cover until it snaps into place. 10. Position the lower seat belt anchor (8) to the base of the inner C-pillar. 11. Install and tighten the screw (9) that secures the lower seat belt anchor to the base of the inner C-pillar. Tighten the screw to 40 N.m (29 ft.lbs.). 12. Reinstall the rear seat into the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Outboard Seat Belt Buckle: Service and Repair Front Outboard WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: A traveling front outboard seat belt buckle is located on the inboard side of each front outboard seat section (40 percent) used on all models. The seat belt buckle on the driver's side front seat for all models also includes a seat belt switch. REMOVAL 1. Move the right or left front outboard seat section (2) to its most rearward position and tilt the seat back forward for easiest access to the front outboard seat belt buckle lower anchor. 2. For easiest access to the front outboard seat belt buckle lower anchor on standard cab models, also move the outboard seat section opposite the side from which the buckle is to be removed to its most forward position and tilt the seat back forward. 3. On standard cab models only, remove the stowage tray from the rear floor panel behind the seat. 4. From behind the front seat on the driver side only, disconnect the seat belt switch pigtail wire (3) connector from the seat wire harness take out and connector for the switch located below the inboard edge of the driver side inboard seat track (4) just forward of the buckle lower anchor. 5. From behind the front seat, remove the screw (5) that secures the front outboard seat belt buckle (1) lower anchor to the bracket on the inboard seat track. 6. From the front of the front seat, reach between the center seat cushion and the adjacent right or left front outboard seat cushion to access and remove the front outboard seat belt buckle from the seat. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Outboard > Page 5472 1. From the front of the front seat, reach between the center seat cushion and the adjacent right or left front outboard seat cushion (2) to position the front outboard seat belt buckle (1) to the seat. Be certain to engage the anti-rotation tab on the buckle anchor into the corresponding hole in the inboard seat track bracket. 2. From behind the front seat, install and tighten the screw (5) that secures the front outboard seat belt buckle lower anchor to the bracket on the inboard seat track (4). Tighten the screw to 25 N.m (18 ft.lbs.). 3. From behind the front seat on the driver side only, reconnect the seat belt switch pigtail wire (3) connector to the seat wire harness take out and connector for the switch located below the inboard edge of the driver side inboard seat track just forward of the buckle lower anchor. 4. On standard cab models only, reinstall the stowage tray onto the rear floor panel behind the seat. 5. On standard cab models, move the outboard seat section opposite the side from which the buckle was replaced to its most rearward position and tilt the seat back to its upright position. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Outboard > Page 5473 Seat Belt Buckle: Service and Repair Front Center and Center Anchor WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: A fixed position front center seat belt buckle is located on the left side of the front center seat section (20 percent) used on all models. Standard cab models also have a unique fixed position black, keyed front center seat belt lower anchor buckle for the three-point center seat belt lower anchor located on the right side of the front center seat section. The following procedure also applies to the fixed position front center seat lap belt located on the right side of the front center seat section of all quad cab models. The three-point front center seat belt and retractor unit is only used on standard cab models. REMOVAL 1. Move the adjacent right or left front outboard seat section (40 percent) to its most forward position for easiest access to the front center seat belt buckle, lap belt lower anchor, or unique black, keyed front center seat belt lower anchor buckle (1). 2. From behind the front seat, remove the screw (5) that secures the front center seat belt buckle, lap belt lower anchor, or unique black, keyed front center seat belt lower anchor buckle to the center seat support bracket (3). 3. From the front of the front seat, reach between the center seat cushion (6) and the adjacent right or left front outboard seat cushion to access and remove the front center seat belt buckle, lap belt unit, or unique black, keyed front center seat belt lower anchor buckle through the elastic strap (2) on the side of the center seat cushion. 4. Remove the front center seat belt buckle, lap belt unit, or unique black, keyed front center seat belt lower anchor buckle from the front seat. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Outboard > Page 5474 1. From the front of the front seat, position the front center seat belt buckle, lap belt unit, or unique black, keyed front center seat belt lower anchor buckle (1) between the center seat cushion (6) and the adjacent right or left front outboard seat cushion. 2. From the front of the front seat, reach between the center seat cushion and the adjacent right or left front outboard seat cushion to route the front center seat belt buckle, lap belt unit lower anchor, or unique black, keyed front center seat belt lower anchor buckle through the elastic strap (2) on the side of the center seat cushion. 3. From behind the front seat, position the front center seat belt buckle, lap belt lower anchor, or unique black, keyed front center seat belt lower anchor buckle to the center seat support bracket (3). Be certain to engage the anti-rotation tab on the buckle or belt anchor into the corresponding hole in the center seat support bracket. 4. Install and tighten the screw (5) that secures the front center seat belt buckle, lap belt lower anchor, or unique black, keyed front center seat belt lower anchor buckle to the center seat support bracket. Tighten the screw to 40 N.m (29 ft.lbs.). 5. Move the adjacent right or left front outboard seat section (40 percent) back to its rearward position. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Outboard > Page 5475 Seat Belt Buckle: Service and Repair Rear Center and Left Outboard WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. REMOVAL 1. Lift up the rear seat cushion into its stowed position against the rear seat back. 2. Remove the screw (3) that secures either the center (5) or the left outboard (4) occupant buckle unit to the rear floor panel (7) near the base of the cab back panel (1). On models with the optional 60/40 split rear bench, the screw that secures the buckle unit also secures one of the rear seat mounting brackets to the rear floor panel. 3. Remove the center or the left outboard occupant buckle unit from the rear floor panel or from the rear seat mounting bracket. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Outboard > Page 5476 1. Position the center (5) or the left outboard (4) occupant buckle unit onto the rear floor panel (7) or onto the rear seat mounting bracket near the base of the cab back panel (1). On models with the optional 60/40 split rear bench, the screw that secures the buckle unit also secures one of the rear seat mounting brackets to the rear floor panel. 2. Install and tighten the screw (3) that secures the center or the left outboard occupant buckle unit to the rear floor panel. Tighten the screw to 40 N.m (29 ft.lbs.). 3. Lower the rear seat cushion back to its normal seating position. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Outboard > Page 5477 Seat Belt Buckle: Service and Repair Rear Center Anchor and Right Outboard WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: The unique black, keyed center seat belt lower anchor buckle and the right outboard occupant buckle are serviced as a unit with their mounting bracket. The rear center seat belt retractor is also secured to the mounting bracket with these two buckles, but can be removed from the mounting bracket and is serviced separately from the two buckles. REMOVAL 1. Reach between the rear seat cushion and the rear seat back to access and unbuckle the rear center seat belt lower anchor latch plate from the unique black, keyed lower anchor center buckle (5). Use an ignition key or a small screwdriver to depress the small white release button on the anchor buckle. 2. Remove the rear seat from the vehicle. On models with the optional 60/40 split rear bench, only the 60 percent section (right side) of the rear seat must be removed. 3. Remove the screw (6) that secures the rear center seat belt retractor (3) to the center anchor and right outboard occupant buckles (1) and mounting bracket (4) unit on the rear floor panel near the cab back panel. 4. Remove the rear center seat belt retractor from the center anchor/right outboard occupant buckle and mounting bracket unit. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Outboard > Page 5478 5. Remove the two screws (3) that secure the center anchor/right outboard occupant buckles and mounting bracket unit to the rear floor panel (7) near the base of the cab back panel(1). 6. Remove the center anchor/right outboard occupant buckles and mounting bracket unit from the rear floor panel. INSTALLATION 1. Position the center anchor and right outboard occupant buckles and mounting bracket unit (6) onto the rear floor panel (7) near the base of the cab back panel (1). 2. Install and tighten the two screws (3) that secure the center anchor and right outboard occupant buckles and mounting bracket unit to the rear floor panel. Tighten the screws to 40 N.m (29 ft.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Outboard > Page 5479 3. Position the rear center seat belt retractor (3) onto the center anchor (5) and right outboard (1) occupant buckles and mounting bracket (4) unit. 4. Install and tighten the screw (6) that secures the rear center seat belt retractor to the center anchor and right outboard occupant buckles and mounting bracket unit. Tighten the screw to 40 N.m (29 ft.lbs.). 5. Reinstall the rear seat into the vehicle. On models with the optional 60/40 split rear bench, only the 60 percent section (right side) of the rear seat must be reinstalled. 6. Reach between the rear seat cushion and the rear seat back to access and buckle the rear center seat belt lower anchor latch plate to the unique black, keyed lower anchor buckle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Description and Operation Seat Belt Buckle Switch: Description and Operation The seat belt switch is a small, normally open, single pole, single throw, leaf contact, momentary switch. Only one seat belt switch is installed in the vehicle, and it is integral to the buckle of the driver side front seat belt buckle-half, located on the inboard side of the driver side front seat track (4). The seat belt switch is connected to the vehicle electrical system through a two-wire pigtail wire (3) and connector on the seat belt buckle-half (1), which is connected to a wire harness connector and take out of the seat wire harness routed beneath the driver side front seat cushion (2) in the passenger compartment. The seat belt switch cannot be adjusted or repaired and, if faulty or damaged, the entire driver side front seat belt buckle-half unit must be replaced. The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the ElectroMechanical Instrument Cluster (EMIC). When the driver side front seat belt tip-half is inserted into the seat belt buckle, the switch closes the path to ground; and, when the driver side front seat belt tip-half is removed from the seat belt buckle, the switch opens the ground path. The switch is actuated by the latch mechanism within the seat belt buckle. The seat belt switch is connected in series between ground and the seat belt switch sense input of the instrument cluster. The seat belt switch receives ground at all times through its pigtail wire connection to the seat wire harness from a take out of the body wire harness. An eyelet terminal connector on the body wire harness ground take out is secured beneath a ground screw on the left cowl side inner panel, beneath the instrument panel. The seat belt switch may de diagnosed using conventional diagnostic tools and methods. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Page 5483 Seat Belt Buckle Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Disconnect and isolate the battery negative cable. Disconnect the seat belt switch pigtail wire connector from the seat wire harness connector for the seat belt switch on the inboard side of the driver side front seat forward of the seat belt buckle-half anchor. Check for continuity between the seat belt switch sense circuit and the ground circuit cavities of the seat belt switch pigtail wire connector. There should be continuity with the seat belt buckled, and no continuity with the seat belt unbuckled. If OK, go to Step 2. If not OK, replace the faulty front seat belt buckle-half assembly. 2. Check for continuity between the ground circuit cavity in the seat wire harness connector for the seat belt switch and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open ground circuit to ground (G301) as required. 3. Remove the instrument cluster from the instrument panel. Check for continuity between the seat belt switch sense circuit cavity of the seat wire harness connector for the seat belt switch and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. 4. Check for continuity between the seat belt switch sense circuit cavities of the seat wire harness connector for the seat belt switch and the instrument panel wire harness connector (Connector C2) for the instrument cluster. There should be continuity. If OK, test and replace the faulty instrument cluster as required. If not OK, repair the open seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Diagrams Seat Belt Height Adjuster: Diagrams Motor-Seat Adjuster-Driver Horizontal Motor-Seat Adjuster-Front Driver Vertical Motor-Seat Adjuster-Front Passenger Vertical Motor-Seat Adjuster-Passenger Horizontal Motor-Seat Adjuster-Rear Passenger Vertical Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Diagrams > Page 5487 Motor-Seat Adjuster-Rear Passenger Vertical Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Diagrams > Page 5488 Seat Belt Height Adjuster: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. REMOVAL 1. Unsnap and remove the trim cover from the front outboard seat belt turning loop to access the screw that secures the turning loop to the height adjuster (2) on the upper inner B-pillar (1). Discard the removed turning loop trim cover as it is not intended for reuse. 2. Remove the screw that secures the seat belt turning loop to the height adjuster. 3. Remove the front seat belt turning loop from the height adjuster. 4. Remove the upper trim from the inner B-pillar. 5. Loosen the two screws (3) that secure the seat belt turning loop height adjuster far enough to remove the adjuster from the upper B-pillar. 6. Disengage the tab near the lower end of the seat belt turning loop height adjuster from the slot in the sheet metal and remove the adjuster from the inner B-pillar. INSTALLATION 1. Position the front seat belt turning loop adjuster (2) to the inner B-pillar (1). 2. Engage the tab near the lower end of the seat belt turning loop height adjuster into the slot in the sheet metal of the inner B-pillar. 3. Hand tighten the lower of the two screws (3) that secure the seat belt turning loop height adjuster to the upper B-pillar far enough to keep the tab on the lower end of the adjuster engaged in the B-pillar slot. 4. Install the upper screw that secures the seat belt turning loop height adjuster to the upper B-pillar, then tighten both the upper and lower screws to 40 N.m (29 ft.lbs.). 5. Reinstall the upper trim onto the inside of the B-pillar. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Diagrams > Page 5489 6. Position the seat belt turning loop onto the height adjuster on the upper inner B-pillar. 7. Install and tighten the screw that secures the seat belt turning loop to the height adjuster. Tighten the screw to 40 N.m (29 ft.lbs.). 8. Engage the lower snap features of the new trim cover over the front outboard seat belt turning loop and, using hand pressure, press firmly and evenly on the top of the trim cover until it snaps into place. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation A seatbelt indicator is standard equipment on all instrument clusters. The seatbelt indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The seatbelt indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Seat Belt" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The seatbelt indicator is serviced as a unit with the instrument cluster. The seatbelt indicator gives an indication to the vehicle operator of the status of the driver side front seatbelt. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hard wired input from the seatbelt switch in the driver side front seatbelt buckle through the seat belt indicator driver circuit. The seatbelt indicator also includes a programmable enhanced seatbelt reminder or "beltminder" feature that is enabled when the vehicle is shipped from the factory. This beltminder feature can be disabled and enabled by the customer using a specific programming event sequence, or by the dealer using a diagnostic scan tool. The seatbelt indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the seatbelt indicator for the following reasons: - Seatbelt Reminder Function - Each time the cluster receives a battery current input on the fused ignition switch output (run-start) circuit, the indicator will be illuminated as a seatbelt reminder for about six seconds, or until the ignition switch is turned to the Off position, whichever occurs first. This reminder function will occur regardless of the status of the seatbelt switch input to the cluster. - Driver Side Front Seatbelt Not Buckled - Beltminder Active - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the Start or On positions, the indicator will be illuminated. In addition, if the driver side front seat belt remains unbuckled about sixty seconds after the conclusion of the seatbelt reminder function with the vehicle speed greater than about 13 kilometers-per-hour (8 miles-per-hour), the seatbelt indicator will begin to cycle between flashing on and off for five seconds, then lighting solid for three seconds. The seatbelt indicator will continue to cycle between flashing and solid illumination for twelve complete cycles, until the seat belt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch is turned to the Off position, whichever occurs first. - Driver Side Front Seatbelt Not Buckled - Beltminder Inactive - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the Start or On positions, the indicator will be illuminated. The seatbelt indicator remains illuminated until the seat belt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch is turned to the Off position, whichever occurs first. - Airbag Indicator Backup - If the instrument cluster detects a fault in the airbag indicator circuit it will send a message indicating the fault to the Airbag Control Module (ACM), store a Diagnostic Trouble Code (DTC) in the cluster memory, then flash the seatbelt indicator on and off. The cluster will continue to flash the seatbelt indicator until the airbag indicator circuit fault is resolved, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the seatbelt indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The seatbelt switch is connected in series between ground and the seat belt indicator driver input to the instrument cluster. The seatbelt switch input to the instrument cluster circuitry may be diagnosed using conventional diagnostic tools and methods. For further diagnosis of the seatbelt indicator or the instrument cluster circuitry that controls the LED, refer to testing. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Service and Repair > Enhanced Seatbelt Reminder Programming Seat Belt Reminder Lamp: Service and Repair Enhanced Seatbelt Reminder Programming The seatbelt indicator also includes a programmable enhanced seatbelt reminder or "beltminder" feature that is enabled when the vehicle is shipped from the factory. This beltminder feature provides extended and modified visual seatbelt indicator and audible chime warning responses to an unbuckled driver side front seat belt. The beltminder feature may be disabled or enabled by the customer using the programming sequence that follows, or by the dealer using a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Service and Repair > Enhanced Seatbelt Reminder Programming > Page 5495 Seat Belt Reminder Lamp: Service and Repair Customer Programming Sequence NOTE: The following sequence of events must occur within sixty (60) seconds of the ignition switch being placed in the On position in order for the programming to be completed successfully. 1. With the ignition switch in any position except On or Start, buckle the driver side front seat belt. 2. Turn the ignition switch to the On position and wait for the seatbelt indicator reminder function to conclude (about six seconds). 3. Unbuckle and buckle the driver side front seat belt three or more times, ending with the belt buckled. 4. Turn the ignition switch to any position except On or Start to toggle the beltminder feature from its current setting (from active to inactive, or from inactive to active). A single chime tone will provide an audible confirmation that the programming sequence has been successfully completed. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation Seat Belt Retractor: Description and Operation AUTOMATIC LOCKING RETRACTOR The seat belt retractors used in all seating positions include an inertia-type, emergency locking mechanism (7) as standard equipment. However, the retractor locking mechanism for the passenger side front seating position is mechanically switchable from an emergency locking retractor to an automatic locking retractor. The primary function of this feature is to securely accommodate a child seat in the passenger side front seating position of the vehicle without the need for a self-cinching seat belt tip half latch plate unit or another supplemental device that would be required to prevent the seat belt webbing from unwinding freely from the retractor spool of an inertia-type emergency locking retractor mechanism. The automatic locking mechanism is integral to the passenger side front seat belt and retractor unit and is concealed beneath a molded plastic cover located on the same side of the retractor spool as the seat belt tensioner housing. The retractor is secured to the inner B-pillar on the right side of the vehicle and is concealed beneath the molded plastic inner B-pillar trim. The automatic locking mechanism cannot be adjusted or repaired and, if faulty or damaged, the entire passenger side front seat belt and retractor unit must be replaced. The automatic locking mode of the retractor is engaged and the retractor is switched from operating as a standard inertia-type emergency locking retractor by first buckling the combination lap and shoulder belt buckle. Then grasp the shoulder belt and pull all of the webbing out of the retractor. Once all of the belt webbing is extracted from the spool, the retractor will automatically become engaged in the pre-locked automatic locking mode and will make an audible clicking or ratcheting sound as the shoulder belt is allowed to retract to confirm that the automatic locking mode is now engaged. Once the automatic locking mode is engaged, the retractor will remain locked and the belt will remain tight around whatever it is restraining. The retractor is returned to standard emergency locking mode by unbuckling the combination lap and shoulder belt buckle and allowing the belt webbing to be almost fully retracted onto the retractor spool. The emergency locking mode is confirmed by the absence of the audible clicking or ratcheting sound as the belt webbing retracts. This mode will allow the belt to unwind from and wind onto the retractor spool freely unless and until a predetermined inertia load is sensed, or until the retractor is again switched to the automatic locking mode. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt Retractor: Service and Repair Front Front Center WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: A front center seat belt and retractor is used only on standard cab models. Quad cab models have a lap belt in the front center seating position. REMOVAL 1. Reach between the center of the front seat cushion and front seat back to access and unbuckle the front center seat belt lower anchor latch plate from the unique black, keyed lower anchor buckle. Use an ignition key or a small screwdriver to depress the small white release button on the anchor buckle. 2. Move the front seat to its most forward position for easiest access to the front center seat belt and retractor unit. 3. Remove the stowage tray from the rear floor panel behind the seat. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry at each side of the front center seat belt bezel (5) on the cab back trim panel (1) to release the snap features that secure the bezel to the panel. 5. Remove the bezel from the webbing of the front center seat belt (4). 6. Remove the trim from the cab back panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 5501 7. Remove the two screws (3) that secure the belt bracket (2) of the front center seat belt (7) to the body bracket (1) on the upper cab back panel (8) reinforcement. 8. Remove the belt bracket of the front center seat belt from the body bracket on the upper cab back panel reinforcement. 9. Remove the two screws (4) that secure the front center seat belt retractor bracket (5) to the floor panel (6) near the base of the cab back panel. 10. Remove the front center seat belt and retractor unit from the floor panel. INSTALLATION 1. Position the front center seat belt and retractor unit (5) to the floor panel (6) at the base of the cab back panel (8) to the right of center. 2. Install and tighten the two screws (4) that secure the front center seat belt retractor bracket to the floor panel near the base of the cab back panel. Tighten the screws to 40 N.m (29 ft.lbs.). 3. Position the belt bracket (2) of the front center seat belt (7) to the body bracket (1) on the upper cab back panel reinforcement. 4. Install and tighten the two screws (3) that secure the belt bracket of the front center seat belt to the body bracket on the upper cab back panel reinforcement. Tighten the screws to 20 N.m (15 ft.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 5502 5. Reinstall the trim (1) onto the cab back panel. 6. Route the webbing of the front center seat belt (4) through the bezel (5) and position the bezel to the belt opening near the top of the cab back trim panel. 7. Using hand pressure, press firmly and evenly on each side of the front center seat belt bezel until it snaps into place on the cab back trim panel. 8. Reinstall the stowage tray onto the rear floor panel behind the seat. 9. Move the front seat back to its rearward position. 10. Reach between the center of the front seat cushion and front seat back to access and buckle the front center seat belt lower anchor latch plate to the unique black, keyed lower anchor buckle. Front Outboard - Quad Cab The seat belt retractor on the passenger's side of all models includes a switchable automatic locking mechanism. WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: - The following procedure is for replacement of a faulty or damaged front outboard seat belt and retractor unit, which includes a seat belt tensioner for this model.The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. - If the seat belt or retractor is faulty or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the front outboard seat belt and retractor from the vehicle. REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 5503 1. Move the front seat to its most forward position for easiest access to the lower seat belt anchor (10) and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the screw (9) that secures the lower seat belt anchor to the floor panel near the base of the inner B-pillar (3). 4. Remove the lower seat belt anchor from the floor panel near the base of the inner B-pillar. 5. Unsnap and remove the trim cover (6) from the front outboard seat belt turning loop (4) to access the screw (5) that secures the turning loop to the height adjuster (1) on the upper inner B-pillar. Discard the removed turning loop trim cover as it is not intended for reuse. 6. Remove the screw that secures the seat belt turning loop to the height adjuster. 7. Remove the seat belt turning loop from the height adjuster. 8. Remove the upper (2) and lower (8) trim from the inner B-pillar. 9. Remove the screw (14) that secures the seat belt web guide (15) to the inner B-pillar near the belt line. 10. Remove the seat belt web guide from the inner B-pillar. 11. Disengage the seat belt tensioner pigtail wire retainer from the hole in the inner B-pillar sheet metal. 12. Disconnect the yellow seat belt tensioner pigtail wire connector from the body wire harness take out and connector (13) for the tensioner. 13. Remove the screw (11) that secures the lower retractor (12) bracket to the lower inner B-pillar below the retractor mounting hole. 14. Disengage the hooks on the upper retractor bracket from the slots in the lower inner B-pillar above the retractor mounting hole. 15. Remove the front outboard seat belt and retractor from the retractor mounting hole in the lower inner B-pillar. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 5504 1. Position the front outboard seat belt and retractor (12) to the retractor mounting hole in the lower inner B-pillar (3). 2. Engage the hooks on the upper retractor bracket into the slots in the lower inner B-pillar above the retractor mounting hole. 3. Install and tighten the screw (11) that secures the lower retractor bracket to the lower inner B-pillar below the retractor mounting hole. Tighten the screw to 40 N.m (29 ft.lbs.). 4. Reconnect the yellow seat belt tensioner pigtail wire connector to the body wire harness take out and connector (13) for the tensioner. 5. Engage the seat belt tensioner pigtail wire retainer into the hole in the inner B-pillar sheet metal. 6. Position the seat belt web guide (15) to its mounting location on the inner B-pillar near the belt line. 7. Install and tighten the screw (14) that secures the seat belt web guide to the inner B-pillar. Tighten the screw to 2 N.m (20 in.lbs.). 8. Reinstall the upper (2) and lower (8) trim onto the inner B-pillar. 9. Position the seat belt turning loop (4) onto the height adjuster (1) on the upper inner B-pillar. 10. Install and tighten the screw (5) that secures the seat belt turning loop to the height adjuster. Tighten the screw to 40 N.m (29 ft.lbs.). 11. Engage the lower snap features of the new trim cover (6) over the front outboard seat belt turning loop and, using hand pressure, press firmly and evenly on the top of the trim cover until it snaps into place. 12. Position the lower seat belt anchor (10) to the floor panel near the base of the inner B-pillar. 13. Install and tighten the screw (9) that secures the lower seat belt anchor to the floor panel near the base of the inner B-pillar. Tighten the screw to 40 N.m (29 ft.lbs.). 14. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. 15. Move the front seat back to its rearward position. Front Outboard - Standard Cab The seat belt retractor on the driver's side of standard cab models only includes a tension reducer. The seat belt retractor on the passenger's side of all models includes a switchable automatic locking mechanism. WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 5505 CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: - The following procedure is for replacement of a faulty or damaged front outboard seat belt and retractor unit, which includes a seat belt tensioner for this model. The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. - If the seat belt or retractor is faulty or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the front outboard seat belt and retractor from the vehicle. REMOVAL 1. Move the front seat to its most forward position for easiest access to the lower seat belt anchor (7) and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the stowage tray from the rear floor panel behind the seat. 4. Remove the screw (8) that secures the lower seat belt anchor to the lower inner B-pillar (14). 5. Remove the lower seat belt anchor from the lower inner B-pillar. 6. Unsnap and remove the trim cover (5) from the front outboard seat belt turning loop (3) to access the screw (4) that secures the turning loop to the height adjuster (1) on the upper inner B-pillar. Discard the removed turning loop trim cover as it is not intended for reuse. 7. Remove the screw that secures the seat belt turning loop to the height adjuster. 8. Remove the seat belt turning loop from the height adjuster. 9. Remove the upper (2) and lower (6) trim from the inner B-pillar. 10. Remove the screw (12) that secures the seat belt web guide (13) to the inner B-pillar near the belt line. 11. Remove the seat belt web guide from the inner B-pillar. 12. On the driver side only, disconnect the body wire harness take out and white connector from the connector receptacle for the seat belt tension reducer located near the bottom of the retractor (10). 13. Disengage the seat belt tensioner pigtail wire retainer from the hole in the inner B-pillar sheet metal. 14. Disconnect the yellow seat belt tensioner pigtail wire connector from the body wire harness take out and connector (11) for the tensioner. 15. Remove the screw (9) that secures the lower retractor bracket to the lower inner B-pillar below the retractor mounting hole. 16. Disengage the hooks on the upper retractor bracket from the slots in the lower inner B-pillar above the retractor mounting hole. 17. Remove the front outboard seat belt and retractor from the retractor mounting hole in the lower inner B-pillar. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 5506 1. Position the front outboard seat belt and retractor (10) to the retractor mounting hole in the lower inner B-pillar (14). 2. Engage the hooks on the upper retractor bracket into the slots in the lower inner B-pillar above the retractor mounting hole. 3. Install and tighten the screw (9) that secures the lower retractor bracket to the lower inner B-pillar below the retractor mounting hole. Tighten the screw to 40 N.m (29 ft.lbs.). 4. Reconnect the yellow seat belt tensioner pigtail wire connector to the body wire harness take out and connector (11) for the tensioner. 5. Engage the seat belt tensioner pigtail wire retainer into the hole in the inner B-pillar sheet metal. 6. On the driver side only, reconnect the body wire harness take out and white connector to the seat belt tension reducer connector receptacle near the bottom of the retractor. 7. Position the seat belt web guide (13) to its mounting location on the inner B-pillar near the belt line. 8. Install and tighten the screw (12) that secures the seat belt web guide to the inner B-pillar. Tighten the screw to 2 N.m (20 in.lbs.). 9. Reinstall the upper (2) and lower (6) trim onto the inner B-pillar. 10. Position the seat belt turning loop (3) onto the height adjuster (1) on the upper inner B-pillar. 11. Install and tighten the screw (4) that secures the seat belt turning loop to the height adjuster. Tighten the screw to 40 N.m (29 ft.lbs.). 12. Engage the lower snap features of the new trim cover (5) over the front outboard seat belt turning loop and, using hand pressure, press firmly and evenly on the top of the trim cover until it snaps into place. 13. Position the lower seat belt anchor (7) to the lower inner B-pillar. 14. Install and tighten the screw (8) that secures the lower seat belt anchor to the B-pillar. Tighten the screw to 40 N.m (29 ft.lbs.). 15. Reinstall the stowage tray onto the rear floor panel behind the seat. 16. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. 17. Move the front seat back to its rearward position. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 5507 Seat Belt Retractor: Service and Repair Rear Rear Center WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: The rear center seat belt retractor is secured with a single screw to a mounting bracket that includes the unique black, keyed center seat belt lower anchor buckle and the right outboard occupant buckle, but can be removed from the mounting bracket and is serviced separately from the two buckles. The center anchor buckle and the right outboard occupant buckle are serviced as a unit with their mounting bracket. REMOVAL 1. Reach between the rear seat cushion and the rear seat back to access and unbuckle the center seat belt lower anchor latch plate (12) from the unique black, keyed center lower anchor buckle (10). Use an ignition key or a small screwdriver to depress the small white release button on the anchor buckle. 2. Remove the rear seat from the vehicle. On models with the optional 60/40 split rear bench, only the 60 percent section (right side) of the rear seat must be removed. 3. Lift upward on the forward edge of the rear center seat belt bezel (3) at the top of the cab back panel (1) to release the snap features that secure the bezel to the belt bracket (5). 4. Remove the bezel from the webbing of the rear center seat belt (2). 5. Lift the rear center seat belt cover (4) off of the belt bracket at the top of the cab back panel and remove the cover from the webbing of the rear center seat belt. 6. Remove the two screws (6) that secure the belt bracket of the rear center seat belt to the body bracket (7) on the upper cab back panel reinforcement. 7. Remove the belt bracket of the rear center seat belt from the body bracket. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 5508 8. Remove the screw (6) that secures the rear center seat belt retractor (3) to the center anchor (5) and right outboard occupant (1) buckles and mounting bracket (4) unit on the rear floor panel near the cab back panel. 9. Remove the rear center seat belt retractor from the center anchor and right outboard occupant buckles and mounting bracket unit. 10. Remove the rear center seat belt and retractor unit from the vehicle. INSTALLATION 1. Position the rear center seat belt and retractor unit (3) onto the center anchor (5) and right outboard occupant (1) buckles and mounting bracket (4) unit on the rear floor panel near the base of the cab back panel. 2. Install and tighten the screw (6) that secures the rear center seat belt retractor bracket to the center anchor and right outboard occupant buckles and mounting bracket unit. Tighten the screw to 40 N.m (29 ft.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 5509 3. Position the belt bracket (5) of the rear center seat belt (2) onto the body bracket (7) on the upper cab back panel (1) reinforcement. 4. Install and tighten the two screws (6) that secure the belt bracket of the rear center seat belt to the body bracket. Tighten the screws to 20 N.m (15 ft.lbs.). 5. Lift the webbing of the rear center seat belt and slide the cover (4) over the belt bracket at the top of the cab back panel until it is fully seated. 6. Route the rear center seat belt bezel (3) over the webbing of the rear center seat belt. 7. Position the rear center seat belt bezel over the cover and belt bracket at the top of the cab back panel and engage the rearward snap features of the bezel with the belt bracket. Using hand pressure, press firmly and evenly downward on the front of the bezel until it snaps into place over the cover and belt bracket. 8. Reinstall the rear seat into the vehicle. On models with the optional 60/40 split rear bench, only the 60 percent section (right side) of the rear seat must be reinstalled. 9. Reach between the rear seat cushion and the rear seat back to buckle the rear center seat belt lower anchor latch plate (12) to the unique black, keyed center lower anchor buckle. Rear Outboard WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 5510 1. Remove the rear seat from the vehicle. 2. Remove the screw (9) that secures the lower seat belt anchor (8) to the base of the inner C-pillar (1). 3. Remove the lower seat belt anchor from the base of the inner C-pillar. 4. Unsnap and remove the trim cover (5) from the rear outboard seat belt turning loop (3) to access the screw (4) that secures the turning loop to the upper inner C-pillar. Discard the removed turning loop trim cover as it is not intended for reuse. 5. Remove the screw that secures the seat belt turning loop to the C-pillar. 6. Remove the seat belt turning loop from the upper inner C-pillar. 7. Remove the upper and lower trim (2) from the inner C-pillar. 8. Remove the screw (7) that secures the seat belt web guide (12) to the inner C-pillar near the belt line. 9. Remove the seat belt web guide from the inner C-pillar. 10. Remove the screw (10) that secures the lower retractor bracket (11) to the lower inner C-pillar below the retractor mounting hole. 11. Disengage the hook on the upper retractor bracket from the slot in the lower inner C-pillar above the retractor mounting hole. 12. Remove the rear outboard seat belt and retractor from the retractor mounting hole in the lower inner C-pillar. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 5511 1. Position the rear outboard seat belt and retractor (11) to the retractor mounting hole in the lower inner C-pillar (1). 2. Engage the hook on the upper retractor bracket into the slot in the lower inner C-pillar above the retractor mounting hole. 3. Install and tighten the screw (10) that secures the lower retractor bracket to the lower inner C-pillar below the retractor mounting hole. Tighten the screw to 40 N.m (29 ft.lbs.). 4. Position the seat belt web guide (12) to the inner C-pillar near the belt line. 5. Install and tighten the screw (7) that secures the seat belt web guide to the inner C-pillar. Tighten the screw to 2 N.m (20 in.lbs.). 6. Reinstall the upper and lower trim (2) onto the inner C-pillar. 7. Position the seat belt turning loop (3) onto the upper inner C-pillar. 8. Install and tighten the screw (4) that secures the seat belt turning loop to the C-pillar. Tighten the screw to 40 N.m (29 ft.lbs.). 9. Engage the lower snap features of the new trim cover (5) over the rear outboard seat belt turning loop and, using hand pressure, press firmly and evenly on the top of the trim cover until it snaps into place. 10. Position the lower seat belt anchor (8) to the base of the inner C-pillar. 11. Install and tighten the screw (9) that secures the lower seat belt anchor to the base of the inner C-pillar. Tighten the screw to 40 N.m (29 ft.lbs.). 12. Reinstall the rear seat into the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Page 5515 Seat Belt Tensioner: Diagrams Seat Belt-Tension Reducer-Driver (Standard Cab) Seat Belt-Tensioner-Driver Seat Belt-Tensioner-Passenger Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Seat Belt Tension Reducer Seat Belt Tensioner: Description and Operation Seat Belt Tension Reducer A seat belt tension reducer (5) is standard equipment for the driver side front outboard seat belt on standard cab versions of this model. The tension reducer is integral to the driver side front outboard seat belt and retractor unit, which is secured to the inner B-pillar on the left side of the vehicle. The retractor is concealed beneath the molded plastic inner B-pillar trim. The seat belt tension reducer consists primarily of a 12-volt Direct Current (DC) solenoid and an integral connector receptacle (6) that is located on the forward facing end housing of the retractor. The seat belt tension reducer is controlled by a battery current output of the ignition switch and a ground path provided by the seat belt switch, and is connected to the vehicle electrical system through a dedicated take out of the body wire harness by a keyed and latching molded plastic connector insulator to ensure a secure connection. The seat belt tension reducer cannot be repaired and, if faulty or damaged, the entire driver side front outboard seat belt and retractor unit must be replaced. The seat belt tension reducer is controlled by a ground signal received from the seat belt switch on the seat belt switch sense circuit and a battery current signal received from the ignition switch on the fused ignition switch output (run-accessory) circuit. When the seat belt switch is closed (the driver side front seat belt is fastened) and the ignition switch is in the On or Accessory positions, the seat belt tension reducer solenoid is energized. When the solenoid is energized, it actuates a mechanism within the driver side front outboard seat belt retractor to reduce the normal recoil spring tension exerted by the retractor spool, which is designed to reel in the seat belt webbing onto the spool. When the driver side seat belt is unbuckled or if the ignition switch is turned to any position except On or Accessory, the tension reducer solenoid is de-energized and the normal recoil spring tension of the retractor is restored. The action of the seat belt tension reducer results in improved seat belt comfort for the driver. Reducing the seat belt retractor recoil spring tension is desirable on standard cab models of this vehicle and not on the quad cab model due to the different mounting position required for the seat belt turning loop on the B-pillar relative to the driver's seat position on the standard cab model. The seat belt tension reducer may be diagnosed using conventional diagnostic tools and methods. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Seat Belt Tension Reducer > Page 5518 Seat Belt Tensioner: Description and Operation Seat Belt Tensioner Front outboard seating position seat belt tensioners supplement the driver and passenger airbags for all versions of this model. The seat belt tensioner is integral to the front outboard seat belt and retractor units, which are secured to the inner B-pillar on the right and left sides of the vehicle. The retractor is concealed beneath the molded plastic inner B-pillar trim. The seat belt tensioner consists primarily of a die cast aluminum tensioner housing or chamber (1), a mechanical clutch unit, a tape-like metal strip, a pair of cutters, a pyrotechnically activated gas generator (2), and a short pigtail wire (3). All of these components are located on one side of the retractor spool on the outside of the retractor housing. The seat belt tensioners are controlled by the Airbag Control Module (ACM) and are connected to the vehicle electrical system through a dedicated take out of the body wire harness by a keyed and latching molded plastic connector insulator to ensure a secure connection. The seat belt tensioners cannot be repaired and, if faulty or damaged, the entire outboard front seat belt and retractor unit must be replaced. If the front airbags have been deployed, the seat belt tensioners have also been deployed. The seat belt tensioners are not intended for reuse and must be replaced following any front airbag deployment. A locked retractor that will not allow the seat belt webbing to be retracted or extracted is a sure indication that the seat belt tensioner has been deployed and requires replacement. The seat belt tensioners are deployed in conjunction with the dual front airbags by a signal generated by the Airbag Control Module (ACM) through the driver or passenger seat belt tensioner line 1 and line 2 (or squib) circuits. When the ACM sends the proper electrical signal to the tensioners, the electrical energy generates enough heat to initiate a small pyrotechnic gas generator. The gas generator is installed at the top of the tensioner housing which contains a long metal tape that is routed through two chambers within the housing. Each end of the tape is wound around the outer sleeve of a mechanical clutch mechanism secured to one end of the torsion bar upon which the retractor spool is secured. As the gas expands, it is directed against the metal tape within the two chambers of the housing causing the tape to unwind from the clutch sleeve. As the clutch rotates it engages the torsion bar, which drives the seat belt retractor spool causing the slack to be removed from the seat belt. Once a seat belt tensioning sequence has been completed, the forward momentum of the occupant results in deformation of the torsion bar. As the torsion bar deforms it allows the seat belt webbing to unwind from the retractor spool, which causes the metal tape to be wound back onto the clutch sleeve until it is pulled tight against two cutter blades within the housing, which immediately cut the metal tape. Removing excess slack from the seat belt not only keeps the occupant properly positioned for an airbag deployment following a frontal impact of the vehicle, but also helps to reduce injuries that the occupant might experience in these situations as a result of a harmful contact with the steering wheel, steering column, instrument panel and/or windshield. Also, the torsion bar is designed to deform in order to control the loading being applied to the occupant by the seat belt during a frontal impact, further reducing the potential for occupant injuries. The ACM monitors the condition of the seat belt tensioners through circuit resistance, and will illuminate the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and store a Diagnostic Trouble Code (DTC) for any fault that is detected. For proper diagnosis of the seat belt tensioners, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Page 5519 Seat Belt Tensioner: Testing and Inspection SEAT BELT TENSION REDUCER The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the seat belt tension reducer from the tension reducer connector receptacle on the driver side front outboard seat belt and retractor unit. Using an ohmmeter, measure the resistance between the seat belt switch sense circuit terminal pin and the fused ignition switch output (run-accessory) circuit terminal pin in the tension reducer connector receptacle on the retractor. Resistance through the tension reducer solenoid coil should be 53 ohms at 20° C (68° F). If OK, go to Step 2. If not OK, replace the faulty driver side front outboard seat belt and retractor unit. 2. Check for continuity between the seat belt switch sense circuit cavity of the body wire harness connector for the seat belt tension reducer and a good ground. There should be continuity with the driver side front seat belt buckled, and no continuity with the driver side front seat belt unbuckled. If OK, go to Step 3. If not OK, repair the shorted or open seat belt switch sense circuit between the tension reducer and the seat belt switch as required. 3. Reconnect the battery negative cable. Check for battery current at the fused ignition switch output (run-accessory) circuit of the body wire harness connector for the seat belt tension reducer. There should be battery current with the ignition switch in the On or Accessory positions, and no battery current with the ignition switch in any other position. If not OK, repair the shorted or open fused ignition switch output (run-accessory) circuit between the tension reducer and the ignition switch as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations Air Bag Deactivation Switch: Locations Rear Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 5524 Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 5525 Left Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 5526 Right Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 5527 Switch-Passenger Airbag On/Off Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 5528 Air Bag Deactivation Switch: Description and Operation The passenger airbag on/off switch (1) is standard equipment on all standard cab versions of this model when they are equipped with the dual front airbag system. This switch is a two-position, resistor multiplexed switch with a single integral red Light-Emitting Diode (LED), and a non-coded key cylinder-type actuator. The switch is located in the lower right corner of instrument panel center bezel, near the center of instrument panel to make the Off indicator (3) visible to all front seat occupants. When the switch is in its installed position, the only components visible through the dedicated opening of the cluster bezel are the switch face plate (2) and nomenclature, and the key cylinder actuator (4). The "Off" position of the switch is illuminated when this switch position is selected, while the "On" position of the switch is designated by text imprinted upon the face plate of the switch, but is not illuminated. The remainder of the switch is concealed behind the switch face plate and the instrument panel center bezel. The passenger airbag on/off switch housing is constructed of molded plastic and has three integral mounting tabs. These mounting tabs are used to secure the switch to the back of the molded plastic switch face plate with three small screws. The molded plastic face plate also has three integral mounting tabs that are used to secure the switch and face plate unit to the instrument panel center bezel with three additional screws. A molded plastic connector receptacle on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The molded plastic harness connector insulator is keyed and latched to ensure proper and secure switch electrical connections. The passenger airbag on/off switch cannot be adjusted or repaired and, if faulty or damaged, the switch must be replaced. The passenger airbag on/off switch allows the customer to turn the passenger airbag function On or Off to accommodate certain uses of the right front seating position where airbag protection may not be desired. See the vehicle glove box for specific recommendations on when to enable or disable the passenger airbag. The Off indicator of the switch will be illuminated whenever the switch is turned to the Off position and the ignition switch is in the On position. The ignition key is the only key or object that should ever be inserted into the key cylinder actuator of the switch. The on/off switch requires only a partial key insertion to fully depress a spring-loaded locking plunger. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. To actuate the passenger airbag on/off switch, insert the ignition key into the switch key actuator far enough to fully depress the plunger, then rotate the actuator to the desired switch position. When the switch key actuator is rotated to its clockwise stop (the key actuator slot will be aligned with the Off indicator), the Off indicator is illuminated and the passenger airbag is disabled. When the switch is rotated to its counterclockwise stop (the key actuator slot will be in a vertical position), the Off indicator will be extinguished and the passenger airbag is enabled. The passenger airbag on/off switch connects one of two internal resistors in series between the passenger airbag mux switch sense and passenger airbag mux switch return circuits of the Airbag Control Module (ACM). The ACM continually monitors the resistance in these circuits to determine the switch position that has been selected. When the switch is in the Off position, the ACM provides a ground input to the switch through the passenger airbag indicator driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the Off indicator of the switch. The ACM will also illuminate the Off indicator of the switch for about seven seconds each time the ignition switch is turned to the On position as a bulb test. The ACM will store a Diagnostic Trouble Code (DTC) for any fault it detects in the passenger airbag on/off switch or Off indicator circuits, and will illuminate the airbag indicator in the instrument cluster if a fault is detected. For proper diagnosis of the passenger airbag on/off switch or the ACM, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 5529 Air Bag Deactivation Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the center bezel (1) from the instrument panel. 3. From the back of the center bezel, remove the three screws (2) that secure the passenger airbag on/off switch and face plate unit (3) to the back of the bezel. 4. Remove the passenger airbag on/off switch and face plate from the center bezel as a unit. INSTALLATION 1. Position the passenger airbag on/off switch and face plate unit (3) to the back of the center bezel (1). 2. Install and tighten the three screws (2) that secure the passenger airbag on/off switch face plate to the back of the center bezel. Tighten the screws to 2 N.m (17 in.lbs.). 3. Reinstall the center bezel onto the instrument panel. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 5533 Impact Sensor: Diagrams Sensor-Side Impact-Left 1 Sensor-Side Impact-Right 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 5534 Impact Sensor: Description and Operation Two side impact sensors (1) are used on this model when it is equipped with the optional side curtain air-bags, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the bi-directional safing sensor that is internal to the Air-bag Control Module (ACM). Each side impact sensor is secured with a nut within the right or left B-pillar just above the front seat belt retractors and behind the lower B-pillar trim within the passenger compartment. The sensor housing has an integral connector receptacle (2), an integral mounting stud (3), and an integral anti-rotation pin. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The side impact sensors cannot be repaired or adjusted and, if damaged or faulty, they must be replaced. The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Airbag Control Module (ACM). The ACM microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ACM. The impact sensors and the ACM communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the side impact sensors and the ACM may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ACM, the impact sensors, or the electronic message inputs to or outputs from the impact sensors. The most reliable, efficient, and accurate means to diagnose the impact sensors, the ACM, and the electronic message communication between the sensors and the ACM requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab Impact Sensor: Service and Repair Standard Cab WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE SIDE IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE SIDE IMPACT SENSOR ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. IF AN IMPACT SENSOR IS ACCIDENTALLY DROPPED DURING SERVICE, THE SENSOR MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Adjust the driver or passenger side front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the front outboard seat belt and retractor from the inside of the B-pillar. 4. Remove the nut (4) that secures the stud of the side impact sensor (1) to the inner B-pillar. 5. Reach through the retractor mounting hole (3) in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 6. Pull the side impact sensor out of the B-pillar far enough to access and disconnect the body wire harness connector (2) from the sensor connector receptacle. 7. Remove the sensor from the B-pillar. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab > Page 5537 1. Position the side impact sensor (1) to the retractor mounting hole (3) in the inner B-pillar. 2. Reconnect the body wire harness connector (2) to the sensor connector receptacle. 3. Reach through the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (4) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in.lbs.). 5. Reinstall the front outboard seat belt and retractor to the inside of the B-pillar. 6. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab > Page 5538 Impact Sensor: Service and Repair Quad Cab WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE SIDE IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE SIDE IMPACT SENSOR ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. IF AN IMPACT SENSOR IS ACCIDENTALLY DROPPED DURING SERVICE, THE SENSOR MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (2) to the inner B-pillar (1). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (4) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Standard Cab > Page 5539 1. Position the side impact sensor (2) to the large hole above the retractor mounting hole in the inner B-pillar (1). 2. Reconnect the body wire harness connector (4) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in.lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation Seat Belt Buckle Switch: Description and Operation The seat belt switch is a small, normally open, single pole, single throw, leaf contact, momentary switch. Only one seat belt switch is installed in the vehicle, and it is integral to the buckle of the driver side front seat belt buckle-half, located on the inboard side of the driver side front seat track (4). The seat belt switch is connected to the vehicle electrical system through a two-wire pigtail wire (3) and connector on the seat belt buckle-half (1), which is connected to a wire harness connector and take out of the seat wire harness routed beneath the driver side front seat cushion (2) in the passenger compartment. The seat belt switch cannot be adjusted or repaired and, if faulty or damaged, the entire driver side front seat belt buckle-half unit must be replaced. The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the ElectroMechanical Instrument Cluster (EMIC). When the driver side front seat belt tip-half is inserted into the seat belt buckle, the switch closes the path to ground; and, when the driver side front seat belt tip-half is removed from the seat belt buckle, the switch opens the ground path. The switch is actuated by the latch mechanism within the seat belt buckle. The seat belt switch is connected in series between ground and the seat belt switch sense input of the instrument cluster. The seat belt switch receives ground at all times through its pigtail wire connection to the seat wire harness from a take out of the body wire harness. An eyelet terminal connector on the body wire harness ground take out is secured beneath a ground screw on the left cowl side inner panel, beneath the instrument panel. The seat belt switch may de diagnosed using conventional diagnostic tools and methods. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Page 5543 Seat Belt Buckle Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Disconnect and isolate the battery negative cable. Disconnect the seat belt switch pigtail wire connector from the seat wire harness connector for the seat belt switch on the inboard side of the driver side front seat forward of the seat belt buckle-half anchor. Check for continuity between the seat belt switch sense circuit and the ground circuit cavities of the seat belt switch pigtail wire connector. There should be continuity with the seat belt buckled, and no continuity with the seat belt unbuckled. If OK, go to Step 2. If not OK, replace the faulty front seat belt buckle-half assembly. 2. Check for continuity between the ground circuit cavity in the seat wire harness connector for the seat belt switch and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open ground circuit to ground (G301) as required. 3. Remove the instrument cluster from the instrument panel. Check for continuity between the seat belt switch sense circuit cavity of the seat wire harness connector for the seat belt switch and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. 4. Check for continuity between the seat belt switch sense circuit cavities of the seat wire harness connector for the seat belt switch and the instrument panel wire harness connector (Connector C2) for the instrument cluster. There should be continuity. If OK, test and replace the faulty instrument cluster as required. If not OK, repair the open seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Service and Repair Antenna, Navigation: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel top cover. 3. Remove the radio. 4. Remove the antenna mounting fasteners. 5. Cut each end of the cable (1) and leave remaining portion in the instrument panel. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Service and Repair > Page 5549 1. Position new antenna cable to wire harness. Secure into place. 2. Install antenna mounting fasteners. 3. Install radio. 4. Install instrument panel top cover. 5. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Diagrams Antenna Cable: Diagrams Antenna Cable - Satellite Radio No.1 Antenna Cable - Satellite Radio No.2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation Alarm Module: Description and Operation The Sentry Key Immobilizer Module (SKIM) (1) is the primary component of the Sentry Key Immobilizer System (SKIS). This module contains a Radio Frequency (RF) transceiver and a central processing unit, which includes the Sentry Key Immobilizer System (SKIS) program logic. The SKIM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKIM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKIM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKIM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKIM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKIM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. The Sentry Key Immobilizer Module (SKIM) transmits Radio Frequency (RF) signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKIM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKIM also communicates over the Programmable Communications Interface (PCI) data bus with the Powertrain Control Module (PCM) for gasoline engines or the Engine Control Module (ECM) for diesel engines, the ElectroMechanical Instrument Cluster (EMIC) and/or a diagnostic scan tool. The SKIM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKIM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKIM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKIM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKIM. For added system security, each SKIM is programmed with a unique Secret Key code. This code is stored in memory, sent over the PCI data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKIM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKIM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKIM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a PCI data bus message from the PCM or ECM during SKIS initialization. In the event that a SKIM replacement is required, the Secret Key code can be transferred to the new SKIM from the PCM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKIM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKIM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On or Start positions, the SKIM transmits an RF signal to excite the transponder in the ignition key. The SKIM then listens for a return RF signal from the transponder. If the SKIM receives an RF signal with a valid "Secret Key" and transponder identification codes, the SKIM sends a "valid key" message to the PCM/ECM over the PCI bus. If the SKIM receives an invalid RF signal or no response, it sends "invalid key" messages to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKIM messages. It is important to note that the default condition in the PCM or ECM is an invalid key. Therefore, if no message is received from the SKIM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 5558 The SKIM also sends electronic messages to the EMIC which control the VTSS indicator. The SKIM sends messages to the EMIC to turn the indicator on for about three seconds when the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKIM sends bus messages to keep the indicator off for a duration of about one second. Then the SKIM sends messages to turn the indicator on or off based upon the results of the SKIS self-tests. If the VTSS indicator comes on and stays on after the bulb test, it indicates that the SKIM has detected a system malfunction and/or that the SKIS has become inoperative. If the SKIM detects an invalid key when the ignition switch is turned to the On position, it sends messages to flash the VTSS indicator. The SKIM can also send messages to flash the indicator and to generate a single audible chime whenever the Customer Learn programming mode is being utilized. The SKIS will store fault information in the form of Diagnostic Trouble Codes (DTC's) in SKIM memory if a system malfunction is detected. For diagnosis or initialization of the SKIM and the PCM/ECM, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 5559 Alarm Module: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Grasp the tilt steering column knob (2) firmly and pull it straight rearward to remove it from the tilt adjuster lever (1) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 5560 8. Disconnect the wire harness connector (2) from the Sentry Key Immobilizer Module (SKIM) (1). 9. Remove the screw (3) that secures the SKIM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKIM. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 5561 1. Position the Sentry Key Immobilizer Module (SKIM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKIM to the steering column housing. Tighten the screw to 2 N.m (20 in.lbs.). 3. Reconnect the wire harness connector (2) to the SKIM (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 5562 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 N.m (20 in.lbs.) 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in.lbs.) 9. Align the tilt steering column knob (2) with the tilt adjuster lever (1) on the left side of the steering column and use hand pressure to snap it back into place. 10. Reconnect the battery negative cable. NOTE: If the SKIM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKIM and to program at least two Sentry Key transponders before the vehicle can be operated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation Alarm System Transponder: Description and Operation Each ignition key (4) used in the Sentry Key Immobilizer System (SKIS) has an integral transponder chip (2) concealed beneath the molded rubber cap (1), where it is secured within a plastic mount in the head (3) of the metal key. In addition to having to be cut to match the mechanical coding of the ignition lock cylinder, each new Sentry Key has a unique transponder identification code that is permanently programmed into it by the manufacturer, and which must be programmed into the Sentry Key Immobilizer Module (SKIM) to be recognized as a valid key. The Sentry Key transponder cannot be adjusted or repaired. If faulty or damaged, the entire key and transponder unit must be replaced. When the ignition switch is turned to the On position, the Sentry Key Immobilizer Module (SKIM) communicates through its antenna with the Sentry Key transponder using a Radio Frequency (RF) signal. The SKIM then listens for a RF response from the transponder through the same antenna. The Sentry Key transponder chip is within the range of the SKIM transceiver antenna ring when it is inserted into the ignition lock cylinder. The SKIM determines whether a valid key is present in the ignition lock cylinder based upon the response from the transponder. If a valid key is detected, that fact is communicated by the SKIM to the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus, and the PCM allows the engine to continue running. If the PCM receives an invalid key message, or receives no message from the SKIM over the PCI data bus, the engine will be disabled after about two seconds of operation. The ElectroMechanical Instrument Cluster (EMIC) will also respond to the invalid key message on the PCI data bus by flashing the security indicator on and off. Each Sentry Key has a unique transponder identification code permanently programmed into it by the manufacturer. Likewise, the SKIM has a unique Secret Key code programmed into it by the manufacturer. When a Sentry Key is programmed into the memory of the SKIM, the SKIM stores the transponder identification code from the Sentry Key, and the Sentry Key learns the Secret Key code from the SKIM. Once the Sentry Key learns the Secret Key code of the SKIM, it is permanently stored in the memory of the transponder. Therefore, once a Sentry Key has been programmed to a particular vehicle, it cannot be used on any other vehicle. The SKIS performs a self-test each time the ignition switch is turned to the On position, and will store key-related fault information in the form of Diagnostic Trouble Code (DTC) in SKIM memory if a Sentry Key transponder problem is detected. The Sentry Key transponder chip can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations RKE Module Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 5570 Module-Sentry Key Immobilizer (SKIM) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 5571 Keyless Entry Module: Description and Operation When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 5572 Keyless Entry Module: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 5573 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster. 3. Remove remote keyless entry module (2) from instrument cluster (1). INSTALLATION 1. Install remote keyless entry module (2) to instrument cluster (1). 2. Install instrument cluster. 3. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Testing and Inspection Keyless Entry Transmitter Battery: Testing and Inspection NOTE: Do not disturb the metal terminal near the batteries. Avoid touching the new batteries. Skin oils may cause battery deterioration. If batteries are touched, clean with rubbing alcohol. The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a thin coin, gently pry at the notch in the center seam of the RKE transmitter case halves near the key ring until the two halves unsnap. Be careful not to damage the rubber gasket when separating the case halves. 2. Lift the back half of the transmitter case off of the RKE transmitter. 3. Remove the two batteries from the RKE transmitter. 4. Replace the two batteries with new 3V lithium 2016 cell. Install the batteries with the positive terminal up. Reference the "+ SIDE UP" on the inside of the bottom half of the transmitter case. 5. Align the two RKE transmitter case halves with each other, and squeeze them firmly and evenly together until they snap back into place. Test transmitter operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams Switch-Cylinder Lock-Driver (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 A security indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional Vehicle Theft Security System (VTSS), this indicator is electronically disabled. This indicator is located in the lower right quadrant of the instrument cluster, between the speedometer and the coolant temperature gauge. The security indicator consists of a small round cutout in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The security indicator is serviced as a unit with the instrument cluster. The security indicator gives an indication to the vehicle operator when the Vehicle Theft Security System (VTSS) is arming or is armed. On models equipped with the Sentry Key Immobilizer System (SKIS), the security indicator also gives an indication to the vehicle operator of the status of the SKIS. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, hard wired inputs to the cluster from the various security system components, electronic messages received by the cluster from the Remote Keyless Entry (RKE) module over a dedicated serial bus, and electronic messages received by the cluster from the Sentry Key Immobilizer Module (SKIM) over the Programmable Communications Interface (PCI) data bus. The security indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused B(+) circuit. Therefore, the LED can be illuminated regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. Depending upon the programmed condition he indicator can be illuminated solid, flashed at a slow rate (0.5 Hertz, 12.5 percent duty cycle), or flashed at a fast rate (1 Hertz, 50 percent duty cycle). The instrument cluster will turn on the security indicator for the following reasons: Bulb Test - On vehicles equipped with the optional SKIS, each time the ignition switch is turned to the On position the SKIM tells the cluster to illuminate the security indicator for about two seconds as a bulb test. - VTSS Indication - During the sixteen second VTSS arming function, the cluster will flash the security indicator on and off repeatedly at a steady, fast rate to indicate that the VTSS is in the process of arming. Following successful VTSS arming, the cluster flashes the security indicator on and off continuously at a slower rate to indicate that the VTSS is armed. The security indicator continues flashing at the slower rate until the VTSS is disarmed or triggered. The security indicator will also flash at the fast rate to indicate that the VTSS has been triggered and is currently alarming. If the VTSS has alarmed until the alarm timed out and then rearmed itself, the cluster will flash the security indicator at a steady, slow rate for about thirty seconds after the VTSS is disarmed. - SKIS Lamp-On Message - Each time the cluster receives a lamp-on message from the SKIM, the security indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the SKIM message. The indicator remains illuminated solid or continues to flash until the cluster receives a SKIS lamp-off message from the SKIM, or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - On vehicles equipped with the optional SKIS, if the cluster receives no SKIS lamp-on or lamp-off messages from the SKIM for twenty consecutive seconds, the security indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid SKIS lamp-on or lamp-off message is received from the SKIM. - Actuator Test - Each time the instrument cluster is put through the actuator test, the security indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The instrument cluster circuitry controls the security indicator whenever the ignition switch is in the Off position and the VTSS is arming, armed, or alarming. Whenever the ignition switch is in the On or Start positions, the SKIM performs a self-test to decide whether the SKIS is in good operating condition and whether a valid key is present in the ignition lock cylinder. The SKIM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For further diagnosis of the security indicator or the instrument cluster circuitry that controls the indicator, refer to testing. If the instrument cluster flashes the security indicator upon ignition On, or turns on the security indicator solid after the bulb test, it indicates that a SKIS malfunction has occurred or that the SKIS is inoperative. For proper diagnosis of the VTSS, the SKIS, the SKIM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the security indicator, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Transceiver > Component Information > Diagrams Receiver-Satellite Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Transceiver > Component Information > Diagrams > Page 5588 Cellular Phone Transceiver: Description and Operation The satellite receiver for the regular cab is located behind the center seat on the floor. The satellite receiver for the quad cab is located in the right rear corner of the cab, on the floor. The satellite receiver module receives signals from the roof mounted antenna and processes this information before it is sent to the radio. The module operates on both battery feed circuits and CAN bus messages. It will operate with the ignition key in the run or accessory position only. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Transceiver > Component Information > Service and Repair > Regular Cab Cellular Phone Transceiver: Service and Repair Regular Cab REMOVAL NOTE: If the owner s satellite service was active before the satellite receiver module was replaced the new satellite receiver module will have to be activated. The existing satellite receiver module will have to be deactivated before the replacement satellite receiver module can be activated. To activate Sirius satellite radio service, call Sirius at their toll-free number. Please have the following information available when activating a system: - Electronic Serial Number/Sirius Identification Number (ESN/SID) of the unit to be replaced - ESN/SID of the replacement receiver - Vehicle Owner's name and address - VIN The ESN/SID number can be obtained through the radio display by following the steps in the satellite radio. The vehicle must be outside with the audio system powered on, in the satellite radio mode, to receive the activation signal. 1. Disconnect and isolate the battery negative cable. 2. Place front passenger seat in the forward position. 3. Remove the mounting fasteners. 4. Disconnect the antenna cable and electrical harness connectors. 5. Remove the satellite receiver. INSTALLATION NOTE: If the owner s satellite service was active before the satellite receiver was replaced, the new satellite receiver will have to be activated. The existing satellite receiver will have to be deactivated before the replacement satellite receiver can be activated. To activate Sirius satellite radio service, call Sirius at their toll-free number. Please have the following information available when activating a system: - Electronic Serial Number/Sirius Identification Number (ESN/SID) of the unit to be replaced - ESN/SID of the replacement receiver - Vehicle Owner's name and address - VIN The ESN/SID number can be obtained through the radio display by following the steps in the satellite radio. The vehicle must be outside with the audio system powered on, in the satellite radio mode, to receive the activation signal. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Transceiver > Component Information > Service and Repair > Regular Cab > Page 5591 1. Connect antenna cable and electrical harness connector to receiver. 2. Position module and install mounting fasteners. Tighten fasteners. 3. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Transceiver > Component Information > Service and Repair > Regular Cab > Page 5592 Cellular Phone Transceiver: Service and Repair Quad Cab REMOVAL NOTE: If the owner's satellite service was active before the satellite receiver module was replaced the new satellite receiver module will have to be activated. The existing satellite receiver module will have to be deactivated before the replacement satellite receiver module can be activated. To activate Sirius satellite radio service, call Sirius at their toll-free number. Please have the following information available when activating a system: - Electronic Serial Number/Sirius Identification Number (ESN/SID) of the unit to be replaced - ESN/SID of the replacement receiver - Vehicle Owner's name and address - VIN The ESN/SID number can be obtained through the radio display by following the steps in the satellite radio. The vehicle must be outside with the audio system powered on, in the satellite radio mode, to receive the activation signal. 1. Disconnect and isolate the battery negative cable. 2. Remove the mounting fasteners. 3. Disconnect the antenna cable and electrical harness connectors. 4. Remove the satellite receiver. INSTALLATION NOTE: If the owner's satellite service was active before the satellite receiver was replaced, the new satellite receiver will have to be activated. The existing satellite receiver will have to be deactivated before the replacement satellite receiver can be activated. To activate Sirius satellite radio service, call Sirius at their toll-free number. Please have the following information available when activating a system: - Electronic Serial Number/Sirius Identification Number (ESN/SID) of the unit to be replaced - ESN/SID of the replacement receiver - Vehicle Owner's name and address - VIN The ESN/SID number can be obtained through the radio display by following the steps in the satellite radio. The vehicle must be outside with the audio system powered on, in the satellite radio mode, to receive the activation signal. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Transceiver > Component Information > Service and Repair > Regular Cab > Page 5593 1. Connect antenna cable and electrical harness connector to receiver. 2. Position receiver and install mounting fasteners. Tighten fasteners. 3. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5598 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5599 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5600 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5601 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5602 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5603 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5604 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5605 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5606 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5607 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5608 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5609 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5610 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5611 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5612 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5613 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5614 Driver/Vehicle Information Display: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5615 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5616 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5617 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5618 Module-Electronic Overhead (Except Base) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 5619 EOM System Schematic Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console Driver/Vehicle Information Display: Description and Operation Overhead Console An overhead console is available on this vehicle and includes the following components: - Front map/reading lamps - A blue-green vacuum-fluorescent display screen - if equipped with trip computer - Universal transmitter - if equipped - Electronic Overhead Module (EOM) The overhead console assembly is mounted by two snap clips and screws securing it to a molded plastic retainer bracket located above the headliner. The EOM is accessed by removing the overhead console from the bracket and pulling it away from the headliner. COMPASS DISPLAY All the available overhead consoles on this model include Compass information. While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle at 5 to 8 kilometers-per-hour (3 to 5 miles-per-hour), on level ground in a square shaped pattern. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the vehicle roof should become magnetized, the demagnetizing procedure may be required to restore proper compass operation. TEMPERATURE DISPLAY All the available overhead consoles on this model include Temperature information. The temperature displays the outside ambient temperature in whole degrees. The temperature display can be toggled from Fahrenheit to Celsius by selecting the desired U.S./Metric option from the customer programmable features. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the temperature display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. When the ignition switch is turned to the Off position, the last displayed temperature reading stays in the electronic control modules, (CMTC, EVIC) memory. When the ignition switch is turned to the On position again, the electronic module will display the memory temperature for one minute; then update the display to the current average temperature reading within five minutes. The temperature function is supported by an ambient temperature sensor. This sensor is mounted outside the passenger compartment near the front and center of the vehicle, and is hard wired to the Front Control Module (FCM). The FCM sends temperature status messages to the module over the Programmable Communications Interface (PCI) data bus circuit. For more information on the ambient temperature sensor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console > Page 5622 Driver/Vehicle Information Display: Description and Operation Universal Transmitter The universal transmitter transceiver is integral to the overhead console (7). The only visible component of the universal transmitter are the three transmitter push buttons (3). The buttons are marked with one, two or three dots, respectively, for identification of each channel. Each of the three universal transmitter push buttons controls an independent radio transmitter channel. Each of these three channels can be trained to transmit a different radio frequency signal for the remote operation of garage door openers, motorized gate openers, home or office lighting, security systems or just about any other device that can be equipped with a radio receiver in the 286 to 399 MegaHertz (MHz) frequency range for remote operation. The universal transmitter is capable of operating systems using either rolling code or non-rolling code technology. The universal transmitter cannot be repaired, and is available for service only as part of the Electronic Overhead Module (EOM). This unit includes the push button switches for both the transmitter and compass mini trip computer. The universal transmitter operates on a non-switched source of battery current so the unit will remain functional, regardless of the ignition switch position. It can learn and store three separate transmitter radio frequency codes to operate garage door openers, security gates and security lighting. The overhead console display provides visual feedback to the driver, showing which transmitter button is pressed. The system will not send operating signals if the vehicle theft security alarm is armed. This prevents a perpetrator from breaking into a vehicle parked outside a home and using the transmitter system to enter the home. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Overhead Console Driver/Vehicle Information Display: Testing and Inspection Overhead Console If the problem with the overhead console is an inaccurate or scrambled display, refer to SELFDIAGNOSTIC TEST. If the problem with the overhead console is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a scan tool and the proper Diagnostic Procedures Information to test for the correct dimming message inputs being received from the Body Control Module (BCM) or Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus circuit. If the problem is a no-display condition, use the following procedure. For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the overhead console from the headliner. 2. Check for battery voltage at the overhead console electrical connector. If OK, go to Step 3. If not OK, Check for battery voltage at the appropriate B(+) fuse in the Integrated Power Module (IPM), repair the open fused B(+) circuit as required. 3. Turn the ignition switch to the On position. Check the fused ignition switch output circuit(s) at the overhead console electrical connector. If OK, go to Step 4. If not OK, repair the open or shorted circuit as required. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the overhead console electrical connector and a good ground. There should be continuity. If OK, refer to SELF- DIAGNOSTIC TEST for further diagnosis of the electronics module and the PCI data bus circuit. If not OK, repair the open ground circuit as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Overhead Console > Page 5625 Driver/Vehicle Information Display: Testing and Inspection Self-Diagnostic Test A self-diagnostic test is used to determine that the EOM is operating properly electrically. Initiate the self-diagnostic test as follows: NOTE: The compass mini-trip computer self - test can also be performed using a scan tool. Refer to Auto Self Test under the System Tests. 1. With the ignition switch in the Off position, simultaneously depress and hold the STEP and RESET buttons while rotating the ignition switch to the Run/On position. 2. Continue to hold both buttons depressed until the EOM enters the display segment test. In this test, all of the Vacuum Fluorescent Display (VFD) segments are lighted while the EOM performs the following checks: Non-Volatile Memory Status (NVM) - RAM Status - ROM Status - ASIC Communication Test Status - Compass Test Status - DC Status - PCI data bus Communications Test NOTE: If module is equipped with the Universal Transmitter, the module also checks "Universal Transmitter Communication Test Status" 3. Following completion of these tests, the compass mini-trip computer will display one of two messages: "FAIL" or "PASS." Press RESET or STEP to exit and enter normal mode. Respond to these test results as follows: If no test result message is displayed, but compass mini-trip computer operation is still improper, the use of a scan tool and the proper Diagnostic Procedures Information are required for further diagnosis. - If the "FAIL" message is displayed, the EOM is inoperative and must be replaced. - If the "PASS" message is displayed, the EOM is OK, no faults are present. - If any VFD segment does not light during the display segment test, the EOM is inoperative and must be replaced. 4. If the first seven tests pass, the compass mini-trip computer shall verify that all the required PCI bus messages are present on the PCI bus. If all required messages are present on the PCI bus, or if the ignition switch is turned to the Off position, the EOM will automatically return to normal operation. The required PCI bus messages are: Dimming message - Fuel Used message - Distance Pulses message - Percentage Fuel Tank Full message - Fuel Type message - VIN (Vehicle Identification Number) - Vehicle Speed message - Last Engine Off Duration message - Ambient Air Temperature message NOTE: - The Fuel Used message shall be ignored if the engine type is Diesel or Compressed Natural Gas. - Pressing the STEP or RESET switches during any portion of the testing procedure will cause the compass mini-trip computer to exit diagnostics and return to compass/temperature mode. - If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. - If the compass reading has blanked out, and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Overhead Console > Page 5626 Driver/Vehicle Information Display: Testing and Inspection Universal Transmitter Radio Frequency Detector #9001 If both the Transmitter and the compass mini trip computer display are inoperative, refer to testing for further diagnosis. If the Universal Transmitter is inoperative, but the compass mini trip computer display is operating normally. Retrain the Transmitter with a known good transmitter as instructed and test the Transmitter operation again. If the unit is still inoperative, test the universal transmitter with the Radio Frequency Detector special tool as described below: 1. Turn the Radio Frequency (RF) Detector ON. A "chirp" will sound and the green power LED will light. If the green LED does not light, replace the battery. 2. Hold the RF detector within one inch of the TRAINED universal transmitter and press any of the transmitters buttons. 3. The red signal detection LEDs will light and the tool will beep if a radio signal is detected. Repeat this test for each button. If any button is inoperative, replace the universal transmitter assembly. For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement Driver/Vehicle Information Display: Service and Repair Module Lens Replacement 1. Remove the overhead console. 2. Remove the electronic overhead module from the overhead console. 3. Unsnap the lens from the module and replace lens as necessary. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 5629 Driver/Vehicle Information Display: Service and Repair Overhead Console REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console retaining screws, located in the sunglass storage bin. 3. Using your fingertips, grasp the sides of the overhead console and pull straight down evenly to disengage the two snap clips at the front of the unit. 4. Lower the overhead console far enough to access the wire harness connectors. 5. Disconnect the Electronic Overhead Module and the reading/courtesy lamps electrical connectors. 6. Remove the overhead console from the vehicle. INSTALLATION 1. Position the overhead console in the vehicle. 2. Connect the Electronic Overhead Module and the reading/courtesy lamps electrical connectors. 3. Grasp the sides of the overhead console and push straight up evenly to engage the two snap clips at the rear of the unit. 4. Install the overhead console retaining screws, located in the sunglass storage bin. Torque the screws to 1.2 N.m (10 in.lbs.). 5. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 5630 Driver/Vehicle Information Display: Service and Repair Module Lamp Replacement 1. Remove the overhead console. 2. Using a flat blade screwdriver twist out socket/lamp (3). 3. Replace lamp(s) as necessary. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 5631 Driver/Vehicle Information Display: Service and Repair Programming Transmitter Codes CAUTION: - Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the transceiver. Exhaust gas can cause serious injury or death. - Your motorized door or gate will open and close while you are training the Universal Transceiver. Do not train the transceiver if people or pets are in the path of the door or gate. A moving door or gate can cause serious injury or death to people and pets or damage to objects. 1. Press and hold the two outer HomeLink buttons, and release only when the EVIC display shows "Channels Cleared" (after 20 seconds). Do not hold the buttons for longer than 30 seconds and do not repeat step one to program a second and/or third hand-held transmitter to the remaining two HomeLink buttons. 2. Position the end of your hand-held transmitter 1-3 inches (3-8 cm) away from the HomeLink buttons. 3. Simultaneously press and hold both the HomeLink button that you want to train and the hand-held transmitter buttons. Do not release the buttons until step 4 has been completed. 4. The EVIC display will show "Channel X Training" (where X is Channel 1, 2, or 3). Release both buttons after the EVIC display shows "Channel X Trained". NOTE: If the EVIC display shows "Did Not Train" repeat steps 2-4. 5. Press and hold the just trained HomeLink button and observe the EVIC display. If the EVIC display shows "Channel X Transmit" (where X is Channel 1, 2, or 3), programming is complete and your device should activate when the HomeLink button is pressed and released. NOTE: To program the remaining two HomeLink buttons, begin with "Programming" step two. Do not repeat step one. - If your hand-held transmitter appears to program the universal transceiver, but your garage door does not operate using the transmitter and your garage door opener was manufactured after 1995, your garage door opener may have a multiple security code system (rolling code system). Please proceed to steps 6-8 to complete the programming of a rolling code equipped device (most common garage door openers require this step. 6. At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. 7. Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) NOTE: There are 30 seconds in which to initiate step eight. 8. Return to the vehicle and firmly press, hold for two seconds and release the programmed HomeLink button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming. 9. HomeLink should now activate your rolling code equipped device. 10. To program the remaining two HomeLink buttons, begin with "Programming" step two. Do not repeat step one. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 5632 Driver/Vehicle Information Display: Service and Repair Module Lens Replacement 1. Remove the overhead console. 2. Remove the electronic overhead module from the overhead console. 3. Unsnap the lens from the module and replace lens as necessary. Overhead Console REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console retaining screws, located in the sunglass storage bin. 3. Using your fingertips, grasp the sides of the overhead console and pull straight down evenly to disengage the two snap clips at the front of the unit. 4. Lower the overhead console far enough to access the wire harness connectors. 5. Disconnect the Electronic Overhead Module and the reading/courtesy lamps electrical connectors. 6. Remove the overhead console from the vehicle. INSTALLATION 1. Position the overhead console in the vehicle. 2. Connect the Electronic Overhead Module and the reading/courtesy lamps electrical connectors. 3. Grasp the sides of the overhead console and push straight up evenly to engage the two snap clips at the rear of the unit. 4. Install the overhead console retaining screws, located in the sunglass storage bin. Torque the screws to 1.2 N.m (10 in.lbs.). 5. Connect the battery negative cable. Module Lamp Replacement 1. Remove the overhead console. 2. Using a flat blade screwdriver twist out socket/lamp (3). 3. Replace lamp(s) as necessary. Programming Transmitter Codes CAUTION: - Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the transceiver. Exhaust gas can cause serious injury or death. - Your motorized door or gate will open and close while you are training the Universal Transceiver. Do not train the transceiver if people or pets are in the path of the door or gate. A moving door or gate can cause serious injury or death to people and pets or damage to objects. 1. Press and hold the two outer HomeLink buttons, and release only when the EVIC display shows "Channels Cleared" (after 20 seconds). Do not hold the buttons for longer than 30 seconds and do not repeat step one to program a second and/or third hand-held transmitter to the remaining two HomeLink buttons. 2. Position the end of your hand-held transmitter 1-3 inches (3-8 cm) away from the HomeLink buttons. 3. Simultaneously press and hold both the HomeLink button that you want to train and the hand-held transmitter buttons. Do not release the buttons Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 5633 until step 4 has been completed. 4. The EVIC display will show "Channel X Training" (where X is Channel 1, 2, or 3). Release both buttons after the EVIC display shows "Channel X Trained". NOTE: If the EVIC display shows "Did Not Train" repeat steps 2-4. 5. Press and hold the just trained HomeLink button and observe the EVIC display. If the EVIC display shows "Channel X Transmit" (where X is Channel 1, 2, or 3), programming is complete and your device should activate when the HomeLink button is pressed and released. NOTE: To program the remaining two HomeLink buttons, begin with "Programming" step two. Do not repeat step one. - If your hand-held transmitter appears to program the universal transceiver, but your garage door does not operate using the transmitter and your garage door opener was manufactured after 1995, your garage door opener may have a multiple security code system (rolling code system). Please proceed to steps 6-8 to complete the programming of a rolling code equipped device (most common garage door openers require this step. 6. At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. 7. Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) NOTE: There are 30 seconds in which to initiate step eight. 8. Return to the vehicle and firmly press, hold for two seconds and release the programmed HomeLink button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming. 9. HomeLink should now activate your rolling code equipped device. 10. To program the remaining two HomeLink buttons, begin with "Programming" step two. Do not repeat step one. Erasing Transmitter Codes NOTE: Individual channels cannot be erased. Erasing the transmitter codes will erase ALL programmed codes. To erase programming from the three buttons (individual buttons cannot be erased but can be "reprogrammed"), follow the step noted: - Press and hold the two outer HomeLink buttons until the indicator light begins to flash-after 20 seconds. Release both buttons. Do not hold for longer that 30 seconds. HomeLink is now in the train (or learning) mode and can be programmed at any time beginning with "Programming. Reprogramming Transmitter Codes CAUTION: - Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the transceiver. Exhaust gas can cause serious injury or death. - Your motorized door or gate will open and close while you are training the Universal Transceiver. Do not train the transceiver if people or pets are in the path of the door or gate. A moving door or gate can cause serious injury or death to people and pets or damage to objects. To program a device to HomeLink using a HomeLink button previously trained, follow these steps: 1. Press and hold the desired HomeLink button. Do NOT release the button. 2. The EVIC display will show "Channel X Transmit" (where X is Channel 1, 2, or 3) for 20 seconds and then change to "Channel X Training". Without releasing the HomeLink button, proceed to step 3. 3. Position the end of your hand-held transmitter 1-3 inches (3-8 cm) away from the HomeLink buttons. 4. Simultaneously press and hold both the HomeLink button that you want to train and the hand-held transmitter buttons. Do not release the buttons until step 4 has been completed. 5. Press and hold the just trained HomeLink button and observe the EVIC display. If the EVIC display shows "Channel X Transmit" (where X is Channel 1, 2, or 3), programming is complete and your device should activate when the HomeLink button is pressed and released. NOTE: To program the remaining two HomeLink buttons, begin with "Programming" step two. Do not repeat step one. - If your hand-held transmitter appears to program the universal transceiver, but your garage door does not operate using the transmitter and your garage door opener was manufactured after 1995, your garage door opener may have a multiple security code system (rolling code system). Please proceed to steps 6-8 to complete the programming of a rolling code equipped device (most common garage door openers require this step. 6. At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. 7. Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) NOTE: There are 30 seconds in which to initiate step eight. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 5634 8. Return to the vehicle and firmly press, hold for two seconds and release the programmed HomeLink button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming. 9. HomeLink should now activate your rolling code equipped device. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Description and Operation Navigation System: Description and Operation TELECOMMUNICATIONS The hands-free cellular system on this vehicle uses Bluet tooth technology to provide wireless communication between the operator's compatible cellular telephone and the vehicle's on-board receiver. The system uses voice recognition technology to control operation. The incoming voice is broadcast through the vehicle's radio speakers, automatically overriding any other audio signals on the front speakers when the hands-free system is in use. A microphone in the rearview mirror picks up vehicle occupant's voices. If a call is in progress when the ignition is switched off, the hands-free system will continue to operate for up to 45 seconds as part of the Accessory Relay Delay function. Thereafter, the call can continue on the hand-held telephone. The system will communicate with a telephone that is anywhere within the vehicle. However, covering the hand held phone or the hands-free phone module with a metal object may block the signal. The system will recognize up to seven telephones, each of which is given a spoken identification by the user during the setup process. The system includes Spanish and French voice recognition in addition to English. Two buttons on the rearview mirror, identified with ISO icons, control the system: A "phone" button turns the system on and off; a "voice recognition" (or voice command) button prompts the hands-free system to listen for a voice command. Two buttons on the rearview mirror, identified with ISO icons, control the system: A "phone" button turns the system on and off; a "voice recognition" (or voice command) button prompts the hands-free system to listen for a voice command. The system includes the following features: - Phone book - Stores telephone numbers for later recall by name or other verbal identification, called a voice tag, and memory location. - Four memory locations - Home, Work, Cellular and Pager. A maximum of 32 unique names or voice tags may be stored at the same time, with a different number in each of the four memory locations. - Voice tag dialing - Dials the number associated with a voice tag and memory location. - Digit dialing - Dials the telephone number by recognizing the names of the digits as they are spoken. - Receiving calls - A voice prompt notifies the user of an incoming call. A voice response accepts or rejects the call without manual intervention. - Privacy Mode - Switches the call to the handheld telephone and the hands-free system and back again using the "voice recognition" (or "voice command") button and a voice command, if desired. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Description and Operation > Page 5638 Navigation System: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel right side end cap. 3. Remove the mounting fasteners. 4. Disconnect the electrical harness connector and remove module. INSTALLATION 1. Connect the electrical harness connector and position module. 2. Install and tighten the mounting fasteners. 3. Install the instrument panel right side end cap. 4. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations Left Steering Column Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 5643 Motor-Adjustable Pedals (Except Base) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 5644 Pedal Positioning Motor: Description and Operation MOTOR - ADJUSTABLE PEDALS DESCRIPTION The Adjustable Pedals System (APS) is designed to enable the fore and aft repositioning of the brake and accelerator pedals. This results in improved ergonomics in relation to the steering wheel for taller and shorter drivers. Being able to adjust the pedal positions also allows the driver to set steering wheel tilt and seat position to the most comfortable position. The position of the brake and accelerator pedals can be adjusted without compromising safety or comfort in actuating the pedals. Change of pedal position is accomplished by means of a motor driven screw. Operating the adjustable pedal switch activates the pedal drive motor (1). The pedal drive motor turns a screw that changes the position of the brake and accelerator pedals. The pedal can be moved rearward (closer to the driver) or for ward (away from driver). The brake pedal is moved on its drive screw to a position where the driver feels most comfortable. The accelerator pedal is moved at the same time and the same distance as the brake pedal. Neither the pedal drive motor (1) nor drive mechanism are subject to the mechanical stress of brake or accelerator application. - SYSTEM FEATURES: Range of Adjustment: The pedals may be adjusted up to 3 inches (75 mm) - Pedal Adjustment Speed: 0.5 inch/seconds (12.5 mm/seconds) - Pedal Adjustment Inhibitors: Pedal adjustment is inhibited when the vehicle is in reverse or when cruise control is activated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 5645 Pedal Positioning Motor: Service and Repair MOTOR - ADJUSTABLE PEDALS REMOVAL 1. Disconnect the negative battery cable. 2. Remove the kneeblocker. 3. Remove the brake light switch and discard. 4. Disconnect the adjustable pedal cables from the brake and accelerator pedals Also clutch pedal if equipped with a manual transmission. 5. Disconnect the electrical connector. 6. Unclip the cable fasteners to the support. 7. Remove the one mounting bolt (2) for the adjustable pedal motor (1). 8. Remove the adjustable pedal motor (1) with the cables. NOTE: Adjustable pedal cables are not serviceable. If they need service the adjustable pedal motor with the cables must be installed. INSTALLATION NOTE: Adjustable pedal cables are not serviceable. If they need service the adjustable pedal motor with the cables must be installed. 1. Install the adjustable pedal motor (1) with the cables. 2. Install the one mounting bolt (2) for the adjustable pedal motor (1). 3. Clip the cable fasteners to the support. 4. Reconnect the electrical connector. 5. Reconnect the adjustable pedal cables to the brake and accelerator pedals Also clutch pedal if equipped with a manual transmission. 6. Install the new brake light switch. 7. Install the kneeblocker. 8. Reconnect the negative battery cable. 9. Check for proper operation of the pedals. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 5652 Left Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 5653 Starter-Adjustable Pedals (Except Base) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 5654 Pedal Positioning Switch: Service and Repair BASE BRAKES SWITCH-ADJUSTABLE PEDALS REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Technical Service Bulletins > Customer Interest for Amplifier: > 08-002-06 > Jan > 06 > Audio System - Crackle/Pop/Static Noise From Speakers Amplifier: Customer Interest Audio System - Crackle/Pop/Static Noise From Speakers NUMBER: 08-002-06 GROUP: Electrical DATE: January 12, 2006 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL JANUARY 30, 2005. SUBJECT: Crackle/pop/Static From Audio System OVERVIEW: This bulletin involves replacing the 2 channel Audio Amplifier (AMP) and 8 channel AMP. MODELS: 2004-2005 (DR) Ram Truck SRT10 SYMPTOM/CONDITION: Crackle, pop, and static sounds heard from subwoofer speaker (most noticeable at key-on). Also reduced subwoofer output is possible. DIAGNOSIS: If the vehicle operator describes the Symptom(s) above, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Use the procedures outlined in TechCONNECT 8-Electrical/Audio/Amplifier/Removal/Installation to replace the center seat mounted 2 channel audio amplifier and instrument panel mounted 8 channel amplifier. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Amplifier: > 08-002-06 > Jan > 06 > Audio System - Crackle/Pop/Static Noise From Speakers Amplifier: All Technical Service Bulletins Audio System - Crackle/Pop/Static Noise From Speakers NUMBER: 08-002-06 GROUP: Electrical DATE: January 12, 2006 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL JANUARY 30, 2005. SUBJECT: Crackle/pop/Static From Audio System OVERVIEW: This bulletin involves replacing the 2 channel Audio Amplifier (AMP) and 8 channel AMP. MODELS: 2004-2005 (DR) Ram Truck SRT10 SYMPTOM/CONDITION: Crackle, pop, and static sounds heard from subwoofer speaker (most noticeable at key-on). Also reduced subwoofer output is possible. DIAGNOSIS: If the vehicle operator describes the Symptom(s) above, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Use the procedures outlined in TechCONNECT 8-Electrical/Audio/Amplifier/Removal/Installation to replace the center seat mounted 2 channel audio amplifier and instrument panel mounted 8 channel amplifier. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Technical Service Bulletins > Page 5669 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Technical Service Bulletins > Page 5670 Amplifier: Diagrams Amplifier - Radio C1 (Premium) Amplifier - Radio C2 (Premium) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Technical Service Bulletins > Page 5671 Amplifier - Subwoofer (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Technical Service Bulletins > Page 5672 Amplifier: Description and Operation The optional Infinity premium speaker system includes a separate Infinity audio power amplifier. The amplifier is an eight-channel unit rated at 368 total output watts. The amplifier is located behind the glove box. If equipped, an additional amplifier rated at 140 watts is located under the center passenger seat. The power amplifier electronically increases the frequency response of the normal audio signal output from the radio amplifier in order to improve the acoustic performance of the speakers. On vehicles equipped with an amplifier, the amplifier section of the radio becomes a pre-amplifier. The amplifier receives audio signal inputs for speaker channels from the radio, then sends amplified audio outputs through six separate channels with dedicated feed and return circuits to the individual speakers. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair > Instrument Panel Mounted Amplifier: Service and Repair Instrument Panel Mounted REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove glove box. 3. Remove instrument panel center bezel. 4. Remove instrument panel lower right center bezel. 5. Disconnect electrical harness connector (4) from amplifier (2) 6. Remove mounting bolts (3) and amplifier. INSTALLATION 1. Connect electrical harness connector (4) and install amplifier (2). 2. Install and tighten mounting bolts (3). 3. Install instrument panel lower right center bezel. 4. Install instrument panel center bezel. 5. Install glove box. 6. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair > Instrument Panel Mounted > Page 5675 Amplifier: Service and Repair Center Seat Mounted REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Raise center seat cushion to access amplifier. 3. Remove mounting fasteners. 4. Disconnect electrical harness connector and remove amplifier. INSTALLATION 1. Connect electrical harness connector and position amplifier. 2. Install and tighten mounting fasteners. 3. Lower center seat. 4. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Technical Service Bulletins > Audio System - CD Changer Operation/Features CD Changer: Technical Service Bulletins Audio System - CD Changer Operation/Features NUMBER: 08-008-03 GROUP: Electrical DATE: Apr. 11, 2003 SUBJECT: Compact Disc (CD) Loading & Ejecting for 6 Disc Radio (Sales Code RBQ) MODELS: 2003 - 2004 (AN) Dakota 2003 (DN) Durango 2003 - 2004 (DR) Ram Truck 2003 - 2004 (KJ) Liberty 2003 - 2004 (PT) PT Cruiser 2004 (RS) Town & Country/Caravan/Voyager 2003 - 2004 (ZB) Viper NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 6 DISC CD CHANGER WITHIN THE RADIO (SALES CODE RBQ). NOTE: THIS INFORMATION SHOULD BE REVIEWED WITH THE CUSTOMER AT THE TIME OF VEHICLE DELIVERY. CAUTION: THIS CD PLAYER WILL ACCEPT 120 MM (4314 IN.) DISCS ONLY. THE USE OF OTHER SIZED DISCS MAY DAMAGE THE CD PLAYER MECHANISM. DISCUSSION: LOADING/EJECTING CD'S LOADING A CD Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Technical Service Bulletins > Audio System - CD Changer Operation/Features > Page 5681 Press the LOAD/EJT button and the preset button (1 through 6) corresponding to the position number where the CD is to be loaded (Fig. 1). After the radio displays "load" insert the CD into the CD slot. Radio display will show "loading" while the CD is being loaded. EJECTING A CD Press the LOAD/EJT button and the preset button (1 through 6) corresponding to the position number where the CD is loaded and the CD will unload and move to the CD slot for easy removal (Fig. 1). Radio display will show "ejecting" while it is being ejected. ADDITIONAL INFORMATION You may either load or eject CD's with the radio and ignition OFF using the procedure above. If the CD player is empty, while the ignition is in the ACCY. or RUN position, if a CD is inserted into the CD slot it will automatically be loaded into one of the 6 positions. This will only occur for the first CD loaded into an empty CD player. If you load a CD with the ignition ON and the radio OFF, the display will show the time of day. If you load a CD with the ignition OFF, the display will show the time of day for about 5 seconds, then go out. If you load a CD with the ignition ON and the radio ON, the unit will switch from radio mode to CD mode and begin to play the CD being loaded. The display will show the CD number, the track number, and index time in minutes and seconds. Play will begin at the start of track 1. If you have ejected a CD and have not removed it from the CD slot within 15 seconds, it will be reloaded. If the CD is reloaded, the radio will begin to play the reloaded CD. If the CD is removed from the CD slot and there are other CD's in the radio, the radio will play the next CD. If the CD is removed and there are no other CD's in the radio, the radio will return to AM or FM mode whichever was previously in use. POLICY: Information Only. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Description and Operation Radio/Stereo Noise Filter: Description and Operation Radio noise suppression devices are Installed on this vehicle. Radio Frequency Interference (RFI) and ElectroMagnetic Interference (EMI) can be produced by any on-board or external source of electromagnetic energy. These electromagnetic energy sources can radiate electromagnetic signals through the air, or conduct them through the vehicle electrical system. When the audio system converts RFI or EMI to an audible acoustic wave form, it is referred to as radio noise. This undesirable radio noise is generally manifested in the form of "buzzing," "hissing," "popping," "clicking," "crackling," and/or "whirring" sounds. In most cases, RFI and EMI radio noise can be suppressed using a combination of vehicle and component grounding, filtering and shielding techniques. This vehicle is equipped with factory-installed radio noise suppression devices that were designed to minimize exposure to typical sources of RFI and EMI; thereby, minimizing radio noise complaints. Factory-installed radio noise suppression is accomplished primarily through circuitry or devices that are integral to the factory-installed radios, audio power amplifiers and other on-board electrical components such as generators, wiper motors, blower motors, and fuel pumps that have been found to be potential sources of RFI or EMI. External radio noise suppression devices that are used on this vehicle to control RFI or EMI, and can be serviced, include the following: - Engine-to-body ground strap - This length of braided ground strap has an eyelet terminal connector crimped to each end. One end is secured to the engine cylinder head(s). The other is secured to the plenum at the exhaust heat shield forward/outer attaching stud. - Resistor-type spark plugs - This type of spark plug has an internal resistor connected in series between the spark plug terminal and the center electrode to help reduce the production of electromagnetic radiation that can result in radio noise. There are two common strategies that can be used to suppress Radio Frequency Interference (RFI) and Electro-Magnetic Interference (EMI) radio noise. The first suppression strategy involves preventing the production of RFI and EMI electromagnetic signals at their sources. The second suppression strategy involves preventing the reception of RFI and EMI electromagnetic signals by the audio system components. The use of braided ground straps in key locations is part of the RFI and EMI prevention strategy. These ground straps ensure adequate ground paths, particularly for high current components such as many of those found in the starting, charging, ignition, engine control and transmission control systems. An insufficient ground path for any of these high current components may result in radio noise caused by induced voltages created as the high current seeks alternative ground paths through components or circuits intended for use by, or in close proximity to the audio system components or circuits. Preventing the reception of RFI and EMI is accomplished by ensuring that the audio system components are correctly installed in the vehicle. Loose, corroded or improperly soldered wire harness connections, improperly routed wiring and inadequate audio system component grounding can all contribute to the reception of RFI and EMI. A properly grounded antenna body and radio chassis, as well as a shielded antenna coaxial cable with clean and tight connections will each help reduce the potential for reception of RFI and EMI. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Description and Operation > Page 5686 Radio/Stereo Noise Filter: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the attaching bolts and strap. INSTALLATION 1. Install the ground strap (3) and mounting fasteners (4). 2. Tighten mounting fasteners. 3. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations Steering Wheel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 5690 Remote Switch: Diagrams Switch-Remote Radio-Left Switch-Remote Radio-Right Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 5691 Remote Switch: Description and Operation Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). The six switches in the two remote radio switch units are normally open, resistor multiplexed momentary switches that are hard wired to the Integrated Power Module (IPM) through the clockspring. The IPM sends a five volt reference signal to both switch units on one circuit, and senses the status of all of the switches by reading the voltage drop on a second circuit. When the IPM senses an input (voltage drop) from any one of the remote radio switches, it sends the proper switch status messages on the Programmable Communication Interface (PCI) data bus network to the radio receiver. The electronic circuitry within the radio receiver is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the IPM or the PCI data bus, the use of a scan tool and the proper Diagnostic Procedures information is recommended. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 5692 Remote Switch: Testing and Inspection Any diagnosis of the Audio system should begin with the use of scan tool. For information on the use of the scan tool. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switch Test Table 3. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 4. If not OK, replace the faulty switch. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Check for 5 volts at the radio control MUX circuit cavities of the steering wheel wire harness connectors for both remote radio switches. If OK, go to Step 5. If not OK, repair the open or shorted radio control MUX circuit to the Integrated Power Module (IPM) as required. 5. Disconnect and isolate the battery negative cable. Disconnect the 22-way instrument panel wire harness connector from the IPM. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted remote radio switch ground circuit to the IPM as required. 6. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and the 22-way instrument panel wire harness connector for the IPM. There should be continuity. If OK, refer to the proper Diagnostic Procedures to test the IPM and the PCI data bus. If not OK, repair the open remote radio switch ground circuit as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 5693 Remote Switch: Service and Repair WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. 3. Remove the speed control switches (2). 4. Unplug the wire harness connector from the remote radio switch (1). 5. Depress the tabs on each side of each switch and push the switch through the rear steering wheel cover. INSTALLATION 1. Install remote radio switch (1) to the steering wheel. 2. Connect the wire harness to the remote radio switch. 3. Install the speed control switches (2). 4. Install the driver airbag. 5. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams Speaker: Diagrams Speaker-Instrument Panel-Center (Premium) Speaker-Instrument Panel-Left Speaker-Instrument Panel-Right Speaker-Left Front Door Speaker-Left Rear Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 5697 Speaker-Right Front Door Speaker-Right Rear Speaker-Subwoofer (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Standard Speaker: Description and Operation Standard The standard equipment speaker system includes speakers in four locations. One 15.2 X 22.8 centimeter (6X9 inch) full-range speaker is located in each front door. There is also one full-range 13.3 centimeter (5.25 inch) diameter full-range speaker located in each rear door (quad cab) or B-pillar (regular cab). Two wires connected to each speaker, one feed circuit (+) and one return circuit (-), allow the audio output signal electrical current to flow through the voice coil. For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Standard > Page 5700 Speaker: Description and Operation Premium The optional premium speaker system features eleven Premium model speakers in seven locations. Each of the standard speakers is replaced with Premium model speakers. One 8.8 centimeter (3.50 inch) diameter speaker is located on each end of the instrument panel top pad. One 6.3 centimeter (2.50 inch) diameter speaker is located in the center of the instrument panel top pad. One 15.2 X 22.8 centimeter (6X9 inch) Premium speaker is located in each front door. There is also one coaxial 13.3 centimeter (5.25 inch) diameter Premium full-range speaker located in each rear door (quad cab) or B-pillar (regular cab). The premium speaker system also includes a power amplifier mounted behind the glove box. The total available power of the premium speaker system is 368 watts. If equipped, a 25.4 centimeter (10 inch) subwoofer is located behind the center passenger seat along with a amplifier (rated at 150 watts) located under the center passenger seat. The total available power if equipped with the subwoofer and second power amplifier is 518 watts. Two wires connected to each speaker, one feed circuit (+) and one return circuit (-), allow the audio output signal electrical current to flow through the voice coil. For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Page 5701 Speaker: Testing and Inspection Any diagnosis of the Audio system should begin with the use of a scan tool. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 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 and/or amplifier may result. 1. If all speakers are inoperative, check the fuses in the Integrated Power Module (IPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check the amplifier fuse (if equipped) in the IPM. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 3. Turn the ignition switch to the ON position. Turn the radio receiver ON. Adjust the balance and fader control controls to check the performance of each individual speaker. Note the speaker locations that are not performing correctly Go to Step 4. 4. Turn the radio receiver OFF. Turn the ignition OFF. Disconnect and isolate the battery negative cable. If vehicle is not equipped with a amplifier, remove the radio receiver. If vehicle is equipped with an amplifier, disconnect wire harness connector at output side of amplifier. Go to Step 5. 5. Check both the speaker feed (+) circuit and return (-) circuit cavities for the inoperative speaker at the radio receiver wire harness connector for continuity to ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted speaker feed (+) and/or return (-) circuits(s) to the speaker as required. 6. Disconnect wire harness connector at the inoperative speaker. Check for continuity between the speaker feed (+) circuit cavities of the radio receiver wire harness connector or if equipped, the amplifier wire harness connector and the speaker wire harness connector. Repeat the check between the speaker return (-) circuit cavities of the radio receiver 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 speaker feed (+) and/or return (-) circuits(s) as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker Speaker: Service and Repair Front Door Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove front door trim panel. 3. Remove mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install front door trim panel. 4. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 5704 Speaker: Service and Repair Instrument Panel Center Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install instrument panel top cover. 4. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 5705 Speaker: Service and Repair Instrument Panel End Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install instrument panel top cover. 4. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 5706 Speaker: Service and Repair Rear Cab Side Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove B-pillar lower trim. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install B-pillar lower trim. 4. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 5707 Speaker: Service and Repair Front Door Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove front door trim panel. 3. Remove mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install front door trim panel. 4. Connect battery negative cable. Instrument Panel Center Speaker REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 5708 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install instrument panel top cover. 4. Connect battery negative cable. Instrument Panel End Speaker REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 5709 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install instrument panel top cover. 4. Connect battery negative cable. Rear Cab Side Speaker REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 5710 1. Disconnect and isolate the battery negative cable. 2. Remove B-pillar lower trim. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install B-pillar lower trim. 4. Connect battery negative cable. Rear Door Speaker REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 5711 1. Disconnect and isolate the battery negative cable. 2. Remove rear door trim panel. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install rear door trim panel 4. Connect battery negative cable. Subwoofer - Regular Cab REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 5712 1. Disconnect and isolate the battery negative cable. 2. Remove mounting fasteners to subwoofer housing. 3. Disconnect electrical harness connector. 4. Remove subwoofer from vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 5713 INSTALLATION 1. Position subwoofer housing into the vehicle. 2. Connect electrical harness connector. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 5714 3. Install mounting fasteners. 4. Connect battery negative cable. Subwoofer - Quad Cab REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Raise left rear seat to access subwoofer. 3. Disconnect electrical harness connector. 4. Remove mounting fasteners and remove subwoofer. INSTALLATION 1. Position subwoofer to vehicle. 2. Connect electrical harness connector. 3. Install and tighten mounting fasteners. 4. Lower seat. 5. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation Alarm Module: Description and Operation The Sentry Key Immobilizer Module (SKIM) (1) is the primary component of the Sentry Key Immobilizer System (SKIS). This module contains a Radio Frequency (RF) transceiver and a central processing unit, which includes the Sentry Key Immobilizer System (SKIS) program logic. The SKIM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKIM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKIM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKIM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKIM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKIM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. The Sentry Key Immobilizer Module (SKIM) transmits Radio Frequency (RF) signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKIM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKIM also communicates over the Programmable Communications Interface (PCI) data bus with the Powertrain Control Module (PCM) for gasoline engines or the Engine Control Module (ECM) for diesel engines, the ElectroMechanical Instrument Cluster (EMIC) and/or a diagnostic scan tool. The SKIM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKIM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKIM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKIM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKIM. For added system security, each SKIM is programmed with a unique Secret Key code. This code is stored in memory, sent over the PCI data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKIM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKIM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKIM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a PCI data bus message from the PCM or ECM during SKIS initialization. In the event that a SKIM replacement is required, the Secret Key code can be transferred to the new SKIM from the PCM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKIM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKIM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On or Start positions, the SKIM transmits an RF signal to excite the transponder in the ignition key. The SKIM then listens for a return RF signal from the transponder. If the SKIM receives an RF signal with a valid "Secret Key" and transponder identification codes, the SKIM sends a "valid key" message to the PCM/ECM over the PCI bus. If the SKIM receives an invalid RF signal or no response, it sends "invalid key" messages to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKIM messages. It is important to note that the default condition in the PCM or ECM is an invalid key. Therefore, if no message is received from the SKIM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 5719 The SKIM also sends electronic messages to the EMIC which control the VTSS indicator. The SKIM sends messages to the EMIC to turn the indicator on for about three seconds when the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKIM sends bus messages to keep the indicator off for a duration of about one second. Then the SKIM sends messages to turn the indicator on or off based upon the results of the SKIS self-tests. If the VTSS indicator comes on and stays on after the bulb test, it indicates that the SKIM has detected a system malfunction and/or that the SKIS has become inoperative. If the SKIM detects an invalid key when the ignition switch is turned to the On position, it sends messages to flash the VTSS indicator. The SKIM can also send messages to flash the indicator and to generate a single audible chime whenever the Customer Learn programming mode is being utilized. The SKIS will store fault information in the form of Diagnostic Trouble Codes (DTC's) in SKIM memory if a system malfunction is detected. For diagnosis or initialization of the SKIM and the PCM/ECM, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 5720 Alarm Module: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Grasp the tilt steering column knob (2) firmly and pull it straight rearward to remove it from the tilt adjuster lever (1) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 5721 8. Disconnect the wire harness connector (2) from the Sentry Key Immobilizer Module (SKIM) (1). 9. Remove the screw (3) that secures the SKIM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKIM. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 5722 1. Position the Sentry Key Immobilizer Module (SKIM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKIM to the steering column housing. Tighten the screw to 2 N.m (20 in.lbs.). 3. Reconnect the wire harness connector (2) to the SKIM (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 5723 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 N.m (20 in.lbs.) 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in.lbs.) 9. Align the tilt steering column knob (2) with the tilt adjuster lever (1) on the left side of the steering column and use hand pressure to snap it back into place. 10. Reconnect the battery negative cable. NOTE: If the SKIM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKIM and to program at least two Sentry Key transponders before the vehicle can be operated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations RKE Module Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 5727 Module-Sentry Key Immobilizer (SKIM) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 5728 Keyless Entry Module: Description and Operation When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 5729 Keyless Entry Module: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 5730 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster. 3. Remove remote keyless entry module (2) from instrument cluster (1). INSTALLATION 1. Install remote keyless entry module (2) to instrument cluster (1). 2. Install instrument cluster. 3. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations Right Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 5734 Voice Activation Module: Diagrams Module-Hands Free C1 Module-Hands Free C2 Module-Hands Free C3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 5735 Voice Activation Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel right side end cap. 3. Remove the mounting fasteners. 4. Disconnect the electrical harness connector and remove module. INSTALLATION 1. Connect the electrical harness connector and position module. 2. Install and tighten the mounting fasteners. 3. Install the instrument panel right side end cap. 4. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams Switch-Cylinder Lock-Driver (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 5743 Left Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 5744 Starter-Adjustable Pedals (Except Base) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 5745 Pedal Positioning Switch: Service and Repair BASE BRAKES SWITCH-ADJUSTABLE PEDALS REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations Steering Wheel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 5749 Remote Switch: Diagrams Switch-Remote Radio-Left Switch-Remote Radio-Right Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 5750 Remote Switch: Description and Operation Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). The six switches in the two remote radio switch units are normally open, resistor multiplexed momentary switches that are hard wired to the Integrated Power Module (IPM) through the clockspring. The IPM sends a five volt reference signal to both switch units on one circuit, and senses the status of all of the switches by reading the voltage drop on a second circuit. When the IPM senses an input (voltage drop) from any one of the remote radio switches, it sends the proper switch status messages on the Programmable Communication Interface (PCI) data bus network to the radio receiver. The electronic circuitry within the radio receiver is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the IPM or the PCI data bus, the use of a scan tool and the proper Diagnostic Procedures information is recommended. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 5751 Remote Switch: Testing and Inspection Any diagnosis of the Audio system should begin with the use of scan tool. For information on the use of the scan tool. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switch Test Table 3. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 4. If not OK, replace the faulty switch. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Check for 5 volts at the radio control MUX circuit cavities of the steering wheel wire harness connectors for both remote radio switches. If OK, go to Step 5. If not OK, repair the open or shorted radio control MUX circuit to the Integrated Power Module (IPM) as required. 5. Disconnect and isolate the battery negative cable. Disconnect the 22-way instrument panel wire harness connector from the IPM. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted remote radio switch ground circuit to the IPM as required. 6. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and the 22-way instrument panel wire harness connector for the IPM. There should be continuity. If OK, refer to the proper Diagnostic Procedures to test the IPM and the PCI data bus. If not OK, repair the open remote radio switch ground circuit as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 5752 Remote Switch: Service and Repair WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. 3. Remove the speed control switches (2). 4. Unplug the wire harness connector from the remote radio switch (1). 5. Depress the tabs on each side of each switch and push the switch through the rear steering wheel cover. INSTALLATION 1. Install remote radio switch (1) to the steering wheel. 2. Connect the wire harness to the remote radio switch. 3. Install the speed control switches (2). 4. Install the driver airbag. 5. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Hook / Bracket > Component Information > Service and Repair Towing Hook / Bracket: Service and Repair FRONT TOW HOOK ASSEMBLY REMOVAL 1. Remove front bumper. 2. Remove the bolts (2) and remove the tow hook assembly (3). 3. If the vehicle is a Heavy Duty, then remove the bolts (1) and remove the tow hook (2). INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Hook / Bracket > Component Information > Service and Repair > Page 5757 1. Install the tow hook assembly (3) and bolts (2) hand tight. 2. If vehicle is a Heavy Duty, install the tow hook (2) and bolts (1) hand tight. 3. Install the front bumper. 4. Line up the tow hooks/tow hook assembly and tighten the bolts to 68 N.m (50 ft.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5762 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5763 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5764 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5765 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5766 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5767 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5768 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5769 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5770 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5771 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5772 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5773 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5774 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5775 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5776 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5777 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5778 Trailer Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5779 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5780 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5781 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5782 Trailer Connector: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-54-2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5783 8w-54-3 (Except Connection Box) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5784 8w-54-4 (Except Add On Trailer Tow) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5785 8w-54-5 (Add On Trailer Tow) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5786 8w-54-6 (Add On Trailer Tow) Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Page 5787 Trailer Connector: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Reach behind the center of the rear bumper to access and disconnect the connector (2) of the body wire harness from the 7-way trailer tow connector (1). 3. Remove the four screws (3) that secure the 7-way trailer tow connector (2) to the tapping plate (4) behind the rear bumper. 4. Remove the 7-way trailer tow connector from the face of the rear bumper and the tapping plate from behind the rear bumper. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Page 5788 1. Position the 7-way trailer tow connector (2) into the mounting hole on the face of the rear bumper (1). 2. Position the tapping plate (4) over the 7-way trailer tow connector on the back of the rear bumper. 3. Install and tighten the four screws (3) that secure the 7-way trailer tow connector to the tapping plate. Tighten the screws to 2 N.m (17 in.lbs.) 4. Reach behind the center of the rear bumper to access and reconnect the connector (2) of the body wire harness to the 7-way trailer tow connector (1). 5. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair TRAILER HITCH REMOVAL 1. Remove the rear bumper. 2. On Light Duty Vehicles, remove the hitch bolts (7) 3. On Heavy Duty Vehicles, remove the hitch bolts (8) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 5792 4. Disconnect all wire harness support push pins. 5. Remove the rear two cargo box bolts (3) and loosen the remaining bolts. 6. Using a suitable lifting device, lift and support the rear of the cargo box and remove the hitch. INSTALLATION 1. On Light Duty Vehicles, install the hitch (5) onto the frame rails and make sure the locators (1 and 2) on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly. 2. Install the hitch bolts (7) and tighten to 170 N.m (125 ft.lbs.). 3. Connect all wire harness support push pins. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 5793 4. On Heavy Duty Vehicles, install the hitch (5) onto the frame rails and make sure the locators (1 and 2) on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly. 5. Install the hitch bolts (8) and tighten to 170 N.m (125 ft.lbs.). 6. Connect all wire harness support push pins. 7. Lower the cargo box and install the rear bolts (3). 8. Install the rear bumper. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Connector Views Trailer Lamps: Connector Views Wiring-Trailer Tow 4-Way Wiring-Trailer Tow 7-Way Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Page 5798 Trailer Lamps: Description and Operation Vehicles equipped with an optional factory-installed trailer towing package have a rear body wire harness that includes an integral trailer tow wiring take out that connects to a heavy duty, sealed, 7-pin trailer tow connector located in the rear bumper. This harness includes an adapter harness that adapts the 7-pin trailer tow connector to a standard, light-duty, 4-pin trailer tow connector. Refer to the appropriate wiring information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5806 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5807 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5808 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5809 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5810 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5811 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5812 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5813 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5814 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5815 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5816 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5817 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5818 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5819 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5820 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5821 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5822 Trailer Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5823 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5824 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5825 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5826 Trailer Connector: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-54-2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5827 8w-54-3 (Except Connection Box) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5828 8w-54-4 (Except Add On Trailer Tow) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5829 8w-54-5 (Add On Trailer Tow) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5830 8w-54-6 (Add On Trailer Tow) Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Page 5831 Trailer Connector: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Reach behind the center of the rear bumper to access and disconnect the connector (2) of the body wire harness from the 7-way trailer tow connector (1). 3. Remove the four screws (3) that secure the 7-way trailer tow connector (2) to the tapping plate (4) behind the rear bumper. 4. Remove the 7-way trailer tow connector from the face of the rear bumper and the tapping plate from behind the rear bumper. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Page 5832 1. Position the 7-way trailer tow connector (2) into the mounting hole on the face of the rear bumper (1). 2. Position the tapping plate (4) over the 7-way trailer tow connector on the back of the rear bumper. 3. Install and tighten the four screws (3) that secure the 7-way trailer tow connector to the tapping plate. Tighten the screws to 2 N.m (17 in.lbs.) 4. Reach behind the center of the rear bumper to access and reconnect the connector (2) of the body wire harness to the 7-way trailer tow connector (1). 5. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations Right Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations > Page 5837 Voice Activation Module: Diagrams Module-Hands Free C1 Module-Hands Free C2 Module-Hands Free C3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations > Page 5838 Voice Activation Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel right side end cap. 3. Remove the mounting fasteners. 4. Disconnect the electrical harness connector and remove module. INSTALLATION 1. Connect the electrical harness connector and position module. 2. Install and tighten the mounting fasteners. 3. Install the instrument panel right side end cap. 4. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Component Information > Diagrams Winch: Diagrams Assembly - Winch Assembly - Winch B(+) Eyelet Assembly - Winch Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5848 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5849 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5850 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5851 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5852 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5853 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5854 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5855 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5856 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5857 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5858 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5859 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5860 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5861 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5862 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5863 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5864 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5865 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5866 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5867 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5868 Body Control Module: Electrical Diagrams Airbag System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5869 Premium Audio System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5870 Base Audio System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5871 Remote Radio Controls Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5872 PCI Bus Communication Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5873 PCM Communication - JTEC PCM Communication - NGC Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5874 ECM Communication - Diesel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5875 Door Ajar System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5876 Heated Mirror System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5877 Rear Window Defogger Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5878 Exterior Lights Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5879 Heating A/C System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5880 Horn System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5881 Instrument Cluster Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5882 Overhead Console Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5883 Power Door Locks Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5884 Telecommunications - Hands Free System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5885 Vehicle Theft Security System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5886 Wipers Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information SERVICING SUB-ASSEMBLIES Some components of the body system are intended to be serviced as an assembly only. Attempting to remove or repair certain system subcomponents may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures should be serviced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 5889 Body Control Module: Vehicle Damage Warnings ELECTRICAL TESTING PRECAUTIONS Before disconnecting any control module, make sure the ignition is "off". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description Body Control Module: Description and Operation System Description IDENTIFICATION OF SYSTEM The vehicle systems that are part of the "body" system are: - Airbag - Audio (with amplifier on premium systems) - Chime - Communication - Door Ajar System - Electrically heated system - Exterior lighting - Heating and A/C - Horn - Instrument Cluster - Interior Lighting - Memory Seat - Overhead Console - Power Door Lock/RKE - Power windows - Telecommunications (hands free phone) - Vehicle theft security system (VTSS) - Windshield Wiper and Washer SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 2004 DR consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI 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 information to perform its function. It will only respond to messages "addressed" to it through binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the communication section of this general information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 5892 Body Control Module: Description and Operation Functional Operation Airbag System The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end or side collisions. The system is most effective when used in conjunction with the seat belt system. On some models the ACM supports Seat Belt Tensioners, Passenger Airbag Off Switch, and others Impact Sensor. It may be necessary to use the DRBIII(R) to reconfigure the ACM to the vehicle equipment. The airbag control module (ACM) is an electronic module that monitors the airbag system for proper operation, stores diagnostic trouble code (DTCs), controls the airbag warning lamp and contains the sensor and actuator that is responsible for driver, passenger, and curtain airbag deployment. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTCs) to the technician through the DRBIII(R) via the PCI bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Electro/Mechanical Instrument Cluster (EMIC) from the ACM via the PCI bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the "run" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6-8 seconds. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds, then goes off, there is usually an intermittent problem in the system. 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 OR DEATH. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. The DR will have two Airbag Control Modules. Each ACM is specifically calibrated for one body type, light duty or heavy duty. To determine the body types the ACM monitors the PCI Bus for a message containing the complete VIN. The ACM uses the 6th digit of the VIN to identify the heavy duty or light duty vehicle. The 6th digit of the VIN will be a number 1 for light-duty vehicle and a 2, 3 or 4 for heavy-duty vehicle. If the PCI Bus VIN message 6th character matches the ACM body type, the VIN will be stored within 5.6 seconds after ignition on. After the VIN is stored, the ACM verifies PCI Bus VIN message within 2.6 seconds after the ignition is turned on. If two valid matching PCI Bus VIN messages are not received within 5.6 seconds the ACM will set a Missing Original VIN DTC. If the ACM and PCM module types, 6th character of the VIN, light-duty or heavy-duty do not match the Calibration Mismatch DTC will be set. CAUTION: Therefore, the practice of exchanging (swapping) airbag control modules, instrument clusters, powertrain control modules and other electronic modules in this vehicle with those removed from another vehicle must always be avoided. DRIVER AIRBAG The airbag protective trim cover is the most visible part of the driver side airbag system. 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. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and hybrid inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. CLOCKSPRING The clockspring is mounted on the steering column behind the steering wheel. This assembly consist of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wiring and the driver airbag, the horn, and the vehicle speed control switches if equipped. The clockspring must be properly centered when it is reinstalled on the steering column following any service procedure, or it could be damaged. The clockspring cannot be repaired and it must be replaced. PASSENGER AIRBAG When supplied with the proper electrical signal the passenger airbag inflator or inflators discharge the gas directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 5893 WARNING: THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE.BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. PASSENGER AIRBAG ON-OFF SWITCH The Passenger Airbag On-Off Switch allows the customer to turn the passenger airbag function ON or OFF. The OFF indicator will be illuminated whenever the switch is turned to the off position and for 2 seconds at ignition on for an indicator bulb test. The switch assembly is mounted in the center of instrument panel to make the OFF indicator visible to all front seat occupants. WARNING: TO AVOID PERSONAL INJURY OR DEATH, ALWAYS CHECK THE PASSENGER AIRBAG ON-OFF SWITCH POSITION BEFORE DRIVING THE VEHICLE. A SWITCH IN THE WRONG POSITION INCREASES THE RISK OF SERIOUS INJURY OR DEATH IN A COLLISION. To operate, insert the ignition key into the switch keyhole, push key in to release the internal plunger, and rotate to the desired switch position. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. The ignition key is the only key or object that should ever be inserted into the switch. NOTE: Do not turn the On-Off switch with the ignition on. The ACM continuously monitors the resistance of the Passenger Airbag On-Off Switch circuits to identify the switch position and provide circuit diagnostics. The on-off switch ON position resistance is 175 to 190 ohms and the OFF position resistance is 820 to 870 ohms. If the on-off switch circuits are open, shorted to ground or battery the ACM will set active and stored DTC. Upon receiving a switch diagnostic trouble code the airbag warning indicator, in the instrument cluster, will be turned on by the ACM. Whenever the airbag warning indicator is illuminated, the ACM should be the first module interrogated. SEAT BELT TENSIONER Front seat belt systems incorporate Tensioner Modules (SET). At the onset of an impact event each tensioner uses a pyrotechnic device, which is triggered simultaneously with the airbags, to rapidly retract the seat belts. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. The ACM module monitors the Seat Belt Tensioners circuit resistance and reports active and stored DTC's if any problem is found. SIDE IMPACT SENSORS The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration and when combined with the ACM Accelerometer provides verification of the direction and severity of a side impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Airbag Control Module. The ACM microprocessor continuously monitors all of the passive restraint system electrical circuits to determine the system readiness. If the ACM detects a system fault, it sets a Diagnostic Trouble Code and controls the airbag warning indicator operation accordingly. The side impact sensors receive battery current and ground through dedicated driver and passenger sensor signal and ground circuits from the ACM. The impact sensors and the ACM communicate by modulating the current in the sensor signal circuit. If the sensor is dropped it must be replaced. Disconnect the battery or remove both airbag fuses before servicing impact sensors. CAUTION: Do not remove or install the impact sensors while the sensor is attached to the vehicle wiring. CURTAIN AIRBAGS The Left and Right curtain airbags are located in the outboard edge of the roof under the headliner, just above the door openings. When supplied with the proper electrical signal the inflator can discharge the compress gas directly into the curtain airbag. Upon deployment, the curtain will tear open the headliner allowing the curtain airbag to fully deploy between the headliner and seat. The curtain airbag cannot be repaired and must be replaced if deployed or in any way damaged. WARNING: THE CURTAIN AIRBAG CONTAINS AN INERT GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 5894 SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. SPECIAL TOOLS Some airbag diagnostic test use special tools, airbag load tools, 8310 and 8443 for testing squib circuits. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of an Driver or Passenger Airbag, curtain airbag, clockspring, or seat belt tensioner (use a jumper if needed). Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective component has been removed from the system and should be replaced. If the DTC is still active, continue this process until all component in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed the squib wiring can be tested for open and shorted conditions. AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRBIII(R). Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. ACTIVE CODES The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. STORED CODES Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned off. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. Maintain a safe distance from all airbags while performing the following inspection. If no obvious problems are found, erase stored codes, and with the ignition "on" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Audio System The factory installed radio receiver communicates on the Programmable Communication Interface (PCI) data bus network. The PCI Bus inputs into the Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 5895 radio are used for VF dimming and remote steering wheel controls. All the radios are capable of displaying faults and allowing certain actuation tests through the use of the DRBIII(R). When attempting to perform PCI Bus diagnostics, the first step is to identify the radio in use in the vehicle. When trouble shooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term output refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio, or wiring could be at fault. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit, A faulty speaker could not cause this DTC. REMOTE RADIO CONTROLS These radios can be controlled via remote radio switches (optional). These switches are located on the back side of the steering wheel. They control mode, preset, seek up, seek down, volume up and volume down functions. These functions are inputs to the Instrument Cluster (MIC) and can be read with the DRBIII(R). The switches are a multiplexed signal to the MIC. The radio control MUX circuit is a 5 volt line that is pulled to ground through different value resistors built into the switches. This causes a voltage drop to be seen by the MIC and it sends a specific message to the radio on the PCI Bus circuit. The radio then responses to the message. This circuit is fairly simple to troubleshoot. The circuit must be complete from the switches in the steering wheel to the MIC. The ground must be complete so that the switches can cause the voltage drop for the MIC to see. The circuit passes through the clockspring so continuity through this devise must be verified. AMPLIFIER (PREMIUM SYSTEM) The Premium Audio Amplifier uses a microprocessor for audio digital signal processing (DSP) and system diagnostics. DSP provides a more accurate and consistent match of the audio system equalization to the vehicle interior. The DR Ram amplifier has six channels for superior sound quality. The amplifier reads the VIN from the PCI bus and sets itself to match the vehicle. The amplifier will send four beeps to the vehicle speakers at ignition on, if it does not read the VIN correctly. A replacement amplifier may beep at the first power up, but if these beeps are heard after the first ignition on, the DRBIII(R) should be used to verify the amplifier is connected to the PCI bus and that the VIN on the PCI bus is correct. The amplifier, wiring to the speakers and the speakers work independently from the radio. The amplifier's microprocessor supports several diagnostic functions. Tests can be run from the DRBIII(R) that will help in diagnosing audio system problems. The DRBIII(R) can display fault messages when an input or output problem to the amplifier is detected. The amplifier can detect wiring shorts and suggest which wires are likely to be shorted. The amplifier can send test signals that can be used to verify that the amplifier, speakers, and wiring to the speakers are operating properly. The amplifier can also be used to test if the radio is sending audio signals to it. The DRBIII(R) can be used to verify the amplifier equalization setting matches the vehicle, in case there is a sound quality complaint. Using the DRBIII(R) audio system diagnostics can determine the nature of the problem. Diagnostic tests the Amplifier can perform through the DRBIII(R): Continuous Tone Test - This test will send a continuous tone to each speaker and will verify the integrity of an individual channel. PCI Amplifier Test - This test will detect a PCI bus or checksum failure. Input Test - This test will detect the activity on the amplifiers input channels from the radio. Speaker Output Test - This test will detect the activity on the amplifiers output channels to the speakers NAVIGATION RADIO The optional navigation radio system receives GPS signals from up to eight satellites to display the position and direction of the vehicle. Map information is supplied through a DVD-ROM. An electronic gyrosensor and the vehicle's speed sensor enable the system to display the present vehicle position even in locations where GPS signals may be blocked. When a destination is selected, the navigation system uses information from the map to quickly calculate a route. As the vehicle is driven along the chosen route, the operator is guided with pictorial displays and voice prompts. For complete operating instructions, refer to the manual included with the vehicle. Communication The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25. Additional tracer colors may be added to the violet in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on this vehicle: - Front Control Module - Airbag Control Module - Controller Antilock Brake Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 5896 - A/C Heater Control Module - Powertrain Control Module (gas only) - Engine Control Module (diesel only) - Radio - Amplifier (if equipped) - Hands Free Module - Transfer Case Control Module (if equipped) - Sentry Key Immobilizer Module - Compass Mini-Trip Computer (if equipped) - Electro/Mechanical Instrument Cluster Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRBIII(R) lab scope. The 12v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open PCI circuit at the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: - All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - Dashed lines in the overhead console ambient temperature display - No response received from any module on the PCI bus (except the ECM/PCM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRBIII(R). Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRBIII(R). If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRBIII(R) may display "BUS ± SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRBIII(R) and in noway indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 5897 NOTE: The 2004 DR 3.7L, 4.7L, and 5.7L vehicles are equipped with the Powertrain Control Module and Transmission Control Module combined in a single control module. This module is the Next Generation Controller (NGC) for DaimlerChrysler and will be referred to as the Powertrain Control Module (PCM). The PCM has four color coded connectors C1/A through C4/D, (C1/A BLK, C2/B - ORANGE, C3/C - WHITE, C4/D -GREEN), with each connector containing 38 pins. The 5.9L Electronic Fuel Injection 24 valve Turbo Diesel has an Engine control module (ECM) CM845. New Diagnostic procedures and New DTC numbers are two of the changes you will see which reflect the new combined module technology. There are new Verification tests and module replacement procedures for the new PCM. Two tools are required to diagnose and repair the PCM terminals and harness connectors: 1. Miller #3638 Terminal Removal Pick must be used to release the connector terminals or harness and connector damage will occur. 2. Miller #8815 Pinout Box must be used to probe the PCM terminals or terminal damage will occur. Door Ajar System The door ajar state is used as an input for various control modules on the vehicle. The DRBIII(R) will display the state of the door ajar switches in Inputs/ Outputs. It's important to note, that when a door is closed, the switch state on the DRBIII(R) will show OPEN, and when the door is open, the switch state will show CLOSED. During diagnosis, if a door is closed and the DRBIII(R) displays the switch state as CLOSED, it indicates a shorted Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 5898 door ajar circuit. If the door is open and the DRBIII(R) displays the switch state as OPEN, it indicates an open door ajar circuit. Compass Mini-Trip Computer (CMTC) When equipped, the Compass/Mini Trip Computer (CMTC) is located in the overhead console. The CMTC supplements the standard vehicle instrumentation. The CMTC uses a vacuum fluorescent (VF) display to supply the vehicle operator with a compass heading, outdoor temperature, average fuel economy, distance to empty, trip odometer, and elapsed ignition on time. If equipped, the CMTC is also available with an integrated Universal Garage Door Opener (UGDO) known as "HomeLink ■. The CMTC function buttons are labeled C/T, RESET, STEP, and US/M. The three UGDO buttons are labeled with dots to indicate the channel number. Most of the CMTC display information is received over the PCI bus. The CMTC sends and receives data over the PCI bus, communicating with the FCM (Diesel), PCM (3.7L, 4.7L, 5.7L), and the Instrument Cluster. VEHICLE INFORMATION DISPLAY The CMTC provides the following functions: - Compass direction - Outside temperature - Elapsed ignition on time - Distance to empty - Average fuel economy - Trip Odometer The CMTC will not display information for any of the screens for which it did not receive the proper PCI bus data. Refer to the symptom list in the Overhead Console section for problems related to the CMTC. The CMTC receives the following messages from the Instrument Cluster: - Verification of US/Metric status - VF display dimming brightness and exterior lamp status - Trip Odometer data The CMTC receives the following message from the PCM: - Vehicle Speed US/M BUTTON The US/M button is used to toggle the display between English and Metric measurement units. STEP BUTTON The STEP Button can be used in one of the following ways: 1. To sequentially select one of 4 displays or blank display in the following order: - Average Fuel Economy - Distance to Empty - Trip Odometer - Time Elapsed . Off (Blank) 2. To set the magnetic variance zone when VARIANCE = X (X = 1 - 15) is indicated in the VF display. RESET BUTTON The RESET Button has two different functions: 1. To clear the trip functions that may be reset 2. To enter and exit the diagnostic mode Pressing the RESET button once will clear the trip function that is currently being displayed and the CMTC will send a PCI bus beep request to the Instrument Cluster. If the RESET button is pressed again within 3 seconds, the CMTC will reset ALL of the trip functions and an additional beep request is sent to the Instrument Cluster. The trip functions that may be reset are: - Average Fuel Economy - Trip Odometer - Elapsed Time A reset will only occur if one of the trip functions that may be reset is currently being displayed. The CMTC module will send a beep request to the Instrument Cluster. Simultaneously pressing the RESET button and the C/T button while turning the ignition from Off to On will enter the CMTC into the self-diagnostic mode. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 5899 COMPASS/TEMPERATURE (C/T) BUTTON Actuating the Compass/Temperature Button (C/T) will cause the CMTC to display the compass and temperature information. This function will operate from another traveler display. The CMTC simultaneously displays the compass reading and the outside temperature. Outside temperature information is received via the PCI bus from the FCM. The CMTC module internally senses and calculates the compass direction. TRAVELER DISPLAY FUNCTIONS Using the STEP button will change the CMTC between modes of operation and display the appropriate information according to data received from the PCI Bus. COMPASS OPERATION Upon ignition on, if the calibration information stored in the CMTC memory is within the normal range, the CMTC will perform in slow Auto-Cal mode. In slow Auto-Cal mode, the CMTC continuously compensates for the slowly changing magnetic field of the vehicle. The compass module detects changes in the vehicle magnetism and makes appropriate internal corrections to ensure proper displayed direction. However, if the calibration information stored in the CMTC memory is not within the normal range at ignition on, the CMTC will enter fast Auto-Cal. CAL is displayed along with the temperature. Auto activation of the fast Auto-Cal mode will also occur when the CMTC is subjected to high magnetic field strength levels, which cause all compass readings to be erroneous for a continuous period of five (5) minutes . During fast Auto-Cal, CAL will be displayed along with the temperature. Fast Auto-Cal can also be performed manually, by pressing and holding the RESET button for 10 seconds during the Compass/Temperature display mode. SETTING MAGNETIC ZONE VARIANCE Variance is the difference between magnetic North and geographic North. For proper compass function, the correct variance zone must be set. Refer to the Zone Variance map for the correct zone. Follow these steps to check or change the variance zone: - The ignition switch must be in the On position and the CMTC display must not be blank. - If the compass/temperature data is not currently being displayed, momentarily press and release the C/T button to display compass/temp information. - Press and hold the RESET button until VARIANCE = XX is displayed. The CMTC will display the variance zone stored in memory and the word VARIANCE. - Use the STEP button to select the proper variance zone number, 1 through 15. - After selecting the proper zone number, momentarily press and release the RESET button. The variance zone is then stored in the memory and the CMTC returns to normal operation. COMPASS CALIBRATION The compass module has 2 types of auto-calibration; slow-cal and fast-cal. Slow-cal ensures that during normal vehicle operation the compass performs auto-calibration functions to keep the compass sensors in their proper operating range. Whenever the ignition is On and the CMTC receives PC I bus data indicating that engine RPM is greater than zero, auto-calibration is performed continuously. If the calibration information stored in the compass module memory is not within the normal range after a power-up cycle, the compass will display CAL. The CMTC will enter into the fast-cal mode until calibration is complete. To enter the compass into Manual Calibration mode, perform the following steps: - Drive the vehicle to an area away from any large metal objects or overhead power lines. - Ensure that the proper variance zone is selected. See "Setting Magnetic Zone Variance." - The ignition switch must be in the On position and the CMTC display must not be blank. - Press the C/T button to view the Compass/ Temperature display. - Press and hold the RESET button until CAL is displayed, then release the button. - Drive slowly, less than 5 MPH (8KPH) in at least 1 complete 360-degree circle. - CAL will remain illuminated to alert the driver that the compass is in the calibration mode. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 5900 - After calibration is complete, CAL will turn off. If the compass appears blank, unable to be calibrated, or the compass displays false indications, the vehicle must be demagnetized. Refer to Compass Demagnetizing Procedure. SELF-CHECK DIAGNOSTICS The CMTC is capable of performing a diagnostic self check on its internal functions. CMTC diagnostics may be performed using a DRBIII(R) or by using the following procedure: 1. With the ignition switch in the OFF position, depress and hold the RESET and the C/T buttons. 2. Turn the ignition switch to the ON position. 3. Continue to hold both buttons until the software versions are displayed, then release the buttons. 4. All of the VFD segments will illuminate for 2-4 seconds. Check for segments that do not illuminate or illuminate all the time. 5. When the self-check is complete the CMTC will display one of the following messages: - PASS - FAIL - NO BUS 6. To exit the self-check mode, depress the RESET button or cycle the ignition switch and the CMTC will return to normal operation. If a Communication fault is displayed, refer to the symptom list. If a FAILED SELF TEST is displayed, the CMTC must be replaced. AMBIENT TEMPERATURE SENSOR The ambient air temperature is monitored by the FCM or the PCM and displayed by the CMTC. For Diesel equipped vehicles, the FCM receives a hardwire input from the ambient temperature sensor (ATS). For 3.7L, 4.7L and 5.7L equipped vehicles, the PCM receives the hardwire input from the ATS. The ATS is a variable resistor that operates on a 5-volt reference signal circuit hardwired from the FCM or PCM. The resistance in the ATS changes as the outside temperature rises or falls. The FCM or PCM senses the change in reference voltage through the ATS resistor. Based on the resistance of the ATS, the FCM or PCM is programmed to correspond to a specific temperature. The FCM or PCM stores and niters the ambient temperature data and transmits this data to the CMTC via the PCI Bus. The ATS cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. AMBIENT TEMPERATURE SENSOR FAULT CODES The outside temperature function is supported by the ambient temperature sensor (ATS), a signal and ground circuit hardwired to the FCM or the PCM, and the CMTC display. If the CMTC display indicates 54° C (130° F) or the ATS sense circuit is open, the temp display will be 54° C (130° F) to indicate an OPEN circuit condition. If the CMTC display indicates -40° C (-40° F) or the ATS sense circuit is shorted to ground, the temp display will be -40° C (-40° F) to indicate a SHORT circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the CMTC VFD can be tested. The ATS is supported by the FCM or PCM. Ambient Temperature Sensor DTCs will be recorded in the FCM or PCM. The ATS can be diagnosed using the following Sensor Test. Test the ATS circuits using the diagnostics in the Body Diagnostic Procedures Manual. If the CMTC passes the self test, and the ATS, the circuits, and PCI bus communications are confirmed to be OK, but the CMTC temperature display is inoperative or incorrect, replace the FCM or PCM as required. AMBIENT TEMPERATURE SENSOR TEST 1. Turn the ignition OFF. 2. Disconnect the ATS harness connector. 3. Measure the resistance of the ATS using the following min/max values: - 0° C (32° F) Sensor Resistance = 29.33 - 35.99 Kiloohms - 10° C (50° F) Sensor Resistance = 17.99 - 21.81 Kiloohms - 20° C (68° F) Sensor Resistance = 11.37 - 13.61 Kiloohms - 25° C (77° F) Sensor Resistance = 9.12 - 10.86 Kiloohms 30° C (86° F) Sensor Resistance = 7.37 - 8.75 Kiloohms - 40° C (104° F) Sensor Resistance = 4.90 - 5.75 Kiloohms The sensor resistance should read between these min/max values. If the resistance values are not OK, replace the Sensor. HOMELINK(R) UNIVERSAL TRANSMITTER If equipped, the HomeLink(R) Universal Transmitter is integrated into the overhead console. For added security it will operate home security systems that use coded signals known generically as Rolling Codes. The overhead console display provides visual feedback to the driver, indicating which HomeLink(R) transmitter channel button is being pressed. The HomeLink(R) can learn and store up to three separate transmitter radio frequency codes to operate garage door openers, security gates, and security lighting. The HomeLink ■ buttons are marked with one, two, or three dots. For complete information, refer to Universal Transmitter. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 5901 Electrically Heated Systems HEATED MIRROR RELAY A button located on the HVAC control head controls the Heated Mirror Relay, which is located in the IPM. The HVAC control will ground the Heated Mirror Relay Control circuit to energize this relay. The relay control circuit is continuously monitored for certain malfunctions that the HVAC will report as DTCs. Exterior Lighting System The Instrument Cluster monitors the Headlamp Switch and Multifunctions Switch on its MUX line. The Instrument Cluster sends a PCI bus message to the Front Control Module (FCM) to actuate the Headlamps ON when the ignition switch is ON and when an open or short failure occurs on the headlamps switch input circuit to the instrument cluster. If the exterior lamps are left ON and the ignition switch OFF for more than 5 minutes, the FCM will turn the exterior lamps off. This feature prevents the battery from being discharged when the Exterior Lamps have been left ON. Front Control Module The Front Control Module (FCM) is a microprocessor-based electrical control and interface center located in the engine compartment. When it is mated to the Power Distribution Center (PDC), it is referred to as the Integrated Power Module (IPM). The IPM, with its fuses and relays provides power and signal distribution throughout most of the vehicle. The FCM receives hardwired analog and resistor multiplexed inputs as well as digital electronic inputs from other electronic modules in the vehicle electrical system through its connection to the IPM and the Programmable Communications Interface (PCI) data bus network. Based on these inputs and programming, the FCM uses high side drivers to provide direct power feeds and low side drivers to provide relay control for some of the vehicle's most critical electrical systems. The FCM provides the following features: Controlled Feeds: - Brake lights - Headlamp power - Turn signals (front & rear) - Windshield washer pump motor Relay Controls - Adjustable pedals relay (when equipped) - Fog lamp relay (when equipped) - Horn relay - Park lamp relay - Trailer tow relays - Wiper on/off relay - Wiper high/low relay Electrical Inputs - Module battery supply - Power ground - Ignition switch RUN or START position status . PCI bus - Wiper park switch - Washer fluid level switch - Ambient Temperature sensor - Battery (+) connection detection CONTROLLED POWER FEEDS Headlamp Power The headlamp switch is a direct input to the instrument cluster which is sometimes known as the Cab Control Node (CCN). The instrument cluster sends a Programmable Communications Interface (PCI) bus message to the FCM informing it of a headlamp switch status change. The FCM then turns power on or off (depending on the bus message) to the headlamps through four "fuseless" circuits. These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied to each filament in a separate circuit. For vehicles equipped with Daytime Running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination levels. Washer Pump Motor The washer switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus message to the FCM informing it of a request to wash. The washer pump motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition, the FCM electronically protects the washer pump motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 5902 If the FCM receives a prolonged request to wash lasting 30 seconds or more, it will treat the request as a stuck switch condition and deactivate the washer pump motor. The FCM will not reactivate the washer pump motor until there is at least a two second break in the request to wash from the instrument cluster. RELAY CONTROLS Adjustable Pedals Relay If equipped, the adjustable pedals relay, when not activated, supplies fused battery power to the adjustable pedals switch. If the FCM receives a bus message that the vehicle is in reverse or that the cruise control is engaged, it will apply a ground to the adjustable pedals relay control circuit. The ground will activate the relay which will open the power circuit to the adjustable pedals switch The relay control circuit is continuously monitored for malfunctions which the FCM will report as DTCs. Fog Lamp Relay If equipped, the fog lamp switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to turn on the fog lamp relay. The fog lamp relay is then actuated by the FCM through low side control. This circuit is electronically controlled and continuously monitored for malfunctions. Horn Relay The Horn Relay, which is internal to the IPM, is controlled by the FCM through PCI bus messages from the instrument cluster. These bus messages will be sent when either the horn switch is pressed which is hard wired to the instrument cluster, panic mode is requested from the RKE or for vehicle theft security reasons (if equipped). The relay control circuit is continuously monitored for malfunctions that the FCM will report as DTCs. The park lamp switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the park lamp relay. The park lamp relay is then actuated through the low side control circuit. This circuit is electronically controlled and continuously monitored for malfunctions. Wiper High/Low Relay The wiper switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the wiper high/ low relay. The relay switches power between the low speed and high speed of the wiper motor. The wiper high/low relay is then actuated through the low side control circuit. This circuit is electronically controlled and continuously monitored for malfunctions. Wiper On/Off Relay The wiper switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the wiper on/off relay. The wiper on/off relay is then actuated through the low side control circuit. This relay switches power to the wiper high/low relay. This circuit is electronically controlled and continuously monitored for malfunctions. ELECTRICAL INPUTS Module Battery Supply 12 Volt input for all FCM functions except headlamp operation. Power Ground Ground source for all FCM functions Ignition Switch RUN or START Position Status 12 volt input to inform the FCM of the ignition switch status for related FCM functions. PCI Bus Approximately 7.5 volt input to allow the FCM to communicate with other modules on the PCI bus. Wiper Park Switch Ground input used to determine the park placement of the wipers. The ground is also used as feedback to the FCM to determine wiper operating mode. Washer Fluid Level Switch Ground input from the washer fluid level switch which closes when washer fluid is low. Battery (+) Connection Detection 12 volt supply used to monitor battery connection to the IPM. The battery connection to the IPM uses an internal switch to check integrity of the connection and that the Connector Positive Assurance (CPA) is engaged. If the CPA is not properly engaged, a voltage is sent to the FCM to be interpreted as an unseated connector which will set a Diagnostic Trouble Code (DTC). Heating & A/C System SYSTEM AVAILABILITY - Depending on the model, either a Single-Zone or Dual-Zone HVAC system is available in these vehicles. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 5903 SYSTEM CONTROLS The Heater Control Module: is fully addressable with the DRBIII(R). - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - controls heated mirror and EBL operation (if equipped). - controls electric door actuator operation. The A/C-Heater Control Module: is fully addressable with the DRBIII(R). - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - provides an A/C request to the Powertrain Control Module (PCM) over the PCI Bus when compressor operation is desired. - controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - controls heated mirror and EBL operation (if equipped). - controls electric door actuator operation. - A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C -Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. The Single-Zone HVAC system uses: one, two-wire electric blend door actuator. - two, two-wire electric mode door actuators. - one, two-wire electric recirculation door actuator. The Dual-Zone HVAC system uses: two, two-wire electric blend door actuators. - two, two-wire electric mode door actuators. - one, two-wire electric recirculation door actuator. SYSTEM REVISIONS The 2004 DR, HVAC system remains carryover from 2003. SYSTEM DIAGNOSTICS Fault detection is through active and stored Diagnostic Trouble Codes (DTCs) . DTCs are displayed by the DRBIII(R). Active DTCs are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTCs are those which occurred in the system since the A/C-Heater Control Module received the last "clear diagnostic info" message. The A/C Cooldown Test: is actuated with the DRBIII(R). - checks A/C system performance based on evaporator temperature sensor input. - will not run if ambient temperature is below 12.7° C (55° F). - will pass if the evaporator temperature drops 6.7° C (20° F) within two minutes of starting the test. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. - will cause the A/C mode switch status indicator to flash while the test is running. - If the test fails, the status indicator will continue to flash until either the test returns passed or the ignition key is cycled. It will also prevent the EBL mode switch status indicator from indicating EBL operating status. However, the EBL mode switch will continue to function in this state. The HVAC Door Recalibration function: is actuated with the DRBIII(R). - monitors for door span faults. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. - will cause the EBL mode switch status indicator to flash while the test is running. - If the test fails, the status indicator will continue to flash until either the test returns passed or the ignition key is cycled. It will also prevent the A/C mode switch status indicator from indicating A/C operating status. However, the A/C mode switch will continue to function in this state. The Actuator Circuit Test: is actuated with the DRBIII(R). - monitors for shorted actuator circuits. - allows service to easily diagnose and troubleshoot up to three simultaneous shorts. - supplements the continuous diagnostics on the actuator drive system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 5904 - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. When Performing The Actuator Circuit Test CAUTION: To ensure a proper diagnosis, repair all Short Too Complex messages first, all common door driver circuit related messages second, and all other door driver circuit related messages last. - The DRBIII(R) can display up to three Actuator Circuit Test messages at a time. After repairing each Actuator Circuit Test message, cycle the ignition switch, then rerun the Actuator Circuit Test to ensure no new messages exist. - The Short Too Complex message: indicates that a specific determination of which lines are shorted could not be made. - is caused by more than three drivers being shorted in the same direction. For example, four drivers all shorted to ground, or two or more drivers shorted with at least one driver shorted to ignition/battery and one driver shorted to ground. - Messages displaying: XXX Driver/Circuit Shorted to Ignition/ Battery will set on a per-driver basis. - XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. - the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together. - When the test returns passed, then troubleshooting should proceed to clearing faults and running the HVAC Door Recalibration system test as a final check of system health. Instrument Cluster The DR Instrument Cluster is a new type of control module that includes the hardware and software necessary to function as the cluster and the body control module. The Instrument Cluster houses the Speedometer, Tachometer, Fuel gauge, Coolant Temperature gauge, Oil Pressure gauge, and the Voltage gauge. The cluster positions all of the gauges using PCI bus messages received from the PCM. The cluster contains certain warning indicators, depending on engine type and options. Some of the indicators are hardwire inputs and some indicators are controlled via PCI bus messages. The warning chime tone generator is contained within the cluster. The cluster includes a vacuum fluorescent (VF) display for the PRNDL, Total and Trip Odometers. The VF will also display warning messages such as door ajar, low washer fluid level, engine hours, and no bus communications. The cluster has the ability to set and store DTCs, communicate on the PCI bus, display engine information, and display certain inputs using the DRBIII(R). The following systems are controlled either completely by the Instrument Cluster or in conjunction with other inputs received by hardwire or via the PCI bus: - Audible Warnings - Brake Lamp Control - Brake Transmission Shift Interlock (BTSI) - Cargo Lamp Control - Central Locking - Door Lock Inhibit - Enhanced Accident Response - Exterior Lighting Control - Exterior Lighting Fail-Safe - Heated Seat Control - Horn Control - Interior Lamp Control - Interior Lamps - Enhanced Accident Response - Interior Lamps Load Shedding - Lamp Out Indicator Control - Panel Lamps Dimming Control - Parade Mode - Power Locks - Remote Keyless Entry (RKE) - Remote Radio Switch Interface - Rolling Door Locks - Turn Signal and Hazard Warning Lamp Control - Vacuum Fluorescent Display Synchronization - Vehicle Theft Security System (VTSS) CAUTION: Instrument clusters used in this model automatically configure themselves for compatibility with the features and optional equipment in the vehicle in which they are initially installed. The instrument cluster is programmed to do this by embedding the Vehicle Identification Number (VIN) and other information critical to proper cluster operation in electronic memory. This embedded information is learned through electronic messages received from other electronic modules in the vehicle over the Programmable Communications Interface (PCI) data bus, and through certain hard wired inputs received when the cluster is connected to the vehicle electrically. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 5905 Once configured, the instrument cluster memory may be irreparably damaged and certain irreversible configuration errors may occur if the cluster is connected electrically to another vehicle; or, if an electronic module from another vehicle is connected that provides data to the instrument cluster (including odometer values) that conflicts with that which was previously learned and stored. Therefore, the practice of exchanging (swapping) instrument clusters and other electronic modules in this vehicle with those removed from another vehicle must always be avoided. Failure to observe this caution may result in instrument cluster damage, which is not reimbursable under the terms of the product warranty. Service replacement instrument clusters are provided with the correct VIN, and the certified odometer and engine hours values embedded in cluster memory, but will otherwise be automatically configured for compatibility with the features and optional equipment in the vehicle in which they are initially installed. DIAGNOSTIC SELF TEST The Instrument Cluster is capable of performing a Diagnostic Self Test. This self test can be initiated manually by depressing and holding the trip reset button while cycling the ignition from the Off to the On position. The self test can also be activated using the DRBIII(R). During the self test, all of the PCI bus indicators will be illuminated. The speedometer, tachometer, fuel gauge, oil pressure gauge, coolant temperature gauge, and voltage gauge will position at their calibration points. The VF display will illuminate all segments and also display the software version. The chime will sound. When the self test is complete, the cluster will return to normal operation. Turning the ignition to the Off position or the cluster detecting engine RPM greater than 0 (zero) will stop the self test. Interior Lighting The Instrument Cluster controls the Interior/ Courtesy Lamps. The Instrument Cluster activates the courtesy lamps when either a Dome Lamp switch is turned on or a door is opened. The Instrument Cluster also monitors the output of the Glove Box and Map lamps. The Cargo lamps are controlled by the Instrument Cluster, it receives an output message from the Headlamp switch to turn on the lamps. The Instrument Cluster provides battery protection by shutting down the interior lamps when a door or courtesy/map lamp is left on or open. Power Door Locks/Remote Keyless Entry The Instrument Cluster in response to the door lock switches or the RKE module directly controls the power door lock motors. The Instrument Cluster monitors the activation of the door lock motors and will set diagnostic trouble codes when there is an open or short condition. When there is a lock or unlock input from a switch or RKE command, the Instrument Cluster will activate the appropriate driver for 300 milliseconds. If a lock or unlock switch remains active, the request will be ignored until the switch transitions back to off. The lock switches are resistive multiplexed input devices hardwired to the Instrument Cluster. AUTOMATIC DOOR LOCKS The Instrument Cluster will automatically lock all the doors when the vehicle speed exceeds 15 MPH (24 KM/H), throttle position exceeds 10 percent and all the doors are closed. If a door is opened the Automatic Door Lock feature shall reset and the Instrument Cluster will lock the doors when the above conditions are met. This feature is programmable by the customer or the DRBIII(R). CENTRAL LOCKING/UNLOCKING The Instrument Cluster will lock all doors when the cylinder lock switch is activated in the "lock" position. When the Instrument Cluster receives an unlock command from the driver cylinder lock switch, it will unlock only that door. If the Instrument Cluster receives a second command within a 5-second period it will unlock all the remaining doors. The illuminated entry will activate during door unlock. DOOR LOCK INHIBIT When the key is in the ignition, in any position, and either front door is open, the door lock switches LOCK functions are disabled. The UNLOCK functions are still functional. This protects against locking the vehicle with the keys still in the ignition. The RKE transmitter will still lock the doors as usual. ENHANCED ACCIDENT RESPONSE Upon detection of an airbag deployment by way of the PCI bus, the Instrument Cluster shall: - Immediately disable the power door lock output - Unlock all doors by activating the door unlock output for approximately 300 milliseconds. - After actuating the door unlock output, allow the door lock motors to be activated if the door lock input has been inactive (not erratic) for 2 seconds since the reception of the airbag deployment message. Remote Keyless Entry The remote keyless entry (RKE) feature is used to control the power door locks and panic feature by using a remote transmitter (keyfob) and receiver located within the instrument cluster. The instrument cluster RKE feature controls the driver door unlock, all doors lock/unlock, horn chirp enabled/ disable, optical chirp enabled/disable, illuminated entry, the panic feature, initiate customer programming, and arming/disarming the Vehicle Theft Security System. When a valid lock message is received from the receiver, the instrument cluster will: - Arm the Vehicle Theft Security System (if equipped and all conditions are met). - Turn off the illuminated entry feature. - Activate the door lock motors. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 5906 - Transmit a PCI bus message to the FCM to perform horn chirp. When a valid unlock code is received from the receiver, the instrument cluster will: - Disarm the Vehicle Theft Security System (if equipped and previously set). - Activate the illuminated entry and cargo lamp. - Activate the driver door unlock motor (if customer programmed for driver door only unlock). - Transmit a PCI bus message to the FCM for optical chirp. Vehicle Theft Security System The Instrument Cluster controls the Vehicle Theft Security System (VTSS). When the VTSS is armed it will monitor the status of the ignition and door ajar switches. If the alarm is tripped it will sound the vehicles horn, flash the exterior lamps and the VTSS indicator located in the instrument cluster. The Instrument Cluster will enable the VTSS feature once it has received PCI bus messages from the Sentry Key Immobilizer Module and has also detected the driver cylinder lock switch being cycled to the lock/unlock position. Arming the system is accomplished following a normal exit sequence of removing the key from the ignition, opening the door pressing the power lock button to lock and closing the door, by using a cylinder lock switch or by pressing the RKE lock button. After all the doors are closed, the VTSS indicator will flash quickly for sixteen-seconds indicating the pre-arm process, after which it will flash at a slower rate indicating the system is armed. If during the pre-arm process a door is opened, the ignition is turned to the Run/Start position or if a RKE unlock button is pressed the system will exit the pre-arming process. Disarming can be accomplished with a RKE unlock, turning the ignition on with a valid Sentry key or unlocking the vehicle with a cylinder lock switch. The Alarming state will last for 18 minutes after which it will time out and return to the armed state. A tamper alert feature will alert the customer to the alarm being tripped while they were away upon returning to the vehicle by flashing the VTSS indicator for 30 seconds after the system has been disarmed. All of the switches for the VTSS system can be monitored using the DRBIII(R). The DRBIII(R) is also useful for a customer complaint of the alarm going off with no apparent reason by viewing the VTSS last alarm caused by display. Windshield Wipers/Washers The Instrument Cluster controls the wiper/ washer system. The instrument cluster receives a signal from the Multifunction Switch wipe position. The instrument cluster sends the message to the Front Control Module (FCM), sending the command to turn the wiper/washers on. Two relays, the High/Low relay and the On/Off relay also control the wipers. Both are located in the PDC or Integrated Power Module. Telecommunications HANDS FREE PHONE The vehicle telecommunications system consists of a Hands Free Module, Rear view Mirror, and a Blue-tooth Hands Free Profile enabled cell phone. The system allows vehicle occupants to use voice recognition technology to make, receive and screen phone calls without physically handling a cell phone. The system has a programmable phone book that can prevent the vehicle operator from becoming distracted searching for a specific number. Seven different wireless phones can be programmed to operate each individual system. Each of the seven phones is given a rank of priority when programmed. Incoming phone messages are transmitted to the vehicle occupants through the vehicles audio system when the ignition is on and the wireless phone is on. Upon receiving the signal from an incoming phone call, the vehicle audio system will fade out the current CD/DVD or radio output. The vehicle occupants are then directed to accept or reject the call. Outgoing audio messages are received through the microphone located in the rearview mirror then transmitted via hardwire to the Hands Free Module and finally transmitted through the wireless phone. Volume of the voice prompts and incoming conversation is controlled using the vehicles' radio audio controls and steering wheel controls if equipped. The rearview mirror contains a Phone Switch, Voice Recognition Switch and a microphone. The rear view mirror transmits these inputs via hardwired circuits to the Hands Free Module. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures Air Bag System Test 1 SYMPTOM AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES POSSIBLE CAUSES - Airbag warning indicator on without active trouble codes - Instrument cluster problems AM/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE this symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Amplifier Pretest Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5909 Test 1 SYMPTOM AMPLIFIER PRETEST POSSIBLE CAUSES - Amplifier pretest - No fault message displayed Any Station Preset Switch Inoperative Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Balance Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5910 Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure CD Eject Switch Inoperative Test 1 SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Equalizer Inoperative Test 1 SYMPTOM EQUALIZER INOPERATIVE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5911 TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure FF/RW Switch Inoperative Test 1 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure HOUR/MINUTE Switches Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5912 Test 1 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Pause/Play Switch Inoperative Test 1 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure PWR Switch Inoperative Test 1 SYMPTOM PWR SWITCH INOPERATIVE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5913 TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Scan Switch Inoperative Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Seek Switch Inoperative Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Set Switch Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5914 Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tape Eject Switch Inoperative Test 1 SYMPTOM TAPE EJECT INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5915 TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Chime Inoperative Test 1 SYMPTOM CHIME INOPERATIVE POSSIBLE CAUSES - Actuate chime with DRBIII(R) - Instrument cluster - chime inoperative Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5916 Test 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER DOOR OPEN KEY REMOVED POSSIBLE CAUSES - Key-in IGN SW status - Key-in ignition switch shorted - Key-in ignition SW sense short to ground - Instrument cluster Key In Ignition and Drivers Door Open Chime Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5917 Test 1 - 3 Test 4 - 5 SYMPTOM KEY IN IGNITION AND DRIVERS DOOR OPEN CHIME INOPERATIVE POSSIBLE CAUSES - Observe the key-in ignition switch status - Key-in ignition switch open - Key-in ignition switch ground circuit open - Key-in ignition switch sense circuit open - Instrument cluster - incorrect key-in ignition switch status Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5918 Vehicle Speed Warning Chime Problem Test 1 SYMPTOM VEHICLE SPEED WARNING CHIME PROBLEM POSSIBLE CAUSES - Incorrect country code programmed in instrument cluster - Instrument cluster Average Fuel Economy Inaccurate or Wrong Test 1 SYMPTOM AVERAGE FUEL ECONOMY INACCURATE OR WRONG POSSIBLE CAUSES - CMTC CMTC or EVIC Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5919 Test 1 - 3 SYMPTOM CMTC OR EVIC INOPERATIVE POSSIBLE CAUSES - Fused B(+) circuit open - Fused ignition switch output circuit open - Ground circuit open - Compass/mini-trip computer Compass Test Failure Test 1 SYMPTOM COMPASS TEST FAILURE POSSIBLE CAUSES - Compass/Mini-trip computer Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5920 Distance to Empty Inaccurate or Wrong Test 1 SYMPTOM DISTANCE TO EMPTY INACCURATE OR WRONG TEST NOTE This symptom is diagnosed using the test AVERAGE FUEL ECONOMY INACCURATE OR WRONG. POSSIBLE CAUSES - CMTC Elapsed Ignition on Time Inaccurate or Wrong Test 1 SYMPTOM ELAPSED IGNITION ON TIME INACCURATE OR WRONG TEST NOTE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5921 This symptom is diagnosed using the test AVERAGE FUEL ECONOMY INACCURATE OR WRONG. POSSIBLE CAUSES - CMTC Temperature Display Inaccurate or Inoperative Test 1 - 2 SYMPTOM TEMPERATURE DISPLAY INACCURATE OR INOPERATIVE POSSIBLE CAUSES - Ambient temperature sensor - Compass/Mini-trip computer Trip Odometer Inaccurate or Wrong Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5922 Test 1 SYMPTOM TRIP ODOMETER INACCURATE OR WRONG TEST NOTE This symptom is diagnosed using the test AVERAGE FUEL ECONOMY INACCURATE OR WRONG. POSSIBLE CAUSES - CMTC Driver Door Ajar Circuit Open Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5923 Test 1 - 4 SYMPTOM DRIVER DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Driver door ajar switch - Driver door ajar switch ground circuit open - Driver door ajar switch sense circuit open - Instrument cluster-driver door ajar open Driver Door Ajar Circuit Shorted to Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5924 Test 1 - 3 SYMPTOM DRIVER DOOR AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Driver door ajar switch shorted to ground - Driver door ajar switch sense circuit shorted to ground - Instrument cluster - driver door ajar shorted Left Rear Door Ajar Circuit Open Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5925 Test 1 - 4 SYMPTOM LEFT REAR DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Left rear door ajar switch - Left rear door ajar switch ground circuit open - Left rear door ajar switch sense circuit open - Instrument cluster - left rear door ajar open Left Rear Door Ajar Circuit Shorted to Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5926 Test 1 - 3 SYMPTOM LEFT REAR DOOR AJAR CIRCUIT SHORT TO GROUND POSSIBLE CAUSES - Left rear door ajar switch shorted to ground - Left rear door ajar switch sense circuit shorted to ground - Instrument cluster - driver door ajar shorted Passenger Door Ajar Circuit Shorted to Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5927 Test 1 - 3 SYMPTOM PASSENGER DOOR AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Passenger door ajar switch shorted to ground - Passenger door ajar switch sense circuit shorted to ground - Instrument cluster - passenger door ajar shorted Passenger Door Ajar CKT Open Test 1 - 4 SYMPTOM PASSENGER DOOR AJAR CKT OPEN POSSIBLE CAUSES - Passenger door ajar switch - Passenger door ajar switch ground circuit open - Passenger door ajar switch sense circuit open - Instrument cluster - passenger door ajar open Right Rear Door Ajar Circuit Open Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5928 Test 1 - 4 SYMPTOM RIGHT REAR DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Right rear door ajar switch - Right rear door ajar switch ground circuit open - Right rear door ajar switch sense circuit open - Instrument cluster - right rear door ajar open Right Rear Door Ajar Circuit Shorted to Ground Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5929 Test 1 - 3 SYMPTOM RIGHT REAR DOOR AJAR CIRCUIT SHORT TO GROUND POSSIBLE CAUSES - Right rear door ajar switch shorted to ground - Right rear door ajar switch sense circuit shorted to ground - Instrument cluster - right rear door ajar shorted A/C Heater Control Illumination Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5930 Test 1 - 3 Test 4 SYMPTOM A/C - HEATER CONTROL ILLUMINATION INOPERATIVE POSSIBLE CAUSES - Check for instrument cluster (MIC) DTCs - Inoperative bulb(s) - A/C - heater control module - Panel lamps driver circuit open - Instrument cluster A/C Status Indicator Flashing Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5931 Test 1 - 2 Test 3 SYMPTOM A/C STATUS INDICATOR FLASHING POSSIBLE CAUSES - A/C cooldown test needs to be run - HVAC door recalibration needs to be run A/C Status Indicator Will Not Illuminate - A/C Heater Control Without EBL SW Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5932 Test 1 SYMPTOM A/C STATUS INDICATOR WILL NOT ILLUMINATE -- A/C - HEATER CONTROL WITHOUT EBL SW POSSIBLE CAUSES - HVAC door recalibration failed - A/C - Heater control module Blend/Mode/Recirc Door Operation Improper - Dual-Zone Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5933 Test 4 - 6 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5934 Test 7 - 8 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER - DUAL-ZONE POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTCs - Check for HVAC door recalibration fault messages - Mode door actuator(s)/linkage(s)/door(s) - Passenger blend door actuator/linkage/door - Driver blend door actuator/linkage/door - Recirculation door actuator/linkage/door Blend/Mode/Recirc Door Operation Improper - Single-Zone Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5935 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5936 Test 4 - 6 Test 7 SYMPTOM Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5937 BLEND/MODE/RECIRC DOOR OPERATION IMPROPER - SINGLE-ZONE POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTCs - Check for HVAC door recalibration fault messages - Mode door actuator(s)/linkage(s)/door(s) - Blend door actuator/linkage/door - Recirculation door actuator/linkage/door Blower Motor Inoperative Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5938 Test 4 - 8 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5939 Test 9 - 10 SYMPTOM BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - IPM fuse #4 - Blower motor feed circuit shorted to ground - Fused B(+) shorted to ground - Blower motor shorted to ground - Blower motor - Blower motor high driver circuit open - Ground circuit open - A/C - heater control module open - Blower motor feed circuit open - Fused B(+) circuit open - Ignition switch open Blower Motor Speeds Incorrect Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5940 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5941 Test 4 - 6 SYMPTOM BLOWER MOTOR SPEEDS INCORRECT POSSIBLE CAUSES - Blower motor driver circuit(s) shorted to ground - A/C - heater control module - Blower motor driver circuit(s) shorted to voltage - Blower motor driver circuits shorted together - A/C - heater control module - speeds incorrect - Blower motor driver circuit(s) open - Blower motor resistor block - open speed EBL Status Indicator Flashing Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5942 Test 1 - 2 Test 3 SYMPTOM EBL STATUS INDICATOR FLASHING TEST NOTE This symptom is diagnosed using the test A/C STATUS INDICATOR FLASHING. POSSIBLE CAUSES - A/C cooldown test needs to be run - HVAC door recalibration needs to be run HVAC System Test Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5943 Test 1 - 2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5944 Test 3 - 4 SYMPTOM HVAC SYSTEM TEST POSSIBLE CAUSES - Attempt to communicate with the PCM - Check for HVAC related DTCs in the PCM - Check for active HVAC DTCs and system test fault messages - Check for HVAC related DTCs in the PCM - Manual A/C system test Horn Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5945 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5946 Test 4 - 8 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5947 Test 9 - 11 SYMPTOM HORNS INOPERATIVE POSSIBLE CAUSES - Horn ground circuit open - Horn relay output circuit open - Horns - Instrument cluster - DTC present - Clockspring - Front control module - Fuse #45 - Horn switch - Horn switch ground - Horn switch sense open - Integrated power module All Gauges Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5948 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5949 Test 4 - 7 Test 8 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5950 SYMPTOM ALL GAUGES INOPERATIVE POSSIBLE CAUSES - No response - PCI BUS - PCI BUS - powertrain control module - PCI BUS - instrument cluster - Fused ignition switch output circuit (unlock/run) short to ground - Instrument cluster ground circuit open - Fused ignition switch output (run/start) circuit open - Fused ignition switch output (run/start) circuit short to ground - Fused ignition switch output (unlock/run) circuit open - Instrument cluster Any PCI Indicator Inoperative Test 1 - 4 SYMPTOM ANY PCI INDICATOR INOPERATIVE POSSIBLE CAUSES - Indicator message not received - No response - instrument cluster Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5951 - No response - PCI BUS - No response - PCI BUS - powertrain control module - Instrument cluster Brake Warning Indicator Always On Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5952 Test 4 - 5 SYMPTOM BRAKE WARNING INDICATOR ALWAYS ON POSSIBLE CAUSES - Brake fluid level switch - Brake fluid level switch sense circuit short to ground - Park brake switch - Park brake switch sense circuit short to ground - Control module - Instrument cluster Brake Warning Indicator Inoperative Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5953 Test 4 - 7 SYMPTOM BRAKE WARNING INDICATOR INOPERATIVE POSSIBLE CAUSES - Brake fluid level switch ground circuit open - Brake fluid level switch - Brake fluid level switch sense circuit open - Park brake switch - Park brake switch sense circuit open - Control module - Instrument cluster Fuel Gauge Inaccurate Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5954 Test 1 - 3 SYMPTOM FUEL GAUGE INACCURATE POSSIBLE CAUSES - DTC present - Instrument cluster - Fuel level sensor wiring - Fuel level sensor One Gauge Inoperative - Gas Engines Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5955 Test 1 - 2 SYMPTOM ONE GAUGE INOPERATIVE - GAS ENGINES POSSIBLE CAUSES - Powertrain control module DTCs - Intermittent condition - Instrument cluster PRNDL Not Displaying Correct Position (EATX Vehicles) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5956 Test 1 - 2 SYMPTOM PRNDL NOT DISPLAYING CORRECT POSITION (EATX VEHICLES) POSSIBLE CAUSES - DTC present - Instrument cluster - Intermittent condition Seat Belt Warning Indicator Always Off Test 1 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS OFF POSSIBLE CAUSES - Seat belt switch sense circuit short to ground - Instrument cluster Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5957 Seat Belt Warning Indicator Always Off - Standard Cab Test 1 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS OFF - STANDARD CAB POSSIBLE CAUSES - Seat belt switch sense circuit short to ground - Instrument cluster Seat Belt Warning Indicator Always on Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5958 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS ON POSSIBLE CAUSES - Seat belt switch - Seat belt switch ground circuit open - Seat belt switch sense circuit open - Instrument cluster Seat Belt Warning Indicator Always on - Standard Cab Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5959 Test 4 - 5 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS ON - STANDARD CAB POSSIBLE CAUSES - Fused ignition switch output (run-acc) circuit open - Seat belt tensioner reducer - Seat belt switch - Seat belt switch ground circuit open - Seat belt switch sense circuit open - Instrument cluster All Door Locks Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5960 Test 1 - 3 SYMPTOM ALL DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - DTC present - Fuse #22 open - Fuse B+ circuit open - Instrument cluster - open circuit Automatic (Rolling) Door Locks Inoperative Test 1 - 4 SYMPTOM AUTO (ROLLING) DOOR LOCKS INOPERATIVE POSSIBLE CAUSES - Check the door ajar switch status - With the DRB check for PCM DTC's - With the DRB enable auto door locks - Instrument cluster - auto door locks fail Cylinder Lock Switch Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5961 Test 1 - 3 Test 4 SYMPTOM CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Cylinder lock switch ground open - Cylinder lock switch MUX circuit open - Cylinder lock switch open - Instrument cluster - open Cylinder Lock Switch Will Not Arm and/or Disarm Alarm Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5962 Test 1 - 3 Test 4 SYMPTOM CYLINDER LOCK SWITCH WILL NOT ARM AND/OR DISARM ALARM TEST NOTE This symptom is diagnosed using the test CYLINDER LOCK SWITCH INOPERATIVE. POSSIBLE CAUSES - DTC present - Cylinder lock switch ground open - Cylinder lock switch MUX circuit open - Cylinder lock switch open - Instrument cluster - open Door Lock Inhibit Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5963 Test 1 SYMPTOM DOOR LOCK INHIBIT INOPERATIVE POSSIBLE CAUSES - Chime inoperative - Instrument cluster - door lock inhibit inoperative Left Doors Fail to Lock and Unlock - Quad Cab Test 1 - 4 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5964 Test 5 SYMPTOM LEFT DOORS FAIL TO LOCK AND UNLOCK - QUAD CAB POSSIBLE CAUSES - DTC present - Instrument cluster - door lock driver left doors open - Door unlock driver left doors wire open - Door lock driver left doors wire open - Door lock motor One Door Lock Motor Inoperative Test 1 SYMPTOM ONE DOOR LOCK MOTOR INOPERATIVE POSSIBLE CAUSES - Door lock motor open - Check door lock motor circuit Right Doors Fail to Lock and Unlock - Quad Cab Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5965 Test 1 - 4 Test 5 SYMPTOM RIGHT DOORS FAIL TO LOCK AND UNLOCK - QUAD CAB POSSIBLE CAUSES - DTC present - Instrument cluster - door lock driver right doors open - Door unlock driver right doors wire open - Door lock driver right doors wire open - Door lock motor RKE Inoperative Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5966 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5967 Test 4 - 6 SYMPTOM RKE INOPERATIVE POSSIBLE CAUSES - Test transmitter with tester - RKE transmitter not programmed - DTC present - Transmitter not programmed - Substitute transmitter - Remote keyless entry module - RKE open - RKE module Alarm Trips On Its Own Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5968 Test 1 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSES - DRB display last VTSS cause - Intermittent condition Driver Door Does Not Trip VTSS Test 1 - 3 SYMPTOM DRIVER DOOR DOES NOT TRIP VTSS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5969 POSSIBLE CAUSES - Driver door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Headlamps Fail to Flash When Alarm Is Tripped Test 1 SYMPTOM HEADLAMPS FAIL TO FLASH WHEN ALARM IS TRIPPED POSSIBLE CAUSES - FCM DTCs or exterior lamp operation - Instrument cluster Horn Fails to Sound When Alarm Is Tripped Test 1 - 2 SYMPTOM HORN FAILS TO SOUND WHEN ALARM IS TRIPPED POSSIBLE CAUSES - DTC present - Horn circuit - Instrument cluster - VTSS Left Rear Door Does Not Trip VTSS (4 Door) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5970 Test 1 - 3 SYMPTOM LEFT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Passenger Door Does Not Trip VTSS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5971 Test 1 - 3 SYMPTOM PASSENGER DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Right Rear Door Does Not Trip VTSS (4 Door) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5972 Test 1 - 3 SYMPTOM RIGHT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSES - Passenger door ajar circuit malfunction - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster VTSS Will Not Arm Properly Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5973 Test 1 - 3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5974 Test 4 - 8 SYMPTOM VTSS WILL NOT ARM PROPERLY POSSIBLE CAUSES - VTSS not enabled - Check for DTCs and VTSS arming inhibitors - Check for SKIM no response - Cylinder lock switch ground open - Instrument cluster - Cylinder lock switch MUX circuit open - Cylinder lock switch open - Instrument cluster - cylinder lock switch MUX open Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5975 Body Control Module: Component Tests and General Diagnostics Six Step Troubleshooting Procedure Diagnosis of the body system 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 Road Testing Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. WARNING: REASSEMBLE ALL COMPONENTS BEFORE ROAD TESTING A VEHICLE. DO NOT TRY TO READ THE DRBIII(R) SCREEN OR OTHER TEST EQUIPMENT DURING A TEST DRIVE. DO NOT HANG THE DRBIII(R) OR OTHER TEST EQUIPMENT FROM THE REARVIEW MIRROR DURING A TEST DRIVE. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRBIII(R) OR OTHER TEST EQUIPMENT. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. Vehicle Preparation For Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Glossary of Terms ABS antilock brake system ACM airbag control module ACT actuator AECM airbag electronic control module (ACM) ASDM airbag system diagnostic module (ACM) BCM body control module BTSI brake transmission shift interlock CAB controller antilock brake CMTC compass/mini-trip computer CPA connector positive assurance DAB driver airbag DLC data link connector DTC diagnostic trouble code EBL electric back lite (rear window defogger) ECM engine control module EVIC electronic vehicle information center FCM front control module HFM hands free module HVAC heater ventilation, air conditioning IC instrument cluster (MIC) IPM integrated power module JB junction block MIC mechanical instrument cluster NGC next generation controller ODO odometer OR occupant restraint controller PAB passenger airbag PCI Programmable Communication Interface (vehicle communication bus) PCM powertrain control module PDC power distribution center PWM pulse width modulated RKE remote keyless entry RX receive SBS seat belt switch SBT seat belt tensioner SKIM sentry key immobilizer module SKIS sentry key immobilizer system SRS supplemental restraint system SUV sport utility vehicle Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5976 TCCM transfer case control module TCM transmission control module TX transmit UGDO universal garage door opener VFD vacuum fluorescent display VTSS vehicle theft security system Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5977 Body Control Module: Scan Tool Testing and Procedures Diagnostic Trouble Code DRB III Error Messages and Blank Screen Under normal operation, the DRBIII(R) will display one of only two error messages: - User-Requested WARM Boot or User Requested COLD Boot. If the DRBIII(R) should display any other error message, record the entire display and call the STAR Center. This is a sample of such an error message display. - User-Requested WARM Boot by pressing MORE and NO at the same time. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5978 ver: 2.29 date: 1 Oct 93 file: key_itf.cc date: Jan 12 1994 line: 544 err: 0x1 User-Requested WARM Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. or User-Requested COLD Boot by pressing MORE and YES at the same time. ver: 2.29 date: 1 Oct 99 file: keyhnd1.cc date: Mar 8 2000 line:1297 err: 0x1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRBIII(R) DOES NOT POWER UP If the LEDs do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRBIII(R). Check for proper ground connection at DLC cavities 4 and 5. If all connections are proper between the DRBIII(R) and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRBIII(R) may be the result of faulty cable or vehicle wiring. DRBIII(R) Scan Tool DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. DRB III Safety Information WARNING: EXCEEDING THE LIMITS OF THE DRBIII(R) MULTIMETER IS DANGEROUS. READ ALL DRBIII(R) INSTRUCTIONS BEFORE USING THE MULTIMETER. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. - Follow the vehicle manufacturer's service specifications at all times. - Do not use the DRBIII(R) if it has been damaged. - Do not use the test leads if the insulation is damaged or if metal is exposed. - To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. - Choose the proper range and functions for the measurement. Do not try voltage or current measurement that may exceed the rated capacity. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5979 - Do not exceed the limits shown in the table below: - Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. - Use caution when measuring voltage above 25v DC or 25v AC. - Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. - When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. - When measuring current, connect the meter in series with the load. - Disconnect the live test lead before disconnecting the common test lead. - When using the meter function, keep the DRBIII(R) away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 5980 Body Control Module: Tools and Equipment DRBIII(R) (diagnostic read-out box) Jumper wires Ohmmeter Voltmeter Test Light 8310 Airbag System Load Tool 8443 SRS Airbag System Load Tool 8815 Diagnostic Pinout Box Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Fascia Front Bumper Cover / Fascia: Service and Repair Front Fascia FRONT FASCIA REMOVAL ST/SLT/SLT+ 1. Remove the two screws (4) at each trailing edge of the fascia. 2. Remove the four push pin fasteners (5) from the upper edge of the close out panel. 3. Using a trim stick (special tool #C-4755) or equivalent, carefully release the six lower clips and remove the close out panel. 4. Using a trim stick or equivalent, carefully remove the step pad (1). 5. Remove and discard the four push pin fasteners (5) and remove the fascia. SPORT 1. Raise and support the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Fascia > Page 5987 2. Remove the three screws (3) at each trailing edge of the fascia. 3. Remove the five lower screws (8). 4. Remove and discard the four upper push pins (7). 5. Using a trim stick (special tool #C-4755) or equivalent, carefully release the six lower clips and remove the close out panel. 6. Using a trim stick or equivalent, carefully remove the step pad (1). 7. Spread the fascia (2) out at the wheels and remove from the vehicle. INSTALLATION ST/SLT/SLT+ NOTE: The left and right inboard bumper to bracket attachments must be secured before installing the fascia and step pad. 1. Install the fascia. 2. Position the close out panel and seat the 6 lower clips fully. 3. Install four new upper push pin fasteners (5). 4. Position the step pad (1) onto the fascia (2) and fully seat the attachment clips. 5. Align the fascia to the fender with a 19 mm (0.75 inch) gap and install the two screws at each trailing edge of the fascia. SPORT Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Fascia > Page 5988 NOTE: The left and right inboard bumper to bracket attachments must be secured before installing the fascia and step pad. 1. Position the fascia (2) onto the bumper. 2. Position the step pad (1) onto the fascia (2) and fully seat the attachment clips. 3. Install four new upper push pin fasteners (7). 4. Install the five lower screws (8). 5. Install the three screws (3) at each trailing edge of the fascia. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Fascia > Page 5989 Front Bumper Cover / Fascia: Service and Repair Fascia-Front SRT-10 FASCIA-FRONT SRT-10 REMOVAL 1. Remove the belly pan screws (1). 2. Remove the screws (1 & 2) from the wheel well. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Fascia > Page 5990 3. Remove the push pin fasteners attaching the upper fascia to the fascia retainer. 4. Lift the fascia off of the support brackets (1 & 2) and remove the fascia. INSTALLATION 1. Position the fascia onto the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Fascia > Page 5991 2. Position the fascia (2) over the side support bracket (1) on one side then around and over the other side support bracket (1). 3. Position the belly pan (2) over the lip of the fascia (1). 4. Install the push pin fasteners into the fascia retainer. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Fascia > Page 5992 5. Install the screws (1 & 2) into the wheel well. 6. Install the screws (1) into the belly pan. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair Rear Bumper Cover / Fascia: Service and Repair FASCIA-REAR SRT-10 1. Remove the screws (1, 3 and 5). 2. Separate end cap (4) and lift off of the support brackets (2). 3. Remove the license plate lamp clips (2). 4. Remove the license plate lamps (4) and disconnect the electrical connectors. 5. Remove the push pin fasteners (3) and remove the fascia. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Page 5997 1. Install the fascia (5) and install the push pin fasteners (3). 2. Connect the electrical connectors and install the license plate lamps (4). 3. Install the lamp clips (2). 4. Position the end caps (4) over the support brackets (2) and install. 5. Install the screws (1, 3 and 5). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair BODY VENT REMOVAL 1. Remove the rear cab trim panel, Refer to Trim Panel. 2. Disengage the retaining tabs (1) that secure the body vent (3) to the cab back panel (2). 3. Remove the vent through the opening in the cab back panel. INSTALLATION 1. Position the body vent (3) into the opening of the cab back panel (2). 2. Install the body vent into the cab back panel and fully engage the retaining tabs (1). 3. Install the rear cab trim panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE REMOVAL 1. Remove the wiper arms. 2. Disconnect the cowl plenum washer hose from the washer supply hose at the molded plastic in-line fitting. 3. Remove the cowl weather seal from the front of the dash panel and the cowl grille (2). 4. Remove the six push pin fasteners (1) that secure the front of the cowl grille to the dash panel. 5. Remove the two screws (3) that secure the rear corners of the cowl grille to the dash panel and remove the grille. 6. If necessary, remove the washer nozzles and the cowl plenum washer hose from the cowl grille. INSTALLATION 1. If removed, install the washer nozzles and the cowl plenum washer hose onto the cowl grille (2). 2. Position the cowl grille onto the dash panel. 3. Install the two screws (3) and the six push-pin fasteners (1) that secure the cowl grille to the dash panel. 4. Install the cowl weather seal onto the front of the dash panel and the cowl grille. 5. Connect the cowl plenum washer hose to the washer supply hose at the molded plastic in-line fitting. 6. Install the wiper arms. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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. Disconnect and isolate the negative battery cable. 2. Remove the door glass. 3. If equipped, disconnect the exterior handle wire lead (7) from the door wire harness connector (3). 4. Disconnect the actuator rods (6 and 8) for the door latch (5) from the exterior handle (1). 5. Remove the two nuts (2) that secure the exterior handle to the door (4) and remove the handle. INSTALLATION 1. Position the exterior handle (1) into the door (4). 2. Install the two nuts (2) that secure the exterior handle to the door. Tighten the nuts to 10 N.m (89 in.lbs.). 3. Connect the actuator rods (6 and 8) for the door latch (5) to the exterior handle. 4. If equipped, connect the exterior handle wire lead (7) to the door wire harness connector (3). 5. Install the door glass. 6. Reconnect the negative battery cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair Front Door Interior Handle: Service and Repair INTERIOR HANDLE ACTUATOR REMOVAL 1. Remove the door trim panel. 2. Position the waterdam out of the way and disconnect the actuator rod (3) from interior door handle actuator (5) and the door latch (2), if necessary. 3. Remove the two nuts (4) that secure the interior door handle actuator to the door (1) and remove the actuator. INSTALLATION 1. Position the interior door handle actuator (5) onto the door (1). 2. Install the two nuts (4) that secure the interior door handle actuator to the door. Tighten the nuts to 10 N.m (89 in.lbs.). 3. Connect the actuator rod (3) to the interior door handle actuator and the door latch (2), if removed. 4. Reposition the waterdam and install the door trim panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair Front Door Hinge: Service and Repair HINGE REMOVAL 1. Remove the door. 2. Using a grease pencil or equivalent, mark the hinge location and remove the bolts (3) and (4). INSTALLATION NOTE: A suitable body sealant should be used when removing or moving the hinges. 1. Install the hinges and bolts. 2. Tighten the upper hinge bolt (1) to hinge pillar to 28 N.m (21 ft.lbs.). 3. Tighten the lower hinge bolt (2) to hinge pillar to 28 N.m (21 ft.lbs.). 4. Tighten the remaining hinge to hinge pillar bolts (3) and (4) to 28 N.m (21 ft.lbs.). 5. Install the door. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams Front Door Latch: Diagrams Latch-Door-Driver (Power Locks) Latch-Door-Driver (Power Locks) Latch-Door-Passenger (Power Locks) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 6021 Front Door Latch: Adjustments ADJUSTMENTS 1. Locate the access hole in the door to adjust the door latch (1) and remove the mylar tape (2). 2. Loosen the adjustment screw (3). 3. Operate the door handles several times to reduce any possible linkage binding and tighten the adjustment screw to 3 N.m (30 in.lbs.). 4. Operate the door handles again to verify proper operation and reinstall the mylar tape. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 6022 Front Door Latch: Service and Repair LATCH REMOVAL 1. Raise the window to the full up position and remove the door trim panel. 2. Position the waterdam out of the way and disconnect the actuator rod (3) from the door latch (2) and the interior door handle actuator (5) and remove the rod. 3. Disconnect the door wire harness connector (2) from the door latch (3). 4. Remove the three bolts (4) that secure the door latch to the door (1) and remove the latch. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 6023 1. Position the door latch (3) into the door (1). 2. Install the three bolts (4) that secure the door latch to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 3. Connect the door wire harness connector (2) to the door latch. 4. Connect the actuator rod (3) to the door latch (2) and the interior door handle actuator (5). 5. Reposition the waterdam to the door (1) and install the door trim panel. 6. If necessary, adjust the latch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures Front Door Panel: Procedures REMOVAL 1. Remove the screw (1) that secures the interior door handle (2) to the interior door handle actuator (3). 2. Remove the interior door handle from the interior door handle actuator. 3. If equipped, remove the manual window crank (1) using a window crank removal tool (2). 4. Remove the two screws (2) that secure the door trim panel (3) to the two screw inserts (1). 5. Remove the two screws (4) that secure the door trim panel to the bottom of the door. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 6028 6. Lift the door trim panel straight upward to disconnect the molded plastic retaining clips (5) from the door. 7. If equipped, disconnect the door wire harness from the power door switch assembly and remove the door trim panel. INSTALLATION 1. If equipped, connect the door wire harness to the power door switch assembly. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not force the door trim panel onto the door or damage to the trim panel and/or the power switch assembly will occur. 2. Position the door trim panel (3) and align the molded plastic retaining clips (5) to the door. 3. Push the door trim panel straight downward until all of the retaining clips are fully engaged to the door. 4. Install the two screws (2) that secure the door trim panel to the two screw inserts (1). 5. Install the two screws (4) that secure the door trim panel to the bottom of the door. 6. if equipped, install the manual window crank. 7. Position the interior door handle (2) onto the interior door handle actuator (3). 8. Install the screw (1) that secures the interior door handle to the interior door handle actuator. Tighten the screw securely. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 6029 Front Door Panel: Removal and Replacement Trim Panel TRIM PANEL REMOVAL 1. Remove the screw (1) that secures the interior door handle (2) to the interior door handle actuator (3). 2. Remove the interior door handle from the interior door handle actuator. 3. If equipped, remove the manual window crank (1) using a window crank removal tool (2). 4. Remove the two screws (2) that secure the door trim panel (3) to the two screw inserts (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 6030 5. Remove the two screws (4) that secure the door trim panel to the bottom of the door. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. 6. Lift the door trim panel straight upward to disconnect the molded plastic retaining clips (5) from the door. 7. If equipped, disconnect the door wire harness from the power door switch assembly and remove the door trim panel. INSTALLATION 1. If equipped, connect the door wire harness to the power door switch assembly. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not force the door trim panel onto the door or damage to the trim panel and/or the power switch assembly will occur. 2. Position the door trim panel (3) and align the molded plastic retaining clips (5) to the door. 3. Push the door trim panel straight downward until all of the retaining clips are fully engaged to the door. 4. Install the two screws (2) that secure the door trim panel to the two screw inserts (1). 5. Install the two screws (4) that secure the door trim panel to the bottom of the door. 6. if equipped, install the manual window crank. 7. Position the interior door handle (2) onto the interior door handle actuator (3). 8. Install the screw (1) that secures the interior door handle to the interior door handle actuator. Tighten the screw securely. Waterdam WATERDAM REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 6031 1. Remove the interior door handle actuator. 2. Remove the speaker. CAUTION: Do not allow the waterdam adhesive to become contaminated with dirt or other foreign substances. If the waterdam becomes contaminated or damaged, replace it. 3. Carefully remove the waterdam (1) from around the perimeter of the door (2). 4. Separate the waterdam from the interior handle actuator rod and the door wire harness (if equipped) and remove the waterdam. INSTALLATION CAUTION: Do not allow the waterdam or adhesive to become contaminated with dirt or other foreign substances. If the waterdam becomes contaminated or damaged, replace it. NOTE: Be sure that the waterdam is fully sealed around the perimeter of the door. 1. Position the interior handle actuator rod and the wire harness (if equipped) through the holes in the waterdam (1) and install the waterdam to the door (2). 2. Install the speaker. 3. Install the interior door handle actuator. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments Front Door Striker: Adjustments ADJUSTMENTS 1. Using a grease pencil or equivalent, mark the location of the door latch striker (1) on the B-pillar (2) to aid in adjustment. 2. Loosen the two bolts (3) that secure the door latch striker to the B-pillar. 3. To adjust the rear gap and flush measurement, change the position of the door latch striker and then tighten the two bolts to 28 N.m (21 ft.lbs.). 4. Verify correct door and latch position. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments > Page 6035 Front Door Striker: Service and Repair LATCH STRIKER REMOVAL 1. Using a grease pencil or equivalent, mark the location of the door latch striker (1) on the B-pillar (2). 2. Remove the two bolts (3) that secure the door latch striker to the B-pillar and remove the striker. INSTALLATION 1. Position the door latch striker (1) onto the B-pillar (2) and loosely install the two bolts (3). 2. Align the door latch striker to the B-pillar using the reference marks made during the removal procedure and tighten the bolts to 28 N.m (21 ft.lbs.). 3. If necessary, adjust the door latch striker. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip Front Door Weatherstrip: Service and Repair Drip Rail Weatherstrip DRIP RAIL WEATHERSTRIP REMOVAL 1. Open the doors and separate the weatherstrip (3) from the drip rail and a-pillar retainers (1 and 7). INSTALLATION 1. Position the weatherstrip (3) onto the drip rail and a-pillar retainers (1 and 7) and seat fully. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6040 Front Door Weatherstrip: Service and Repair A-Pillar Weatherstrip Retainer A-PILLAR WEATHERSTRIP RETAINER REMOVAL 1. Remove the drip rail weatherstrip retainer (1). 2. Remove the five screws (8) and remove the A-pillar weatherstrip retainer (7). INSTALLATION 1. Install the A-pillar weatherstrip retainer (7) and install the screws (8). 2. Install the drip rail weatherstrip retainer (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6041 Front Door Weatherstrip: Service and Repair Door Opening Seal DOOR OPENING SEAL REMOVAL FRONT DOOR SEAL 1. Remove the cowl trim panel (1), Refer to Trim Panel. 2. If vehicle is a Standard Cab, remove the lower b-pillar trim panel (3), Refer to Trim Panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6042 3. If vehicle is a Quad Cab, remove the lower b-pillar trim panel (1), Refer to Trim Panel. 4. Separate the front door opening seal (6) from the door opening flange. REAR DOOR SEAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6043 1. Remove the lower b-pillar trim panel (1), Refer to Trim Panel. 2. Remove the lower c-pillar trim (1), Refer to Trim Panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6044 3. Separate the rear door opening seal (5) from the door opening flange. INSTALLATION FRONT DOOR SEAL 1. Position the front door seal (6) to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. If vehicle is a Standard Cab, install the lower b-pillar trim (3). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6045 3. If vehicle is a Quad Cab, install the lower b-pillar trim (1). 4. Install the cowl trim panel (1). NOTE: When installing a new weatherstrip on the front door opening, remove the tear strip starting at the splice and moving around the front of the door to the back of the opening. REAR DOOR SEAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6046 1. Position the rear door seal to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. Install the lower c-pillar trim (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6047 3. Install the lower b-pillar trim (1). NOTE: When installing a new weatherstrip on the rear door opening, remove the tear strip starting at the splice and moving around the back of the door to the front of the opening. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6048 Front Door Weatherstrip: Service and Repair Drip Rail Weatherstrip Retainer DRIP RAIL WEATHERSTRIP RETAINER REMOVAL 1. Separate the drip rail weatherstrip (3) from the weatherstrip retainer (1). 2. Remove the seven screws (2) and remove the retainer (1). INSTALLATION 1. Install the weatherstrip retainer (1) and install the seven screws (2). 2. Position the weatherstrip (3) over the retainer flange and seat fully. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Molding FRONT DOOR OUTER BELT MOLDING REMOVAL 1. Remove the screw (4) and separate the belt molding (1) from the door (5) flange from the back to the front. INSTALLATION 1. Position the belt molding (1) onto the door (5) flange and seat fully. 2. Install the screw (4). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 6054 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove the door glass. 2. Separate the front door glass run weatherstrip (2) out of the door frame (5) and remove through the window opening. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 6055 NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the front door glass run weatherstrip (2) into the door (5) through the window opening. 2. Position the weatherstrip into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip between the corners and then down the sides firmly. 4. Install the door glass. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 6056 Front Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL FRONT-ALL MODELS 1. Raise the window glass to the full up position and remove the window regulator. 2. Loosen the two bolts (2 and 3) that secure the front glass run channel (1) to the door (5). 3. Slide the front glass run channel upward and disengage it from the door. 4. Remove the front glass run channel from the door through the door panel opening (4). 5. If required, remove the weatherstrip from the front glass run channel. REAR-QUAD CAB 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the lower bolt (1) that secures the rear glass run channel (3) to the door. 3. Loosen the upper bolt (4) that secures the rear glass run channel to the door. 4. Slide the rear glass run channel upward and disengage the upper screw from the door. 5. Remove the rear glass run channel from the door through the door panel opening (2). 6. If required, remove the weatherstrip from the rear glass run channel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 6057 REAR-STANDARD CAB 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1) that secure the rear glass run channel (2) to the door. 3. Remove the rear glass run channel from the door through the door panel opening (3). 4. If required, remove the weatherstrip from the rear glass run channel. INSTALLATION FRONT-ALL MODELS 1. If removed, install the weatherstrip onto the front glass run channel (1). 2. Position the front glass run channel into the door (5) through the door panel opening (4). 3. Engage the two bolts (2 and 3) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. REAR-QUAD CAB Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 6058 1. If removed, install the weatherstrip onto the rear glass run channel (3). 2. Position the rear glass run channel into the door through the door panel opening (2). 3. Engage the upper bolt (4) that secures the rear glass run channel to the door. 4. Install the lower bolt (1) that secures the rear glass run channel to the door. Tighten both the upper and lower bolts to 10 N.m (89 in.lbs.). 5. Install the window regulator and verify correct window operation. REAR-STANDARD CAB 1. If removed, install the weatherstrip onto the rear glass run channel (2). 2. Position the rear glass run channel into the door through the door panel opening (3). 3. Install the two bolts (1) that secure the rear glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 6059 Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Molding FRONT DOOR INNER BELT MOLDING REMOVAL 1. Remove the door trim panel (3). 2. Separate the belt molding (1) from the door (3) mounting flange from the back to the front. INSTALLATION 1. Position the belt molding (1) and seat onto the door (3) mounting flange fully. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 6060 2. Install the door trim panel (3). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures Front Door Window Regulator: Procedures REMOVAL 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 8. Remove the bolt (5) that secures the window regulator to the door and loosen the other two regulator bolts (7). 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (6). INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 6065 1. Connect the door wire harness (6) to the window regulator (4) and install the regulator through the opening in the door (2). 2. Engage the two regulator bolts (7) to the door. 3. Install the bolt (5) that secure the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (2) to the position shown. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 6066 Front Door Window Regulator: Removal and Replacement Window Regulator-Power WINDOW REGULATOR-POWER REMOVAL 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Front Door Panel. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 8. Remove the bolt (5) that secures the window regulator to the door and loosen the other two regulator bolts (7). 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (6). INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 6067 1. Connect the door wire harness (6) to the window regulator (4) and install the regulator through the opening in the door (2). 2. Engage the two regulator bolts (7) to the door. 3. Install the bolt (5) that secure the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (2) to the position shown. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Window Regulator-Manual WINDOW REGULATOR-MANUAL REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 6068 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Front Door Panel. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 7. Remove the two bolts (5) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 6069 1. Install the window regulator (4) through the opening in the door (2). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolt (5) that secure the window regulator to the door and tighten all four regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (2) to the position shown and remove the manual window crank. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Install the waterdam. 9. Install the inner belt molding. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Remove the front glass run channel, Refer to Window Track. 2. Disconnect the actuator rod (1) from the exterior door handle (2). 3. Remove the two nuts (3) that secure the exterior door handle to the door and remove the handle. INSTALLATION 1. Position the exterior handle (2) into the door. 2. Install the two nuts (3) that secure the exterior handle to the door. Tighten the nuts to 10 N.m (89 in.lbs.). 3. Connect the actuator rod (1) to the exterior handle. 4. Install the front glass run channel, Refer to Window Track. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair Rear Door Interior Handle: Service and Repair INTERIOR HANDLE ACTUATOR REMOVAL 1. Remove the door trim panel. 2. Position the waterdam out of the way and disconnect the actuator rod (2) from interior door handle actuator (3). 3. Remove the two bolts (1) that secure the interior door handle actuator to the door and remove the actuator. INSTALLATION 1. Position the interior door handle actuator (3) onto the door. 2. Install the two bolts (1) that secure the interior door handle actuator to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 3. Connect the actuator rod (2) to the interior door handle actuator. 4. Reposition the waterdam and install the door trim panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair Rear Door Hinge: Service and Repair HINGE REMOVAL NOTE: - It is not necessary to remove the door to replace the hinges if they are replaced one at a time. - The epoxy coated washers should not be removed from the hinge. If the washers are removed the door may have to be re-adjusted. 1. Open the front door UPPER HINGE 1. Using a grease pencil or equivalent, mark the position of the hinge (2) on the door and b-pillar. 2. Remove the nut (1) and bolt (9) attaching the hinge (2) to the door. 3. Remove the three bolts (6) attaching the hinge to the b-pillar and remove the hinge. LOWER HINGE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Page 6081 1. Using a grease pencil or equivalent, mark the position of the hinge on the door and b-pillar. 2. Remove the lower b-pillar trim. Refer to Trim Panel. 3. Remove the nut (1) and bolt (9) attaching the hinge to the door. 4. Remove the two bolts (5) attaching the hinge to the b-pillar. 5. From the inside of the vehicle remove the remaining bolt (4) attaching the hinge to the b-pillar and remove the hinge. INSTALLATION UPPER HINGE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Page 6082 1. Install the hinge to door washers, if there were removed previously, nut (1) and bolt (9) and tighten to 28 N.m (21 ft.lbs.). 2. Tighten the upper hinge bolt (2) to 28 N.m (21 ft.lbs.). 3. Tighten the upper hinge bolt (1) to 28 N.m (21 ft.lbs.). 4. Tighten the upper hinge bolt (3) to 28 N.m (21 ft.lbs.). 5. Adjust the door if needed. LOWER HINGE Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Page 6083 1. Install the hinge and install the b-pillar bolts. 2. Tighten the upper hinge bolt (2) to 28 N.m (21 ft.lbs.). 3. Tighten the upper hinge bolt (1) to 28 N.m (21 ft.lbs.). 4. Tighten the upper hinge bolt (3) to 28 N.m (21 ft.lbs.). 5. Install the hinge to door washers, if there were removed previously, nut and bolt and tighten to 28 N.m (21 ft.lbs.). 6. Adjust the door if needed. 7. Install the lower b-pillar trim. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams Rear Door Latch: Diagrams Latch-Door-Left Rear (Base) Latch-Door-Left Rear (Power Locks) Latch-Door-Right Rear (Base) Latch-Door-Right Rear (Power Locks) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 6087 Rear Door Latch: Adjustments ADJUSTMENTS 1. Locate the access hole in the door to adjust the door latch (1) and remove the mylar tape (2). 2. Loosen the adjustment screw (3). 3. Operate the door handles several times to reduce any possible linkage binding and tighten the adjustment screw to 3 N.m (30 in.lbs.). 4. Operate the door handles again to verify proper operation and reinstall the mylar tape. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 6088 Rear Door Latch: Service and Repair LATCH REMOVAL 1. Raise the window to the full up position and remove the door trim panel. 2. Position the waterdam out of the way and disconnect the actuator rod (1) from the interior door handle actuator (2) and the door latch (5) and remove the rod. 3. Disconnect the two actuator rods (3 and 4) from the door latch. 4. Disconnect the door wire harness connector (2) from the door latch (3). 5. Remove the three bolts (4) that secure the door latch to the door (1) and remove the latch. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 6089 1. Position the door latch (3) into the door (1). 2. Install the three bolts (4) that secure the door latch to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 3. Connect the door wire harness connector (2) to the door latch. 4. Connect the two actuator rods (3 and 4) to the door latch (5) 5. Connect the actuator rod (1) to the door latch and the interior door handle actuator (2). 6. Reposition the waterdam to the door and install the door trim panel. 7. If necessary, adjust the latch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Procedures Rear Door Panel: Procedures Trim Panel REMOVAL 1. Remove the screw (3) that secures the interior door handle (2) to the interior door handle actuator (1). 2. Remove the interior door handle from the interior door handle actuator. 3. If equipped, remove the manual window crank (1) using a window crank removal tool (2). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Procedures > Page 6094 4. Remove the screw (4) that secures the door trim panel (5) to the screw insert located in the center of the door (1). CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. 5. Lift the door trim panel straight upward to disconnect the molded plastic retaining clips (3) from the door. 6. If equipped, disconnect the door wire harness (2) from the power door switch assembly and remove the door trim panel. INSTALLATION 1. If equipped, connect the door wire harness (2) to the power door switch assembly. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not force the door trim panel onto the door or damage to the trim panel and/or the power switch assembly will occur. 2. Position the door trim panel (5) and align the molded plastic retaining clips (3) to the door (1). 3. Push the door trim panel straight downward until all of the retaining clips are fully engaged to the door. 4. Install the screw (4) that secures the door trim panel to the screw insert located in the center of the door. 5. if equipped, install the manual window crank. Water Dam REMOVAL 1. Remove the interior door handle actuator. 2. Remove the speaker. CAUTION: Do not allow the waterdam adhesive to become contaminated with dirt or other foreign substances. If the waterdam becomes contaminated or damaged, replace it. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Procedures > Page 6095 3. Carefully remove the waterdam (1) from around the perimeter of the rear door (2). 4. Separate the waterdam from the interior handle actuator rod and the door wire harness (if equipped) and remove the waterdam. INSTALLATION CAUTION: Do not allow the waterdam or adhesive to become contaminated with dirt or other foreign substances. If the waterdam becomes contaminated or damaged, replace it. NOTE: Be sure that the waterdam is fully sealed around the perimeter of the door. 1. Position the interior handle actuator rod and the wire harness (if equipped) through the holes in the waterdam (1) and install the waterdam to the door (2). 2. Install the speaker. 3. Install the interior door handle actuator. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Procedures > Page 6096 Rear Door Panel: Removal and Replacement Trim Panel TRIM PANEL REMOVAL 1. Remove the screw (3) that secures the interior door handle (2) to the interior door handle actuator(1). 2. Remove the interior door handle from the interior door handle actuator. 3. If equipped, remove the manual window crank (2) using a window crank removal tool (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Procedures > Page 6097 4. Remove the screw (4) that secures the door trim panel (5) to the screw insert located in the center of the door (1). CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. 5. Lift the door trim panel straight upward to disconnect the molded plastic retaining clips (3) from the door. 6. If equipped, disconnect the door wire harness (2) from the power door switch assembly and remove the door trim panel. INSTALLATION 1. If equipped, connect the door wire harness (2) to the power door switch assembly. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not force the door trim panel onto the door or damage to the trim panel and/or the power switch assembly will occur. 2. Position the door trim panel (5) and align the molded plastic retaining clips (3) to the door (1). 3. Push the door trim panel straight downward until all of the retaining clips are fully engaged to the door. 4. Install the screw (4) that secures the door trim panel to the screw insert located in the center of the door. 5. if equipped, install the manual window crank. Waterdam WATERDAM REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Procedures > Page 6098 1. Remove the interior door handle actuator. 2. Remove the speaker. CAUTION: Do not allow the waterdam adhesive to become contaminated with dirt or other foreign substances. If the waterdam becomes contaminated or damaged, replace it. 3. Carefully remove the waterdam (1) from around the perimeter of the rear door (2). 4. Separate the waterdam from the interior handle actuator rod and the door wire harness (if equipped) and remove the waterdam. INSTALLATION CAUTION: Do not allow the waterdam or adhesive to become contaminated with dirt or other foreign substances. If the waterdam becomes contaminated or damaged, replace it. NOTE: Be sure that the waterdam is fully sealed around the perimeter of the door. 1. Position the interior handle actuator rod and the wire harness (if equipped) through the holes in the waterdam (1) and install the waterdam to the door (2). 2. Install the speaker. 3. Install the interior door handle actuator. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments Rear Door Striker: Adjustments ADJUSTMENTS 1. Using a grease pencil or equivalent, mark the location of the door latch striker (1) on the C-pillar (2) to aid in adjustment. 2. Loosen the two bolts (3) that secure the door latch striker to the C-pillar. 3. To adjust the rear gap and flush measurement, change the position of the door latch striker and then tighten the two bolts to 28 N.m (21 ft.lbs.). 4. Verify correct door and latch position. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments > Page 6102 Rear Door Striker: Service and Repair LATCH STRIKER REMOVAL 1. Using a grease pencil or equivalent, mark the location of the door latch striker (1) on the C-pillar (2). 2. Remove the two bolts (3) that secure the door latch striker to the C-pillar and remove the striker. INSTALLATION 1. Position the door latch striker (1) onto the C-pillar (2) and loosely install the two bolts (3). 2. Align the door latch striker to the C-pillar using the reference marks made during the removal procedure and tighten the bolts to 28 N.m (21 ft.lbs.). 3. If necessary, adjust the door latch striker. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip Rear Door Weatherstrip: Service and Repair Drip Rail Weatherstrip DRIP RAIL WEATHERSTRIP REMOVAL 1. Open the doors and separate the weatherstrip (3) from the drip rail and a-pillar retainers (1 and 7). INSTALLATION 1. Position the weatherstrip (3) onto the drip rail and a-pillar retainers (1 and 7) and seat fully. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6107 Rear Door Weatherstrip: Service and Repair Door Opening Seal DOOR OPENING SEAL REMOVAL FRONT DOOR SEAL 1. Remove the cowl trim panel (1), Refer to Trim Panel. 2. If vehicle is a Standard Cab, remove the lower b-pillar trim panel (3), Refer to Trim Panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6108 3. If vehicle is a Quad Cab, remove the lower b-pillar trim panel (1), Refer to Trim Panel. 4. Separate the front door opening seal (6) from the door opening flange. REAR DOOR SEAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6109 1. Remove the lower b-pillar trim panel (1), Refer to Trim Panel. 2. Remove the lower c-pillar trim (1), Refer to Trim Panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6110 3. Separate the rear door opening seal (5) from the door opening flange. INSTALLATION FRONT DOOR SEAL 1. Position the front door seal (6) to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. If vehicle is a Standard Cab, install the lower b-pillar trim (3). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6111 3. If vehicle is a Quad Cab, install the lower b-pillar trim (1). 4. Install the cowl trim panel (1). NOTE: When installing a new weatherstrip on the front door opening, remove the tear strip starting at the splice and moving around the front of the door to the back of the opening. REAR DOOR SEAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6112 1. Position the rear door seal to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. Install the lower c-pillar trim (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6113 3. Install the lower b-pillar trim (1). NOTE: When installing a new weatherstrip on the rear door opening, remove the tear strip starting at the splice and moving around the back of the door to the front of the opening. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel Rear Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL FRONT 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1) that secure the front glass run channel (2) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the front glass run channel. Mega Cab Models 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1 & 3) that secure the front glass run channel (2) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the front glass run channel. REAR Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6119 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (2) that secure the rear glass run channel (1) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the rear glass run channel. INSTALLATION FRONT 1. If removed, install the weatherstrip onto the front glass run channel (2). 2. Position the front glass run channel into the door through the door panel opening. 3. Install the two bolts (1) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Mega Cab Models Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6120 1. If removed, install the weatherstrip onto the front glass run channel (2). 2. Position the front glass run channel into the door through the door panel opening. 3. Install the two bolts (1 & 3) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. REAR 1. If removed, install the weatherstrip onto the rear glass run channel (1). 2. Position the rear glass run channel into the door through the door panel opening. 3. Install the two bolts (2) that secure the rear glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6121 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Molding REAR DOOR OUTER BELT MOLDING REMOVAL 1. Remove the screw (3) and separate the belt molding (1) from the door (2) flange from the back to the front. INSTALLATION 1. Position the belt molding (1) onto the door (2) flange and seat fully. 2. Install the screw (3). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6122 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Lower the glass. 2. Separate the rear door glass run weatherstrip (5) out of the door frame (2) and remove through the window opening. INSTALLATION NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the rear door glass run weatherstrip (5) into the door (2) through the window opening. 2. Position the weatherstrip (5) into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip (5) between the corners and then down the sides firmly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6123 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Molding REAR DOOR INNER BELT MOLDING REMOVAL 1. Remove the door trim panel (5). 2. Separate the belt molding (2) from the rear door mounting flange from the back to the front. INSTALLATION 1. Position the belt molding (2) and seat onto the rear door mounting flange fully. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6124 2. Install the door trim panel (5). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures Rear Door Window Regulator: Procedures REMOVAL 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (4) and the sight window (5) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (5) and remove the two nuts (3) that secure the regulator stabilizer (4) to the door (1). 7. Remove the two bolts (2) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 6129 1. Install the window regulator (5) through the opening in the door (1). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolts (2) that secure the window regulator to the door and tighten all four regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (4) onto the door and install the two nuts (3). Tighten the nuts to 10 N·m (89 in. lbs.). 5. Raise the window regulator (3) to the position shown and remove the manual window crank. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Install the waterdam. 9. Install the inner belt molding. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 6130 Rear Door Window Regulator: Removal and Replacement Window Regulator-Power WINDOW REGULATOR-POWER REMOVAL 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Rear Door Panel. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (5) and the sight window (4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (2) and remove the two nuts that secure the regulator stabilizer to the door. 8. Remove the lower bolt (1) that secures the window regulator to the door and loosen the other two regulator bolts. 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (3). INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 6131 1. Connect the door wire harness (3) to the window regulator (2) and install the regulator through the opening in the door. 2. Engage the two upper regulator bolts (1) to the door. 3. Install the lower regulator bolt that secures the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer into the door and install the two nuts. Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (3) to the position shown. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator (3) through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Window Regulator-Manual WINDOW REGULATOR-MANUAL REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 6132 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Rear Door Panel. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (5) and the sight window (4) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (5) and remove the two nuts (3) that secure the regulator stabilizer (4) to the door (1). 7. Remove the two bolts (2) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 6133 1. Install the window regulator (5) through the opening in the door (1). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolts (2) that secure the window regulator to the door and tighten all four regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (4) onto the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (3) to the position shown and remove the manual window crank. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Install the waterdam. 9. Install the inner belt molding . Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair Fuel Door: Service and Repair FUEL FILL DOOR REMOVAL 1. Open the fuel filler door (1). 2. Remove the two bolts (2) that secure the fuel filler door to the cargo box and remove the door. INSTALLATION 1. Position and align the fuel filler door (1) to the cargo box. 2. Install the two bolts (2) that secure the fuel filler door to the cargo box. Tighten the bolts to 9 N.m (80 in.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair Hood Hinge: Service and Repair HINGE NOTE: It is not necessary to remove the hood to replace the hood hinges. Hood hinges can be replaced one at a time. REMOVAL 1. Remove the cowl grille. 2. Using a grease pencil or equivalent, mark the position of the hood hinge (3) on the hood for the hinge being serviced. 3. Support the hood and disconnect the support cylinder from the hood, Refer to Hood Shock / Support. 4. Remove the two nuts that secure the hood to the hood hinge. 5. Remove the bolt (2) that secures the front fender (1) to the hood hinge. 6. Remove the wheelhouse splash shield. 7. Remove the bolts (3) that secure the hood hinge (2) to the fender rail (1). 8. Slide the hood hinge forward and remove the hinge. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Page 6141 1. Position the hood hinge (2) onto the fender rail (1) and slide it rearward to its installed location. 2. Install the bolts (3) that secure the hood hinge to the fender rail. Tighten the bolts to 20 N.m (15 ft.lbs.). 3. Install the bolt (2) that secures the front fender (1) to the hood hinge (3). Tighten the bolt to 12.5 N.m (9 ft.lbs.). 4. Loosely install the two nuts that secure the hood to the hood hinge. 5. Align the hood to the hood hinge using the reference marks made during the Removal procedure and tighten the nuts to 23 N.m (17 ft.lbs.). 6. Install the support cylinder. 7. If required, adjust the hood to the correct position. 8. Install the wheelhouse splash shield. 9. Install the cowl grille. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Latch Hood Latch: Service and Repair Latch LATCH REMOVAL 1. Using a grease pencil or equivalent, mark the position of the hood latch (1) on the upper radiator crossmember. 2. Remove the two bolts (3) that secure the hood latch to the upper radiator crossmember. 3. Disconnect the hood latch cable (2) from the hood latch and remove the latch. INSTALLATION 1. Connect the hood latch cable (2) to the hood latch (1). 2. Position the hood latch to the upper radiator cross-member and loosely install the two bolts (3) that secure the latch to the crossmember. 3. Align the hood latch to the upper radiator cross-member using the reference marks made during the Removal procedure and tighten the bolts to 11 N.m (8 ft.lbs.). 4. If required, adjust the hood to the correct position. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Latch > Page 6146 Hood Latch: Service and Repair Latch Striker/Secondary Catch LATCH STRIKER/SECONDARY CATCH REMOVAL 1. Disconnect the release handle (4) from the secondary hood latch and striker assembly (2) and remove the handle from the grille frame (5). 2. Remove the two bolts (3) that secure the secondary hood latch and striker assembly to the hood and remove the assembly. INSTALLATION 1. Position the secondary hood latch and striker assembly (2) to the hood. 2. Install the two bolts (3) that secure the secondary hood latch and striker assembly to the hood. Tighten the bolts to 11 N.m (8 ft.lbs.). 3. Install the release handle (4) through the grille frame (5) and connect it to the secondary hood latch. 4. If required, adjust the hood to the correct position. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair Hood Latch Release Cable: Service and Repair LATCH RELEASE CABLE/HANDLE ASSEMBLY REMOVAL 1. Remove the hood latch. 2. Remove the battery tray from the left side of the engine compartment. 3. Remove the three hood release cable retainers from the upper radiator crossmember and the left fender rail. 4. From inside the vehicle, remove the two bolts (1) that secure the hood release handle (2) to the instrument panel bracket (3). 5. Remove the grommet (4) from the cowl panel and remove the hood release cable and handle assembly. INSTALLATION 1. Route the hood release cable through the cowl panel and install the grommet (4). 2. Position the hood release handle (2) onto the instrument panel bracket (3). 3. Install the two bolts (1) that secure the hood release handle to the instrument panel bracket. Tighten the bolts to 9 N.m (80 in.lbs.). 4. Route the hood release cable along the left fender rail and the upper radiator crossmember and install the three hood release cable retainers. 5. Install the battery tray to the left side of the engine compartment. 6. Install the hood latch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair Hood Shock / Support: Service and Repair SUPPORT CYLINDER REMOVAL NOTE: The hood support cylinders can be replaced one at a time. 1. Open and support the hood. CAUTION: Do not pull on the hood support cylinders at the middle of the support cylinder during removal. Failure to follow this caution can result in damage to the hood support cylinders. 2. Using a small flat bladed tool, or equivalent (3), release the retaining clip (2) at each end of the support cylinder while carefully pulling the ball socket (1) away from the ball stud (4). NOTE: Lift the clips (1) only enough to release the ball studs (3). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair > Page 6153 3. Disconnect the hood support cylinder (5) from the hood (1) and the fender rail (3). 4. If required, remove the upper ball stud (2) from hood and the lower ball stud (4) from the fender rail. INSTALLATION 1. If removed, install the upper ball stud (2) onto the hood (1) and the lower ball stud (4) onto the fender rail (3). Install the ball studs securely. CAUTION: Do not push on the hood support cylinders at the middle of the support cylinder during installation. Failure to follow this caution can result in damage to the hood support cylinders. NOTE: Install the hood support cylinders with the cylinder end connected to the hood as shown. - If required, only release each retaining clip enough to install the ball socket onto the ball stud. 2. Install the hood support cylinder (5) over the upper and lower ball studs and fully engage the retaining clips. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Striker > Component Information > Service and Repair Hood Striker: Service and Repair LATCH STRIKER/SECONDARY CATCH REMOVAL 1. Disconnect the release handle (4) from the secondary hood latch and striker assembly (2) and remove the handle from the grille frame (5). 2. Remove the two bolts (3) that secure the secondary hood latch and striker assembly to the hood and remove the assembly. INSTALLATION 1. Position the secondary hood latch and striker assembly (2) to the hood. 2. Install the two bolts (3) that secure the secondary hood latch and striker assembly to the hood. Tighten the bolts to 11 N.m (8 ft.lbs.). 3. Install the release handle (4) through the grille frame (5) and connect it to the secondary hood latch. 4. If required, adjust the hood to the correct position. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair Body Emblem: Service and Repair EXTERIOR NAME PLATES NOTE: Mega Cab model shown in the illustration. Exterior name plates and decals for all other cab models are similar. Exterior name plate and decal usage vary by model. REMOVAL Name Plates 1. As a guide for installation, apply a length of masking tape on the body (1), parallel to the top edge and, to one end of the name plate or decal (2) being removed. CAUTION: Do not exceed 52 degrees C (120 degrees F) when heating name plates, decals or body panels. Failure to follow this caution may result in damage to the name plates, decals and/or the vehicle paint finish. 2. If the temperature is below 21 degrees C (70 degrees F), warm the name plate or decal with a heat lamp or heat gun. NOTE: The exterior name plates are attached to the body with adhesive tape. 3. Using a trim stick C-4755 or equivalent, carefully remove the name plate or decal from the body panel, as necessary. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Page 6161 Name Plates 1. Thoroughly clean all residue from the name plate or decal attachment areas of the body (1). 2. Wipe the attachment areas with a clean, lint-free cloth, moistened with a 50% solution of water and alcohol and then wipe dry the areas immediately with a dry, lint-free cloth. CAUTION: Do not exceed 52 degrees C (120 degrees F) when heating name plates, decals or body panels. Failure to follow this caution may result in damage to the name plates, decals and/or the vehicle paint finish. NOTE: If ambient temperatures are below 21 degrees C (70 degrees F), warm the name plate or decal and body panel with a heat lamp or gun to assure proper adhesion. 3. Remove the protective covering from the back of name plate or decal (2) and position the name plate or decal onto the body using the previously installed guide tape. NOTE: To ensure proper name plate or decal adhesion, apply consistent and uniform pressure of approximately 40 p.s.i. over the entire surface of each name plate or decal. 4. Install the name plate or decal onto the body. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Bug Guard > Component Information > Technical Service Bulletins > Customer Interest for Bug Guard: > 23-011-04 > Apr > 04 > Body - Bug Deflector Loose Rattling Bug Guard: Customer Interest Body - Bug Deflector Loose Rattling NUMBER: 23-011-04 GROUP: Body DATE: April 20, 2004 SUBJECT: Bug Deflector Loose/Rattling OVERVIEW: This bulletin involves replacing the bug deflector fasteners. MODELS: 2003 - 2004 (DR) Ram Truck NOTE: This Bulletin Applies To Vehicles Equipped With A Factory Installed Bug Deflector, Sales Code MXB. SYMPTOM/CONDITION: The bug deflector or air dam located on the front of the hood may become loose and rattle. The deflector could become dislodged in an automatic car wash. DIAGNOSIS: If the condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Remove the original fasteners and install new fasteners, p/n 06508197AA. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Bug Guard > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Bug Guard: > 23-011-04 > Apr > 04 > Body - Bug Deflector Loose Rattling Bug Guard: All Technical Service Bulletins Body - Bug Deflector Loose Rattling NUMBER: 23-011-04 GROUP: Body DATE: April 20, 2004 SUBJECT: Bug Deflector Loose/Rattling OVERVIEW: This bulletin involves replacing the bug deflector fasteners. MODELS: 2003 - 2004 (DR) Ram Truck NOTE: This Bulletin Applies To Vehicles Equipped With A Factory Installed Bug Deflector, Sales Code MXB. SYMPTOM/CONDITION: The bug deflector or air dam located on the front of the hood may become loose and rattle. The deflector could become dislodged in an automatic car wash. DIAGNOSIS: If the condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: Remove the original fasteners and install new fasteners, p/n 06508197AA. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE REMOVAL 1. Remove the wiper arms. 2. Disconnect the cowl plenum washer hose from the washer supply hose at the molded plastic in-line fitting. 3. Remove the cowl weather seal from the front of the dash panel and the cowl grille (2). 4. Remove the six push pin fasteners (1) that secure the front of the cowl grille to the dash panel. 5. Remove the two screws (3) that secure the rear corners of the cowl grille to the dash panel and remove the grille. 6. If necessary, remove the washer nozzles and the cowl plenum washer hose from the cowl grille. INSTALLATION 1. If removed, install the washer nozzles and the cowl plenum washer hose onto the cowl grille (2). 2. Position the cowl grille onto the dash panel. 3. Install the two screws (3) and the six push-pin fasteners (1) that secure the cowl grille to the dash panel. 4. Install the cowl weather seal onto the front of the dash panel and the cowl grille. 5. Connect the cowl plenum washer hose to the washer supply hose at the molded plastic in-line fitting. 6. Install the wiper arms. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Body Side Moldings Lower Side Moulding / Trim: Service and Repair Body Side Moldings BODY SIDE MOLDINGS NOTE: Quad Cab model shown in the illustration. Body side moldings for Regular cab models are similar. REMOVAL 1. As a guide for installation, apply a length of masking tape on the rocker panels (1), parallel to the top edge and, to one end of the body side molding (2 and 3) being removed CAUTION: Do not exceed 52 degrees C (120 degrees F) when heating the moldings or rocker panels. Failure to follow this caution may result in damage to the moldings and/or the vehicle paint finish. 2. If the temperature is below 21 degrees C (70 degrees F), warm the body side moldings with a heat lamp or heat gun. NOTE: The body side moldings are attached to the cab with adhesive tape. 3. Using a trim stick C-4755 or equivalent, carefully remove the moldings from the rocker panels, as necessary. INSTALLATION 1. Thoroughly clean all residue from the molding attachment areas of the rocker panels (1). 2. Wipe the attachment areas with a clean, lint-free cloth, moistened with a 50% solution of water and alcohol and then wipe dry the areas immediately with a dry, lint-free cloth. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Body Side Moldings > Page 6182 CAUTION: Do not exceed 52 degrees C (120 degrees F) when heating the moldings or rocker panels. Failure to follow this caution may result in damage to the moldings and/or the vehicle paint finish. NOTE: If ambient temperatures are below 21 degrees C (70 degrees F), warm the body side molding and rocker panel with a heat lamp or gun to assure proper adhesion. 3. Remove the protective covering from the back of the body side molding (2 and 3) and position the molding onto the rocker panel using the previously installed guide tape. NOTE: To ensure proper molding adhesion, apply consistent and uniform pressure of approximately 40 p.s.i. over the entire surface of each body side molding. 4. Install the body side molding onto the rocker panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Body Side Moldings > Page 6183 Lower Side Moulding / Trim: Service and Repair Cladding-Body Side-Box-SRT-10 CLADDING-BODY SIDE-BOX-SRT-10 REMOVAL 1. As a guide for installation, apply a length of masking tape on the cargo box (2), parallel to the top edge of the body side cladding (1) 2. Remove the three screws (1, 2 and 3) that secure the body side cladding to the rear of the cargo box. CAUTION: Do not exceed 52 degrees C (120 degrees F) when heating the cladding or body panels. Failure to follow this caution may result in damage to the cladding and/or the vehicle paint finish. 3. If the temperature is below 21 degrees C (70 degrees F), warm the body side cladding with a heat lamp or heat gun. NOTE: The body side cladding is attached to the cargo box with adhesive tape and w-type retainers. If required, apply 3M(TM) General Purpose Adhesive Cleaner or equivalent onto the cladding area to help loosen the adhesive tape. 4. Using a trim stick C-4755 or equivalent, disengage the w-clip retainers and remove and discard the cladding. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Body Side Moldings > Page 6184 1. Using 3M(TM) General Purpose Adhesive Cleaner or equivalent, remove any adhesive tape residue from the cargo box. NOTE: Install new cladding within 20 minutes of body panel cleaning. 2. Wipe the attachment areas (2) with a clean, lint-free cloth, moistened with a 50% solution of water and alcohol, starting 120 mm (4.75 in.) above the character line (1) and then wipe dry the areas immediately with a dry, lint-free cloth. CAUTION: Do not exceed 52 degrees C (120 degrees F) when heating the cladding or body panels. Failure to follow this caution may result in damage to the cladding and/or the vehicle paint finish. NOTE: If ambient temperatures are below 21 degrees C (70 degrees F), warm the body side cladding and body panel with a heat lamp or gun to assure proper adhesion. 3. Remove the protective covering from the adhesive tape (3) on the back of the body side cladding (1) and position the cladding onto the cargo box using the previously installed guide tape. NOTE: To ensure proper cladding adhesion, apply consistent and uniform pressure of approximately 40 p.s.i. over the entire surface of the cladding. 4. Install the body side cladding onto the cab. Fully seat the w-clip retainers (2). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Body Side Moldings > Page 6185 5. Install the three screws that secure the body side cladding to the rear of the cargo box in the sequence shown. Tighten the screws to 5 N.m (44 in.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Body Side Moldings > Page 6186 Lower Side Moulding / Trim: Service and Repair Cladding-Body Side-Cab-SRT-10 CLADDING-BODY SIDE-CAB-SRT-10 REMOVAL 1. As a guide for installation, apply a length of masking tape on the cab (2), parallel to the top edge of the body side cladding (1). CAUTION: Do not exceed 52 degrees C (120 degrees F) when heating the cladding or body panels. Failure to follow this caution may result in damage to the cladding and/or the vehicle paint finish. 2. If the temperature is below 21 degrees C (70 degrees F), warm the body side cladding with a heat lamp or heat gun. NOTE: The body side cladding is attached to the cab with adhesive tape. If required, apply 3M(TM) General Purpose Adhesive Cleaner or equivalent onto the cladding area to help loosen the adhesive tape. 3. Using a trim stick C-4755 or equivalent, remove and discard the cladding. INSTALLATION 1. Using 3M(TM) General Purpose Adhesive Cleaner or equivalent, remove any adhesive tape residue from the cab. NOTE: Install new cladding within 20 minutes of body panel cleaning. 2. Wipe the attachment area (2) with a clean, lint-free cloth, moistened with a 50% solution of water and alcohol, starting 120 mm (4.75 in.) above the character line (1) and then wipe dry the area immediately with a dry, lint-free cloth. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Body Side Moldings > Page 6187 CAUTION: Do not exceed 52 degrees C (120 degrees F) when heating the cladding or body panels. Failure to follow this caution may result in damage to the cladding and/or the vehicle paint finish. NOTE: If ambient temperatures are below 21 degrees C (70 degrees F), warm the body side cladding and body panel with a heat lamp or gun to assure proper adhesion. 3. Remove the protective covering from the adhesive tape on the back of the body side cladding (1) and position the cladding onto the cab using the previously installed guide tape. NOTE: To ensure proper cladding adhesion, apply consistent and uniform pressure of approximately 40 p.s.i. over the entire surface of the cladding. 4. Install the body side cladding onto the cab. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Body Side Moldings > Page 6188 Lower Side Moulding / Trim: Service and Repair Cladding-Body Side-Door-SRT-10 CLADDING-BODY SIDE-DOOR-SRT-10 REMOVAL 1. As a guide for installation, apply a length of masking tape on the door (2), parallel to the top edge of the body side cladding (1). CAUTION: Do not exceed 52 degrees C (120 degrees F) when heating the cladding or body panels. Failure to follow this caution may result in damage to the cladding and/or the vehicle paint finish. 2. If the temperature is below 21 degrees C (70 degrees F), warm the body side cladding with a heat lamp or heat gun. NOTE: The body side cladding is attached to the door panel with adhesive tape and push-pin type retainers. If required, apply 3M(TM) General Purpose Adhesive Cleaner or equivalent onto the cladding area to help loosen the adhesive tape. 3. Using a trim stick C-4755 or equivalent, disengage the push-pin retainers and remove and discard the cladding. INSTALLATION 1. Using 3M(TM) General Purpose Adhesive Cleaner or equivalent, remove any adhesive tape residue from the door panel. NOTE: Install new cladding within 20 minutes of body panel cleaning. 2. Wipe the attachment area (2) with a clean, lint-free cloth, moistened with a 50% solution of water and alcohol, starting 120 mm (4.75 in.) above the character line (1) and then wipe dry the area immediately with a dry, lint-free cloth. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Body Side Moldings > Page 6189 CAUTION: Do not exceed 52 degrees C (120 degrees F) when heating the cladding or body panels. Failure to follow this caution may result in damage to the cladding and/or the vehicle paint finish. NOTE: If ambient temperatures are below 21 degrees C (70 degrees F), warm the body side cladding and body panel with a heat lamp or gun to assure proper adhesion. 3. Remove the protective covering from the adhesive tape on the back of the body side cladding (2) and position the cladding onto the door panel using the previously installed guide tape. NOTE: To ensure proper cladding adhesion, apply consistent and uniform pressure of approximately 40 p.s.i. over the entire surface of the cladding. 4. Install the body side cladding onto the door panel using the locating pin (1). Fully engage the push-pin retainers (3). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Body Side Moldings > Page 6190 Lower Side Moulding / Trim: Service and Repair Cladding-Body Side-Fender-SRT-10 CLADDING-BODY SIDE-FENDER SRT-10 REMOVAL 1. As a guide for installation, apply a length of masking tape on the body panel, parallel to the top edge and, to one end of the body side cladding (1). 2. Remove the two screws (3) that secure the body side cladding to the front fender (2). CAUTION: Do not exceed 52 degrees C (120 degrees F) when heating the cladding or body panels. Failure to follow this caution may result in damage to the cladding and/or the vehicle paint finish. 3. If the temperature is below 21 degrees C (70 degrees F), warm the body side cladding with a heat lamp or heat gun. NOTE: The body side cladding is attached to the body panel with adhesive tape. If required, apply 3M(TM) General Purpose Adhesive Cleaner or equivalent onto the cladding area to help loosen the adhesive tape. 4. Using a trim stick C-4755 or equivalent, remove and discard the cladding. INSTALLATION 1. Using 3M(TM) General Purpose Adhesive Cleaner or equivalent, remove any adhesive tape residue from the front fender. NOTE: Install new cladding within 20 minutes of body panel cleaning. 2. Wipe the attachment area (2) with a clean, lint-free cloth, moistened with a 50% solution of water and alcohol, starting 120 mm (4.75 in.) above Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Body Side Moldings > Page 6191 the character line (1) and then wipe dry the area immediately with a dry, lint-free cloth. CAUTION: Do not exceed 52 degrees C (120 degrees F) when heating the cladding or body panels. Failure to follow this caution may result in damage to the cladding and/or the vehicle paint finish. NOTE: If ambient temperatures are below 21 degrees C (70 degrees F), warm the body side cladding and body panel with a heat lamp or gun to assure proper adhesion. 3. Remove the protective covering from the back of the body side cladding and position the cladding onto the front fender using the previously installed guide tape. NOTE: To ensure proper cladding adhesion, apply consistent and uniform pressure of approximately 40 p.s.i. over the entire surface of the cladding. 4. Install the body side cladding onto the front fender. 5. Install the two screws (3) that secure the body side cladding to the front fender. Tighten the screws to 5 N.m (44 in.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Underbody Cover > Component Information > Service and Repair Underbody Cover: Service and Repair BELLY PAN-SRT-10 REMOVAL 1. Remove the fifteen screws (1) that secure the belly pan to the front bumper (2) and the vehicle under-body. 2. Remove the belly pan from under the front of the vehicle. INSTALLATION 1. Position the belly pan (2) under the front of the vehicle. 2. Install the fifteen screws (1) that secure the belly pan to the front bumper (3) and the vehicle under-body. Tighten the screws securely. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair FRONT WHEELHOUSE SPLASH SHIELD REMOVAL 1. Open the hood and disengage any wiring or component retaining clips from the front splash shield (4) (depending on application and shield being serviced). 2. Raise and support the vehicle. 3. Remove the eight screws (3) that secure the front splash shield to the fender rail (1) and the front fender (2). 4. Disconnect the front splash shield from the support bracket located on the front bumper and remove the splash shield. INSTALLATION 1. Install the front edge of the front splash shield (4) into the support bracket located on the front bumper. 2. Position the front splash shield onto the fender rail (1) and the front fender (2). 3. Install the eight screws (3) that secure the front splash shield to the fender rail and the front fender. Tighten the screws to 5 N.m (44 in.lbs.). 4. Lower the vehicle and engage any wiring or component retaining clips to the front splash shield (depending on application and shield being serviced). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair Rear Fender Liner: Service and Repair REAR WHEELHOUSE SPLASH SHIELD REMOVAL 1. Raise and support the vehicle. 2. Remove the three screws (2) that secure the rear splash shield (3) to the cargo box (1) and remove the splash shield. INSTALLATION 1. Position the rear splash shield (3) onto the cargo box (1). 2. Install the three screws (2) that secure the rear splash shield to the cargo box. Tighten the screws to 5 N.m (44 in.lbs.). 3. Lower the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair Body / Frame Mount Bushing: Service and Repair BODY ISOLATORS NOTE: Quad Cab model shown in the illustration. Body isolators for Regular cab models are similar. REMOVAL 1. Loosen all cab to frame mounting bolts (5) (six Regular cab, eight Quad Cab). 2. Remove the mounting bolts and rebound cushions (3) as necessary. NOTE: If servicing the rear isolators (2), remove the reinforcement plates (6) and the washers (4). 3. Using a floor jack and wooden block under the cab sill (1), lift the body to gain access to the isolators and remove the isolators as necessary. INSTALLATION 1. Position the isolators (2) under the cab as necessary. CAUTION: If servicing the rear isolators, install the reinforcement plates (6) and the washers (4). 2. Lower the cab onto the isolators and install the mounting bolts (5) and rebound cushions (3) as necessary (six Regular cab, eight Quad Cab). 3. Tighten the mounting bolts to 81 N.m (60 ft.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair Front Cross-Member: Service and Repair TRANSMISSION CROSSMEMBER REMOVAL 1. Raise and support the vehicle. 2. Remove the transfer case skid plate (3-if equipped). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Page 6212 3. Support the transmission (1) with a transmission jack (2) or suitable lifting device. 4. 2WD Vehicles-Remove the transmission mount nuts (3). 5. Remove the bolts and remove the crossmember (2). 6. 4WD Vehicles-Remove the transmission mount nuts (5). 7. Remove the bolts (3) and remove the crossmember (4). INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Page 6213 1. On Light Duty Vehicles, install the crossmember (2) and the bolts (4). Tighten the bolts to 102 N.m (75 ft.lbs.). 2. Install the transmission mount nuts and tighten to 54 N.m (40 ft.lbs.). 3. On Heavy Duty Vehicles, install the crossmember (4) and the bolts (3). Tighten the bolts to 115 N.m (85 ft.lbs.). 4. Install the transmission mount nuts and tighten to 54 N.m (40 ft.lbs.). 5. Remove the transmission support (2). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Page 6214 6. Install the transfer case skid plate (3-if equipped). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Front Skid Plate Skid Plate: Service and Repair Front Skid Plate FRONT SKID PLATE REMOVAL 1. Raise and support the vehicle. 2. Remove the bolts (3). 3. Slide skid plate (2) back off of the crossmember (1) and remove. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Front Skid Plate > Page 6219 1. Snap the rear tabs over the front crossmember (1) and install the skid plate (2). 2. Install the bolts (3) and tighten to 34 N.m (25 ft.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Front Skid Plate > Page 6220 Skid Plate: Service and Repair Transfer Case Skid Plate TRANSFER CASE SKID PLATE REMOVAL 1. Raise and support the vehicle. 2. Support the skid plate (3) and remove the bolts (4). 3. Remove the skid plate (3). 4. Support the skid plate crossmember (2) and remove the bolts (1). 5. Remove the skid plate crossmember (2). INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Front Skid Plate > Page 6221 1. Install the skid plate crossmember (2) and bolts (1). 2. Tighten the bolts (1) to 34 N.m (25 ft.lbs.). 3. Install the skid plate (3) and bolts (4). 4. Tighten the bolts (4) to 34 N.m (25 ft.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair TRAILER HITCH REMOVAL 1. Remove the rear bumper. 2. On Light Duty Vehicles, remove the hitch bolts (7) 3. On Heavy Duty Vehicles, remove the hitch bolts (8) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 6225 4. Disconnect all wire harness support push pins. 5. Remove the rear two cargo box bolts (3) and loosen the remaining bolts. 6. Using a suitable lifting device, lift and support the rear of the cargo box and remove the hitch. INSTALLATION 1. On Light Duty Vehicles, install the hitch (5) onto the frame rails and make sure the locators (1 and 2) on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly. 2. Install the hitch bolts (7) and tighten to 170 N.m (125 ft.lbs.). 3. Connect all wire harness support push pins. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 6226 4. On Heavy Duty Vehicles, install the hitch (5) onto the frame rails and make sure the locators (1 and 2) on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly. 5. Install the hitch bolts (8) and tighten to 170 N.m (125 ft.lbs.). 6. Connect all wire harness support push pins. 7. Lower the cargo box and install the rear bolts (3). 8. Install the rear bumper. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Grille Grille: Service and Repair Grille GRILLE REMOVAL 1. Open the hood (2) and remove the six screws (5) that secure the grille (3) to the grille frame (4). 2. Remove the six nuts (1) that secure the grille to the hood and remove the grille. 3. If required, remove the grille frame from the hood. INSTALLATION 1. If removed, install the grille frame (4). 2. Position and align the grille (3) onto the hood (2) 3. Install the six nuts (1) that secure the grille to the hood. Tighten the nuts to 5 N.m (44 in.lbs.). 4. Install the six screws (5) that secure the grille to the grille frame. Tighten the screws to 2.2 N.m (20 in.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Grille > Page 6234 Grille: Service and Repair Grille Frame GRILLE FRAME REMOVAL 1. Remove the grille. 2. Remove the six screws (3) that secure the grille frame (2) to the hood (1) and remove the frame. INSTALLATION 1. Position the grille frame (2) onto the hood (1). 2. Install the six screws (3) that secure the grille frame to the hood. Tighten the screws to 5 N.m (44 in.lbs.). 3. Install the grille. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair Arm Rest: Service and Repair CENTER ARMREST/SEAT BACK REMOVAL 1. Before proceeding with the following repair procedure, review all warnings and cautions. Refer to Seats / Service Precautions. NOTE: Do not reuse the seat fasteners, always replace with new ones. 2. Remove the center seat. 3. Disconnect the storage bin/cushion cover j-straps and position aside. 4. Remove and discard the hinge bolts (2) and separate the seat back from the storage bin/cushion (1). INSTALLATION 1. Before proceeding with the following repair procedure, review all warnings and cautions. Refer to Seats / Service Precautions. NOTE: Do not reuse the seat fasteners, always replace with new ones. 2. Install the seat back onto the storage bin/cushion (1) and install new hinge bolts (2). 3. Tighten the hinge to storage bin/cushion bolts (2) to 25 N.m (18 ft.lbs.). 4. Connect the storage bin/cushion cover j-straps. 5. Install the center seat. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair Ash Tray: Service and Repair REMOVAL 1. Open the ash receiver (3) and apply force in a downward motion to disengage the locking tabs (1) from the instrument panel (2). 2. Roll the ash receiver further downward and remove it from the instrument panel. INSTALLATION 1. Position the bottom of the ash receiver (3) into the opening of the instrument panel (2). 2. Pivot the ash receiver upward and fully seat the retaining clips (1) into the instrument panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Customer Interest: > 23-004-04 > Feb > 04 > Interior - Cup Holder Sticking/Binding Carpet: Customer Interest Interior - Cup Holder Sticking/Binding NUMBER: 23-004-04 GROUP: Body DATE: February 10, 2004 SUBJECT: Cup Holder Bind Or Sticks OVERVIEW: This bulletin involves adjusting the instrument panel trim to provide clearance for the cup holder. MODELS: 2004 (DR) Ram Truck SYMPTOM/CONDITION: DIAGNOSIS: Operate the cup holder. If the cup holder binds or will not open or only opens partially, perform the Repair Procedure. REPAIR PROCEDURE: 1. Using a plastic trim stick, or suitable tool, gently pry on each side of the Airbag Control Module (ACM) cover located under the cup holder and remove the ACM cover. 2. Operated the cup holder with the ACM cover removed. If the cup holder now operates freely, there is an interference between the ACM cover and bottom of the cup holder. If the cup holder binds with the ACM cover removed, proceed to Step 6. 3. Install the ACM cover and inspect the area where the cup holder and the ACM cover come together (Fig. 1). There must be a gap between the ACM cover and the bottom of the cup holder. If the ACM cover is in contact with cup holder, try realigning the cover by pushing the bottom of the cover towards the front. if this provides a gap and the cup holder now operates freely, the repair is complete. If the gap cannot be achieved by adjusting the ACM cover proceed to the next step. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Customer Interest: > 23-004-04 > Feb > 04 > Interior - Cup Holder Sticking/Binding > Page 6250 4. The ACM wire harness runs rearward along the left side of the tunnel under the carpet. (Fig. 2). Rub your hand along the carpet in the area of the bottom of the ACM cover and feel for the harness. If the harness can be felt, it may be pushing the ACM cover upward and into the cup holder. If this is happening it may be necessary to reroute the harness or remove carpet padding from the area. 5. Roll the carpet back and make sure that there are no plastic retainers in the area that could cause the interference. If a retainer is present remove it. Make sure that the harness is not sitting on a raised portion of the floor. If it is, reroute the harness to a lower area on the floor. Remove the any carpet padding from the area where the harness contacts the carpet to gain additional clearance. This should provide the clearance needed. and complete the repair. 6. Remove the cup holder. 7. Operate the cup holder out of the vehicle. If the cup holder still binds it must be replaced. If it operates freely, inspect the metal bracket where the cup holder fasteners attach as shown. (Fig. 3). If the bracket is bent, it could cause the cup holder to twist or distort when the screws are installed. Straighten the bracket and install the cup holder. If the cup holder operates freely the repair is complete. if the cup holder still binds, it must be replaced. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Customer Interest: > 23-004-04 > Feb > 04 > Interior - Cup Holder Sticking/Binding > Page 6251 TIME ALLOWANCE: FAILURE CODE: Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-004-04 > Feb > 04 > Interior - Cup Holder Sticking/Binding Carpet: All Technical Service Bulletins Interior - Cup Holder Sticking/Binding NUMBER: 23-004-04 GROUP: Body DATE: February 10, 2004 SUBJECT: Cup Holder Bind Or Sticks OVERVIEW: This bulletin involves adjusting the instrument panel trim to provide clearance for the cup holder. MODELS: 2004 (DR) Ram Truck SYMPTOM/CONDITION: DIAGNOSIS: Operate the cup holder. If the cup holder binds or will not open or only opens partially, perform the Repair Procedure. REPAIR PROCEDURE: 1. Using a plastic trim stick, or suitable tool, gently pry on each side of the Airbag Control Module (ACM) cover located under the cup holder and remove the ACM cover. 2. Operated the cup holder with the ACM cover removed. If the cup holder now operates freely, there is an interference between the ACM cover and bottom of the cup holder. If the cup holder binds with the ACM cover removed, proceed to Step 6. 3. Install the ACM cover and inspect the area where the cup holder and the ACM cover come together (Fig. 1). There must be a gap between the ACM cover and the bottom of the cup holder. If the ACM cover is in contact with cup holder, try realigning the cover by pushing the bottom of the cover towards the front. if this provides a gap and the cup holder now operates freely, the repair is complete. If the gap cannot be achieved by adjusting the ACM cover proceed to the next step. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-004-04 > Feb > 04 > Interior - Cup Holder Sticking/Binding > Page 6257 4. The ACM wire harness runs rearward along the left side of the tunnel under the carpet. (Fig. 2). Rub your hand along the carpet in the area of the bottom of the ACM cover and feel for the harness. If the harness can be felt, it may be pushing the ACM cover upward and into the cup holder. If this is happening it may be necessary to reroute the harness or remove carpet padding from the area. 5. Roll the carpet back and make sure that there are no plastic retainers in the area that could cause the interference. If a retainer is present remove it. Make sure that the harness is not sitting on a raised portion of the floor. If it is, reroute the harness to a lower area on the floor. Remove the any carpet padding from the area where the harness contacts the carpet to gain additional clearance. This should provide the clearance needed. and complete the repair. 6. Remove the cup holder. 7. Operate the cup holder out of the vehicle. If the cup holder still binds it must be replaced. If it operates freely, inspect the metal bracket where the cup holder fasteners attach as shown. (Fig. 3). If the bracket is bent, it could cause the cup holder to twist or distort when the screws are installed. Straighten the bracket and install the cup holder. If the cup holder operates freely the repair is complete. if the cup holder still binds, it must be replaced. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-004-04 > Feb > 04 > Interior - Cup Holder Sticking/Binding > Page 6258 TIME ALLOWANCE: FAILURE CODE: Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Other Service Bulletins for Carpet: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Clutch Control Solenoid Valve: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Page 6269 Carpet: Service and Repair CARPETS AND FLOOR MATS NOTE: Carpet for Quad Cab model shown. Regular cab similar. REMOVAL 1. Remove the front seats. 2. If equipped, remove the floor console. 3. If equipped, remove the three bolts (1) that secure the rear storage compartment (2) to the floor panel (3) and remove the storage compartment from the rear trim panel (4). 4. On Quad Cab models, remove the rear seats (1). 5. On Quad Cab models, remove the rear cup holder (2) using a trim stick C-4755 or equivalent. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Page 6270 6. Remove the lower B-pillar trim panels, Refer to Trim Panel. 7. On Quad Cab models, remove the bolt that secures the lower seat belt anchor to the floor panel near the B-pillars. 8. Remove the retaining screw (1) that secures the jack assembly (2) to the floor panel (3) and remove the jack assembly. 9. Remove the two bolts (4) that secure the jack assembly to the floor panel. 10. For trucks equipped with a scissor type jack, remove the bolts (1) and remove the jack (2). 11. Remove the screws and remove the load floor storage strap snaps (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Page 6271 12. On Quad Cab models, remove the eleven pushpin fasteners (1) that secure the rear of the carpet (2) to the floor panel (3). 13. Remove the carpet from the vehicle. INSTALLATION 1. Position the carpet (2) into the vehicle. 2. On Quad Cab models, install the eleven push-pin fasteners (1) that secure the carpet to the floor panel (3). 3. Install the load floor storage snaps and screws (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Page 6272 4. On trucks equipped with a scissor jack, install the jack and install the bolts (1). 5. Install the two bolts (4) that secure the jack assembly (2) to the floor panel (3). 6. Position the jack assembly onto the two bolts and install the retaining screw (1). Tighten the screw securely. 7. On Quad Cab models, install the bolt that secures the lower seat belt anchors the floor panel near the B-pillars. Tighten the bolt to 40 N.m (30 ft.lbs.). 8. Install the lower B-pillar trim panels. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Page 6273 9. On Quad Cab models, install the rear seat (1). 10. On Quad Cab models, install the rear cup holder (2). 11. If equipped, position the rear storage compartment (2) onto the rear cab trim panel (4) and install the three bolts (1). Tighten the bolts to 6 N.m (55 in.lbs.). 12. If equipped, install the floor console. 13. Install the front seats. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions Console: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6278 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6279 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6280 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6281 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6282 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6283 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6284 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6285 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6286 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6287 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6288 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6289 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6290 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6291 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6292 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6293 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6294 Console: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6295 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6296 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6297 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6298 Console: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-49-2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6299 8w-49-3 (NGC) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6300 8w-49-4 (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6301 8w-49-5 (Except SRT) Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 6302 Console: Service and Repair FLOOR CONSOLE REMOVAL Mini Floor Console 1. If equipped, remove the 4WD gear shift boot. 2. If equipped with a manual transmission, remove the transmission gear shift lever extension. 3. Remove the console inserts, if equipped. 4. Remove the bolts (2) that secure the rear console (1) to the floor panel. 5. Lift up the rear of the floor console to clear the gear shift lever, if equipped. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 6303 6. Remove the bolts (2) and separate the front console (3) from the floor. 7. Separate the front clips (1) and remove the mini console. Full Floor Console 1. Before proceeding with the following repair procedure, review all warnings and cautions. Refer to Seats / Service Precautions. 2. Using a trim stick C-4755 or equivalent, separate the seven front console bezel clips (2), lift up the back of the bezel (1) and remove. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 6304 3. Remove the bolts (1) and lift the rear of the base up to release the front guide pins (5). 4. Remove the front base (2). NOTE: Do not reuse the seat fasteners, always replace with new ones. 5. Remove and discard the front bolts (4). 6. Position the seats forward, remove the rear bolts (2) and discard. 7. Disconnect the 12 v power supply electrical connector (3-if equipped). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 6305 8. Fold the seat backs forward and roll the seat assembly (1) back in the vehicle. 9. Remove the nuts (2) attaching the center seat console (1) to the drivers seat and the passenger seat and discard. 10. Remove the nuts (4) attaching the center console (2) to the drivers seat (3) and the passenger seat in the rear of the seat and discard. 11. Disconnect the electrical connector (1-if equipped). 12. Roll the seat assembly forward and remove the center seat console. INSTALLATION Mini Floor Console Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 6306 1. Position the console and seat the front clips (1) fully. 2. Install the bolts (2). 3. Install the bolts (2) that secure the rear console (1) to the floor panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 6307 4. Install the inserts. 5. Install the gear shift lever extension. 6. Install the 4WD gear shift boot. Full Floor Console 1. Before proceeding with the following repair procedure, review all warnings and cautions. Refer to Seats / Service Precautions. NOTE: Do not reuse the seat fasteners, always replace with new ones. 2. Position the center seat console onto the front seat assembly and roll the seat assembly back in the vehicle. 3. Install new nuts (4) attaching the center console to the drivers (3) and passenger seat. 4. Connect the electrical connector (1-if equipped). 5. Tighten the nuts (4) to 25 N.m (18 ft.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 6308 6. Install new nuts (2) attaching the center console (1) to the drivers and passenger seat. 7. Tighten the nuts to 25 N.m (18 ft.lbs.). 8. Connect the electrical connector (3 and 5-if equipped). 9. Roll the seat assembly forward and install new rear bolts (2). 10. Connect the 12 v power supply electrical connector (3-if equipped). 11. Tighten the rear bolts to 40 N.m (30 ft.lbs.). 12. Fold the seat backs up and slide the seats to the rear. 13. Install new front bolts (4) and tighten to 28 N.m (21 ft.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING 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 disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > Customer Interest for Drink Holders: > 23-004-04 > Feb > 04 > Interior - Cup Holder Sticking/Binding Drink Holders: Customer Interest Interior - Cup Holder Sticking/Binding NUMBER: 23-004-04 GROUP: Body DATE: February 10, 2004 SUBJECT: Cup Holder Bind Or Sticks OVERVIEW: This bulletin involves adjusting the instrument panel trim to provide clearance for the cup holder. MODELS: 2004 (DR) Ram Truck SYMPTOM/CONDITION: DIAGNOSIS: Operate the cup holder. If the cup holder binds or will not open or only opens partially, perform the Repair Procedure. REPAIR PROCEDURE: 1. Using a plastic trim stick, or suitable tool, gently pry on each side of the Airbag Control Module (ACM) cover located under the cup holder and remove the ACM cover. 2. Operated the cup holder with the ACM cover removed. If the cup holder now operates freely, there is an interference between the ACM cover and bottom of the cup holder. If the cup holder binds with the ACM cover removed, proceed to Step 6. 3. Install the ACM cover and inspect the area where the cup holder and the ACM cover come together (Fig. 1). There must be a gap between the ACM cover and the bottom of the cup holder. If the ACM cover is in contact with cup holder, try realigning the cover by pushing the bottom of the cover towards the front. if this provides a gap and the cup holder now operates freely, the repair is complete. If the gap cannot be achieved by adjusting the ACM cover proceed to the next step. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > Customer Interest for Drink Holders: > 23-004-04 > Feb > 04 > Interior - Cup Holder Sticking/Binding > Page 6321 4. The ACM wire harness runs rearward along the left side of the tunnel under the carpet. (Fig. 2). Rub your hand along the carpet in the area of the bottom of the ACM cover and feel for the harness. If the harness can be felt, it may be pushing the ACM cover upward and into the cup holder. If this is happening it may be necessary to reroute the harness or remove carpet padding from the area. 5. Roll the carpet back and make sure that there are no plastic retainers in the area that could cause the interference. If a retainer is present remove it. Make sure that the harness is not sitting on a raised portion of the floor. If it is, reroute the harness to a lower area on the floor. Remove the any carpet padding from the area where the harness contacts the carpet to gain additional clearance. This should provide the clearance needed. and complete the repair. 6. Remove the cup holder. 7. Operate the cup holder out of the vehicle. If the cup holder still binds it must be replaced. If it operates freely, inspect the metal bracket where the cup holder fasteners attach as shown. (Fig. 3). If the bracket is bent, it could cause the cup holder to twist or distort when the screws are installed. Straighten the bracket and install the cup holder. If the cup holder operates freely the repair is complete. if the cup holder still binds, it must be replaced. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > Customer Interest for Drink Holders: > 23-004-04 > Feb > 04 > Interior - Cup Holder Sticking/Binding > Page 6322 TIME ALLOWANCE: FAILURE CODE: Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drink Holders: > 23-004-04 > Feb > 04 > Interior - Cup Holder Sticking/Binding Drink Holders: All Technical Service Bulletins Interior - Cup Holder Sticking/Binding NUMBER: 23-004-04 GROUP: Body DATE: February 10, 2004 SUBJECT: Cup Holder Bind Or Sticks OVERVIEW: This bulletin involves adjusting the instrument panel trim to provide clearance for the cup holder. MODELS: 2004 (DR) Ram Truck SYMPTOM/CONDITION: DIAGNOSIS: Operate the cup holder. If the cup holder binds or will not open or only opens partially, perform the Repair Procedure. REPAIR PROCEDURE: 1. Using a plastic trim stick, or suitable tool, gently pry on each side of the Airbag Control Module (ACM) cover located under the cup holder and remove the ACM cover. 2. Operated the cup holder with the ACM cover removed. If the cup holder now operates freely, there is an interference between the ACM cover and bottom of the cup holder. If the cup holder binds with the ACM cover removed, proceed to Step 6. 3. Install the ACM cover and inspect the area where the cup holder and the ACM cover come together (Fig. 1). There must be a gap between the ACM cover and the bottom of the cup holder. If the ACM cover is in contact with cup holder, try realigning the cover by pushing the bottom of the cover towards the front. if this provides a gap and the cup holder now operates freely, the repair is complete. If the gap cannot be achieved by adjusting the ACM cover proceed to the next step. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drink Holders: > 23-004-04 > Feb > 04 > Interior - Cup Holder Sticking/Binding > Page 6328 4. The ACM wire harness runs rearward along the left side of the tunnel under the carpet. (Fig. 2). Rub your hand along the carpet in the area of the bottom of the ACM cover and feel for the harness. If the harness can be felt, it may be pushing the ACM cover upward and into the cup holder. If this is happening it may be necessary to reroute the harness or remove carpet padding from the area. 5. Roll the carpet back and make sure that there are no plastic retainers in the area that could cause the interference. If a retainer is present remove it. Make sure that the harness is not sitting on a raised portion of the floor. If it is, reroute the harness to a lower area on the floor. Remove the any carpet padding from the area where the harness contacts the carpet to gain additional clearance. This should provide the clearance needed. and complete the repair. 6. Remove the cup holder. 7. Operate the cup holder out of the vehicle. If the cup holder still binds it must be replaced. If it operates freely, inspect the metal bracket where the cup holder fasteners attach as shown. (Fig. 3). If the bracket is bent, it could cause the cup holder to twist or distort when the screws are installed. Straighten the bracket and install the cup holder. If the cup holder operates freely the repair is complete. if the cup holder still binds, it must be replaced. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drink Holders: > 23-004-04 > Feb > 04 > Interior - Cup Holder Sticking/Binding > Page 6329 TIME ALLOWANCE: FAILURE CODE: Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > Page 6330 Drink Holders: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: - A storage bin replaces the cup holder in the instrument panel when the vehicle is equipped with a floor console. - If the cup holder is binding or sticking. 1. Remove the center bezel. 2. Remove the airbag control module cover. 3. Remove the four screws (1) that secure the cup holder (2) to the instrument panel. 4. Open the cup holder (2) and remove the two screws (1) that secure the cup holder to the instrument panel. 5. Remove the cup holder from the vehicle. Cup Holder Binds or Sticks Repair Procedure Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > Page 6331 1. Using a trim stick C-4755 or equivalent, gently pry on each side of the Airbag Control Module (ACM) cover located under the cup holder and remove the ACM cover. 2. Operated the cup holder with the ACM cover removed. If the cup holder now operates freely, there is an interference between the ACM cover and bottom of the cup holder. If the cup holder binds with the ACM cover removed, proceed to Step 6. 3. Install the ACM cover and inspect the area where the cup holder and the ACM cover come together (3). There must be a gap between the ACM cover and the bottom of the cup holder. If the ACM cover is in contact with cup holder, try realigning the cover by pushing the bottom of the cover towards the front, if this provides a gap and the cup holder now operates freely, the repair is complete. If the gap cannot be achieved by adjusting the ACM cover proceed to the next step. 4. The ACM wire harness (1) runs rearward along the left side of the tunnel under the carpet. Rub your hand along the carpet in the area of the bottom of the ACM cover and feel for the harness. If the harness can be felt, it may be pushing the ACM cover upward and into the cup holder. If this is happening it may be necessary to reroute the harness or remove carpet padding from the area. 5. Roll the carpet back and make sure that there are no plastic retainers in the area that could cause the interference. If a retainer is present remove it. Make sure that the harness is not sitting on a raised portion of the floor. If it is, reroute the harness to a lower area on the floor. Remove the any carpet padding from the area where the harness contacts the carpet to gain additional clearance. This should provide the clearance needed, and complete the repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > Page 6332 6. Remove the cup holder. 7. Operate the cup holder out of the vehicle. If the cup holder still binds it must be replaced. If it operates freely inspect the metal bracket (1) where the cup holder fasteners attach as shown. If the bracket is bent, it could cause the cup holder to twist or distort when the screws are installed. Straighten the bracket and install the cup holder. If the cup holder operates freely the repair is complete. if the cup holder still binds, it must be replaced. INSTALLATION NOTE: A storage bin replaces the cup holder in the instrument panel when the vehicle is equipped with a floor console. 1. Position the cup holder (2) into the instrument panel. 2. Install the four screws (1) that secure the cup holder to the instrument panel. Tighten the screws to 2.2 N.m (20 in.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > Page 6333 3. Open the cup holder (1) and install the two screws (2) that secure the cup holder to the instrument panel. Tighten the screws to 2.2 N.m (20 in.lbs.) . 4. Install the center bezel. 5. Install the airbag control module cover. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box Glove Compartment: Service and Repair Glove Box REMOVAL 1. Open the glove box (1). 2. Release the two glove box stops (2) and lower the glove box downward past the stops. 3. Disengage the glove box hinges from the instrument panel and remove the glove box. INSTALLATION 1. Engage the hinges of the glove box (1) to the instrument panel. 2. Press downward on the back edge of the glove box bin and raise the glove box past the two stops (2). 3. Close the glove box. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box > Page 6338 Glove Compartment: Service and Repair Glove Box Latch Replacement REMOVAL 1. Remove the glove box and place it on a workbench. 2. Remove the 15 screws (1) that secure the glove box bin (2) and the inner glove box door panel (3) to the outer glove box door panel (4). 3. Remove the glove box bin and the inner glove box door panel from the outer glove box door panel. 4. Remove the two screws (1) that secure the glove box latch (2) to the outer glove box door panel (3) and remove the latch. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box > Page 6339 1. Position the glove box latch (2) into the outer glove box door panel (3). 2. Install the two screws (1) that secure the glove box latch to the outer glove box door panel. Tighten the screws to 2 N.m (17 in.lbs.). 3. Position the inner glove box door panel (3) and the glove box bin (2) onto the outer glove box door panel (4). 4. Install the fifteen screws (1) that secure the inner glove box door panel and the glove box bin to the outer glove box door panel. Tighten the screws to 2 N.m (17 in.lbs.). 5. Install the glove box. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair HEADLINER NOTE: Headliner for Quad Cab model shown. Regular cab similar. REMOVAL 1. Remove the A-pillar trim panels, Refer to Trim Panel. 2. Remove the upper B-pillar trim panels, Refer to Trim Panel. 3. On Quad Cab models, remove the upper C-pillar trim panels, Refer to Trim Panel. 4. Disconnect the wire harness connector (1) located at the left A-pillar from the headliner wire harness (2). 5. Disconnect the headliner wire harness connector (3) from the inside rear view mirror. 6. Remove the overhead console. 7. Remove the sun visors (4). 8. Remove the sun visor supports (5). 9. Remove the dome lamp (6). 10. Remove the two coat hooks (7). 11. Lower the rear of the headliner (9) downward from the roof panel (10) and disconnect the headliner wire harness connector (8) from the center high mounted stop lamp. 12. Lower the front of the headliner downward and remove the headliner through the passenger door opening. INSTALLATION 1. Position the headliner (9) into the vehicle through the passenger door opening. 2. Connect the headliner wire harness connector (8) to the center high mounted stop lamp. 3. Raise the rear of the headliner upward and install the two coat hooks (7). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 6343 4. Raise the front of the headliner upward and install the sun visor supports (5). 5. Install the sun visors (4). 6. Install the dome lamp (6). 7. Install the overhead console. 8. Connect the headliner wire harness connector (3) to the inside rear view mirror. 9. Connect the headliner wire harness (2) to the wire harness connector (1) located at the left A-pillar. 10. On Quad Cab models, install the upper C-pillar trim panel. 11. Install the upper B-pillar trim panels. 12. Install the upper A-pillar trim panels. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sun Visor Sun Visor: Service and Repair Sun Visor SUN VISOR REMOVAL 1. Remove the three screws (1) that secure each sun visor (2) to the roof panel and remove the visor from the headliner (3). 2. If equipped, disconnect the wire harness connector for the illuminated vanity mirror (4). INSTALLATION 1. If equipped, connect the wire harness connector for the illuminated vanity mirror (4). 2. Position the sun visor (2) onto the headliner (3). 3. Install the three screws (1) that secure each sun visor to the roof panel. Tighten the screws to 2.2 N.m (20 in.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sun Visor > Page 6348 Sun Visor: Service and Repair Sun Visor Support SUN VISOR SUPPORT REMOVAL 1. Using a trim stick C-4755 or equivalent, disengage the release clip (3) as shown and remove the sun visor support (1) from the headliner (2) INSTALLATION 1. Position the sun visor support (1) through the headliner (2) and fully seat the base of the support to the roof panel. 2. Engage the release clip (3). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures Trim Panel: Procedures HEAT STAKING 1. Remove trim panel. 2. Bend or move the trim panel components at the heat staked joints. Observe the heat staked locations and/or component seams for looseness. 3. Heat stake the components. a. If the heat staked or component seam location is loose, hold the two components tightly together and using a soldering gun with a flat tip, melt the material securing the components together. Do not over heat the affected area, damage to the exterior of the trim panel may occur. b. If the heat staked material is broken or missing, use a hot glue gun to apply new material to the area to be repaired. The panels that are being heat staked must be held together while the applying the glue. Once the new material is in place, it may be necessary to use a soldering gun to melt the newly applied material. Do not over heat the affected area, damage to the exterior of the trim panel may occur. 4. Allow the repaired area to cool and verify the repair. 5. Install trim panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6353 Trim Panel: Removal and Replacement Cowl Trim COWL TRIM REMOVAL 1. Using a trim stick C-4755 or equivalent, disengage the retaining tabs of the cowl trim panel (1) from the retainer clips (2) in the door sill (3). 2. Pull the cowl trim panel rearward and remove it from the vehicle. INSTALLATION 1. Position the cowl trim panel (1) onto the door sill (3). 2. Push the cowl trim panel forward and then engage the retaining tabs that secure the sill trim panel to the rear door sill. Front Door Trim Panel TRIM PANEL REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6354 1. Remove the screw (1) that secures the interior door handle (2) to the interior door handle actuator (3). 2. Remove the interior door handle from the interior door handle actuator. 3. If equipped, remove the manual window crank (1) using a window crank removal tool (2). 4. Remove the two screws (2) that secure the door trim panel (3) to the two screw inserts (1). 5. Remove the two screws (4) that secure the door trim panel to the bottom of the door. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. 6. Lift the door trim panel straight upward to disconnect the molded plastic retaining clips (5) from the door. 7. If equipped, disconnect the door wire harness from the power door switch assembly and remove the door trim panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6355 INSTALLATION 1. If equipped, connect the door wire harness to the power door switch assembly. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not force the door trim panel onto the door or damage to the trim panel and/or the power switch assembly will occur. 2. Position the door trim panel (3) and align the molded plastic retaining clips (5) to the door. 3. Push the door trim panel straight downward until all of the retaining clips are fully engaged to the door. 4. Install the two screws (2) that secure the door trim panel to the two screw inserts (1). 5. Install the two screws (4) that secure the door trim panel to the bottom of the door. 6. if equipped, install the manual window crank. 7. Position the interior door handle (2) onto the interior door handle actuator (3). 8. Install the screw (1) that secures the interior door handle to the interior door handle actuator. Tighten the screw securely. Load Floor LOAD FLOOR REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6356 1. Move the rear seat cushion (1) to the up position. 2. Remove the two nuts (2) that secure the rear of the load floor (3) to the floor panel. 3. Move the load floor (2) to the up position. 4. Remove the two bolts (3) that secure the load floor to the floor panel (1) and remove the load floor. 5. If required, remove the support cylinder (4), Refer to Utility Storage Compartment. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6357 1. If removed, install the load floor support cylinder (4). 2. Position the load floor (2) into the vehicle and install the two bolts (3) that secure it to the floor panel (1). Tighten the bolts to 40 N.m (30 ft.lbs.). 3. Move the load floor (3) to the down position and install the two nuts (2) that secure the load floor to the floor panel. Tighten the nuts to 25 N.m (18 ft.lbs.). 4. Move the rear seat cushion (1) to the down position. A-Pillar Trim A-PILLAR TRIM/GRAB HANDLE REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6358 1. Using a small flat-bladed tool, carefully open the two fastener covers (3) located in the a-pillar trim panel (2). 2. Remove the two bolts (4) that secure the a-pillar trim panel to the a-pillar (1) and remove the trim panel. INSTALLATION 1. Position the locating tab of the A-pillar trim panel (2) into the slot located in the top of the instrument panel. 2. Install the A-pillar trim panel onto the A-pillar (1) and install the two bolts (4). Tighten the bolts to 6 N.m (55 in.lbs.). 3. Close the two fastener covers (3) located in the A-pillar trim panel. B-Pillar Grab Handle B-PILLAR GRAB HANDLE REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6359 1. Using a small flat-bladed tool, carefully open the two fastener covers (2) located on the grab handle (1). 2. Remove the two bolts (3) that secure the grab handle to the B-pillar and remove the grab handle. INSTALLATION 1. Install the grab handle (1) onto the B-pillar and install the two bolts (3). Tighten the bolts to 6 N.m (55 in.lbs.). 2. Close the two fastener covers (2) located on the grab handle. B-Pillar Lower Trim B-PILLAR LOWER TRIM REMOVAL REGULAR CAB Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6360 1. Remove the cowl trim panel, Refer to Trim Panel. 2. Remove the upper B-pillar trim panel, Refer to Trim Panel. 3. Remove the bolt (2) that secures the seat belt (1) to the bottom of the B-pillar (4) and position the seat belt out of the way. 4. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the lower B-pillar trim panel (3) to the B-pillar. 5. Remove the seat belt from the lower B-pillar trim panel through the slot provided and remove the trim panel. QUAD CAB 1. Remove the cowl trim panel, Refer to Trim Panel. 2. Remove the rear door sill trim cover, Refer to Trim Panel. 3. Remove the upper B-pillar trim panel, Refer to Trim Panel. 4. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the lower B-pillar trim panel (1) to the B-pillar (2). 5. Remove the seat belt (3) from the lower B-pillar trim panel through the slot provided and remove the trim panel. INSTALLATION REGULAR CAB Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6361 1. Route the seat belt (1) through the slot in the lower B-pillar trim panel (3) and position the trim panel to the B-pillar (4). 2. Engage the retaining tabs that secure the lower B-pillar trim panel to the B-pillar. 3. Install the bolt (2) that secures the seat belt to the bottom of the B-pillar. Tighten the bolt to 40 N.m (30 ft.lbs.). 4. Install the upper B-pillar trim panel. 5. Install the cowl trim panel. QUAD CAB 1. Route the seat belt (3) through the slot in the lower B-pillar trim panel (1) and position the trim panel to the B-pillar (2). 2. Engage the retaining tabs that secure the lower B-pillar trim panel to the B-pillar. 3. Install the upper B-pillar trim panel. 4. Install the rear door sill trim cove, Refer to Trim Panel. 5. Install the cowl trim panel. B-Pillar Upper Trim B-PILLAR UPPER TRIM REMOVAL REGULAR CAB Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6362 1. Remove the cap (1) and then the bolt (2) that secures the seat belt (3) to the top of the B-pillar (4) and position the seat belt out of the way. 2. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the upper B-pillar trim panel (5) to the B-pillar and remove the trim panel. QUAD CAB 1. Using a small flat-bladed tool, carefully open the two fastener covers (2) located on the grab handle (1). 2. Remove the two bolts (3) that secure the grab handle to the B-pillar and remove the grab handle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6363 3. Remove the cap (1) and the bolt (2) that secures the seat belt (3) to the top of the B-pillar (4) and position the seat belt out of the way. 4. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the upper B-pillar trim panel (5) to the B-pillar and remove the trim panel. INSTALLATION REGULAR CAB 1. Position the upper B-pillar trim panel (5) to the B-pillar (4). 2. Engage the retaining tabs that secure the upper B-pillar trim panel to the B-pillar. 3. Install the bolt (2) that secures the seat belt (3) to the top of the B-pillar. Tighten the bolt to 40 N.m (30 ft.lbs.). 4. Install the cap (1) onto the seat belt. QUAD CAB Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6364 1. Position the upper B-pillar trim panel (5) to the B-pillar (4). 2. Engage the retaining tabs that secure the upper B-pillar trim panel to the B-pillar. 3. Install the bolt (2) that secures the seat belt (3) to the top of the B-pillar. Tighten the bolt to 40 N.m (30 ft.lbs.). 4. Install the cap (1) onto the seat belt. 5. Install the grab handle (1) onto the B-pillar and install the two bolts (3). Tighten the bolts to 6 N.m (55 in.lbs.). 6. Close the two fastener covers (2) located on the grab handle. C-Pillar Lower Trim C-PILLAR LOWER TRIM REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6365 1. Remove the upper C-pillar trim panel, Refer to Trim Panel. 2. Remove the bolt (3) that secures the seat belt (2) to the bottom of the C-pillar (4) and position the seat belt out of the way. 3. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the lower C-pillar trim panel (1) to the C-pillar. 4. Remove the seat belt from the lower C-pillar trim panel through the slot provided and remove the trim panel. INSTALLATION 1. Route the seat belt (2) through the slot in the lower C-pillar trim panel (1) and position the trim panel to the C-pillar (4). 2. Engage the retaining tabs that secure the lower C-pillar trim panel to the C-pillar. 3. Install the bolt (3) that secures the seat belt to the bottom of the C-pillar. Tighten the bolt to 40 N.m (30 ft.lbs.). 4. Install the upper C-pillar trim panel. C-Pillar Upper Trim C-PILLAR UPPER TRIM REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6366 1. Remove the cap (1) and then the bolt (2) that secures the seat belt (3) to the top of the C-pillar (4) and position the seat belt out of the way. 2. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the upper C-pillar trim panel (5) to the C-pillar and remove the trim panel. INSTALLATION 1. Position the upper C-pillar trim panel (5) to the C-pillar (4). 2. Engage the retaining tabs that secure the upper C-pillar trim panel to the C-pillar. 3. Install the bolt (2) that secures the seat belt (3) to the top of the C-pillar. Tighten the bolt to 40 N.m (30 ft.lbs.). 4. Install the cap (1) onto the seat belt. Rear Cab Back Panel Trim REAR CAB BACK PANEL TRIM REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6367 1. If equipped, remove the three bolts (1) that secure the rear storage compartment (2) to the floor panel (3) and remove the storage compartment from the rear cab trim panel (4). 2. If equipped, using a trim stick C-4755 or equivalent, disengage the latch (4) for the utility hook cover (3) and open the cover to gain access to the screw (1) that secures the utility hook (2) to the rear cab back panel. 3. On Regular cab models, remove the lower B-pillar trim panels, Refer to Trim Panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6368 4. On Regular cab models, remove the utility hook (3) or the storage bin latch (4) (depending on application) from the rear cab trim panel (1) and remove the trim panel. 5. On Quad Cab models, remove the child seat tether straps from the rear cab back panel (2). 6. On Quad Cab models, remove the center seat belt trim bezel. 7. On Quad Cab models, remove the lower C-pillar trim panels, Refer to Trim Panel. 8. On Quad Cab models, remove the two push-pin fasteners (1 and 4) that secure the rear cab trim panel (3) to the rear cab back panel and remove the trim panel. INSTALLATION 1. On Quad Cab models, position the rear cab trim panel (3) onto the rear cab back panel (2) and install the two push-pin fasteners (1 and 4). 2. On Quad Cab models, install the lower C-pillar trim panels. 3. On Quad Cab models, install the center seat belt trim bezel. 4. On Quad Cab models, install the child seat tether straps. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6369 5. On Regular cab models, position the rear cab trim panel (1) onto the rear cab back panel (2) and install the utility hook (3) or the storage bin latch (4) (depending on application). 6. On Regular cab models, install the lower B-pillar trim panels. 7. If equipped, position the rear storage compartment (2) onto the rear cab trim panel (4) and install the three bolts (1). Tighten the bolts to 6 N.m (55 in.lbs.). Rear Door Scuff Plate REAR DOOR SILL TRIM COVER REMOVAL 1. Using a trim stick C-4755 or equivalent, disengage the retaining tabs of the sill trim panel (1) from the retainer clips in the rear door sill (2) and remove the trim panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6370 INSTALLATION 1. Position the sill trim panel (1) onto the rear door sill (2). 2. Engage the retaining tabs that secure the sill trim panel to the rear door sill. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage Compartment Latch > Component Information > Service and Repair Utility Storage Compartment Latch: Service and Repair UNDER SEAT STORAGE BIN LATCH REMOVAL 1. Open the under seat storage bin. 2. Remove the two screws and remove the latch assembly. INSTALLATION 1. Install the latch assembly and install the screws. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair LOCK CYLINDER REMOVAL 1. Remove the exterior door handle (1). 2. Remove the clip (3) that secures the lock cylinder lever (5) and the electric lock switch (4), if equipped, to the door lock cylinder (6). 3. Remove the screw (2) that secures the door lock cylinder to the exterior handle and remove the lock cylinder. INSTALLATION 1. Position the door lock cylinder (6) into the exterior door handle (1). 2. Install the screw (2) that secures the door lock cylinder to the exterior door handle. Tighten the screw securely. 3. Install the electric lock switch (4), if equipped, and the lock cylinder lever (5) to the door lock cylinder. 4. Install the clip (3) that secures the lock cylinder lever and the electric lock switch, if equipped, to the door lock cylinder. 5. Install the exterior door handle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder Switch > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder Switch > Component Information > Locations > Page 6383 Door Lock Cylinder Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Disconnect the door cylinder lock switch pigtail wire connector from the door wire harness connector. Door Cylinder Lock Switch Tests 3. Using an ohmmeter, perform the resistance tests between the two pins in the door cylinder lock switch pigtail wire connector. Actuate the switch by rotating the key in the door lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Door Cylinder Lock Switch Tests table. 4. If the switch fails any of the resistance tests, replace the faulty door cylinder lock switch as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder Switch > Component Information > Locations > Page 6384 Door Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the exterior handle and lock cylinder (1) from the outside of the driver side front door as a unit. 3. Remove the bowed clip (3) that secures the lever arm (4) to the shaft on the back of the lock cylinder. 4. Remove the lever arm from the lock cylinder shaft. 5. Remove the door cylinder lock switch (2) from the back of the lock cylinder. INSTALLATION 1. Position the door cylinder lock switch (2) over the shaft on the back of the lock cylinder (1). 2. Position the lever arm (4) onto the shaft over the switch. 3. Install the bowed clip (3) that secures the lever arm to the shaft. 4. Reinstall the exterior handle and lock cylinder onto the outside of the driver side front door as a unit. 5. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations RKE Module Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6389 Module-Sentry Key Immobilizer (SKIM) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6390 Keyless Entry Module: Description and Operation When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6391 Keyless Entry Module: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6392 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster. 3. Remove remote keyless entry module (2) from instrument cluster (1). INSTALLATION 1. Install remote keyless entry module (2) to instrument cluster (1). 2. Install instrument cluster. 3. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Testing and Inspection Keyless Entry Transmitter Battery: Testing and Inspection NOTE: Do not disturb the metal terminal near the batteries. Avoid touching the new batteries. Skin oils may cause battery deterioration. If batteries are touched, clean with rubbing alcohol. The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a thin coin, gently pry at the notch in the center seam of the RKE transmitter case halves near the key ring until the two halves unsnap. Be careful not to damage the rubber gasket when separating the case halves. 2. Lift the back half of the transmitter case off of the RKE transmitter. 3. Remove the two batteries from the RKE transmitter. 4. Replace the two batteries with new 3V lithium 2016 cell. Install the batteries with the positive terminal up. Reference the "+ SIDE UP" on the inside of the bottom half of the transmitter case. 5. Align the two RKE transmitter case halves with each other, and squeeze them firmly and evenly together until they snap back into place. Test transmitter operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Cylinder Switch > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Cylinder Switch > Component Information > Locations > Page 6401 Door Lock Cylinder Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Disconnect the door cylinder lock switch pigtail wire connector from the door wire harness connector. Door Cylinder Lock Switch Tests 3. Using an ohmmeter, perform the resistance tests between the two pins in the door cylinder lock switch pigtail wire connector. Actuate the switch by rotating the key in the door lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Door Cylinder Lock Switch Tests table. 4. If the switch fails any of the resistance tests, replace the faulty door cylinder lock switch as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Cylinder Switch > Component Information > Locations > Page 6402 Door Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the exterior handle and lock cylinder (1) from the outside of the driver side front door as a unit. 3. Remove the bowed clip (3) that secures the lever arm (4) to the shaft on the back of the lock cylinder. 4. Remove the lever arm from the lock cylinder shaft. 5. Remove the door cylinder lock switch (2) from the back of the lock cylinder. INSTALLATION 1. Position the door cylinder lock switch (2) over the shaft on the back of the lock cylinder (1). 2. Position the lever arm (4) onto the shaft over the switch. 3. Install the bowed clip (3) that secures the lever arm to the shaft. 4. Reinstall the exterior handle and lock cylinder onto the outside of the driver side front door as a unit. 5. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation Power Door Lock Actuator: Description and Operation The lock mechanisms are actuated by a reversible electric motor mounted within each door. The power lock motors are integral to the door latch units. The power lock motors cannot be adjusted or repaired and, if faulty or damaged, the door latch unit must be replaced. The door lock motors are controlled by the instrument cluster. A positive and negative battery connection to the two motor terminals will cause the motor to move in one direction. Reversing the current will cause the motor to move in the opposite direction. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation > Page 6406 Power Door Lock Actuator: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations Left Front Door Premium Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 6410 Right Front Door Premium Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 6411 Power Door Lock Switch: Diagrams Switch-Door Lock-Passenger Switch-Window/Door Lock Driver C1 Switch-Window/Door Lock Driver C1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 6412 Power Door Lock Switch: Description and Operation A window/lock switch is used on all models equipped with power locks, power windows, and power mirrors. The window/lock switch houses the following switches: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch selects the right or left power mirror for adjustment, or turns the power mirror system Off. Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, there are individual master switches for each passenger door power window. The window/lock switch also incorporates several green Light-Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility. The window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster input, which allows the instrument cluster to sense the switch position. Based upon the power lock switch input, the instrument cluster controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit. The switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window is labeled "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The power mirror switch circuitry is connected to battery current through a fuse in the IPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral Off position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the power mirror switch is connected to battery current through the power window circuit breaker in the IPM on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the On or Accessory positions. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Switch-Power Lock Power Door Lock Switch: Testing and Inspection Switch-Power Lock The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Integrated Power Module (IPM) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the window/lock switch. If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the On position. If OK, replace the faulty switch. 1. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel. Disconnect the door wire harness connector for the power lock switch from the switch connector receptacle. Power Lock Switch Test Table 2. Test the power lock switch resistance. See the Power Lock Switch Test chart to determine if the resistance is correct for the switch in each switch position. If not OK, replace the faulty power lock switch as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Switch-Power Lock > Page 6415 Power Door Lock Switch: Testing and Inspection Window/Lock Switch The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Integrated Power Module (IPM). If all of the LEDs are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Switch-Power Lock > Page 6416 Driver Door Module Switch Tests 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty DDM as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Switch-Power Lock Power Door Lock Switch: Service and Repair Switch-Power Lock REMOVAL The power lock switch on the driver side front door trim panel is integral to the window/lock switch. 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Switch-Power Lock > Page 6419 Power Door Lock Switch: Service and Repair Switch-Window/Door Lock REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Install switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Mirror Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Mirror Relay > Component Information > Locations > Page 6424 Heated Mirror Relay: Description and Operation The heated mirror relay (1) is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns (2). The heated mirror relay is a electromechanical device that switches battery current through a fuse in the integrated power module (IPM) to the outside rear view mirror heating grids. The heated mirror relay is energized when the relay coil is provided a ground path by the control circuitry within the A/C-heater control. The heated mirror relay is located in the IPM in the engine compartment. The ISO-standard heated mirror relay is an electromechanical switch that uses a low current input controlled by the A/C-heater control to control the high current output to the outside rear view mirror heating grids. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the outside rear view mirror heating grids. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The heated mirror relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the heated mirror relay include: - Terminal (30) receives fused battery current at all times. - Terminal (86) receives a ground through the defogger relay control circuit only when the A/C-heater control electronically pulls the circuit to ground. - Terminal (85) receives fused battery current through an ignition switch output circuit only when the ignition switch is in the Run position. - Terminal (87) provides battery current to the heated outside rear view mirror grids through the heated mirror relay output circuit only when the heated mirror relay coil is energized. - Terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the heated mirror relay coil is de-energized. The heated mirror relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard relay and for complete heated mirror system wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Mirror Relay > Component Information > Locations > Page 6425 Heated Mirror Relay: Service and Repair NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for heated mirror relay location. REMOVAL 1. Disconnect and isolate the negative battery cable (1). 2. Remove the cover from the integrated power module (IPM) (2) located in the engine compartment. 3. Remove the heated mirror relay from the IPM. INSTALLATION 1. Position the heated mirror relay into the proper receptacle of the integrated power module (IPM) (2). 2. Align the heated mirror relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection Power Mirror Switch: Testing and Inspection The power mirror switch is included with the window/lock switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Page 6429 Power Mirror Switch: Service and Repair The power mirror switch is included with the window/lock switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes Paint: Application and ID Paint Codes PAINT CODES Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 6435 Paint: Application and ID Paint Code Location PAINT CODE LOCATION (TYPICAL-ALL MODELS) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Description and Operation > Basecoat/Clearcoat Finish - Description Paint: Description and Operation Basecoat/Clearcoat Finish - Description BASECOAT/CLEARCOAT FINISH DESCRIPTION The original equipment paint finish is a multi step process that involves cleaning, applying electro de-position (E-coat), anti-chip primer, basecoat, and clearcoat steps. CAUTION: Do not use abrasive chemicals, abrasive compounds or harsh alkaline based cleaning solvents on the painted surfaces of a vehicle. Failure to follow this caution can result in damage to vehicle finish. On most vehicles a two-part paint application (basecoat/clearcoat) is used. Color paint that is applied to primer is called basecoat. A clear coat paint is then applied to protect the basecoat from ultraviolet light and to provide a durable high-gloss finish. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Description and Operation > Basecoat/Clearcoat Finish - Description > Page 6438 Paint: Description and Operation Paint Code - Description PAINT CODE DESCRIPTION Exterior vehicle body color(s) are identified on the Vehicle Certification Label, Refer to Information Labels or Paint. The first digit of the paint code listed on the vehicle indicates the sequence of application, i.e.: P = primary coat, Q = secondary coat. The color names provided in the Paint and Trim Code Description chart are the same color names used on most repair product containers, Refer to Paint. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up Paint: Service and Repair Paint Touch-Up PAINT TOUCH-UP DESCRIPTION If the painted metal surface of a vehicle becomes scratched or chipped, it should be touched-up as soon as possible to avoid corrosion. WARNING: Use an OSHA approved respirator and safety glasses when spraying paint or solvents in a confined area. Failure to follow this warning may result in possible personal injury or death. When repairing painted metal surfaces, for best results, use MOPAR(R) Scratch Filler/Primer, Touch-Up Paints and Clear Top Coat. STANDARD PROCEDURE PAINT TOUCH-UP 1. Scrape any loose paint and corrosion from inside the scratch or chip. WARNING: Avoid prolonged skin contact with petroleum or alcohol-based cleaning solvents. Failure to follow this warning can result in possible personal injury or death. 2. Clean affected area with MOPAR(R) Tar/Road Oil Remover or equivalent, and allow to dry. 3. Fill the inside of the scratch or chip with a coat of filler/primer. Do not overlap primer onto good surface finish. The applicator brush should be wet enough to puddle-fill the scratch or chip without running. Do not stroke brush applicator on body surface. Allow the filler/primer to dry hard. 4. Cover the filler/primer with color touch-up paint. Do not overlap touch-up color onto the original color coat around the scratch or chip. Butt the new color to the original color, if possible. Do not stroke applicator brush on body surface. Allow touch-up paint to dry hard. 5. On vehicles without clearcoat, the touch-up color can be lightly finesse sanded (1500 grit) and polished with rubbing compound. 6. On vehicles with clearcoat, apply clear top coat to touch-up paint with the same technique as described in Step 4. Allow clear top coat to dry hard. If desired, the clearcoat can be lightly finesse sanded (1500 grit) and polished with rubbing compound. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up > Page 6441 Paint: Service and Repair Finesse Sanding, Buffing, And Polishing - Description FINESSE SANDING/BUFFING AND POLISHING DESCRIPTION CAUTION: - Do not remove more than 0.5 mils of clearcoat finish when sanding, hand buffing or polishing. Basecoat paint must retain clearcoat for durability. - If the finish has been finesse sanded in the past, it cannot be repeated. Failure to follow this caution can result in damage to vehicle finish. NOTE: Finesse sanding should only be performed by a trained automotive paint technician. Minor acid etching, orange peel, or smudging in a clearcoat or single-stage finish can be reduced with light finesse sanding, hand buffing and polishing. Use a Paint Thickness Gauge #PR-ETG-2X or equivalent to determine clearcoat or single-stage paint thickness before and after the repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair Radiator Support: Service and Repair UPPER RADIATOR CROSSMEMBER REMOVAL 1. Remove the hood latch from the upper radiator crossmember (3) and position the latch out of the way. 2. Remove the bolts (1 and 2) that secure the A/C condenser and the radiator to the upper radiator crossmember. 3. Remove the four bolts (1 and 3) that secure the upper radiator crossmember (2) to the fender rails and remove the crossmember. INSTALLATION 1. Position and align the upper radiator crossmember (2) to the fender rails. 2. Install the four bolts (1 and 3) that secure the upper radiator crossmember to the fender rails. Tighten the bolts to 28 N.m (21 ft.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Page 6445 3. Install the bolts (1 and 2) that secure the A/C condenser and the radiator to the upper radiator cross-member (3). Tighten the bolts to 8 N.m (75 in.lbs.). 4. Install the hood latch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations > Page 6450 Heated Mirror Relay: Description and Operation The heated mirror relay (1) is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns (2). The heated mirror relay is a electromechanical device that switches battery current through a fuse in the integrated power module (IPM) to the outside rear view mirror heating grids. The heated mirror relay is energized when the relay coil is provided a ground path by the control circuitry within the A/C-heater control. The heated mirror relay is located in the IPM in the engine compartment. The ISO-standard heated mirror relay is an electromechanical switch that uses a low current input controlled by the A/C-heater control to control the high current output to the outside rear view mirror heating grids. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the outside rear view mirror heating grids. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The heated mirror relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the heated mirror relay include: - Terminal (30) receives fused battery current at all times. - Terminal (86) receives a ground through the defogger relay control circuit only when the A/C-heater control electronically pulls the circuit to ground. - Terminal (85) receives fused battery current through an ignition switch output circuit only when the ignition switch is in the Run position. - Terminal (87) provides battery current to the heated outside rear view mirror grids through the heated mirror relay output circuit only when the heated mirror relay coil is energized. - Terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the heated mirror relay coil is de-energized. The heated mirror relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard relay and for complete heated mirror system wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations > Page 6451 Heated Mirror Relay: Service and Repair NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for heated mirror relay location. REMOVAL 1. Disconnect and isolate the negative battery cable (1). 2. Remove the cover from the integrated power module (IPM) (2) located in the engine compartment. 3. Remove the heated mirror relay from the IPM. INSTALLATION 1. Position the heated mirror relay into the proper receptacle of the integrated power module (IPM) (2). 2. Align the heated mirror relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations RKE Module Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 6455 Module-Sentry Key Immobilizer (SKIM) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 6456 Keyless Entry Module: Description and Operation When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 6457 Keyless Entry Module: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 6458 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster. 3. Remove remote keyless entry module (2) from instrument cluster (1). INSTALLATION 1. Install remote keyless entry module (2) to instrument cluster (1). 2. Install instrument cluster. 3. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Pedal Positioning Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation Power Seat Control Module: Description and Operation The heated seat module (2) is also known as the Seat Heat Interface Module. The heated seat module is located under the drivers front seat cushion, where it is secured to a mounting bracket. The heated seat module has a single connector receptacle (3) that allows the module to be connected to all of the required inputs and outputs through the seat wire harness. The heated seat module is an electronic microprocessor controlled device designed and programmed to use inputs from the battery, the two heated seat switches and the two heated seat sensors to operate and control the heated seat elements in both front seats and the two heated seat indicator lamp Light-Emitting Diodes (LEDs) in each heated seat switch. The heated seat module is also programmed to perform self-diagnosis of certain heated seat system functions and provide feedback of that diagnosis through the heated seat switch indicator lamps. The heated seat module cannot be repaired. If the heated seat module is damaged or faulty, the entire module must be replaced. The heated seat module operates on fused battery current received from the integrated power module. Inputs to the module include a resistor multiplexed heated seat switch request circuit for each of the two heated seat switches and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements and sensors, and controls the ground for the heated seat switch indicator lamps. When a heated seat switch (Driver or Passenger) is depressed a signal is received by the heated seat module, the module energizes the proper indicator LED (Low or High) in the switch by grounding the indicator lamp circuit to indicate that the heated seat system is operating. At the same time, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. The Low heat set point is about 36° C (96.8° F), and the High heat set point is about 42°C (107.6° F). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an N-channel Field Effect Transistor (N-FET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the N-FET which de-energizes the heated seat elements. The heated seat module will continue to cycle the N-FET as needed to maintain the selected temperature set point. If the heated seat module detects a heated seat sensor value input that is out of range or a shorted or open heated seat element circuit, it will notify the vehicle operator or the repair technician of this condition by flashing the High and/or Low indicator lamps in the affected heated seat switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation > Page 6465 Power Seat Control Module: Testing and Inspection If a heated seat fails to heat and one or both of the indicator lamps on a heated seat switch flash. If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate, test the heated seat switch. If the heated seat switch checks OK, proceed as follows. 1. Check the heated seat element. 2. Check the heated seat sensor. 3. Check the heated seat switch. NOTE: Refer to Wiring for the location of complete heated seat system wiring diagrams and connector pin-out information. 4. Using a voltmeter, backprobe the heated seat module connector, do not disconnect. Check for voltage at the appropriate pin cavities. 12v should be present. If OK go to Step 5, if Not, Repair the open or shorted voltage supply circuit as required. 5. Using a ohmmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK replace the heated seat module with a known good unit and retest system, if Not OK, Repair the open or shorted ground circuit as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation > Page 6466 Power Seat Control Module: Service and Repair REMOVAL 1. Position the driver seat to the full rearward and inclined position. 2. Working under the driver front seat, remove the two heated seat module retaining screws. Due to the fact that the retaining screws are installed with the seat cushion pan removed, a small right angle screwdriver will be required to access and remove the screws. 3. Disconnect the seat wire harness connector from the connector receptacle on the back of the heated seat module. Depress the connector retaining tab and pull straight apart. 4. Remove the heated seat module from under the front seat. INSTALLATION 1. Position the heated seat module under the front seat. 2. Connect the seat wire harness connector on the connector receptacle on the back of the heated seat module. 3. Working under the driver front seat, install the heated seat module retaining screws. 4. Re-position the driver seat. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams Module-Heated Seats Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 6470 Seat Heater Control Module: Description and Operation The heated seat module is also known as the Seat Heat Interface Module. The heated seat module is located under the drivers front seat cushion, where it is secured to a mounting bracket. The heated seat module has a single connector receptacle that allows the module to be connected to all of the required inputs and outputs through the seat wire harness. The heated seat module is an electronic microprocessor controlled device designed and programmed to use inputs from the battery, the two heated seat switches and the two heated seat sensors to operate and control the heated seat elements in both front seats and the two heated seat indicator lamp Light-Emitting Diodes (LEDs) in each heated seat switch. The heated seat module is also programmed to perform self-diagnosis of certain heated seat system functions and provide feedback of that diagnosis through the heated seat switch indicator lamps. The heated seat module cannot be repaired. If the heated seat module is damaged or faulty, the entire module must be replaced. The heated seat module operates on fused battery current received from the integrated power module. Inputs to the module include a resistor multiplexed heated seat switch request circuit for each of the two heated seat switches and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements and sensors, and controls the ground for the heated seat switch indicator lamps. When a heated seat switch (Driver or Passenger) is depressed a signal is received by the heated seat module, the module energizes the proper indicator LED (Low or High) in the switch by grounding the indicator lamp circuit to indicate that the heated seat system is operating. At the same time, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. The Low heat set point is about 36° C (96.8° F), and the High heat set point is about 42° C (107.6° F). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an Nm-channel Field Effect Transistor (Nm-FEET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the Nm-FEET which de-energizes the heated seat elements. The heated seat module will continue to cycle the Nm-FEET as needed to maintain the selected temperature set point. If the heated seat module detects a heated seat sensor value input that is out of range or a shorted or open heated seat element circuit, it will notify the vehicle operator or the repair technician of this condition by flashing the High and/or Low indicator lamps in the affected heated seat switch. Refer to Diagnosis and Testing Heated Seat System in Heated Systems for flashing LED diagnosis and testing procedures. Refer to Diagnosis and Testing Heated Seat Module for heated seat module diagnosis and testing procedures. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 6471 Seat Heater Control Module: Testing and Inspection If a heated seat fails to heat and one or both of the indicator lamps on a heated seat switch flash, refer to Diagnosis and Testing Heated Seat System in Heated Seats for the location of flashing LED heated seat system diagnosis and testing procedures. If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate, test the heated seat switch. Refer to Diagnosis and Testing Heated Seat Switch in Heated Seats for heated seat switch diagnosis and testing procedures. If the heated seat switch checks OK, proceed as follows. 1. Check the heated seat element. 2. Check the heated seat sensor. 3. Check the heated seat switch. NOTE: Refer to Wiring for the location of complete heated seat system wiring diagrams and connector pin-out information. 4. Using a voltmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for voltage at the appropriate pin cavities. 12v should be present. If OK go to Step 5, if Not, Repair the open or shorted voltage supply circuit as required. 5. Using a ohmmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK replace the heated seat module with a known good unit and retest system, if Not OK, Repair the open or shorted ground circuit as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 6472 Seat Heater Control Module: Service and Repair REMOVAL 1. Position the driver seat to the full rearward and inclined position. 2. Working under the driver front seat, remove the two heated seat module retaining screws. Due to the fact that the retaining screws are installed with the seat cushion pan removed, a small right angle screwdriver will be required to access and remove the screws. 3. Disconnect the seat wire harness connector from the connector receptacle on the back of the heated seat module. Depress the connector retaining tab and pull straight apart. 4. Remove the heated seat module from under the front seat. INSTALLATION 1. Position the heated seat module under the front seat. 2. Connect the seat wire harness connector on the connector receptacle on the back of the heated seat module. 3. Working under the driver front seat, install the heated seat module retaining screws. 4. Re-position the driver seat. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > Customer Interest: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof Sunroof / Moonroof Cable: Customer Interest Body - Ratcheting Noise When Operating Sunroof NUMBER: 23-004-08 GROUP: Body DATE: January 16, 2008 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 23-045-06 DATED OCTOBER 14, 2006 AND 23-51-06 DATED NOVEMBER 4, 2006. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF WH/XH/L2 MODELS AND 2008 MODEL YEAR VEHICLES. SUBJECT: Ratcheting Sound During Sunroof Operation OVERVIEW: This bulletin involves replacing the sunroof drive cable conduit. MODELS: 2004 - **2008** (DR) Ram Truck **2007 (L2) 300C (China)** 2005 - **2008** (LE) 300C/300C Touring (International Markets) 2005 - 2008 (LX) 300/Charger/Magnum **2005 - 2008 (WH) Grand Cherokee (International Markets)** 2005 - **2008** (WK) Grand Cherokee **2006 - 2008 (XH) Commander (International Markets)** 2006 - 2008 (XK) Commander NOTE: This bulletin applies to DR/L2/LE/LX/WH/WK models with a Power Sunroof (sales code GWA) built before October 31, 2007 (MDH1031XX) and XH models with a Power Sunroof (sales code GWF) built before December 19, 2007 (MDH1219XX) and XK models with a Power Sunroof (sales code GWF) built before November 07, 2007 (MDH1107XX). SYMPTOM/CONDITION: A ratcheting sound is heard from sunroof module as the glass approaches the full open position. DIAGNOSIS: Lower the headliner to view the rear of the sunroof module assembly. Inspect the cable conduit tube(s) located at the rear corners of the sunroof module assembly for a kinked condition. Kinked condition most frequently occurs at passenger rear corner. If a kinked conduit is discovered, perform the appropriate Repair Procedure based on the vehicle below. PARTS REQUIRED: REPAIR PROCEDURE - DRIL2/LE/LX/WH/WK: 1. Ensure the sunroof module is in the full closed position. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > Customer Interest: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 6486 2. Remove M6 mounting bolts (4) at rear portion of sunroof module. 3. Remove the kinked cable conduit(s) from sunroof module retaining features starting from the end at the metal clip and work back to motor area, see (Fig 1). 4. Assemble new cable conduit, p/n 68003812AA, in reverse order of Step # 3) by inserting the flared end over the exposed end of the drive cable. Insure the flared end is sitting in the notch on the rear bulk head of sunroof module, (Fig 2). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > Customer Interest: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 6487 5. Snap the cable conduit into the retaining features in the rear bulk head (5 places) with the end of the tube retained in spring clip on the aluminum guide. Ensure the clip is within the provided scribe lines on aluminum guide, (Fig 3). 6. Torque the mounting bolts to 9 Nm (80 in. lbs.). 7. Operate Sunroof module. 8. Install headliner. REPAIR PROCEDURE - XH/XK: 1. Put the sunroof in the closed or vent position. 2. Drop headliner right front corner, by removing the right side A-pillar trim, B-pillar trim sun visor, sun visor clip and rear view mirror. 3. Look at and/or feel the drive cable conduit in the radius above the drain hose this is where the conduit will be kinked. 4. Remove 2 sunroof mounting fasteners, (Fig 4). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > Customer Interest: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 6488 5. Remove conduit from clip at side of sunroof module, (Fig 5). 6. Push the conduit up and inboard to release it from the retention feature on the front beam, (Fig 6) item 4. 7. Push the conduit up to release it from the additional retention features, (Fig. 6) item 2. 8. Pull the conduit out from over/off the drive cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > Customer Interest: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 6489 9. Slide the new conduit, p/n 68003816AA, back over the drive cable. See (Fig. 6) item 1, to ensure conduit is seated into notch to the rear of the steel drive cable tube. 10. Secure the conduit in the retention features shown in (Fig. 6). 11. Install the conduit in the side clip. 12. Operate the sunroof to ensure the ratcheting noise is eliminated. 13. Install the mounting bolts. 14. Install the headliner, A-pillar trim, sun visor and visor clip. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof Sunroof / Moonroof Cable: All Technical Service Bulletins Body - Ratcheting Noise When Operating Sunroof NUMBER: 23-004-08 GROUP: Body DATE: January 16, 2008 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 23-045-06 DATED OCTOBER 14, 2006 AND 23-51-06 DATED NOVEMBER 4, 2006. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF WH/XH/L2 MODELS AND 2008 MODEL YEAR VEHICLES. SUBJECT: Ratcheting Sound During Sunroof Operation OVERVIEW: This bulletin involves replacing the sunroof drive cable conduit. MODELS: 2004 - **2008** (DR) Ram Truck **2007 (L2) 300C (China)** 2005 - **2008** (LE) 300C/300C Touring (International Markets) 2005 - 2008 (LX) 300/Charger/Magnum **2005 - 2008 (WH) Grand Cherokee (International Markets)** 2005 - **2008** (WK) Grand Cherokee **2006 - 2008 (XH) Commander (International Markets)** 2006 - 2008 (XK) Commander NOTE: This bulletin applies to DR/L2/LE/LX/WH/WK models with a Power Sunroof (sales code GWA) built before October 31, 2007 (MDH1031XX) and XH models with a Power Sunroof (sales code GWF) built before December 19, 2007 (MDH1219XX) and XK models with a Power Sunroof (sales code GWF) built before November 07, 2007 (MDH1107XX). SYMPTOM/CONDITION: A ratcheting sound is heard from sunroof module as the glass approaches the full open position. DIAGNOSIS: Lower the headliner to view the rear of the sunroof module assembly. Inspect the cable conduit tube(s) located at the rear corners of the sunroof module assembly for a kinked condition. Kinked condition most frequently occurs at passenger rear corner. If a kinked conduit is discovered, perform the appropriate Repair Procedure based on the vehicle below. PARTS REQUIRED: REPAIR PROCEDURE - DRIL2/LE/LX/WH/WK: 1. Ensure the sunroof module is in the full closed position. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 6495 2. Remove M6 mounting bolts (4) at rear portion of sunroof module. 3. Remove the kinked cable conduit(s) from sunroof module retaining features starting from the end at the metal clip and work back to motor area, see (Fig 1). 4. Assemble new cable conduit, p/n 68003812AA, in reverse order of Step # 3) by inserting the flared end over the exposed end of the drive cable. Insure the flared end is sitting in the notch on the rear bulk head of sunroof module, (Fig 2). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 6496 5. Snap the cable conduit into the retaining features in the rear bulk head (5 places) with the end of the tube retained in spring clip on the aluminum guide. Ensure the clip is within the provided scribe lines on aluminum guide, (Fig 3). 6. Torque the mounting bolts to 9 Nm (80 in. lbs.). 7. Operate Sunroof module. 8. Install headliner. REPAIR PROCEDURE - XH/XK: 1. Put the sunroof in the closed or vent position. 2. Drop headliner right front corner, by removing the right side A-pillar trim, B-pillar trim sun visor, sun visor clip and rear view mirror. 3. Look at and/or feel the drive cable conduit in the radius above the drain hose this is where the conduit will be kinked. 4. Remove 2 sunroof mounting fasteners, (Fig 4). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 6497 5. Remove conduit from clip at side of sunroof module, (Fig 5). 6. Push the conduit up and inboard to release it from the retention feature on the front beam, (Fig 6) item 4. 7. Push the conduit up to release it from the additional retention features, (Fig. 6) item 2. 8. Pull the conduit out from over/off the drive cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 6498 9. Slide the new conduit, p/n 68003816AA, back over the drive cable. See (Fig. 6) item 1, to ensure conduit is seated into notch to the rear of the steel drive cable tube. 10. Secure the conduit in the retention features shown in (Fig. 6). 11. Install the conduit in the side clip. 12. Operate the sunroof to ensure the ratcheting noise is eliminated. 13. Install the mounting bolts. 14. Install the headliner, A-pillar trim, sun visor and visor clip. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Cable: > 21-001-04 > Feb > 04 > A/T/Engine Controls - False Solenoid DTC's Set Throttle Valve Solenoid: All Technical Service Bulletins A/T/Engine Controls - False Solenoid DTC's Set NUMBER: 21-001-04 GROUP: Transmission DATE: February 10, 2004 SUBJECT: Transmission Solenoid Replacement MODELS: 2004 (AN) Dakota 2004 (DR) Ram Truck 2004 (CS) Pacifica 2004 (JR) Stratus/Sebring 2004 (PL) Neon 2004 (PT) PT Cruiser 2004 (RS) Caravan/Voyager/Town & Country 2004 (RG) Chrysler Voyager (International Markets) NOTE: This Bulletin Applies To Vehicles Equipped With 41TE, 42RLE or 45RFE Transmissions. DISCUSSION: When servicing an automatic transmission on any of the vehicles listed above, Diagnostic Trouble Codes (DTC's) displayed relating to transmission solenoids, may be misleading. The following DTC's: P0755, P0750, P0760, P0765, P0770, P2706, could be displayed indicating solenoid faults when the Powertrain Control Module (PCM) is actually at fault. If any of these DTC's are encountered, Check the Powertrain Control Module manufacture date. The date is shown in the Module Serial Number on the label attached to the front of the module. The serial number is a 14 digit alpha numeric code which is located on the bottom of the part label. A sample of the number is shown below: MODULE S/N T65EH2333D55N6 The manufacture date code is shown in the 6th through 9th digits. In this case the manufacture date code would be: H235 3 (Day of the Year - Year) day 235 of year 2003. If any of these DTC's are present and the PCM manufacture date code is between H2313 and H2393 The fault is likely to be in the PCM. Replace the PCM and check for any other DTC's before replacing the solenoids. The "H" in the code indicates modules built in Huntsville. This bulletin applies only to Huntsville Modules. POLICY Information only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof Sunroof / Moonroof Cable Housing: Customer Interest Body - Ratcheting Noise When Operating Sunroof NUMBER: 23-004-08 GROUP: Body DATE: January 16, 2008 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 23-045-06 DATED OCTOBER 14, 2006 AND 23-51-06 DATED NOVEMBER 4, 2006. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF WH/XH/L2 MODELS AND 2008 MODEL YEAR VEHICLES. SUBJECT: Ratcheting Sound During Sunroof Operation OVERVIEW: This bulletin involves replacing the sunroof drive cable conduit. MODELS: 2004 - **2008** (DR) Ram Truck **2007 (L2) 300C (China)** 2005 - **2008** (LE) 300C/300C Touring (International Markets) 2005 - 2008 (LX) 300/Charger/Magnum **2005 - 2008 (WH) Grand Cherokee (International Markets)** 2005 - **2008** (WK) Grand Cherokee **2006 - 2008 (XH) Commander (International Markets)** 2006 - 2008 (XK) Commander NOTE: This bulletin applies to DR/L2/LE/LX/WH/WK models with a Power Sunroof (sales code GWA) built before October 31, 2007 (MDH1031XX) and XH models with a Power Sunroof (sales code GWF) built before December 19, 2007 (MDH1219XX) and XK models with a Power Sunroof (sales code GWF) built before November 07, 2007 (MDH1107XX). SYMPTOM/CONDITION: A ratcheting sound is heard from sunroof module as the glass approaches the full open position. DIAGNOSIS: Lower the headliner to view the rear of the sunroof module assembly. Inspect the cable conduit tube(s) located at the rear corners of the sunroof module assembly for a kinked condition. Kinked condition most frequently occurs at passenger rear corner. If a kinked conduit is discovered, perform the appropriate Repair Procedure based on the vehicle below. PARTS REQUIRED: REPAIR PROCEDURE - DRIL2/LE/LX/WH/WK: 1. Ensure the sunroof module is in the full closed position. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 6517 2. Remove M6 mounting bolts (4) at rear portion of sunroof module. 3. Remove the kinked cable conduit(s) from sunroof module retaining features starting from the end at the metal clip and work back to motor area, see (Fig 1). 4. Assemble new cable conduit, p/n 68003812AA, in reverse order of Step # 3) by inserting the flared end over the exposed end of the drive cable. Insure the flared end is sitting in the notch on the rear bulk head of sunroof module, (Fig 2). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 6518 5. Snap the cable conduit into the retaining features in the rear bulk head (5 places) with the end of the tube retained in spring clip on the aluminum guide. Ensure the clip is within the provided scribe lines on aluminum guide, (Fig 3). 6. Torque the mounting bolts to 9 Nm (80 in. lbs.). 7. Operate Sunroof module. 8. Install headliner. REPAIR PROCEDURE - XH/XK: 1. Put the sunroof in the closed or vent position. 2. Drop headliner right front corner, by removing the right side A-pillar trim, B-pillar trim sun visor, sun visor clip and rear view mirror. 3. Look at and/or feel the drive cable conduit in the radius above the drain hose this is where the conduit will be kinked. 4. Remove 2 sunroof mounting fasteners, (Fig 4). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 6519 5. Remove conduit from clip at side of sunroof module, (Fig 5). 6. Push the conduit up and inboard to release it from the retention feature on the front beam, (Fig 6) item 4. 7. Push the conduit up to release it from the additional retention features, (Fig. 6) item 2. 8. Pull the conduit out from over/off the drive cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 6520 9. Slide the new conduit, p/n 68003816AA, back over the drive cable. See (Fig. 6) item 1, to ensure conduit is seated into notch to the rear of the steel drive cable tube. 10. Secure the conduit in the retention features shown in (Fig. 6). 11. Install the conduit in the side clip. 12. Operate the sunroof to ensure the ratcheting noise is eliminated. 13. Install the mounting bolts. 14. Install the headliner, A-pillar trim, sun visor and visor clip. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof Sunroof / Moonroof Cable Housing: All Technical Service Bulletins Body - Ratcheting Noise When Operating Sunroof NUMBER: 23-004-08 GROUP: Body DATE: January 16, 2008 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 23-045-06 DATED OCTOBER 14, 2006 AND 23-51-06 DATED NOVEMBER 4, 2006. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF WH/XH/L2 MODELS AND 2008 MODEL YEAR VEHICLES. SUBJECT: Ratcheting Sound During Sunroof Operation OVERVIEW: This bulletin involves replacing the sunroof drive cable conduit. MODELS: 2004 - **2008** (DR) Ram Truck **2007 (L2) 300C (China)** 2005 - **2008** (LE) 300C/300C Touring (International Markets) 2005 - 2008 (LX) 300/Charger/Magnum **2005 - 2008 (WH) Grand Cherokee (International Markets)** 2005 - **2008** (WK) Grand Cherokee **2006 - 2008 (XH) Commander (International Markets)** 2006 - 2008 (XK) Commander NOTE: This bulletin applies to DR/L2/LE/LX/WH/WK models with a Power Sunroof (sales code GWA) built before October 31, 2007 (MDH1031XX) and XH models with a Power Sunroof (sales code GWF) built before December 19, 2007 (MDH1219XX) and XK models with a Power Sunroof (sales code GWF) built before November 07, 2007 (MDH1107XX). SYMPTOM/CONDITION: A ratcheting sound is heard from sunroof module as the glass approaches the full open position. DIAGNOSIS: Lower the headliner to view the rear of the sunroof module assembly. Inspect the cable conduit tube(s) located at the rear corners of the sunroof module assembly for a kinked condition. Kinked condition most frequently occurs at passenger rear corner. If a kinked conduit is discovered, perform the appropriate Repair Procedure based on the vehicle below. PARTS REQUIRED: REPAIR PROCEDURE - DRIL2/LE/LX/WH/WK: 1. Ensure the sunroof module is in the full closed position. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 6526 2. Remove M6 mounting bolts (4) at rear portion of sunroof module. 3. Remove the kinked cable conduit(s) from sunroof module retaining features starting from the end at the metal clip and work back to motor area, see (Fig 1). 4. Assemble new cable conduit, p/n 68003812AA, in reverse order of Step # 3) by inserting the flared end over the exposed end of the drive cable. Insure the flared end is sitting in the notch on the rear bulk head of sunroof module, (Fig 2). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 6527 5. Snap the cable conduit into the retaining features in the rear bulk head (5 places) with the end of the tube retained in spring clip on the aluminum guide. Ensure the clip is within the provided scribe lines on aluminum guide, (Fig 3). 6. Torque the mounting bolts to 9 Nm (80 in. lbs.). 7. Operate Sunroof module. 8. Install headliner. REPAIR PROCEDURE - XH/XK: 1. Put the sunroof in the closed or vent position. 2. Drop headliner right front corner, by removing the right side A-pillar trim, B-pillar trim sun visor, sun visor clip and rear view mirror. 3. Look at and/or feel the drive cable conduit in the radius above the drain hose this is where the conduit will be kinked. 4. Remove 2 sunroof mounting fasteners, (Fig 4). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 6528 5. Remove conduit from clip at side of sunroof module, (Fig 5). 6. Push the conduit up and inboard to release it from the retention feature on the front beam, (Fig 6) item 4. 7. Push the conduit up to release it from the additional retention features, (Fig. 6) item 2. 8. Pull the conduit out from over/off the drive cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 6529 9. Slide the new conduit, p/n 68003816AA, back over the drive cable. See (Fig. 6) item 1, to ensure conduit is seated into notch to the rear of the steel drive cable tube. 10. Secure the conduit in the retention features shown in (Fig. 6). 11. Install the conduit in the side clip. 12. Operate the sunroof to ensure the ratcheting noise is eliminated. 13. Install the mounting bolts. 14. Install the headliner, A-pillar trim, sun visor and visor clip. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams Motor-Sunroof Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams > Page 6533 Sunroof / Moonroof Motor: Testing and Inspection NOTE: If there is no sunroof movement when the "OPEN" or "CLOSED" button are pushed but the sunroof operates when the "VENT" button is pushed and held the sunroof motor/module is out of calibration. Complete the sunroof position calibration procedure prior to performing any sunroof diagnostics. The wire harness connectors for the sunroof motor/module are located above the vehicle headliner. Removal of the headliner may be necessary for access to the connector and proper diagnosis of the motor/module. For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Verify that all other power accessories are in proper operating condition. If not, a common electrical problem may exist. 2. Disconnect the sunroof motor/module. Connect a test light between the harness connector pin 6 and a known good ground. The test light should illuminate brightly. If OK, go to Step 3. If not OK repair the ground circuit as necessary. 3. Connect a test light between the harness connector pin 8 and a known good ground. The test light should illuminate brightly. If OK, go to Step 4. If not OK repair the B+ circuit as necessary. 4. Turn the ignition key to the "RUN" position. Connect a test light between the harness connector pin 9 and a known good ground. The test light should illuminate brightly. If OK, go to Step 5. If not OK repair the Accessory Delay circuit as necessary. 5. Using an ohmmeter check the sunroof switch feed circuit for continuity between the sunroof motor/module and sunroof switch. Continuity should be present. If OK replace the inoperative motor/module. If not OK repair the sunroof switch feed circuit as necessary. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Procedures Sunroof / Moonroof Motor: Procedures Excessive Force Limitation (EFL) Calibration NOTE: Verify the battery is in good condition prior to performing this procedure. Do not leave the vehicle on a battery charger while performing this procedure. If the voltage at the sunroof motor/module drops below 11 volts or exceeds 15 volts at anytime while this procedure is being performed, the Excessive Force Limitation (EFL) function will not be properly calibrated. 1. Turn the ignition to the RUN position. 2. Press the vent button on the power sunroof switch and hold until the sunroof glass panel has moved to the full vent position and the motor movement has stopped for at least 1 second. 3. Press the close position on the power sunroof switch and release. The sunroof glass panel should continue travel to the full closed position. This will be considered the first sunroof closed position in a series of four sunroof closes. 4. Press the vent button on the power sunroof switch and release. The sunroof glass panel should move to the full vent position. After the sunroof motor/module has stopped, press the close position on the power sunroof switch and release. The sunroof glass panel should continue travel to the full closed position. This will be considered the second sunroof closed position in a series of four sunroof closes. 5. Continue to move the sunroof glass to the "vent" then "closed" positions two more times so that the sunroof glass has moved to the closed position a total of four times starting with the first sunroof close in step 3. 6. Press the open position on the power sunroof switch and release. The sunroof glass panel should continue travel to the full open position. 7. Press the close position on the power sunroof switch and release. The sunroof glass panel should continue travel to the full closed position. This will be considered the first sunroof closed position in a series of five sunroof closes. 8. Press the open position on the power sunroof switch and release. The sunroof glass panel should move to the full open position. After the sunroof motor/module has stopped, press the close position on the power sunroof switch and release. The sunroof glass panel should continue travel to the full closed position. Continue to move the sunroof glass to the "open" then "closed" position four more times so that the sunroof glass has moved to the closed position a total of five times starting with the first sunroof close in step 7. Verify proper EFL calibration by placing a standard pencil at the front of the sunroof and then moving the sunroof to the full closed position. The sunroof should reverse direction upon contact without damage to the pencil. Sunroof Position Calibration Press the power sunroof switch (Open, Closed, and Vent). If no movement occurs when either the open switch or closed switch is pressed, but the system does move when the vent button is pressed and held, the system is not calibrated. Perform the following procedure to position calibrate the power sunroof system. 1. Turn the ignition to the RUN position. 2. Press the vent button on the power sunroof switch and hold until the sunroof glass panel has moved to the full vent position and the motor movement has stopped for atleast 1 second. 3. Press the close switch on the power sunroof switch and hold for a moment (at least 100ms) and release. The sunroof glass panel should continue travel to the full close position. If the sunroof glass panel does not return to the full close position, refer to the appropriate diagnostic information for full system diagnosis. 4. Verify proper system operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Procedures > Page 6536 Sunroof / Moonroof Motor: Removal and Replacement WARNING: THE EXCESSIVE FORCE LIMITATION (EFL) FEATURE MUST BE CALIBRATED ANY TIME A SUNROOF MOTOR/MODULE IS REPLACED WITH A NEW COMPONENT. FAILURE TO PERFORM THIS PROCEDURE COULD RESULT IN VEHICLE DAMAGE AND/OR PERSONAL INJURY. REMOVAL 1. Disconnect the battery negative cable. 2. Remove the vehicle headliner. 3. Remove the power sunroof motor/module electrical connector (2). 4. Remove the retaining screws (3) and remove the motor/module (1) from the vehicle. INSTALLATION 1. Position the power sunroof motor/module (1) in the vehicle. 2. Install the motor/module retaining screws (3). Tighten the screws to 4 N.m (35 in.lbs.). 3. Connect the motor/module electrical connector (2). 4. Connect the battery negative cable and move the sunroof through one open and close cycle to confirm proper system operation. 5. Install the vehicle headliner. 6. Perform the sunroof position calibration. 7. Perform the Excessive Force Limitation (EFL) calibration. 8. Verify proper operation of the power sunroof system. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams Switch-Sunroof Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 6540 Sunroof / Moonroof Switch: Description and Operation The power sunroof switch (3) is a combination push button and rocker switch module mounted in the overhead console. The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) The power sunroof switch is part of the overhead console assembly and cannot be replaced separately. If the switch is damaged or inoperative the overhead console must be replaced. The power sunroof switch is hard wired to the sunroof motor/module assembly. The switch receives battery current from the motor/module when the ignition switch is in the RUN and ACCESSORY positions or the vehicle Accessory Delay System is active. When one of the switch positions is pressed it sends battery current back to the motor/ module, signaling it to move the power sunroof to the appropriate position. The motor/module will perform one of the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 6541 Sunroof / Moonroof Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. If completing the appropriate diagnostic information results in the sunroof switch being inoperative, perform the following test prior to switch replacement. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console. 3. Disconnect the power sunroof switch wire harness connector. Power Sunroof Switch Continuity Table 4. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage. Use a scan tool and the proper Diagnostic Procedures Information to complete diagnosis of the power sunroof system. If not OK, replace the overhead console. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Headrest Head Rest: Service and Repair Headrest HEADREST REMOVAL 1. Raise the headrest. 2. Press the headrest release button and remove the headrest. INSTALLATION 1. Position the headrest. 2. Press the release button and install the headrest. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Headrest > Page 6547 Head Rest: Service and Repair Headrest Sleeve HEADREST SLEEVE REMOVAL 1. Remove the headrest. 2. Grasp the sleeves and pull up and out of the seat back to remove. INSTALLATION 1. Position each headrest sleeve into correct seat back hole and press into place fully. 2. Install the headrest. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Description and Operation Power Seat Control Module: Description and Operation The heated seat module (2) is also known as the Seat Heat Interface Module. The heated seat module is located under the drivers front seat cushion, where it is secured to a mounting bracket. The heated seat module has a single connector receptacle (3) that allows the module to be connected to all of the required inputs and outputs through the seat wire harness. The heated seat module is an electronic microprocessor controlled device designed and programmed to use inputs from the battery, the two heated seat switches and the two heated seat sensors to operate and control the heated seat elements in both front seats and the two heated seat indicator lamp Light-Emitting Diodes (LEDs) in each heated seat switch. The heated seat module is also programmed to perform self-diagnosis of certain heated seat system functions and provide feedback of that diagnosis through the heated seat switch indicator lamps. The heated seat module cannot be repaired. If the heated seat module is damaged or faulty, the entire module must be replaced. The heated seat module operates on fused battery current received from the integrated power module. Inputs to the module include a resistor multiplexed heated seat switch request circuit for each of the two heated seat switches and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements and sensors, and controls the ground for the heated seat switch indicator lamps. When a heated seat switch (Driver or Passenger) is depressed a signal is received by the heated seat module, the module energizes the proper indicator LED (Low or High) in the switch by grounding the indicator lamp circuit to indicate that the heated seat system is operating. At the same time, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. The Low heat set point is about 36° C (96.8° F), and the High heat set point is about 42°C (107.6° F). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an N-channel Field Effect Transistor (N-FET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the N-FET which de-energizes the heated seat elements. The heated seat module will continue to cycle the N-FET as needed to maintain the selected temperature set point. If the heated seat module detects a heated seat sensor value input that is out of range or a shorted or open heated seat element circuit, it will notify the vehicle operator or the repair technician of this condition by flashing the High and/or Low indicator lamps in the affected heated seat switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Description and Operation > Page 6551 Power Seat Control Module: Testing and Inspection If a heated seat fails to heat and one or both of the indicator lamps on a heated seat switch flash. If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate, test the heated seat switch. If the heated seat switch checks OK, proceed as follows. 1. Check the heated seat element. 2. Check the heated seat sensor. 3. Check the heated seat switch. NOTE: Refer to Wiring for the location of complete heated seat system wiring diagrams and connector pin-out information. 4. Using a voltmeter, backprobe the heated seat module connector, do not disconnect. Check for voltage at the appropriate pin cavities. 12v should be present. If OK go to Step 5, if Not, Repair the open or shorted voltage supply circuit as required. 5. Using a ohmmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK replace the heated seat module with a known good unit and retest system, if Not OK, Repair the open or shorted ground circuit as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Description and Operation > Page 6552 Power Seat Control Module: Service and Repair REMOVAL 1. Position the driver seat to the full rearward and inclined position. 2. Working under the driver front seat, remove the two heated seat module retaining screws. Due to the fact that the retaining screws are installed with the seat cushion pan removed, a small right angle screwdriver will be required to access and remove the screws. 3. Disconnect the seat wire harness connector from the connector receptacle on the back of the heated seat module. Depress the connector retaining tab and pull straight apart. 4. Remove the heated seat module from under the front seat. INSTALLATION 1. Position the heated seat module under the front seat. 2. Connect the seat wire harness connector on the connector receptacle on the back of the heated seat module. 3. Working under the driver front seat, install the heated seat module retaining screws. 4. Re-position the driver seat. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams Power Seat Motor: Diagrams Motor-Lumbar Driver Motor-Lumbar-Passenger Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams Power Seat Switch: Diagrams Switch-Seat Belt-Driver Switch-Seat Driver Switch-Seat-Passenger (Quad Cab) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 6559 Switch-Seat Passenger (Standard Cab) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 6560 Power Seat Switch: Description and Operation The power seats on this vehicle can be adjusted in eight different directions, up, down, front up, front down, rear up, rear down, rearward and forward. The power seat switch is located on the outboard side of the seat cushion on the seat cushion side shield. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or inoperative, the entire power seat switch assembly must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 6561 Power Seat Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Power Seat Switch Test Table 3. Using an ohmmeter to test the continuity of the power seat switches in each position. Refer to the POWER SEAT SWITCH TEST TABLE. If not OK, replace the inoperative power seat switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 6562 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. 3. Pull the switch bezel or side shield unit (1) out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module (2). 4. Remove the screws (3) that secure the power seat switch (2) to the side shield unit (1). INSTALLATION 1. Position the power seat switch (2) on the seat cushion side shield (1) and install the screws (3). 2. Connect the electrical connector. 3. Install the seat cushion side shield on the seat. 4. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Diagrams Seat Cushion: Diagrams Heater - Seat Cushion Driver Heated - Seat Cushion-Passenger Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Connector Views Seat Heater: Connector Views C316 (Heated Seats) C322 (Heated Seats) C322 (Heated Seats) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Connector Views > Page 6570 C323 (Heated Seats) C323 (Heated Seats) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seat System Seat Heater: Description and Operation Heated Seat System Individually controlled, electrically heated front seats are available as a factory-installed option on some DR models. Vehicles with this option can be visually identified by the leather trim seats and two separate heated seat switches mounted in the lower center of the instrument panel. The heated seat system allows the front seat driver and passenger to select from two different levels of electrical seat heating, or no seat heating to suit their individual comfort requirements. The heated seat system for this vehicle includes the following major components, which are described in further detail later: - Heated Seat Switches - Two heated seat switches are used per vehicle. One switch is used for each front seat. The switches are mounted in the instrument panel, below the radio. Each switch also includes two Light-Emitting Diode (LED) indicator lamps and an incandescent back lighting bulb. - Heated Seat Module - also referred to as the Seat Heat Interface Module (SHIM), this module contains the solid state electronic control and diagnostic logic circuitry for the heated seat system. One heated seat module is used per vehicle and is mounted under the drivers front seat cushion. Refer to the Electronic Control Modules for additional heated seat module information. - Heated Seat Elements - Four heated seat elements are used per vehicle. One element is used for each front seat back and one element and sensor assembly is used for each front seat cushion. The heating elements are integral to the individual front seat and seat back cushions and cannot be removed once installed at the factory. Replacement seat heating elements are available, without having to replace the entire seat cushion or trim cover. Refer to the detailed procedure later. - Heated Seat Sensors - Two heated seat sensors are used per vehicle. One heated seat temperature sensor is used for each front seat cushion. The sensors are integral to the individual front seat cushion heating elements and cannot be removed once installed at the factory. Replacement seat heating elements with the sensors are available, without having to replace the entire seat cushion or trim cover. Refer to the detailed procedure later. Following are general descriptions and operations of the major components in the heated seat system. See the owner's manual in the vehicle glove box for more information on the features, use and operation of the heated seat system. Refer to Wiring for the location of complete heated seat system wiring diagrams. The heated seat module receives fused battery current through the Integrated Power Module. The heated seat switches receive battery current from the Cab Compartment Node (CCN) only when the ignition switch is in the On position and the engine is running. The heated seat module shares a common ground circuit with each of the heated seat elements. The heated seat system will control the surface temperature of the seat cushion to within the designed temperature set points of the system. The heated seat system will also automatically turn off whenever the ignition switch is turned to any position except On, or if the engine quits running. If Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seat System > Page 6573 the ignition switch is turned to the Off position or if the engine quits running while a heated seat is ON, the heated seat will remain Off after the engine is restarted until a heated seat switch is depressed again. This helps prevent the vehicles battery from being drained by the heated seat system. The heated seat module monitors inputs from the heated seat sensors and the heated seat switches. In response to these inputs the heated seat module uses its internal programming to control 12v to the heated seat elements in both front seats and to control the heated seat LED indicator lamps located in both of the heated seat switches. The heated seat module is also programmed to provide self-diagnostics, if a problem with the heated seat system is detected. If the module detects certain failures within the heated seat system, it will provide a visual indication of the failure by flashing the indicator lamps in the appropriate heated seat switch. The heated seat module will automatically turn off the heated seat elements if it detects a short or open in the heated seat element circuit or a heated seat sensor value that is out of range. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seat System > Page 6574 Seat Heater: Description and Operation Heated Seat Element Heating Element Installed On Seat Cushion Foam Vehicles equipped with the optional heated seat system have two sets of electrically operated heating element grids located in each front seat, one set for the seat cushion and the other set for the seat back. Each of the heated seat element grids consists of a single length of resistor wire that is routed in a zigzag pattern and captured between a covering and the adhesive foam rubber backing. Short pigtail wires with connectors are soldered to each end of each resistor wire element grid, which connect all of the element grids to the heated seat module through the seat wire harness. One temperature sensor is used for each front seat, and it is located in the center insert area of the seat cushion element. The heated seat sensors and their pigtail wires are also captured between a covering and the adhesive foam rubber backing. The heated seat sensors are Negative Thermal Coefficient (NTC) thermistors. The sensors for both front seats receive a voltage feed from a single output of the heated seat module, but the module receives individual sensor inputs from the driver side and passenger side sensors. The heated seat elements and sensors should not be repaired. If damaged or faulty, the heated seat element assembly must be replaced. One end of the heated seat element resistor wire is connected to ground at all times through a splice in the heated seat module ground circuit. Battery current is directed to the other end of the heated seat element resistor wire by the energized N-channel Field Effect Transistor (N-FET) located within the heated seat module. The heated seat module will energize the N-FET only when the heated seat switch is in the Low or High position and the heated seat sensor indicates that the seat cushion surface temperature is below the selected (Low or High) temperature set point. As electrical current passes through the heating element grid, the resistance of the wire used in the element disperses some of that electrical current in the form of heat. The heat produced by the heated seat element grid then radiates through the seat trim cover, warming its occupant. The resistance of the heated seat sensor increases and decreases as the surface temperature of the seat cushion cover changes. The heated seat module supplies each sensor with a 5v voltage feed, then uses the sensor resistance to determine when the heated seat element grids need to be cycled on or off in order to maintain the selected temperature set point. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat Element Seat Heater: Testing and Inspection Heated Seat Element The heated seat module will self-diagnose shorted or open heated seat element circuits and sensor circuits. Refer to Heated Seat System Diagnosis and Testing for additional diagnosis and testing procedures. To manually check the heated seat element, proceed as follows. The wire harness connectors for the seat cushion and seat back heating elements and sensor are located on the right side of the seat, near the edge of the seat cushion frame. The proper connector can be identified by the foam wrapping. NOTE: When checking heated seat elements for continuity, be certain to move the heating element being checked. Moving the element, such as sitting in the seat will eliminate the possibility of an intermittent open in the element which would only be evident if the element was in a certain position. Failure to check the element in various positions could result in an incomplete test. 1. Position the appropriate seat in the full forward position. 2. Make certain the ignition switch is in the OFF position. 3. Disconnect the heated seat element connector which requires testing. Check for continuity between the two heated seat element circuit cavities while moving the appropriate seat cushion. Refer to Wiring for the location of complete heated seat system wiring diagrams. There should be continuity. If OK, the elements within the seat assembly test OK, go to Step 4. If not OK, replace the faulty seat heating element, refer to the procedure. 4. Test the seat wire harness between the heated seat module connector and the appropriate heated seat wire harness connector for shorted or open circuits. If OK, element is OK, proceed with testing the heated seat sensor and module. If not OK, repair the shorted or open seat wire harness as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat Element > Page 6577 Seat Heater: Testing and Inspection Heated Seat System HEATED SEAT SYSTEM SELF-DIAGNOSIS The heated seat system is capable of performing some self-diagnostics. The following table depicts the various monitored failures which will be reported to the vehicle operator or technician by flashing the individual heated seat switch Light Emitting Diode (LED) indicator lamps. Refer to the HEATED SEAT SYSTEM SELF-DIAGNOSIS table for failure identification. The drivers heated seat switch indicator lamps will flash if a failure occurs in the driver heated seat, and the passengers heated seat switch indicator lamps will flash for a passenger heated seat failure. If a monitored heated seat system failure occurs, the switch indicator lamps will flash at a pulse rate of about one-half second on, followed by about one-half second off for a duration of about one minute after the switch for the faulty heated seat is depressed in either the Low or High direction. This process will repeat every time the faulty heated seat switch is actuated until the problem has been corrected. Diagnostic logic is built into the heated seat module to help the person trying to locate the problem by the most efficient means possible. Anytime a problem is suspected, locate the diagnosis and testing procedure for the component in question and follow the steps until the specific problem is located and resolved. Once the problem is thought to be corrected, verify correct system operation. If the heated seat system is functioning correctly return the vehicle to service. If a problem could not be verified such as not finding anything wrong when following the diagnostic procedure, this is a good indication that a INTERMITTENT problem may be present. You must then attempt to find the intermittent problem, such as moving the heating element within the seat while testing continuity or wiggling the wire harness's/electrical connectors under the seat while testing continuity. Always, eliminate all other potential problems before attempting to replace the heated seat module. PRELIMINARY TEST Refer to Wiring for the location of complete heated seat system wiring diagrams. Before testing the individual components in the heated seat system, perform the following preliminary checks: WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE, THEN WAIT TWO MINUTES FOR THE AIR-BAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - If the heated seat switch back lighting and the cluster illumination lamps do not illuminate with the headlamps or park lamps turned On, refer to the Instrument Cluster for the location of cluster illumination lamp diagnosis and testing procedures. If the heated seat switch back lighting does not illuminate, but the cluster illumination lamps do illuminate with the headlamps or park lamps turned On, refer to Diagnosis and Testing the Heated Seat Switch for the location of the heated seat switch diagnosis and testing procedures. - If a single LED indicator lamp for one heated seat switch does not operate and the heated seat elements do heat, refer to Diagnosis and Testing the Heated Seat Switch for heated seat switch diagnosis and testing procedures. - If both LED indicator lamps for a heated seat switch operate, but the heated seat elements do not heat, refer to Diagnosis and Testing the Heated Seat Module in Electronic Control Modules for heated seat module diagnosis and testing procedures. - If the indicator lamp on either heated seat switch remains illuminated after the heated seat has been turned Off, refer to Diagnosis and Testing the Heated Seat Module in Electronic Control Modules for heated seat module diagnosis and testing procedures. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Page 6578 Seat Heater: Service and Repair HEATED SEAT ELEMENT REMOVAL Do not remove the heating element from the seat or seat back cushion. The original element is permanently attached to the seat cushions and cannot be removed without damaging the cushion. The replacement heating element is designed to be applied directly over the original seat heating element. 1. Disconnect and isolate the negative battery cable. 2. Remove the appropriate seat cushion or seat back trim cover. Refer to the Body section of this manual for the procedures. 3. Disconnect the inoperative heated seat cushion or seat back element electrical connectors. 4. Locate the wires leading from the inoperative heating element and cut them off flush with the edge of the original heating element. INSTALLATION 1. Peel off the adhesive backing on the back of the replacement heating element and stick directly over the original heating element. CAUTION: During the installation of the replacement heating element, be careful not to fold or crease the element assembly. Folds or creases will cause premature failure. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Page 6579 Heating Element Installed On Seat Cushion Foam 2. Connect the new heating element electrical connectors. 3. Connect the battery negative cable. 4. Verify heated seat system operation. 5. Install the appropriate seat cushion or seat back trim cover. Make certain the seat wire harness is correctly routed through the seat and seat back. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams Module-Heated Seats Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 6583 Seat Heater Control Module: Description and Operation The heated seat module is also known as the Seat Heat Interface Module. The heated seat module is located under the drivers front seat cushion, where it is secured to a mounting bracket. The heated seat module has a single connector receptacle that allows the module to be connected to all of the required inputs and outputs through the seat wire harness. The heated seat module is an electronic microprocessor controlled device designed and programmed to use inputs from the battery, the two heated seat switches and the two heated seat sensors to operate and control the heated seat elements in both front seats and the two heated seat indicator lamp Light-Emitting Diodes (LEDs) in each heated seat switch. The heated seat module is also programmed to perform self-diagnosis of certain heated seat system functions and provide feedback of that diagnosis through the heated seat switch indicator lamps. The heated seat module cannot be repaired. If the heated seat module is damaged or faulty, the entire module must be replaced. The heated seat module operates on fused battery current received from the integrated power module. Inputs to the module include a resistor multiplexed heated seat switch request circuit for each of the two heated seat switches and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements and sensors, and controls the ground for the heated seat switch indicator lamps. When a heated seat switch (Driver or Passenger) is depressed a signal is received by the heated seat module, the module energizes the proper indicator LED (Low or High) in the switch by grounding the indicator lamp circuit to indicate that the heated seat system is operating. At the same time, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. The Low heat set point is about 36° C (96.8° F), and the High heat set point is about 42° C (107.6° F). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an Nm-channel Field Effect Transistor (Nm-FEET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the Nm-FEET which de-energizes the heated seat elements. The heated seat module will continue to cycle the Nm-FEET as needed to maintain the selected temperature set point. If the heated seat module detects a heated seat sensor value input that is out of range or a shorted or open heated seat element circuit, it will notify the vehicle operator or the repair technician of this condition by flashing the High and/or Low indicator lamps in the affected heated seat switch. Refer to Diagnosis and Testing Heated Seat System in Heated Systems for flashing LED diagnosis and testing procedures. Refer to Diagnosis and Testing Heated Seat Module for heated seat module diagnosis and testing procedures. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 6584 Seat Heater Control Module: Testing and Inspection If a heated seat fails to heat and one or both of the indicator lamps on a heated seat switch flash, refer to Diagnosis and Testing Heated Seat System in Heated Seats for the location of flashing LED heated seat system diagnosis and testing procedures. If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate, test the heated seat switch. Refer to Diagnosis and Testing Heated Seat Switch in Heated Seats for heated seat switch diagnosis and testing procedures. If the heated seat switch checks OK, proceed as follows. 1. Check the heated seat element. 2. Check the heated seat sensor. 3. Check the heated seat switch. NOTE: Refer to Wiring for the location of complete heated seat system wiring diagrams and connector pin-out information. 4. Using a voltmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for voltage at the appropriate pin cavities. 12v should be present. If OK go to Step 5, if Not, Repair the open or shorted voltage supply circuit as required. 5. Using a ohmmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK replace the heated seat module with a known good unit and retest system, if Not OK, Repair the open or shorted ground circuit as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 6585 Seat Heater Control Module: Service and Repair REMOVAL 1. Position the driver seat to the full rearward and inclined position. 2. Working under the driver front seat, remove the two heated seat module retaining screws. Due to the fact that the retaining screws are installed with the seat cushion pan removed, a small right angle screwdriver will be required to access and remove the screws. 3. Disconnect the seat wire harness connector from the connector receptacle on the back of the heated seat module. Depress the connector retaining tab and pull straight apart. 4. Remove the heated seat module from under the front seat. INSTALLATION 1. Position the heated seat module under the front seat. 2. Connect the seat wire harness connector on the connector receptacle on the back of the heated seat module. 3. Working under the driver front seat, install the heated seat module retaining screws. 4. Re-position the driver seat. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Description and Operation Seat Heater Sensor: Description and Operation The heated seat temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. One temperature sensor is used for each seat. This temperature sensor is located in the seat cushion heating element on all models. The heated seat temperature sensor cannot be repaired or adjusted and must be replaced if defective. The heated seat cushion element must be replaced if the temperature sensor is defective. Refer to the procedure. When the temperature of the seat cushion cover rises, the resistance of the sensor decreases. The heated seat module supplies five-volts to one side of each sensor, and monitors the voltage drop through the sensor on a return circuit. The heated seat module uses this temperature sensor input to monitor the temperature of the seat, and regulates the current flow to the seat heating elements accordingly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Description and Operation > Page 6589 Seat Heater Sensor: Testing and Inspection NOTE: Any resistance values (OHMS) given in the following text are supplied using the automatic range generated by a FLUKE(R) automotive meter. If another type of measuring device is used, the values generated may not be the same as the results shown here, or may have to be converted to the range used here. 1. Position the driver seat in the full rearward position. 2. Unclip the heated seat module from the bottom of the drivers seat cushion pan. 3. Back-probe the heated seat module wire harness connector, do not disconnect. Check cavity (#7 for passenger, #8 for driver seat) for a range in voltage from approx. 1.72 - 3.0 volts. It should be within this range, If OK check the heated seat element. If NOT OK, check for the proper 5 volt supply to the heated seat sensor, from the module. Refer to Wiring for specific information. If 5 volts is not being supplied to the sensor from the module, replace the heated seat module. 4. Test the seat wire harness between the heated seat module connector and the heated seat wire harness connector for shorted or open circuits. If OK, refer to Diagnosis and Testing the Heated Seat Module in Electronic Control Modules, for the proper heated seat module diagnosis and testing procedures. If not OK, repair the shorted or open heated seat wire harness as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Description and Operation > Page 6590 Seat Heater Sensor: Service and Repair REMOVAL 1. For heated seat sensor replacement procedure. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations Seat Heater Switch: Locations Rear Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 6594 Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 6595 Center Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 6596 Seat Heater Switch: Diagrams Switch-Heated Seat Driver Switch-Heated Seat-Passenger Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 6597 Seat Heater Switch: Description and Operation The momentary, bidirectional rocker-type heated seat switch provides a resistor-multiplexed signal to the heated seat module via a mux circuit. Each switch has a center neutral position and momentary Low and High positions so that both the driver and the front seat passenger can select a preferred level of seat heating. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected mode (Low or High) of the seat heater. These indicator lamps also provide diagnostic feedback for the heated seat system. Each switch also has an incandescent bulb, which provides dimmer controlled back lighting of the switch when the headlamps or park lamps are on. The heated seat switches are both mounted in the instrument panel center bezel, located in the lower center of the instrument panel. The two switches are snapped into the mounting holes of the heated seat switch bezel, and the heated seat switch bezel is secured with screws to the instrument panel center bezel. The heated seat switches are differentiated by the keyway in the connector receptacle on the backs of the switches and keyway on the switch housing. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles on the switches so that the two heated seat switches can only be connected to the proper heated seat electrical. The two LED indicator lamps and the incandescent bulb in each heated seat switch cannot be repaired. If the indicator lamps or back lighting bulb are faulty or damaged, the individual heated seat switch must be replaced. The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hardwired resistance signal to the heated seat module. This signal tells the module to energize the heated seat element of the selected seat and maintain the requested temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new selection. If a heated seat switch is depressed a second time, the heated seat module interprets the second input as a request to turn the seat heater OFF. The High and Low LED indicator lamps in the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The ground side of each indicator lamp is controlled by the heated seat module. This control of the switch indicator lamps also allows the module to provide diagnostic feedback to the vehicle operator or technician to indicate heated seat system faults by flashing the indicator lamps on and off. One side of the incandescent back lighting bulb in each heated seat switch is connected to ground at all times. The other side of the incandescent bulb is connected to the fused panel lamps dimmer switch signal circuit. These bulbs are energized when the park lamps or headlamps are turned on, and their illumination intensity is controlled by the panel lamps dimmer switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 6598 Seat Heater Switch: Testing and Inspection Refer to Wiring Diagrams for connector pin-outs and the location of complete heated seat system wiring diagrams. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. If the problem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps operate, go to Step 2. If the problem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps are also inoperative. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do not heat, proceed. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do heat, go to Step 6. If the problem being diagnosed involves a heated seat switch indicator lamp that remains illuminated after the heated seat has been turned Off. 2. Disconnect and isolate the battery negative cable. Remove the heated seat switch and bezel unit from the instrument panel. Disconnect the heated seat switch to be tested. Check for continuity between the ground circuit cavity of the heated seat switch and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open ground circuit to ground as required. 3. Reconnect the battery negative cable. Turn the park lamps on with the headlamp switch. Rotate the panel lamps dimmer thumb wheel on the headlamp switch upward to just before the interior lamps detent. Check for battery voltage at the fused panel lamps dimmer circuit cavity of the heated seat switch. If OK, go to Step 4. If not OK, repair the open fused panel lamps dimmer switch signal circuit to the fuse in the Integrated Power Module as required. 4. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the heated seat switch. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run) circuit as required. 5. Check the continuity and resistance values of the heated seat switch in the Neutral, Low and High positions as shown in the Heated Seat Switch Continuity chart. If OK, refer to Step 6. If not OK, replace the faulty heated seat switch. 6. Replace the inoperative heated seat switch with a known good unit and test the operation of the switch indicator lamps. If OK, discard the faulty heated seat switch. If not OK. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 6599 Seat Heater Switch: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Wait two minutes for the system reserve capacitor to discharge before beginning any airbag or instrument panel service. 3. Remove the center bezel from the instrument panel. 4. Remove the screws that secure the heated seat switch bezel to the instrument panel center bezel. 5. Remove the heated seat switch bezel and both switches from the instrument panel as a unit. 6. From the back of the heated seat switch bezel, gently pry the switch free and push the heated seat switch out through the front of the bezel. INSTALLATION NOTE: When installing the heated seat switches, be certain they are installed in the proper mounting holes of the heated seat switch bezel. The heated seat switches are differentiated by the keyway in the connector receptacle on the backs of the switches and keyway on the switch housing. 1. From the back of the heated seat switch bezel, gently push the heated seat switch in through the front of the bezel. 2. Position the heated seat switch bezel to the instrument panel center bezel and install the retaining screws. 3. Install the center bezel on the instrument panel. 4. Connect the battery negative cable. 5. Verify vehicle and system operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation Seat Track: Description and Operation The eight-way power seat option includes a power seat track assembly (1) located under each front seat. The power seat track assembly replaces the standard manually operated seat tracks. The lower half of the power seat track is secured at the front with two bolts to the floor panel seat cross member, and at the rear with two bolts to the floor panel. Four nuts secure the bottom of the seat cushion frame to the upper half of the power seat track unit. The power seat track assembly cannot be repaired, and is serviced only as a complete assembly. If any component in this assembly is inoperative or damaged, the entire power seat track must be replaced. The power seat track unit includes three reversible electric motors that are secured to the upper half of the track unit. Each motor moves the seat adjuster through a combination of worm-drive gearboxes and screw-type drive units. The front and rear of the seat are operated by two separate vertical adjustment motors. These motors can be operated independently of each other, tilting the entire seat assembly forward or rearward; or, they can be operated in unison by selecting the proper power seat switch functions, which will raise or lower the entire seat assembly. The third motor is the horizontal adjustment motor, which moves the seat track in the forward and rearward directions. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation > Page 6603 Seat Track: Testing and Inspection For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 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 track fails to operate in only one direction, move the seat track a short distance in the opposite direction and test again to be certain that the track is not at its travel limit. If the power seat track still fails to operate in only one direction, refer to testing for power seat switch diagnosis. If the power seat track fails to operate in more than one direction, proceed as follows: 1. Check the power seat fuse in the integrated power module. If OK, go to Step 2. If not OK, repair the circuit as necessary and replace the inoperative fuse. 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 3. If not OK, repair the open circuit to the integrated power module 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 4. If not OK, repair the open circuit to ground as required. 4. Test the power seat switch. If the switch tests OK, check the wire harness between the power seat switch and the motor for shorts or opens. If the circuits check OK, replace the inoperative power seat track (adjuster) assembly. If the circuits are not OK, repair the wire harness as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation > Page 6604 Seat Track: Service and Repair REMOVAL 1. Remove the appropriate seat from the vehicle. 2. Remove the power seat switch from the seat. 3. Remove four seat track mounting nuts from cushion pan. 4. Disconnect the power seat electrical connectors and remove the seat track from the seat cushion. 5. Remove the necessary components that must be transferred to the replacement seat track (seat belt buckles, wire harness, etc.). INSTALLATION 1. Install the necessary components that must be transferred to the replacement seat track (seat belt buckles, wire harness, etc.). 2. Position the seat track and install the retaining nuts on the seat cushion pan studs. Torque the bolts to 25 N.m. 3. Route and connect the power seat electrical connectors on the seat track and cushion pan. 4. Install the power seat switch on the seat. 5. Install the seat in the vehicle. 6. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Locations > Page 6609 Door Lock Cylinder Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Disconnect the door cylinder lock switch pigtail wire connector from the door wire harness connector. Door Cylinder Lock Switch Tests 3. Using an ohmmeter, perform the resistance tests between the two pins in the door cylinder lock switch pigtail wire connector. Actuate the switch by rotating the key in the door lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Door Cylinder Lock Switch Tests table. 4. If the switch fails any of the resistance tests, replace the faulty door cylinder lock switch as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Locations > Page 6610 Door Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the exterior handle and lock cylinder (1) from the outside of the driver side front door as a unit. 3. Remove the bowed clip (3) that secures the lever arm (4) to the shaft on the back of the lock cylinder. 4. Remove the lever arm from the lock cylinder shaft. 5. Remove the door cylinder lock switch (2) from the back of the lock cylinder. INSTALLATION 1. Position the door cylinder lock switch (2) over the shaft on the back of the lock cylinder (1). 2. Position the lever arm (4) onto the shaft over the switch. 3. Install the bowed clip (3) that secures the lever arm to the shaft. 4. Reinstall the exterior handle and lock cylinder onto the outside of the driver side front door as a unit. 5. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Position Switch > Component Information > Locations Left Front Door Premium Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Position Switch > Component Information > Locations > Page 6614 Door Position Switch: Description and Operation Vehicles that are equipped with the optional Vehicle Theft Security System (VTSS) have a door cylinder lock switch (1) secured to the back of the key lock cylinder inside the driver side front door. The door cylinder lock switch is a resistor multiplexed momentary switch that is hard wired in series between ground and the cylinder lock switch mux circuit input to the ElectroMechanical Instrument Cluster (EMIC) through a pigtail wire (2) connected to the left front door wire harness. The door cylinder lock switch is driven by the key lock cylinder and contains two internal resistors. One resistor value is used for the Lock position, and one for the Unlock position. The door cylinder lock switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The door cylinder lock switch is actuated by the key lock cylinder when the key is inserted in the lock cylinder and turned to the lock or unlock positions. The door cylinder lock switch closes a circuit between ground and the cylinder lock switch mux circuit through one of two internal resistors for the ElectroMechanical Instrument Cluster (EMIC) when the driver side front door key lock cylinder is in the Lock, or Unlock positions. The EMIC reads the switch status through an internal pull-up, then uses this information as an input for the Vehicle Theft Security System (VTSS) operation, as well as for control of a central locking feature for the power lock system. The door cylinder lock switch and circuit may be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC or its responses to the cylinder lock switch inputs. The most reliable, efficient, and accurate means to diagnose the door cylinder lock switch, the EMIC, and both the hard wired and electronic message inputs and outputs affected by the door cylinder lock switch inputs requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 6618 Left Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 6619 Starter-Adjustable Pedals (Except Base) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 6620 Pedal Positioning Switch: Service and Repair BASE BRAKES SWITCH-ADJUSTABLE PEDALS REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations Left Front Door Premium Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 6624 Right Front Door Premium Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 6625 Power Door Lock Switch: Diagrams Switch-Door Lock-Passenger Switch-Window/Door Lock Driver C1 Switch-Window/Door Lock Driver C1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 6626 Power Door Lock Switch: Description and Operation A window/lock switch is used on all models equipped with power locks, power windows, and power mirrors. The window/lock switch houses the following switches: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch selects the right or left power mirror for adjustment, or turns the power mirror system Off. Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, there are individual master switches for each passenger door power window. The window/lock switch also incorporates several green Light-Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility. The window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster input, which allows the instrument cluster to sense the switch position. Based upon the power lock switch input, the instrument cluster controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit. The switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window is labeled "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The power mirror switch circuitry is connected to battery current through a fuse in the IPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral Off position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the power mirror switch is connected to battery current through the power window circuit breaker in the IPM on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the On or Accessory positions. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Switch-Power Lock Power Door Lock Switch: Testing and Inspection Switch-Power Lock The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Integrated Power Module (IPM) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the window/lock switch. If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the On position. If OK, replace the faulty switch. 1. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel. Disconnect the door wire harness connector for the power lock switch from the switch connector receptacle. Power Lock Switch Test Table 2. Test the power lock switch resistance. See the Power Lock Switch Test chart to determine if the resistance is correct for the switch in each switch position. If not OK, replace the faulty power lock switch as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Switch-Power Lock > Page 6629 Power Door Lock Switch: Testing and Inspection Window/Lock Switch The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Integrated Power Module (IPM). If all of the LEDs are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Switch-Power Lock > Page 6630 Driver Door Module Switch Tests 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty DDM as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Switch-Power Lock Power Door Lock Switch: Service and Repair Switch-Power Lock REMOVAL The power lock switch on the driver side front door trim panel is integral to the window/lock switch. 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Switch-Power Lock > Page 6633 Power Door Lock Switch: Service and Repair Switch-Window/Door Lock REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Install switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection Power Mirror Switch: Testing and Inspection The power mirror switch is included with the window/lock switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Page 6637 Power Mirror Switch: Service and Repair The power mirror switch is included with the window/lock switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Power Seat Switch: Diagrams Switch-Seat Belt-Driver Switch-Seat Driver Switch-Seat-Passenger (Quad Cab) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 6641 Switch-Seat Passenger (Standard Cab) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 6642 Power Seat Switch: Description and Operation The power seats on this vehicle can be adjusted in eight different directions, up, down, front up, front down, rear up, rear down, rearward and forward. The power seat switch is located on the outboard side of the seat cushion on the seat cushion side shield. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or inoperative, the entire power seat switch assembly must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 6643 Power Seat Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Power Seat Switch Test Table 3. Using an ohmmeter to test the continuity of the power seat switches in each position. Refer to the POWER SEAT SWITCH TEST TABLE. If not OK, replace the inoperative power seat switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 6644 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. 3. Pull the switch bezel or side shield unit (1) out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module (2). 4. Remove the screws (3) that secure the power seat switch (2) to the side shield unit (1). INSTALLATION 1. Position the power seat switch (2) on the seat cushion side shield (1) and install the screws (3). 2. Connect the electrical connector. 3. Install the seat cushion side shield on the seat. 4. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Description and Operation Seat Heater Sensor: Description and Operation The heated seat temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. One temperature sensor is used for each seat. This temperature sensor is located in the seat cushion heating element on all models. The heated seat temperature sensor cannot be repaired or adjusted and must be replaced if defective. The heated seat cushion element must be replaced if the temperature sensor is defective. Refer to the procedure. When the temperature of the seat cushion cover rises, the resistance of the sensor decreases. The heated seat module supplies five-volts to one side of each sensor, and monitors the voltage drop through the sensor on a return circuit. The heated seat module uses this temperature sensor input to monitor the temperature of the seat, and regulates the current flow to the seat heating elements accordingly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Description and Operation > Page 6648 Seat Heater Sensor: Testing and Inspection NOTE: Any resistance values (OHMS) given in the following text are supplied using the automatic range generated by a FLUKE(R) automotive meter. If another type of measuring device is used, the values generated may not be the same as the results shown here, or may have to be converted to the range used here. 1. Position the driver seat in the full rearward position. 2. Unclip the heated seat module from the bottom of the drivers seat cushion pan. 3. Back-probe the heated seat module wire harness connector, do not disconnect. Check cavity (#7 for passenger, #8 for driver seat) for a range in voltage from approx. 1.72 - 3.0 volts. It should be within this range, If OK check the heated seat element. If NOT OK, check for the proper 5 volt supply to the heated seat sensor, from the module. Refer to Wiring for specific information. If 5 volts is not being supplied to the sensor from the module, replace the heated seat module. 4. Test the seat wire harness between the heated seat module connector and the heated seat wire harness connector for shorted or open circuits. If OK, refer to Diagnosis and Testing the Heated Seat Module in Electronic Control Modules, for the proper heated seat module diagnosis and testing procedures. If not OK, repair the shorted or open heated seat wire harness as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Description and Operation > Page 6649 Seat Heater Sensor: Service and Repair REMOVAL 1. For heated seat sensor replacement procedure. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations Seat Heater Switch: Locations Rear Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 6653 Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 6654 Center Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 6655 Seat Heater Switch: Diagrams Switch-Heated Seat Driver Switch-Heated Seat-Passenger Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 6656 Seat Heater Switch: Description and Operation The momentary, bidirectional rocker-type heated seat switch provides a resistor-multiplexed signal to the heated seat module via a mux circuit. Each switch has a center neutral position and momentary Low and High positions so that both the driver and the front seat passenger can select a preferred level of seat heating. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected mode (Low or High) of the seat heater. These indicator lamps also provide diagnostic feedback for the heated seat system. Each switch also has an incandescent bulb, which provides dimmer controlled back lighting of the switch when the headlamps or park lamps are on. The heated seat switches are both mounted in the instrument panel center bezel, located in the lower center of the instrument panel. The two switches are snapped into the mounting holes of the heated seat switch bezel, and the heated seat switch bezel is secured with screws to the instrument panel center bezel. The heated seat switches are differentiated by the keyway in the connector receptacle on the backs of the switches and keyway on the switch housing. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles on the switches so that the two heated seat switches can only be connected to the proper heated seat electrical. The two LED indicator lamps and the incandescent bulb in each heated seat switch cannot be repaired. If the indicator lamps or back lighting bulb are faulty or damaged, the individual heated seat switch must be replaced. The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hardwired resistance signal to the heated seat module. This signal tells the module to energize the heated seat element of the selected seat and maintain the requested temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new selection. If a heated seat switch is depressed a second time, the heated seat module interprets the second input as a request to turn the seat heater OFF. The High and Low LED indicator lamps in the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The ground side of each indicator lamp is controlled by the heated seat module. This control of the switch indicator lamps also allows the module to provide diagnostic feedback to the vehicle operator or technician to indicate heated seat system faults by flashing the indicator lamps on and off. One side of the incandescent back lighting bulb in each heated seat switch is connected to ground at all times. The other side of the incandescent bulb is connected to the fused panel lamps dimmer switch signal circuit. These bulbs are energized when the park lamps or headlamps are turned on, and their illumination intensity is controlled by the panel lamps dimmer switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 6657 Seat Heater Switch: Testing and Inspection Refer to Wiring Diagrams for connector pin-outs and the location of complete heated seat system wiring diagrams. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. If the problem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps operate, go to Step 2. If the problem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps are also inoperative. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do not heat, proceed. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do heat, go to Step 6. If the problem being diagnosed involves a heated seat switch indicator lamp that remains illuminated after the heated seat has been turned Off. 2. Disconnect and isolate the battery negative cable. Remove the heated seat switch and bezel unit from the instrument panel. Disconnect the heated seat switch to be tested. Check for continuity between the ground circuit cavity of the heated seat switch and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open ground circuit to ground as required. 3. Reconnect the battery negative cable. Turn the park lamps on with the headlamp switch. Rotate the panel lamps dimmer thumb wheel on the headlamp switch upward to just before the interior lamps detent. Check for battery voltage at the fused panel lamps dimmer circuit cavity of the heated seat switch. If OK, go to Step 4. If not OK, repair the open fused panel lamps dimmer switch signal circuit to the fuse in the Integrated Power Module as required. 4. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the heated seat switch. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run) circuit as required. 5. Check the continuity and resistance values of the heated seat switch in the Neutral, Low and High positions as shown in the Heated Seat Switch Continuity chart. If OK, refer to Step 6. If not OK, replace the faulty heated seat switch. 6. Replace the inoperative heated seat switch with a known good unit and test the operation of the switch indicator lamps. If OK, discard the faulty heated seat switch. If not OK. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 6658 Seat Heater Switch: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Wait two minutes for the system reserve capacitor to discharge before beginning any airbag or instrument panel service. 3. Remove the center bezel from the instrument panel. 4. Remove the screws that secure the heated seat switch bezel to the instrument panel center bezel. 5. Remove the heated seat switch bezel and both switches from the instrument panel as a unit. 6. From the back of the heated seat switch bezel, gently pry the switch free and push the heated seat switch out through the front of the bezel. INSTALLATION NOTE: When installing the heated seat switches, be certain they are installed in the proper mounting holes of the heated seat switch bezel. The heated seat switches are differentiated by the keyway in the connector receptacle on the backs of the switches and keyway on the switch housing. 1. From the back of the heated seat switch bezel, gently push the heated seat switch in through the front of the bezel. 2. Position the heated seat switch bezel to the instrument panel center bezel and install the retaining screws. 3. Install the center bezel on the instrument panel. 4. Connect the battery negative cable. 5. Verify vehicle and system operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Switch-Sunroof Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 6662 Sunroof / Moonroof Switch: Description and Operation The power sunroof switch (3) is a combination push button and rocker switch module mounted in the overhead console. The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) The power sunroof switch is part of the overhead console assembly and cannot be replaced separately. If the switch is damaged or inoperative the overhead console must be replaced. The power sunroof switch is hard wired to the sunroof motor/module assembly. The switch receives battery current from the motor/module when the ignition switch is in the RUN and ACCESSORY positions or the vehicle Accessory Delay System is active. When one of the switch positions is pressed it sends battery current back to the motor/ module, signaling it to move the power sunroof to the appropriate position. The motor/module will perform one of the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 6663 Sunroof / Moonroof Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. If completing the appropriate diagnostic information results in the sunroof switch being inoperative, perform the following test prior to switch replacement. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console. 3. Disconnect the power sunroof switch wire harness connector. Power Sunroof Switch Continuity Table 4. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage. Use a scan tool and the proper Diagnostic Procedures Information to complete diagnosis of the power sunroof system. If not OK, replace the overhead console. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations Sound Proofing / Insulation: Locations NVH/SOUND DEADENER LOCATIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 6667 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 6668 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 6669 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Spoiler-SRT-10 Spoiler: Service and Repair Spoiler-SRT-10 SPOILER-SRT-10 REMOVAL WITHOUT CARGO BOX COVER 1. Remove the two bolts (2) that secure the spoiler to the rear of the cargo box. 2. Slide the spoiler rearward to disengage the two studs (1) and remove the spoiler. 3. If required, remove the two nuts that secure the two studs to the rear of the cargo box and remove the studs. WITH CARGO BOX COVER 1. Remove the five nuts (1) that secure the spoiler (2) to the cargo box cover (3). 2. Remove the spoiler from the cargo box cover INSTALLATION WITHOUT CARGO BOX COVER Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Spoiler-SRT-10 > Page 6675 1. If removed, position the two studs (1) onto the rear of the cargo box and install the retaining nuts. Tighten the nuts to 9 N.m (80 in.lbs.). 2. Position the spoiler over the two studs and slide the spoiler forward until the studs fully engage. 3. Install the two bolts (2) that secure the spoiler to the rear of the cargo box. Tighten the bolts to 6 N.m (50 in.lbs.). WITH CARGO BOX COVER 1. Position the spoiler (2) onto the rear of the cargo box cover (3). 2. Install the five nuts (1) that secure the spoiler to the cargo box cover. Tighten the nuts to 9 N.m (80 in.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Spoiler-SRT-10 > Page 6676 Spoiler: Service and Repair Front Air Dam FRONT AIR DAM REMOVAL 1. Remove the two outboard screws. 2. Remove the three middle screws and remove the air dam. INSTALLATION 1. Position the air dam onto the bumper and seat the carrot type fasteners fully. 2. Starting at the center screw install the three middle screws. 3. Install the two outboard screws. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Cover > Component Information > Service and Repair Tailgate Cover: Service and Repair COVER REMOVAL 1. Open the tailgate (1) and remove the tailgate liner, if equipped. 2. Remove the ten bolts (2) that secure the tailgate cover (3) to the inside of the tailgate and remove the cover. INSTALLATION 1. Position the tailgate cover (3) onto the inside of the tailgate (1). 2. Install the ten bolts (2) that secure the tailgate cover to the tailgate. Tighten the bolts securely. 3. If equipped, install the tailgate liner onto the tailgate. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Service and Repair Tailgate Hinge: Service and Repair HINGE REMOVAL 1. Remove the tailgate. 2. If required, remove the bushing (3) from each tailgate hinge (1). 3. Remove the two bolts (4) that secure each tailgate hinge (1) to the cargo box (2) and remove the hinge(s) as necessary. INSTALLATION 1. Position the tailgate hinge(s) onto the cargo box (2) as necessary. 2. Install the two bolts (4) that secure each tailgate hinge to the cargo box. Tighten the bolts to 34 N.m (25 ft.lbs.). 3. If removed, install the bushing (3) onto each tailgate hinge. 4. Install the tailgate. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch Tailgate Latch: Service and Repair Tailgate Latch LATCH REMOVAL 1. Open the tailgate and remove the tailgate liner, if equipped. 2. Remove the ten bolts (5) that secure the tailgate cover (4) to the inside of the tailgate and remove the cover. 3. Using a grease pencil or equivalent, mark the actuator rod (3) at the control (2) for the latch (1) being serviced. 4. Disconnect the actuator rod from the control. 5. Remove the two bolts (7 and 8) that secure the latch (5) to the tailgate (4) and position the tailgate check cable (6) out of the way. 6. Remove the latch and actuator rod from the tailgate as an assembly. 7. If required, remove the actuator rod from the latch. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch > Page 6688 1. If removed, install the actuator rod onto the latch (5) being serviced. 2. Install the latch and actuator rod into the tailgate (4) as an assembly. 3. Position the tailgate check cable (6) onto the tailgate and install the two bolts (7 and 8) that secure the latch and the check cable to the tailgate. Tighten the bolts to 23 N.m (17 ft.lbs.). 4. Locate the actuator rod (3) to the control (2) using the reference mark made during the removal procedure and connect the rod to the control. 5. Position the tailgate cover (4) onto the inside of the tailgate. 6. Install the ten bolts (5) that secure the tailgate cover to the tailgate. Tighten the bolts securely. 7. If equipped, install the tailgate liner onto the tailgate. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch > Page 6689 Tailgate Latch: Service and Repair Tailgate Latch Striker LATCH STRIKER REMOVAL 1. Open the tailgate and using a grease pencil or equivalent, mark the location of the tailgate striker (1) being serviced. 2. Remove the striker from the cargo box (2). INSTALLATION 1. Position the striker (1) onto the cargo box (2) using the reference mark made during the removal procedure. 2. Tighten the striker to 34 N.m (25 ft.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair Tailgate Release Handle: Service and Repair RELEASE HANDLE REMOVAL 1. Open the tailgate and remove the tailgate liner, if equipped. 2. Remove the ten bolts (5) that secure the tailgate cover (4) to the inside of the tailgate and remove the cover. 3. Using a grease pencil or equivalent, mark the location of the actuator rods (3) at the control (2). 4. Disconnect the actuator rods from the control. 5. Remove the two nuts (3) that secure the release handle (1) and the control (2) to the tailgate (4). 6. Remove the control and the release handle from the tailgate. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Page 6693 1. Position the release handle and the control onto the tailgate. 2. Install the two nuts that secure the release handle and control to the tailgate. Tighten the nuts to 7 N.m (60 in.lbs.). 3. Locate the actuator rods (3) to the control (2) using the reference marks made during the removal procedure and connect the rods to the control. 4. Position the tailgate cover (4) onto the inside of the tailgate. 5. Install the ten bolts (5) that secure the tailgate cover to the tailgate. Tighten the bolts securely. 6. If equipped, install the tailgate liner onto the tailgate. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Service and Repair Tailgate Shock / Support: Service and Repair CABLE-CHECK REMOVAL 1. Open the tailgate and locate the tailgate check cable (3) on the left and right of the cargo box below the tailgate striker (1) as necessary. 2. Pry the cable lock tab(s) (4) outward using a screwdriver or flat bladed tool (2) and remove the tailgate check cable(s) from the cargo box. 3. Remove the bolt (1) that secures the tailgate check cable (2) to the left and right side of the tailgate (3) as necessary. 4. Remove the tailgate check cable(s) from the tailgate. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Service and Repair > Page 6697 1. Position the tailgate check cable (2) onto the left and right side of the tailgate (3) as necessary. 2. Install the bolt (1) that secures the small end of the tailgate check cable(s) to the tailgate. Tighten the bolt(s) to 23 N.m (17 ft.lbs.). 3. Position the tailgate check cable (3) to the left and right side of the cargo box below the tailgate striker (1) as necessary. 4. Install the large end of the tailgate check cable(s) onto the cargo box. Make sure that the cable lock tab(s) (4) fully engage. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Towing Hook / Bracket > Component Information > Service and Repair Towing Hook / Bracket: Service and Repair FRONT TOW HOOK ASSEMBLY REMOVAL 1. Remove front bumper. 2. Remove the bolts (2) and remove the tow hook assembly (3). 3. If the vehicle is a Heavy Duty, then remove the bolts (1) and remove the tow hook (2). INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Towing Hook / Bracket > Component Information > Service and Repair > Page 6701 1. Install the tow hook assembly (3) and bolts (2) hand tight. 2. If vehicle is a Heavy Duty, install the tow hook (2) and bolts (1) hand tight. 3. Install the front bumper. 4. Line up the tow hooks/tow hook assembly and tighten the bolts to 68 N.m (50 ft.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Truck Bed: Service and Repair Cargo Box CARGO BOX NOTE: Long cargo box shown in illustration. Short cargo box similar. REMOVAL 1. Remove the screws (1) that secure the fuel filler (2) to the cargo box (3). 2. Remove the fuel filler from the cargo box and position it out of the way. 3. If necessary, remove the fuel filler door from the cargo box. 4. Disconnect the tail lamp wire harness from the underbody wire harness. 5. If necessary, remove the tail lamp units and wire harness from the cargo box. 6. If necessary, remove the tailgate. 7. If necessary, remove the rear bumper. 8. Remove the bolts (3) that secure the cargo box (1) to the frame (2) (six short box, eight long box) and remove the cargo box. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box > Page 6706 1. Position the cargo box (1) onto the frame (2) and loosely install the bolts (3) (six short box, eight long box). 2. Align the cargo box to the cab and tighten the bolts to 108 N.m (80 ft.lbs.). 3. If removed, install tail lamp units and wire harness onto the cargo box. 4. Connect the tail lamp wire harness to the underbody wire harness. 5. If removed, install the tailgate. 6. If removed, install the rear bumper. 7. If removed, install the fuel filler door. 8. Position the fuel filler (2) to the cargo box (3). 9. Install the screws (1) that secure the fuel filler to the cargo box. Tighten the screws to 2.2 N.m (20 in.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box > Page 6707 Truck Bed: Service and Repair Cargo Box-Tie Down CARGO BOX-TIE DOWN REMOVAL 1. Remove the two bolts (1) that secure each cargo box tie down (2) to the cargo bed and remove the cleats as necessary. INSTALLATION 1. Position the cargo box tie downs (2) to the cargo box as necessary. 2. Install the two bolts (1) that secure each cargo box tie down to the cargo box. Tighten the bolts to 34 N.m (25 ft.lbs.). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE REMOVAL 1. Remove the wiper arms. 2. Disconnect the cowl plenum washer hose from the washer supply hose at the molded plastic in-line fitting. 3. Remove the cowl weather seal from the front of the dash panel and the cowl grille (2). 4. Remove the six push pin fasteners (1) that secure the front of the cowl grille to the dash panel. 5. Remove the two screws (3) that secure the rear corners of the cowl grille to the dash panel and remove the grille. 6. If necessary, remove the washer nozzles and the cowl plenum washer hose from the cowl grille. INSTALLATION 1. If removed, install the washer nozzles and the cowl plenum washer hose onto the cowl grille (2). 2. Position the cowl grille onto the dash panel. 3. Install the two screws (3) and the six push-pin fasteners (1) that secure the cowl grille to the dash panel. 4. Install the cowl weather seal onto the front of the dash panel and the cowl grille. 5. Connect the cowl plenum washer hose to the washer supply hose at the molded plastic in-line fitting. 6. Install the wiper arms. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip Front Door Weatherstrip: Service and Repair Drip Rail Weatherstrip DRIP RAIL WEATHERSTRIP REMOVAL 1. Open the doors and separate the weatherstrip (3) from the drip rail and a-pillar retainers (1 and 7). INSTALLATION 1. Position the weatherstrip (3) onto the drip rail and a-pillar retainers (1 and 7) and seat fully. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6718 Front Door Weatherstrip: Service and Repair A-Pillar Weatherstrip Retainer A-PILLAR WEATHERSTRIP RETAINER REMOVAL 1. Remove the drip rail weatherstrip retainer (1). 2. Remove the five screws (8) and remove the A-pillar weatherstrip retainer (7). INSTALLATION 1. Install the A-pillar weatherstrip retainer (7) and install the screws (8). 2. Install the drip rail weatherstrip retainer (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6719 Front Door Weatherstrip: Service and Repair Door Opening Seal DOOR OPENING SEAL REMOVAL FRONT DOOR SEAL 1. Remove the cowl trim panel (1), Refer to Trim Panel. 2. If vehicle is a Standard Cab, remove the lower b-pillar trim panel (3), Refer to Trim Panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6720 3. If vehicle is a Quad Cab, remove the lower b-pillar trim panel (1), Refer to Trim Panel. 4. Separate the front door opening seal (6) from the door opening flange. REAR DOOR SEAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6721 1. Remove the lower b-pillar trim panel (1), Refer to Trim Panel. 2. Remove the lower c-pillar trim (1), Refer to Trim Panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6722 3. Separate the rear door opening seal (5) from the door opening flange. INSTALLATION FRONT DOOR SEAL 1. Position the front door seal (6) to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. If vehicle is a Standard Cab, install the lower b-pillar trim (3). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6723 3. If vehicle is a Quad Cab, install the lower b-pillar trim (1). 4. Install the cowl trim panel (1). NOTE: When installing a new weatherstrip on the front door opening, remove the tear strip starting at the splice and moving around the front of the door to the back of the opening. REAR DOOR SEAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6724 1. Position the rear door seal to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. Install the lower c-pillar trim (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6725 3. Install the lower b-pillar trim (1). NOTE: When installing a new weatherstrip on the rear door opening, remove the tear strip starting at the splice and moving around the back of the door to the front of the opening. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6726 Front Door Weatherstrip: Service and Repair Drip Rail Weatherstrip Retainer DRIP RAIL WEATHERSTRIP RETAINER REMOVAL 1. Separate the drip rail weatherstrip (3) from the weatherstrip retainer (1). 2. Remove the seven screws (2) and remove the retainer (1). INSTALLATION 1. Install the weatherstrip retainer (1) and install the seven screws (2). 2. Position the weatherstrip (3) over the retainer flange and seat fully. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Molding FRONT DOOR OUTER BELT MOLDING REMOVAL 1. Remove the screw (4) and separate the belt molding (1) from the door (5) flange from the back to the front. INSTALLATION 1. Position the belt molding (1) onto the door (5) flange and seat fully. 2. Install the screw (4). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 6731 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove the door glass. 2. Separate the front door glass run weatherstrip (2) out of the door frame (5) and remove through the window opening. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 6732 NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the front door glass run weatherstrip (2) into the door (5) through the window opening. 2. Position the weatherstrip into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip between the corners and then down the sides firmly. 4. Install the door glass. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 6733 Front Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL FRONT-ALL MODELS 1. Raise the window glass to the full up position and remove the window regulator. 2. Loosen the two bolts (2 and 3) that secure the front glass run channel (1) to the door (5). 3. Slide the front glass run channel upward and disengage it from the door. 4. Remove the front glass run channel from the door through the door panel opening (4). 5. If required, remove the weatherstrip from the front glass run channel. REAR-QUAD CAB 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the lower bolt (1) that secures the rear glass run channel (3) to the door. 3. Loosen the upper bolt (4) that secures the rear glass run channel to the door. 4. Slide the rear glass run channel upward and disengage the upper screw from the door. 5. Remove the rear glass run channel from the door through the door panel opening (2). 6. If required, remove the weatherstrip from the rear glass run channel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 6734 REAR-STANDARD CAB 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1) that secure the rear glass run channel (2) to the door. 3. Remove the rear glass run channel from the door through the door panel opening (3). 4. If required, remove the weatherstrip from the rear glass run channel. INSTALLATION FRONT-ALL MODELS 1. If removed, install the weatherstrip onto the front glass run channel (1). 2. Position the front glass run channel into the door (5) through the door panel opening (4). 3. Engage the two bolts (2 and 3) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. REAR-QUAD CAB Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 6735 1. If removed, install the weatherstrip onto the rear glass run channel (3). 2. Position the rear glass run channel into the door through the door panel opening (2). 3. Engage the upper bolt (4) that secures the rear glass run channel to the door. 4. Install the lower bolt (1) that secures the rear glass run channel to the door. Tighten both the upper and lower bolts to 10 N.m (89 in.lbs.). 5. Install the window regulator and verify correct window operation. REAR-STANDARD CAB 1. If removed, install the weatherstrip onto the rear glass run channel (2). 2. Position the rear glass run channel into the door through the door panel opening (3). 3. Install the two bolts (1) that secure the rear glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 6736 Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Molding FRONT DOOR INNER BELT MOLDING REMOVAL 1. Remove the door trim panel (3). 2. Separate the belt molding (1) from the door (3) mounting flange from the back to the front. INSTALLATION 1. Position the belt molding (1) and seat onto the door (3) mounting flange fully. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 6737 2. Install the door trim panel (3). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip Rear Door Weatherstrip: Service and Repair Drip Rail Weatherstrip DRIP RAIL WEATHERSTRIP REMOVAL 1. Open the doors and separate the weatherstrip (3) from the drip rail and a-pillar retainers (1 and 7). INSTALLATION 1. Position the weatherstrip (3) onto the drip rail and a-pillar retainers (1 and 7) and seat fully. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6742 Rear Door Weatherstrip: Service and Repair Door Opening Seal DOOR OPENING SEAL REMOVAL FRONT DOOR SEAL 1. Remove the cowl trim panel (1), Refer to Trim Panel. 2. If vehicle is a Standard Cab, remove the lower b-pillar trim panel (3), Refer to Trim Panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6743 3. If vehicle is a Quad Cab, remove the lower b-pillar trim panel (1), Refer to Trim Panel. 4. Separate the front door opening seal (6) from the door opening flange. REAR DOOR SEAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6744 1. Remove the lower b-pillar trim panel (1), Refer to Trim Panel. 2. Remove the lower c-pillar trim (1), Refer to Trim Panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6745 3. Separate the rear door opening seal (5) from the door opening flange. INSTALLATION FRONT DOOR SEAL 1. Position the front door seal (6) to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. If vehicle is a Standard Cab, install the lower b-pillar trim (3). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6746 3. If vehicle is a Quad Cab, install the lower b-pillar trim (1). 4. Install the cowl trim panel (1). NOTE: When installing a new weatherstrip on the front door opening, remove the tear strip starting at the splice and moving around the front of the door to the back of the opening. REAR DOOR SEAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6747 1. Position the rear door seal to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. Install the lower c-pillar trim (1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 6748 3. Install the lower b-pillar trim (1). NOTE: When installing a new weatherstrip on the rear door opening, remove the tear strip starting at the splice and moving around the back of the door to the front of the opening. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel Rear Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL FRONT 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1) that secure the front glass run channel (2) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the front glass run channel. Mega Cab Models 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1 & 3) that secure the front glass run channel (2) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the front glass run channel. REAR Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6753 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (2) that secure the rear glass run channel (1) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the rear glass run channel. INSTALLATION FRONT 1. If removed, install the weatherstrip onto the front glass run channel (2). 2. Position the front glass run channel into the door through the door panel opening. 3. Install the two bolts (1) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Mega Cab Models Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6754 1. If removed, install the weatherstrip onto the front glass run channel (2). 2. Position the front glass run channel into the door through the door panel opening. 3. Install the two bolts (1 & 3) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. REAR 1. If removed, install the weatherstrip onto the rear glass run channel (1). 2. Position the rear glass run channel into the door through the door panel opening. 3. Install the two bolts (2) that secure the rear glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6755 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Molding REAR DOOR OUTER BELT MOLDING REMOVAL 1. Remove the screw (3) and separate the belt molding (1) from the door (2) flange from the back to the front. INSTALLATION 1. Position the belt molding (1) onto the door (2) flange and seat fully. 2. Install the screw (3). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6756 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Lower the glass. 2. Separate the rear door glass run weatherstrip (5) out of the door frame (2) and remove through the window opening. INSTALLATION NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the rear door glass run weatherstrip (5) into the door (2) through the window opening. 2. Position the weatherstrip (5) into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip (5) between the corners and then down the sides firmly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6757 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Molding REAR DOOR INNER BELT MOLDING REMOVAL 1. Remove the door trim panel (5). 2. Separate the belt molding (2) from the rear door mounting flange from the back to the front. INSTALLATION 1. Position the belt molding (2) and seat onto the rear door mounting flange fully. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6758 2. Install the door trim panel (5). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations Cruise Control Servo: Locations Left Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6763 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6764 Servo-Speed Control (Gas Except 5.7L) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6765 Cruise Control Servo: Description and Operation A speed control servo is not used with any 5.7L V-8 engine, or with the 5.9L diesel engine. The speed control servo is attached to the bottom of the battery tray. The servo unit consists of a solenoid valve body, and a vacuum chamber. The solenoid valve body contains three solenoids: - Vacuum - Vent - Dump The vacuum chamber contains a diaphragm with a cable attached to control the throttle linkage. A speed control servo is not used with any 5.7L V-8 engine, or with the 5.9L diesel engine. The following information applies only to vehicles equipped with a mechanical servo. When/if a servo is used on gasoline powered vehicles, 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. The servo unit cannot be repaired and is serviced only as a complete assembly. Power is supplied to the servo's by the PCM through the brake switch. The PCM controls the ground path for the vacuum and vent solenoids. The dump solenoid is energized anytime it receives power. If power to the dump solenoid is interrupted, the solenoid dumps vacuum in the servo. This provides a safety backup to the vent and vacuum solenoids. The vacuum and vent solenoids must be grounded at the PCM to operate. When the PCM grounds the vacuum servo solenoid, the solenoid allows vacuum to enter the servo and pull open the throttle plate using the cable. When the PCM breaks the ground, the solenoid closes and no more vacuum is allowed to enter the servo. The PCM also operates the vent solenoid via ground. The vent solenoid opens and closes a passage to bleed or hold vacuum in the servo as required. The PCM duty cycles the vacuum and vent solenoids to maintain the set speed, or to accelerate and decelerate the vehicle. To increase throttle opening, the PCM grounds the vacuum and vent solenoids. To decrease throttle opening, the PCM removes the grounds from the vacuum and vent solenoids. When the brake is released, if vehicle speed exceeds 30 mph to resume, 35 mph to set, and the RES/ACCEL switch has been depressed, ground for the vent and vacuum circuits is restored. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6766 Cruise Control Servo: Service and Repair REMOVAL The speed control servo assembly is attached to the bottom of the battery tray (1). 1. Disconnect negative battery cable at battery (both cables at both batteries if diesel). 2. To gain access to servo, remove plastic wheel-house splash shield over left-front wheel. 3. Disconnect vacuum line (7) at servo. 4. Disconnect electrical connector (4) at servo. 5. Remove 3 servo mounting screws (5). Depending on engine application, different sets of mounting lugs (2) are used to support servo to battery tray. While removing, note proper lugs. 6. Disconnect servo cable at throttle body. 7. Remove 2 mounting nuts (1) holding servo cable sleeve to bracket. 8. Pull speed control cable sleeve and servo away from servo mounting bracket to expose cable retaining clip (3) and remove clip. NOTE: The servo mounting bracket displayed is a typical bracket and may/may not be applicable to this model vehicle. 9. Remove servo (2) from mounting bracket. While removing, note orientation of servo to 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 2 servo-to-mounting bracket nuts and tighten. Refer to torque specifications. 5. Position servo assembly to correct mounting lugs on battery tray and install 3 screws. Tighten 3 screws. Refer to torque specifications. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6767 6. Connect vacuum line at servo. 7. Connect electrical connector at servo. 8. Connect servo cable to throttle body. 9. Install left-front wheel-well liner. 10. Connect negative battery cable to battery (connect both cables if diesel). 11. Before starting engine, operate accelerator pedal to check for any binding. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams Cruise Control Switch: Diagrams Switch-Speed Control-Left (ETC) Switch-Speed Control-Left (Except ETC) Switch-Speed Control-Right (ETC) Switch-Speed Control-Right (Except ETC) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6771 Cruise Control Switch: Description and Operation Two separate switch pods operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM (to the ECM for diesel) for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Depending on engine control computer (JTEC having a 3- plug connector or NGC having a 4- plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switch used with the NGC system has an attached pigtail lead. The switch used with the JTEC system does not have an attached pigtail lead. When speed control is selected by depressing the ON, OFF switch, the PCM (ECM for diesel) allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral (auto. trans.) - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal (manual trans.). - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM (ECM for diesel). NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's/ECM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM (ECM for diesel) is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's/ECM's RAM when the ACCEL switch is released. The PCM/ECM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM/ECM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's/ECM's ON, OFF input, and the battery voltage to the brake switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6772 Cruise Control Switch: Service and Repair REMOVAL Depending on engine control computer (JTEC having a 3-plug connector or 5.7L V-8 NGC having a 4-plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switches used with the NGC system have attached pigtail leads. The switch used with the JTEC system does not have an attached pigtail lead. 1. Remove switch mounting screw (2). 2. Pull switch (2) from steering wheel. 3. Unplug electrical connector from switch, or, switch pigtail wire harness from steering wheel wire harness (4) and remove switch. INSTALLATION 1. Plug electrical connector into switch, or connect pigtail wire harness to steering wheel wire harness. Be sure wires are not pinched. 2. Position switch to steering wheel. 3. Install switch mounting screw and tighten. Refer to torque specifications. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Description and Operation Cruise Control Vacuum Reservoir: Description and Operation The vacuum reservoir is a plastic storage tank connected to an engine vacuum source by vacuum lines. A vacuum reservoir is not used with diesel engines or the 5.7L gas powered engine. The 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Description and Operation > Page 6776 Cruise Control Vacuum Reservoir: Testing and Inspection 1. Disconnect vacuum hose at speed control servo and install a vacuum gauge into the disconnected hose. 2. Start engine and observe gauge at idle. Vacuum gauge should read at least ten inches of mercury. 3. If vacuum is less than ten inches of mercury, determine source of leak. Check vacuum line to engine for leaks. Also check actual engine intake manifold vacuum. If manifold vacuum does not meet this requirement, check for poor engine performance and repair as necessary 4. If vacuum line to engine is not leaking, check for leak at vacuum reservoir. To locate and gain access to reservoir, refer to Vacuum Reservoir Removal/Installation. Disconnect vacuum line at reservoir and connect a hand-operated vacuum pump to reservoir fitting. Apply vacuum. Reservoir vacuum should not bleed off. If vacuum is being lost, replace reservoir. 5. Verify operation of one-way check valve and check it for leaks. Certain models may be equipped with 2 check-valves. a. Locate one-way check valve. The valve is located in vacuum line between vacuum reservoir and engine vacuum source. Disconnect vacuum hoses (lines) at each end of valve. b. Connect a hand-operated vacuum pump to reservoir end of check valve. Apply vacuum. Vacuum should not bleed off. If vacuum is being lost, replace one-way check valve. c. Connect a hand-operated vacuum pump to vacuum source end of check valve. Apply vacuum. Vacuum should flow through valve. If vacuum is not flowing, replace one-way check valve. Seal the fitting at opposite end of valve with a finger and apply vacuum. If vacuum will not hold, diaphragm within check valve has ruptured. Replace valve. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Description and Operation > Page 6777 Cruise Control Vacuum Reservoir: Service and Repair REMOVAL The vacuum reservoir (1) is located in the engine compartment under the fresh air cowl grill panel. 1. Remove wiper blades and arms. 2. Remove fresh air cowl grill. 3. Disconnect vacuum line (2) at reservoir. 4. Remove 2 reservoir mounting nuts (3). 5. Remove reservoir from cowl. INSTALLATION 1. Position reservoir onto 2 weld studs. 2. Install 2 mounting nuts and tighten. Refer to torque specifications. 3. Connect vacuum line to reservoir fitting. 4. Install cowl grill. 5. Install wiper arms/blades. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams Cruise Control Switch: Diagrams Switch-Speed Control-Left (ETC) Switch-Speed Control-Left (Except ETC) Switch-Speed Control-Right (ETC) Switch-Speed Control-Right (Except ETC) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6782 Cruise Control Switch: Description and Operation Two separate switch pods operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM (to the ECM for diesel) for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Depending on engine control computer (JTEC having a 3- plug connector or NGC having a 4- plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switch used with the NGC system has an attached pigtail lead. The switch used with the JTEC system does not have an attached pigtail lead. When speed control is selected by depressing the ON, OFF switch, the PCM (ECM for diesel) allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral (auto. trans.) - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal (manual trans.). - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM (ECM for diesel). NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's/ECM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM (ECM for diesel) is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's/ECM's RAM when the ACCEL switch is released. The PCM/ECM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM/ECM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's/ECM's ON, OFF input, and the battery voltage to the brake switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6783 Cruise Control Switch: Service and Repair REMOVAL Depending on engine control computer (JTEC having a 3-plug connector or 5.7L V-8 NGC having a 4-plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switches used with the NGC system have attached pigtail leads. The switch used with the JTEC system does not have an attached pigtail lead. 1. Remove switch mounting screw (2). 2. Pull switch (2) from steering wheel. 3. Unplug electrical connector from switch, or, switch pigtail wire harness from steering wheel wire harness (4) and remove switch. INSTALLATION 1. Plug electrical connector into switch, or connect pigtail wire harness to steering wheel wire harness. Be sure wires are not pinched. 2. Position switch to steering wheel. 3. Install switch mounting screw and tighten. Refer to torque specifications. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Locations ABS Light: Locations The ABS indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Locations > Page 6788 ABS Light: Description and Operation ABS INDICATOR An Antilock Brake System (ABS) indicator is standard equipment on all instrument clusters. However, the instrument cluster can be programmed to disable this indicator on vehicles that are not equipped with the ABS or Rear Wheel Anti-Lock (RWAL) brake systems, which are not available in some markets. On vehicles equipped with a gasoline engine, the ABS indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. On vehicles equipped with a diesel engine, the ABS indicator is located on the right side of the instrument cluster, to the right of the engine temperature gauge. The ABS indicator consists of a stencillike cutout of the International Control and Display Symbol icon for "Failure of Anti-lock Braking System" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ABS indicator is serviced as a unit with the instrument cluster. The ABS indicator gives an indication to the vehicle operator when the ABS system is faulty or inoperative. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Programmable Communications Interface (PCI) data bus. The ABS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (RUN/START) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the ABS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the ABS indicator is illuminated by the cluster for about two seconds as a bulb test. - ABS Lamp-On Message - Each time the cluster receives a lamp-on message from the CAB, the ABS indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB, or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster receives no lamp-on or lamp-off messages from the CAB for three consecutive seconds, the ABS indicator is illuminated. The indicator remains illuminated until the cluster receives a valid message from the CAB, or until the ignition switch is turned to the Off position, whichever occurs first. Actuator Test - Each time the instrument cluster is put through the actuator test, the ABS indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. - ABS Diagnostic Test - The ABS indicator is blinked on and off by lamp-on and lamp-off messages from the CAB during the performance of the ABS diagnostic 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 lamp-on or lamp-off messages to the instrument cluster. If the CAB sends a lamp-on message after the bulb test, it indicates that the CAB has detected a system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ABS indicator fails to light due to an open or short in the cluster ABS indicator circuit, the cluster sends a message notifying the CAB of the condition, then the instrument cluster and the CAB will each store a DTC. For proper diagnosis of the antilock brake system, the CAB, the PCI data bus, or the electronic message inputs to the instrument cluster that control the ABS indicator, a DRBIII scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6793 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6794 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6795 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6796 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6797 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6798 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6799 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6800 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6801 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6802 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6803 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6804 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6805 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6806 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6807 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6808 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6809 Audible Warning Device: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6810 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6811 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6812 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6813 Chime System Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 6814 Audible Warning Device: Description and Operation CHIME WARNING SYSTEM A chime warning system is standard factory-installed equipment on this model. The chime warning system uses a single chime tone generator that is integral to the instrument cluster to provide an audible indication of various vehicle conditions that may require the attention of the vehicle operator. The chime warning system includes the following major components, which are described in further detail elsewhere in this service information: - Door Ajar Switch - A door ajar switch is integral to each door latch. This switch provides an input to the chime warning system indicating whether the front doors are open or closed. - Ignition Switch - A key-in ignition switch is integral to the ignition switch. The key-in ignition switch provides an input to the chime warning system indicating whether a key is present in the ignition lock cylinder. - Instrument Cluster - The instrument cluster contains an integral chime tone generator, integrated circuitry, a central processing unit and the programming to provide all of the proper chime warning system features based upon the monitored inputs. The instrument cluster circuitry monitors hard-wired switch inputs, as well as message inputs received from other vehicle electronic modules on the Programmable Communications Interface (PCI) data bus network. - Headlamp Switch - The headlamp switch provides an input to the chime warning system indicating when the exterior lamps are turned On or Off. - Seat Belt Switch - A seat belt switch is integral to the driver seat belt buckle-half unit. The seat belt switch provides an input to the chime warning system indicating whether the driver seat belt is fastened. Hard wired circuitry connects many of the chime warning system components to each other through the electrical system of the vehicle. These hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many different methods. Refer to the appropriate wiring information. The instrument cluster chime warning system circuitry and the integral chime tone generator cannot be adjusted or repaired. If the instrument cluster or the chime tone generator are damaged or faulty, the instrument cluster must be replaced. The chime warning system is designed to provide an audible output as an indication of various conditions that may require the attention or awareness of the vehicle operator. The chime warning system components operate on battery voltage received through the Ignition-Off Draw (IOD) fuse in the Power Distribution Center (PDC) so that the system may operate regardless of the ignition switch position. The chime warning system provides an audible warning to the vehicle operator under the following conditions: - Air Bag Warning - The instrument cluster chime tone generator will generate a single chime tone when the airbag indicator is illuminated for an airbag system fault condition. The instrument cluster uses airbag indicator lamp-on and lamp-off message inputs received from the Airbag Control Module (ACM) over the Programmable Communications Interface (PCI) data bus indicating that the airbag indicator should be illuminated for an airbag system fault condition. - Door Ajar Warning - The instrument cluster chime tone generator will generate a single chimes to announce that the hard wired inputs from the door ajar switches and the ignition switch as well as an engine speed message input received from the PCM over the PCI data bus indicate that a driver or passenger door is opened with the ignition switch in the On position and vehicle speed present. - Engine Coolant Temperature High Warning (Diesel Engine Only) - The instrument cluster chime tone generator will generate a single chime tone when the check gauges indicator is illuminated for a high or critical engine coolant temperature condition. The instrument cluster uses engine coolant temperature message inputs received from the diesel Engine Control Module (ECM) over the PCI data bus to illuminate the check gauges indicator for a coolant temperature high condition. - Fasten Seat Belt Warning - The instrument cluster chime tone generator will generate repetitive chimes at a slow rate each time the ignition switch is turned to the On or Start positions to announce that the hard wired inputs from the seat belt switch and the ignition switch indicate that the driver side front seat belt is not fastened. The chimes will continue to sound for a duration of about six seconds, until the driver side front seat belt is fastened, or until the ignition switch is turned to the Off position, whichever occurs first. - Head/Park Lamps-On Warning - The instrument cluster chime tone generator will generate repetitive chimes at a slow rate to announce that the hard wired inputs from the driver door ajar switch, the ignition switch, and the exterior lighting circuitry of the headlamp switch indicate that the exterior lamps are turned On with the driver door opened and the ignition switch in the Off position. The chimes will continue to sound until the exterior lamps are turned Off, the driver door is closed, or the ignition switch is turned to the On position, or the battery protection time-out expires, whichever occurs first. - Key-In-Ignition Warning - The instrument cluster chime tone generator will generate repetitive chimes at a slow rate to announce that the hard wired inputs from the driver door ajar switch, the ignition switch, and the key-in ignition circuitry of the ignition switch indicate that the key is in the ignition lock cylinder with the driver door opened and the ignition switch in the Off position. The chimes will continue to sound until the key is removed from the ignition lock cylinder, the driver door is closed, or the ignition switch is turned to the On position, whichever occurs first. - Low Fuel Warning - The instrument cluster chime tone generator will generate one chime tone when the low fuel indicator is illuminated by the instrument cluster. The instrument cluster uses a percent tank full message input received from the PCM over the PCI data bus indicating that there is less than about one-eighth tank of fuel remaining to illuminate the low fuel indicator. This chime feature will only occur once in an ignition cycle. - Low Oil Pressure Warning (Diesel Engine Only) - The instrument cluster chime tone generator will generate repetitive chimes at a fast rate when the check gauges indicator is illuminated for a low oil pressure condition. The instrument cluster uses engine speed and oil pressure message inputs received from the diesel Engine Control Module (ECM) over the PCI data bus indicating that the engine is running and that the oil pressure is low to illuminate the check gauges indicator. The chimes will continue to sound for five seconds, until the engine oil pressure message indicates that the oil pressure is not low, or until the engine speed message indicates that the engine is not running, whichever occurs first. This chime tone will only occur once in an ignition cycle. - Low Wash Warning - The instrument cluster chime tone generator will generate one chime tone when the low washer fluid indicator is illuminated Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 6815 by the instrument cluster. The instrument cluster uses a message input received from the Front Control Module (FCM) over the PCI data bus indicating that washer fluid level is low within the washer reservoir. This chime feature will only occur once in an ignition cycle. - Overspeed Warning - The instrument cluster chime tone generator will generate one chime tone to announce that a vehicle speed message input received from the PCM over the PCI data bus indicates that the vehicle speed is above a pre-programed limit. - Park Brake Reminder - The instrument cluster chime tone generator will generate ten repetitive chimes at a slow rate to announce that the hard wired input from the park brake switch and a vehicle speed message input received from the PCM over the PCI data bus indicates that the park brake is applied and the vehicle is moving. This chime feature will repeat each time the input conditions are met. - Sentry Key Immobilizer System "Customer Learn" Mode Announcement - This chime feature is only active on vehicles equipped with the optional Sentry Key Immobilizer System (SKIS) and sold in markets where the optional "Customer Learn" programming feature is available. The instrument cluster chime tone generator will generate one chime to announce that a status message input received from the Sentry Key Immobilizer Module (SKIM) over the PCI data bus indicates that the SKIS is in the "Customer Learn" mode, which is used for programming additional sentry key transponders. - Transmission Temperature High Warning (Automatic Transmission only) - The instrument cluster chime tone generator will generate repetitive chimes at a slow rate when the transmission temperature indicator is illuminated for a high or critical transmission fluid temperature condition. The instrument cluster uses transmission temperature message inputs received from the Transmission Control Module (TCM) over the PCI data bus to illuminate the indicator for a transmission temperature high condition. - Turn Signal On Warning - The instrument cluster chime tone generator will generate repetitive chimes at a slow rate to announce that the hard wired input for the right or left turn signal indicator as well as vehicle distance and speed message inputs received from the PCM over the PCI data bus indicate that a turn signal has been active continuously for 1.6 kilometers (1 mile) with the vehicle speed greater than 22 kilometers-per-hour (15 miles-per hour). Vehicles built for markets other than the United States and Canada have a revised distance threshold of 4 kilometers for this feature. The chime will continue until the turn signal input becomes inactive, the status changes, or until the vehicle speed message indicates that the speed is less than 22 kilometers-per-hour (15 miles-per-hour), whichever occurs first. The hazard warning flashers will not activate this chime feature. - Warning Lamp Announcement - The instrument cluster chime tone generator will generate a single chime when the check gauges indicator is illuminated when any critical engine and transmission systems are out of their operating parameters. The instrument cluster uses system inputs received over the PCI data bus to illuminate the check gauges indicator. The instrument cluster provides chime service for all available features in the chime warning system. The instrument cluster relies upon its internal programming, hard wired inputs from numerous switches, and electronic message inputs received from other electronic modules over the PCI data bus network. Upon receiving the proper inputs, the instrument cluster activates the integral chime tone generator to provide the audible chime to the vehicle operator. The chime tone generator in the instrument cluster is capable of producing single chime tones, or repeated chime tones at two different rates: about fifty chime tones per minute, or about 180 chime tones per minute. The internal programming of the instrument cluster determines the priority of each chime request input that is received, as well as the rate and duration of each chime that is to be generated. The hard wired chime warning system inputs to the instrument cluster, as well as other hard wired circuits for this system may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the instrument cluster or the PCI data bus network. The most reliable, efficient and accurate means to diagnose the instrument cluster and the PCI data bus network inputs for the chime warning system requires the use of a DRBIII(R) scan tool. Refer to the appropriate diagnostic information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 6816 Audible Warning Device: Testing and Inspection CHIME WARNING SYSTEM Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 6817 The chime warning system features driven by hard wired inputs to the instrument cluster may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the chime warning system features driven by message inputs to the instrument cluster over the Programmable Communications Interface (PCI) data bus network. The most reliable, efficient and accurate means to diagnose the instrument cluster and the PCI data bus network inputs for the chime warning system requires the use of a DRBIII(R) scan tool. Refer to the appropriate diagnostic and wiring information. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Service Precautions Brake Warning Indicator: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Service Precautions > Page 6821 Brake Warning Indicator: Description and Operation ABS WARNING INDICATOR AND RED BRAKE WARNING INDICATOR (EBC 125 AND EBC 325) The system is equipped with an amber ABS and a red Brake warning indicator to alert the driver of a malfunction it has detected. The CAB can signal the operation of both the amber ABS warning indicator and the red Brake warning indicator via PCI BUS. The CAB controls the ABS warning indicator by making it do one of three things: Light steady for 3.4 seconds during an initial test at the beginning of an ignition cycle to function as a bulb check. - Light steady when a system malfunction exists. - Flash if a vehicle tooth or tire parameter is faulty or missing. The Instrument Cluster controls the amber antilock brake system warning indicator. All Dodge Truck Instrument Clusters have direct control over the ABS warning indicator and Brake warning indicator. The Instrument Cluster transmits a message over the PCI BUS relating to diagnostics and current lamp status for the ABS and Brake indicator. The Instrument Cluster will expect a PCI BUS message back from the CAB indicating whether the indicator should be turned on or off. In the event that no signal is received from the CAB for a certain number of time, the Instrument Cluster will illuminate the ABS warning indicator. The indicator provides notice of ABS system-related problems and the need to take diagnostic action. The vehicle Instrument Cluster has a red Brake warning indicator to alert the driver to the following conditions: Brake fluid level low - Parking Brake applied - ABS system malfunction The Instrument Cluster controls the red Brake warning indicator. There is a parallel path to chassis ground that will illuminate the red Brake warning indicator: Through the parking Brake switch contacts - Through the Brake fluid level switch - Through the CAB via PCI BUS The CAB can control the operation of both the amber ABS warning indicator and the red Brake warning indicator: If the CAB is disconnected, the amber ABS warning indicator and red Brake warning indicator will be illuminated - If the axle type or tire size are not programmed properly, the amber indicator will blink - If any Foundation Brake system problem exists - If any ABS system DTC is set, both the amber and red indicators will be illuminated The ABS Enabling Strategy (FMVSS105) is for vehicles above 10,000-lbs. gross vehicle weight. This allows different operators to be alerted that an ABS fault existed in the last ignition cycle. When the ignition is cycled to the ON position the ABS system will be disabled if the vehicle speed was zero on the last ignition cycle. The disabled ABS system will illuminate the amber ABS and red BRAKE warning lamps until the vehicle speed reaches 7 km/h (4 mph)then the amber ABS and red BRAKE warning lamps will extinguish. If an ABS fault exists; the ABS is still disabled, the amber ABS and red BRAKE warning lamps will still be illuminated, and a CAB DTC is then set. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Service Precautions > Page 6822 Brake Warning Indicator: Testing and Inspection BRAKE INDICATOR The diagnosis found here addresses an inoperative brake indicator condition. If there are problems with several indicators in the instrument cluster, refer to Instrument Cluster Diagnosis And Testing. If no brake system problem is found, the following procedures will help to locate a shorted or open circuit, or a faulty park brake switch input. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Indicator Illuminates During Bulb Test, But Does Not When Park Brake Applied 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. Indicator Remains Illuminated - Brake System Checks Ok 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Description and Operation Check Gauges Lamp: Description and Operation A check gauges indicator is standard equipment on all instrument clusters. On vehicles equipped with a gasoline engine, the check gauges indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. On vehicles equipped with a diesel engine, the check gauges indicator is located on the left side of the instrument cluster, to the left of the voltage gauge. The check gauges indicator consists of a stencil-like cutout of the words "CHECK GAGES" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "CHECK GAGES" text to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The check gauges indicator is serviced as a unit with the instrument cluster. The check gauges indicator gives an indication to the vehicle operator when certain instrument cluster gauge readings reflect a condition requiring immediate attention. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The check gauges indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the check gauges indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the check gauges indicator is illuminated for about two seconds as a bulb test. - Engine Temperature High Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine coolant temperature of a gasoline engine is about 122° C (252° F) or higher, or of a diesel engine is about 112° C (233° F) or higher, the check gauges indicator will be illuminated and a single chime is sounded. The indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine coolant temperature of a gasoline engine is below about 122° C (252° F), or of a diesel engine is below about 112° C (233° F), or until the ignition switch is turned to the Off position, whichever occurs first. - Engine Oil Pressure Low Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine oil pressure is about 41 kPa (6 psi) or lower, the check gauges indicator will be illuminated and a single chime is sounded. The indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine oil pressure is above about 41 kPa (6 psi), or until the ignition switch is turned to the Off position, whichever occurs first. The cluster will only turn the indicator on in response to an engine oil pressure low message if the engine speed is greater than zero. - System Voltage Low (Charge Fail) Message - Each time the cluster receives three consecutive messages from the PCM or ECM indicating the electrical system voltage is less than about 9.0 volts (charge fail condition) or that the battery temperature sensor input is an open circuit, the check gauges indicator will be illuminated and a single chime is sounded. The indicator remains illuminated until the cluster receives a single message from the PCM or ECM indicating the electrical system voltage is greater than about 9.5 volts (but less than about 15.5 volts), or until the ignition switch is turned to the Off position, whichever occurs first. - System Voltage High Message - Each time the cluster receives three consecutive messages from the PCM or ECM indicating the electrical system voltage is greater than about 15.5 volts, the check gauges indicator will be illuminated and a single chime is sounded. The indicator remains illuminated until the cluster receives a single message from the PCM or ECM indicating the electrical system voltage is less than about 15.0 volts (but greater than about 9.5 volts), or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the check gauges indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the engine temperature, oil pressure, and electrical system voltage, then sends the proper messages to the instrument cluster. On vehicles with a diesel engine, the ECM continually monitors the engine temperature, oil pressure, and electrical system voltage, then sends the proper messages to the instrument cluster. For proper diagnosis of the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the check gauges indicator, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6830 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6831 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6832 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6833 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6834 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6835 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6836 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6837 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6838 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6839 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6840 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6841 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6842 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6843 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6844 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6845 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6846 Cigarette Lighter: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6847 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6848 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6849 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6850 Cigarette Lighter: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-41-2 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6851 8w-41-3 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6852 8w-41-4 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6853 Cigarette Lighter: Testing and Inspection For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Check the fused B(+) fuse in the Integrated Power Module (IPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the inoperative fuse. 2. Turn the ignition switch to the Run position. Check for battery voltage at the fused B(+) fuse in the IPM. If OK, go to Step 3. If not OK, repair the open or short as required. 3. Remove the cigar lighter knob and element from the cigar lighter outlet shell. Check for continuity between the inside circumference of the cigar lighter outlet shell and a good ground. there should be continuity. If OK, go to Step 4. If not OK, go to Step 5. 4. Turn the ignition switch to the Run position. Check for battery voltage at the insulated contact located at the back of the cigar lighter outlet shell. If OK, replace the inoperative cigar lighter knob and element. If not OK, go to Step 5. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. 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 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Turn the ignition switch to the Accessory or Run positions. Check for battery voltage at the fused B(+) circuit cavity of the cigar lighter wire harness connector. If OK, replace the inoperative cigar lighter outlet. If not OK, repair the open fused B(+) circuit to the IPM fuse as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6854 Cigarette Lighter: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Pull the cigar lighter knob and element (1) out of the cigar lighter receptacle base (6), or unsnap the protective cap from the power outlet receptacle base (6). 3. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses (3) of the mount that secures the receptacle base to the panel (4). 4. Insert a pair of external snap ring pliers (5) into the cigar lighter or 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 the mount. 6. Pull the receptacle base away from the instrument panel far enough to access the instrument panel wire harness connector (2). 7. Disconnect the instrument panel wire harness connector (2) from the cigar lighter or power outlet receptacle base (6). 8. Remove the cigar lighter or power outlet mount from the instrument panel. INSTALLATION 1. Connect the instrument panel wire harness connector to the cigar lighter or power outlet receptacle base connector receptacle. 2. Install the cigar lighter or power outlet mount into the instrument panel. 3. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 4. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 5. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 6. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation Compass: Description and Operation MODULE-COMPASS TEMPERATURE The compass mini-trip computer is located in the overhead console (7) on models equipped with this option. The compass mini-trip computer includes a Vacuum-Fluorescent Display (VFD) (6), an Electronic Overhead Module (EOM) and push button function switches (1, 2, 4 and 5). The compass mini-trip computer module contains a central processing unit and interfaces with other electronic modules in the vehicle on the Programmable Communications Interface (PCI) data bus. The PCI data bus 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 compass mini-trip computer provides several electronic functions and features. Some of the functions and features that the compass mini-trip computer supports and/or controls, include the following display options: - Compass and temperature - provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. - Trip odometer (TRIP ODO) - shows the distance travelled since the last trip computer reset. - Average fuel economy (AVG ECO) - shows the average fuel economy since the last trip computer reset. - Distance to empty (DTE) - shows the estimated distance that can be travelled with the fuel remaining in the fuel tank. This estimated distance is computed using the level of the fuel in the tank and a weighted average of long term and recent Average Fuel Economy. - Elapsed time (ET) - shows the accumulated ignition-on time since the last trip computer reset. - Blank screen - the compass mini-trip VFD is turned off. The ambient temperature sensor is hard wired to the Front Control Module (FCM). Data input for all other compass mini-trip computer functions, including VFD dimming level, is received through PCI data bus messages. The compass mini-trip computer uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests. If these tests prove inconclusive, the use of a scan tool and the proper Diagnostic Procedures Information are recommended for further testing of the EOM and the PCI data bus. The EOM cannot be repaired, and is available for service only as a unit. This unit includes the push button switches, the Universal Garage Door Transmitter and the plastic module and display lens. If any of these components is inoperative or damaged, the complete EOM must be replaced. COMPASS While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle in one or two complete circles, on level ground, in not less than 16 seconds. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the vehicle roof should become magnetized. TEMPERATURE The temperature displays the outside ambient temperature in whole degrees. The temperature display can be changed from Fahrenheit to Celsius using Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation > Page 6858 the U.S./Metric push button. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the temperature display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. When the ignition switch is turned to the Off position, the last displayed temperature reading stays in the temperature unit memory. When the ignition switch is turned to the On position again, the temperature will display the memory temperature if the engine OFF time is less than 90 minutes. If the engine OFF time is more than 90 minutes, the temperature will display the actual temperature sensed by the ambient temperature sensor. The temperature display update interval varies with the vehicle speed. The temperature function is supported by an ambient temperature sensor. The sensor is mounted outside the passenger compartment near the front and center of the vehicle, and is hard wired to the FCM, which sends temperature over the PCI data bus circuit. The ambient temperature sensor is available as a separate service item. NOTE: The compass mini-trip computer will display min and max temperatures of -40° C (-40° F) and 54° C (130° F). The compass mini-trip computer only operates with the ignition switch in the On position. When the ignition switch is turned to the On position, all of the segments in the compass mini-trip computer Vacuum-Fluorescent Display (VFD) will be turned off for one second, then the display will return to the last function being displayed before the ignition was turned to the Off position. With the ignition switch in the On position, momentarily depressing and releasing the Step push button (4) will cause the compass-mini-trip computer to change its mode of operation. Momentarily depressing and releasing the U.S./Metric push button (1) will cause the unit to toggle between U.S. and Metric measurements. Momentarily depressing and releasing the C/T (compass/temperature) push button (5) will cause the compass mini-trip computer to return to the compass/temperature display mode from any other mode. This compass mini-trip computer features several functions that can be reset. If the RESET push button (2) is depressed for more than one second with the ignition switch in the On position, the trip computer information that can be reset is reset. However, the reset will only occur if the function currently displayed is a function that can be reset. The functions that can be reset are: TRIP ODO, AVG ECO, and ET. All three of these functions can be reset at once by pressing the RESET button twice within 3 seconds while any one of the three functions is selected. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation > Page 6859 Compass: Adjustments Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and true geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give false readings. If this problem occurs, the compass variance must be set. To set the compass variance: 1. Using the Variance Settings map, find your geographic location and note the zone number. 2. Turn the ignition switch to the On/Run position. If the compass/temperature data is not currently being displayed, momentarily depress and release the C/T push button to step through the display options until you have reached the compass/temperature display. 3. Press and hold the Reset push button down until "VAR" appears in the display. This takes about five seconds. 4. Momentarily depress and release the STEP push button to step through the zone numbers (1-15), until the zone number for your geographic location appears in the display. 5. Momentarily depress and release the Reset push button to enter the displayed zone number into the compass unit memory. 6. Confirm that the correct directions are now indicated by the compass. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Illumination Lamp Compass: Service and Repair Illumination Lamp WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: There are provisions for three bulb/bulb holder units on the Compass Mini-Trip Computer (CMTC) circuit board. The two outboard bulbs illuminate the CMTC push buttons, while the center bulb illuminates the optional universal transmitter push buttons. Therefore, the center bulb location is only populated on vehicles equipped with the optional universal transmitter. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (1) from the head-liner. 3. Use a small thin-bladed screwdriver to rotate the bulb holder (3) counterclockwise about 30 degrees to unlock it from the keyed opening in the Compass Mini-Trip Computer (CMTC) unit (2) circuit board. 4. Pull the bulb holder and bulb straight out of the circuit board. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Illumination Lamp > Page 6862 1. Align the bulb holder and bulb (3) with the keyed opening in the circuit board of the Compass Mini-Trip Computer (CMTC) (2). 2. Insert the bulb holder and bulb straight into the circuit board until the bulb holder is firmly seated. 3. Using a small thin-bladed screwdriver, rotate the bulb holder clockwise about 30 degrees on the circuit board to lock it into place. 4. Reinstall the overhead console (1) onto the head-liner. 5. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Illumination Lamp > Page 6863 Compass: Service and Repair Compass Calibration CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not use magnetic tools when servicing the overhead console. The electronic compass unit features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or out of calibration, perform the following calibration procedure. Also, new service replacement compass mini-trip computer modules must have their compass calibrated using this procedure. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. NOTE: Whenever the compass is calibrated manually, the variation number must also be reset. Calibrate the compass manually as follows: 1. Turn the ignition switch to the On position. If the compass/temperature data is not currently being displayed, momentarily depress and release the C/T push button to step through the display options until you have reached the compass/temperature display. 2. Depress and hold the RESET push button. Hold the push buttons down until "CAL" appears in the display. This takes about ten seconds. 3. Drive the vehicle on a level surface, away from large metal objects and power lines, through one or two complete circles in not less than 16 seconds. The "CAL" message will disappear from the display to indicate that the compass is now calibrated. NOTE: - A blank compass display indicates that vehicle degaussing (demagnetizing) is necessary. - If the "CAL" message remains in the display, either there is excessive magnetism near the compass, or the unit is faulty. Repeat the calibration procedure at least one more time. - If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the calibration procedure in another location. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Illumination Lamp > Page 6864 Compass: Service and Repair Compass Demagnetizing Degaussing Tool #6029 A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the overhead console forward mounting screw and the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel and the overhead console forward mounting screw, proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. 2. Connect the degaussing tool to an electrical outlet, while keeping the tool atleast 61 centimeters (2 feet) away from the compass unit. 3. Slowly approach the head of the overhead console forward mounting screw with the degaussing tool connected. 4. Contact the head of the screw with the plastic coated tip of the degaussing tool for about two seconds. 5. With the degaussing tool still energized, slowly back it away from the screw. When the tip of the tool is atleast 61 centimeters (2 feet) from the screw head, disconnect the tool. 6. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 7. Connect the degaussing tool to an electrical outlet, while keeping the tool atleast 61 centimeters (2 feet) away from the compass unit. 8. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 9. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool atleast 11 centimeters (4 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Illumination Lamp > Page 6865 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 10. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is atleast 61 centimeters (2 feet) from the roof panel, disconnect the tool. 11. Calibrate the compass Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Illumination Lamp > Page 6866 Compass: Service and Repair Module - Compass Temperature REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (1) from the head-liner. 3. Remove the screws (4) that secure the Electronic Overhead Module (EOM) (2) to the overhead console housing (1). 4. Disconnect the overhead console wire harness connector from the EOM connector receptacle. 5. Remove the EOM (2) from the overhead console housing (1). INSTALLATION NOTE: If a new Electronic overhead Module (EOM) has been installed, the compass will have to be calibrated and the variance set. 1. Position the Electronic overhead Module (EOM) (2) onto the overhead console housing (1). 2. Reconnect the overhead console wire harness connector to the EOM connector receptacle. 3. Install the screws (4) that secure the EOM (2) to the overhead console housing (1). Tighten the screws to 2.2 N.m (20 in.lbs.). 4. Install the overhead console (1) onto the headliner. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Illumination Lamp > Page 6867 5. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 A cruise indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional speed control system, this indicator is electronically disabled. The cruise indicator consists of the word "CRUISE", which appears in the lower portion of the gear selector indicator Vacuum-Fluorescent Display (VFD) unit. The gear selector indicator VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The "CRUISE" text appears in a blue-green color and at the same lighting level as the gear selector indicator information when it is illuminated by the instrument cluster electronic circuit board. The cruise indicator is serviced as a unit with the VFD in the instrument cluster. The cruise indicator gives an indication to the vehicle operator when the speed control system is turned On, regardless of whether the speed control is engaged. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The cruise indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the cruise indicator for the following reasons: - Cruise Lamp-On Message - Each time the cluster receives a cruise lamp-on message from the PCM indicating the speed control system has been turned On, the cruise indicator is illuminated. The indicator remains illuminated until the cluster receives a cruise lamp-off message from the PCM or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the cruise indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The PCM continually monitors the speed control switches to determine the proper outputs to the speed control servo. The PCM then sends the proper cruise indicator lamp-on and lamp-off messages to the instrument cluster. For proper diagnosis of the speed control system, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the cruise indicator, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING 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 disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams Dimmer Switch: Diagrams Lamp-Center Bezel Lamp CHMSL Aftermarket - 1 Way Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation Door/Trunk Ajar Indicator/Lamp: Description and Operation The door ajar switches are integral to the door latches on each door. The switches close a path to ground for the Instrument Cluster when a door is opened. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Refer to the Body section under Doors for the removal and installation procedure. The door ajar switches close a path to ground for the Instrument Cluster when a door is opened. The passenger front door is connected in a parallel-series circuit between ground and the Instrument Cluster, while the driver side front door ajar switch is connected in series between ground and the Instrument Cluster to provide a unique input. The Instrument Cluster reads the switch status, then sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed using conventional diagnostic tools and methods. Refer to the Body section under Doors for the Removal and Installation procedures. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Description and Operation Door Switch: Description and Operation This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if faulty or damaged, the door latch unit must be replaced. The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the Electro-Mechanical Instrument Cluster (EMIC). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the PCI data bus, or the electronic messaging used to convey door ajar switch status to other modules in the vehicle. The most reliable, efficient, and accurate means to diagnose the EMIC, the PCI data bus, and both the hard wired and electronic message inputs and outputs affected by the door ajar switch inputs requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6888 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6889 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6890 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6891 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6892 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6893 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6894 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6895 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6896 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6897 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6898 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6899 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6900 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6901 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6902 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6903 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6904 Driver/Vehicle Information Display: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6905 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6906 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6907 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6908 Module-Electronic Overhead (Except Base) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6909 EOM System Schematic Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console Driver/Vehicle Information Display: Description and Operation Overhead Console An overhead console is available on this vehicle and includes the following components: - Front map/reading lamps - A blue-green vacuum-fluorescent display screen - if equipped with trip computer - Universal transmitter - if equipped - Electronic Overhead Module (EOM) The overhead console assembly is mounted by two snap clips and screws securing it to a molded plastic retainer bracket located above the headliner. The EOM is accessed by removing the overhead console from the bracket and pulling it away from the headliner. COMPASS DISPLAY All the available overhead consoles on this model include Compass information. While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle at 5 to 8 kilometers-per-hour (3 to 5 miles-per-hour), on level ground in a square shaped pattern. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the vehicle roof should become magnetized, the demagnetizing procedure may be required to restore proper compass operation. TEMPERATURE DISPLAY All the available overhead consoles on this model include Temperature information. The temperature displays the outside ambient temperature in whole degrees. The temperature display can be toggled from Fahrenheit to Celsius by selecting the desired U.S./Metric option from the customer programmable features. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the temperature display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. When the ignition switch is turned to the Off position, the last displayed temperature reading stays in the electronic control modules, (CMTC, EVIC) memory. When the ignition switch is turned to the On position again, the electronic module will display the memory temperature for one minute; then update the display to the current average temperature reading within five minutes. The temperature function is supported by an ambient temperature sensor. This sensor is mounted outside the passenger compartment near the front and center of the vehicle, and is hard wired to the Front Control Module (FCM). The FCM sends temperature status messages to the module over the Programmable Communications Interface (PCI) data bus circuit. For more information on the ambient temperature sensor. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console > Page 6912 Driver/Vehicle Information Display: Description and Operation Universal Transmitter The universal transmitter transceiver is integral to the overhead console (7). The only visible component of the universal transmitter are the three transmitter push buttons (3). The buttons are marked with one, two or three dots, respectively, for identification of each channel. Each of the three universal transmitter push buttons controls an independent radio transmitter channel. Each of these three channels can be trained to transmit a different radio frequency signal for the remote operation of garage door openers, motorized gate openers, home or office lighting, security systems or just about any other device that can be equipped with a radio receiver in the 286 to 399 MegaHertz (MHz) frequency range for remote operation. The universal transmitter is capable of operating systems using either rolling code or non-rolling code technology. The universal transmitter cannot be repaired, and is available for service only as part of the Electronic Overhead Module (EOM). This unit includes the push button switches for both the transmitter and compass mini trip computer. The universal transmitter operates on a non-switched source of battery current so the unit will remain functional, regardless of the ignition switch position. It can learn and store three separate transmitter radio frequency codes to operate garage door openers, security gates and security lighting. The overhead console display provides visual feedback to the driver, showing which transmitter button is pressed. The system will not send operating signals if the vehicle theft security alarm is armed. This prevents a perpetrator from breaking into a vehicle parked outside a home and using the transmitter system to enter the home. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Overhead Console Driver/Vehicle Information Display: Testing and Inspection Overhead Console If the problem with the overhead console is an inaccurate or scrambled display, refer to SELFDIAGNOSTIC TEST. If the problem with the overhead console is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a scan tool and the proper Diagnostic Procedures Information to test for the correct dimming message inputs being received from the Body Control Module (BCM) or Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus circuit. If the problem is a no-display condition, use the following procedure. For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the overhead console from the headliner. 2. Check for battery voltage at the overhead console electrical connector. If OK, go to Step 3. If not OK, Check for battery voltage at the appropriate B(+) fuse in the Integrated Power Module (IPM), repair the open fused B(+) circuit as required. 3. Turn the ignition switch to the On position. Check the fused ignition switch output circuit(s) at the overhead console electrical connector. If OK, go to Step 4. If not OK, repair the open or shorted circuit as required. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the overhead console electrical connector and a good ground. There should be continuity. If OK, refer to SELF- DIAGNOSTIC TEST for further diagnosis of the electronics module and the PCI data bus circuit. If not OK, repair the open ground circuit as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Overhead Console > Page 6915 Driver/Vehicle Information Display: Testing and Inspection Self-Diagnostic Test A self-diagnostic test is used to determine that the EOM is operating properly electrically. Initiate the self-diagnostic test as follows: NOTE: The compass mini-trip computer self - test can also be performed using a scan tool. Refer to Auto Self Test under the System Tests. 1. With the ignition switch in the Off position, simultaneously depress and hold the STEP and RESET buttons while rotating the ignition switch to the Run/On position. 2. Continue to hold both buttons depressed until the EOM enters the display segment test. In this test, all of the Vacuum Fluorescent Display (VFD) segments are lighted while the EOM performs the following checks: Non-Volatile Memory Status (NVM) - RAM Status - ROM Status - ASIC Communication Test Status - Compass Test Status - DC Status - PCI data bus Communications Test NOTE: If module is equipped with the Universal Transmitter, the module also checks "Universal Transmitter Communication Test Status" 3. Following completion of these tests, the compass mini-trip computer will display one of two messages: "FAIL" or "PASS." Press RESET or STEP to exit and enter normal mode. Respond to these test results as follows: If no test result message is displayed, but compass mini-trip computer operation is still improper, the use of a scan tool and the proper Diagnostic Procedures Information are required for further diagnosis. - If the "FAIL" message is displayed, the EOM is inoperative and must be replaced. - If the "PASS" message is displayed, the EOM is OK, no faults are present. - If any VFD segment does not light during the display segment test, the EOM is inoperative and must be replaced. 4. If the first seven tests pass, the compass mini-trip computer shall verify that all the required PCI bus messages are present on the PCI bus. If all required messages are present on the PCI bus, or if the ignition switch is turned to the Off position, the EOM will automatically return to normal operation. The required PCI bus messages are: Dimming message - Fuel Used message - Distance Pulses message - Percentage Fuel Tank Full message - Fuel Type message - VIN (Vehicle Identification Number) - Vehicle Speed message - Last Engine Off Duration message - Ambient Air Temperature message NOTE: - The Fuel Used message shall be ignored if the engine type is Diesel or Compressed Natural Gas. - Pressing the STEP or RESET switches during any portion of the testing procedure will cause the compass mini-trip computer to exit diagnostics and return to compass/temperature mode. - If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. - If the compass reading has blanked out, and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Overhead Console > Page 6916 Driver/Vehicle Information Display: Testing and Inspection Universal Transmitter Radio Frequency Detector #9001 If both the Transmitter and the compass mini trip computer display are inoperative, refer to testing for further diagnosis. If the Universal Transmitter is inoperative, but the compass mini trip computer display is operating normally. Retrain the Transmitter with a known good transmitter as instructed and test the Transmitter operation again. If the unit is still inoperative, test the universal transmitter with the Radio Frequency Detector special tool as described below: 1. Turn the Radio Frequency (RF) Detector ON. A "chirp" will sound and the green power LED will light. If the green LED does not light, replace the battery. 2. Hold the RF detector within one inch of the TRAINED universal transmitter and press any of the transmitters buttons. 3. The red signal detection LEDs will light and the tool will beep if a radio signal is detected. Repeat this test for each button. If any button is inoperative, replace the universal transmitter assembly. For complete circuit diagrams, The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement Driver/Vehicle Information Display: Service and Repair Module Lens Replacement 1. Remove the overhead console. 2. Remove the electronic overhead module from the overhead console. 3. Unsnap the lens from the module and replace lens as necessary. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 6919 Driver/Vehicle Information Display: Service and Repair Overhead Console REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console retaining screws, located in the sunglass storage bin. 3. Using your fingertips, grasp the sides of the overhead console and pull straight down evenly to disengage the two snap clips at the front of the unit. 4. Lower the overhead console far enough to access the wire harness connectors. 5. Disconnect the Electronic Overhead Module and the reading/courtesy lamps electrical connectors. 6. Remove the overhead console from the vehicle. INSTALLATION 1. Position the overhead console in the vehicle. 2. Connect the Electronic Overhead Module and the reading/courtesy lamps electrical connectors. 3. Grasp the sides of the overhead console and push straight up evenly to engage the two snap clips at the rear of the unit. 4. Install the overhead console retaining screws, located in the sunglass storage bin. Torque the screws to 1.2 N.m (10 in.lbs.). 5. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 6920 Driver/Vehicle Information Display: Service and Repair Module Lamp Replacement 1. Remove the overhead console. 2. Using a flat blade screwdriver twist out socket/lamp (3). 3. Replace lamp(s) as necessary. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 6921 Driver/Vehicle Information Display: Service and Repair Programming Transmitter Codes CAUTION: - Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the transceiver. Exhaust gas can cause serious injury or death. - Your motorized door or gate will open and close while you are training the Universal Transceiver. Do not train the transceiver if people or pets are in the path of the door or gate. A moving door or gate can cause serious injury or death to people and pets or damage to objects. 1. Press and hold the two outer HomeLink buttons, and release only when the EVIC display shows "Channels Cleared" (after 20 seconds). Do not hold the buttons for longer than 30 seconds and do not repeat step one to program a second and/or third hand-held transmitter to the remaining two HomeLink buttons. 2. Position the end of your hand-held transmitter 1-3 inches (3-8 cm) away from the HomeLink buttons. 3. Simultaneously press and hold both the HomeLink button that you want to train and the hand-held transmitter buttons. Do not release the buttons until step 4 has been completed. 4. The EVIC display will show "Channel X Training" (where X is Channel 1, 2, or 3). Release both buttons after the EVIC display shows "Channel X Trained". NOTE: If the EVIC display shows "Did Not Train" repeat steps 2-4. 5. Press and hold the just trained HomeLink button and observe the EVIC display. If the EVIC display shows "Channel X Transmit" (where X is Channel 1, 2, or 3), programming is complete and your device should activate when the HomeLink button is pressed and released. NOTE: To program the remaining two HomeLink buttons, begin with "Programming" step two. Do not repeat step one. - If your hand-held transmitter appears to program the universal transceiver, but your garage door does not operate using the transmitter and your garage door opener was manufactured after 1995, your garage door opener may have a multiple security code system (rolling code system). Please proceed to steps 6-8 to complete the programming of a rolling code equipped device (most common garage door openers require this step. 6. At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. 7. Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) NOTE: There are 30 seconds in which to initiate step eight. 8. Return to the vehicle and firmly press, hold for two seconds and release the programmed HomeLink button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming. 9. HomeLink should now activate your rolling code equipped device. 10. To program the remaining two HomeLink buttons, begin with "Programming" step two. Do not repeat step one. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 6922 Driver/Vehicle Information Display: Service and Repair Module Lens Replacement 1. Remove the overhead console. 2. Remove the electronic overhead module from the overhead console. 3. Unsnap the lens from the module and replace lens as necessary. Overhead Console REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console retaining screws, located in the sunglass storage bin. 3. Using your fingertips, grasp the sides of the overhead console and pull straight down evenly to disengage the two snap clips at the front of the unit. 4. Lower the overhead console far enough to access the wire harness connectors. 5. Disconnect the Electronic Overhead Module and the reading/courtesy lamps electrical connectors. 6. Remove the overhead console from the vehicle. INSTALLATION 1. Position the overhead console in the vehicle. 2. Connect the Electronic Overhead Module and the reading/courtesy lamps electrical connectors. 3. Grasp the sides of the overhead console and push straight up evenly to engage the two snap clips at the rear of the unit. 4. Install the overhead console retaining screws, located in the sunglass storage bin. Torque the screws to 1.2 N.m (10 in.lbs.). 5. Connect the battery negative cable. Module Lamp Replacement 1. Remove the overhead console. 2. Using a flat blade screwdriver twist out socket/lamp (3). 3. Replace lamp(s) as necessary. Programming Transmitter Codes CAUTION: - Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the transceiver. Exhaust gas can cause serious injury or death. - Your motorized door or gate will open and close while you are training the Universal Transceiver. Do not train the transceiver if people or pets are in the path of the door or gate. A moving door or gate can cause serious injury or death to people and pets or damage to objects. 1. Press and hold the two outer HomeLink buttons, and release only when the EVIC display shows "Channels Cleared" (after 20 seconds). Do not hold the buttons for longer than 30 seconds and do not repeat step one to program a second and/or third hand-held transmitter to the remaining two HomeLink buttons. 2. Position the end of your hand-held transmitter 1-3 inches (3-8 cm) away from the HomeLink buttons. 3. Simultaneously press and hold both the HomeLink button that you want to train and the hand-held transmitter buttons. Do not release the buttons Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 6923 until step 4 has been completed. 4. The EVIC display will show "Channel X Training" (where X is Channel 1, 2, or 3). Release both buttons after the EVIC display shows "Channel X Trained". NOTE: If the EVIC display shows "Did Not Train" repeat steps 2-4. 5. Press and hold the just trained HomeLink button and observe the EVIC display. If the EVIC display shows "Channel X Transmit" (where X is Channel 1, 2, or 3), programming is complete and your device should activate when the HomeLink button is pressed and released. NOTE: To program the remaining two HomeLink buttons, begin with "Programming" step two. Do not repeat step one. - If your hand-held transmitter appears to program the universal transceiver, but your garage door does not operate using the transmitter and your garage door opener was manufactured after 1995, your garage door opener may have a multiple security code system (rolling code system). Please proceed to steps 6-8 to complete the programming of a rolling code equipped device (most common garage door openers require this step. 6. At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. 7. Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) NOTE: There are 30 seconds in which to initiate step eight. 8. Return to the vehicle and firmly press, hold for two seconds and release the programmed HomeLink button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming. 9. HomeLink should now activate your rolling code equipped device. 10. To program the remaining two HomeLink buttons, begin with "Programming" step two. Do not repeat step one. Erasing Transmitter Codes NOTE: Individual channels cannot be erased. Erasing the transmitter codes will erase ALL programmed codes. To erase programming from the three buttons (individual buttons cannot be erased but can be "reprogrammed"), follow the step noted: - Press and hold the two outer HomeLink buttons until the indicator light begins to flash-after 20 seconds. Release both buttons. Do not hold for longer that 30 seconds. HomeLink is now in the train (or learning) mode and can be programmed at any time beginning with "Programming. Reprogramming Transmitter Codes CAUTION: - Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the transceiver. Exhaust gas can cause serious injury or death. - Your motorized door or gate will open and close while you are training the Universal Transceiver. Do not train the transceiver if people or pets are in the path of the door or gate. A moving door or gate can cause serious injury or death to people and pets or damage to objects. To program a device to HomeLink using a HomeLink button previously trained, follow these steps: 1. Press and hold the desired HomeLink button. Do NOT release the button. 2. The EVIC display will show "Channel X Transmit" (where X is Channel 1, 2, or 3) for 20 seconds and then change to "Channel X Training". Without releasing the HomeLink button, proceed to step 3. 3. Position the end of your hand-held transmitter 1-3 inches (3-8 cm) away from the HomeLink buttons. 4. Simultaneously press and hold both the HomeLink button that you want to train and the hand-held transmitter buttons. Do not release the buttons until step 4 has been completed. 5. Press and hold the just trained HomeLink button and observe the EVIC display. If the EVIC display shows "Channel X Transmit" (where X is Channel 1, 2, or 3), programming is complete and your device should activate when the HomeLink button is pressed and released. NOTE: To program the remaining two HomeLink buttons, begin with "Programming" step two. Do not repeat step one. - If your hand-held transmitter appears to program the universal transceiver, but your garage door does not operate using the transmitter and your garage door opener was manufactured after 1995, your garage door opener may have a multiple security code system (rolling code system). Please proceed to steps 6-8 to complete the programming of a rolling code equipped device (most common garage door openers require this step. 6. At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. 7. Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) NOTE: There are 30 seconds in which to initiate step eight. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 6924 8. Return to the vehicle and firmly press, hold for two seconds and release the programmed HomeLink button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming. 9. HomeLink should now activate your rolling code equipped device. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Electronic Throttle Control Indicator > Component Information > Description and Operation Electronic Throttle Control Indicator: Description and Operation An Electronic Throttle Control (ETC) indicator is standard equipment on all gasoline engine instrument clusters. However, on vehicles not equipped with the I/I optional 5.7 liter gasoline engine, this indicator is electronically disabled. The ETC indicator is located on the right side of the instrument cluster, to the right of the engine temperature gauge. The ETC indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Electronic Throttle Control" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ETC indicator is serviced as a unit with the instrument cluster. The Electronic Throttle Control (ETC) indicator gives an indication to the vehicle operator when the ETC system is faulty or inoperative. The ETC indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The ETC indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the ETC indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the ETC indicator is illuminated for about six seconds. The entire six second bulb test is a function of the PCM. - ETC Lamp-On Message - Each time the cluster receives a lamp-on message from the PCM, the ETC indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the PCM message. The indicator remains illuminated solid or continues to flash for about twelve seconds or until the cluster receives a lamp-off message from the PCM, whichever is longer. If the indicator is illuminated solid with the engine running the vehicle will usually remain drivable. If the indicator is flashing with the engine running the vehicle may require towing. A flashing indicator means the ETC system requires immediate service. - Communication Error - If the cluster receives no ETC lamp messages for three consecutive seconds, the ETC indicator is illuminated. The indicator remains illuminated until the cluster receives a single lamp-off message from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the ETC indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The actuator test illumination of the ETC indicator is a function of the PCM. The PCM continually monitors the ETC system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-on or lamp-off messages to the instrument cluster. If the PCM sends a lamp-on message after the bulb test, it indicates that the PCM has detected a system malfunction and/or that the ETC system is inoperative. The PCM will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ETC indicator fails to illuminate due to an open or short in the cluster ETC indicator circuit, the cluster sends a message notifying the PCM of the condition, the instrument cluster and the PCM will each store a DTC. For proper diagnosis of the ETC system, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the ETC indicator, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagnostic Aids Fuel Gauge: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagnostic Aids > Page 6932 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagnostic Aids > Page 6933 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagnostic Aids > Page 6934 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Page 6935 Fuel Gauge: Description and Operation A fuel gauge is standard equipment on all instrument clusters. This gauge is located in the lower left quadrant of the instrument cluster, below the voltage gauge. The fuel gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "E" (or Empty) to "F" (or Full). An International Control and Display Symbol icon for "Fuel" is located on the cluster overlay, directly below the right end of the gauge scale. An arrowhead pointed to the left side of the vehicle is imprinted on the cluster overlay next to the "Fuel" icon in the fuel gauge to provide the driver with a reminder as to the location of the fuel filler access. On vehicles equipped with a diesel engine, text that specifies "DIESEL ONLY" is located across the fuel gauge below the gauge scale, but above the hub of the gauge needle. On all models except SRT-10 the fuel gauge graphics are black against a white field. On SRT-10 the gauge graphics are black against a silver field except for a single red graduation at the low end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black gauge graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The fuel gauge is serviced as a unit with the instrument cluster. The fuel gauge gives an indication to the vehicle operator of the level of fuel in the fuel tank. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The fuel gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Percent Tank Full Message - Each time the cluster receives a message from the PCM or ECM indicating the percent tank full, the cluster programming applies an algorithm to calculate the proper gauge needle position, then moves the gauge needle to the proper relative position on the gauge scale. The algorithm is used to dampen gauge needle movement against the negative effect that fuel sloshing within the fuel tank can have on accurate inputs from the fuel tank sending unit to the PCM or ECM. - Less Than Fifteen Percent Tank Full Message - Each time the cluster receives messages from the PCM or ECM indicating the percent tank full is about fifteen percent or less for ten consecutive seconds and the vehicle speed is zero, or for sixty consecutive seconds and the vehicle speed is greater than zero, the gauge needle is moved to between the one-sixteenth and one-eighth graduations or below on the gauge scale, the low fuel indicator is illuminated, and a single chime tone is sounded. The low fuel indicator remains illuminated until the cluster receives messages from the PCM or ECM indicating that the percent tank full is greater than about fifteen percent for ten consecutive seconds and the vehicle speed is zero, or for sixty consecutive seconds and the vehicle speed is greater than zero, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the low fuel indicator is cycled off and then on again by the appropriate percent tank full messages from the PCM or ECM. - Less Than Empty Percent Tank Full Message - Each time the cluster receives a message from the PCM or ECM indicating the percent tank full is less than empty, the gauge needle is moved to the far left end of the gauge scale and the low fuel indicator is illuminated immediately. This message would indicate that the fuel tank sender input to the PCM or ECM is a short circuit. - more than Full Percent Tank Full Message - Each time the cluster receives a message from the PCM or ECM indicating the percent tank full is more than full, the gauge needle is moved to the far left end of the gauge scale and the low fuel indicator is illuminated immediately. This message would indicate that the fuel tank sender input to the PCM or ECM is an open circuit. - Communication Error - If the cluster fails to receive a percent tank full message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the fuel gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the fuel tank sending unit to determine the level of the fuel in the fuel tank. On vehicles with a diesel engine, the ECM continually monitors the fuel tank sending unit to determine the level of the fuel in the fuel tank. The PCM or ECM then sends the proper fuel level messages to the instrument cluster. For further diagnosis of the fuel gauge or the instrument cluster circuitry that controls the gauge, refer to testing. For proper diagnosis of the fuel tank sending unit, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Page 6936 control the fuel gauge, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Sensor-Fuel Level Sending Unit Fuel Gauge Sender: Locations Sensor-Fuel Level Sending Unit The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Sensor-Fuel Level Sending Unit > Page 6941 Fuel Gauge Sender: Locations Fuel Pump Module The fuel pump module assembly is located on the top of the fuel tank. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6944 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6945 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6946 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6947 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6948 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6949 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6950 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6951 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6952 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6953 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6954 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6955 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6956 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6957 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6958 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6959 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6960 Fuel Gauge Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6961 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6962 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6963 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Page 6964 Fuel Gauge Sender: Description and Operation 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 variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit 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 diagnostic 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Page 6965 Fuel Gauge Sender: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation. 2. Disconnect 4-wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. Refer to Special Tools in Wiring for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4-wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/ Installation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING 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 disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation KEY-IN IGNITION SWITCH DESCRIPTION The key-in ignition switch is integral to the ignition switch, which is mounted on the left side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition key cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition key cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Description and Operation Lamp Out Indicator: Description and Operation A lamp out indicator is standard equipment on all instrument clusters. The lamp out indicator consists of the words "LAMP OUT", which appear in the lower portion of the odometer/trip odometer Vacuum-Fluorescent Display (VFD) unit. The odometer/trip odometer VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the lamp out indicator from being clearly visible when it is not illuminated. The words "LAMP OUT" appear in an amber color and at the same lighting level as the odometer/trip odometer information when they are illuminated by the instrument cluster electronic circuit board. The lamp out indicator is serviced as a unit with the VFD in the instrument cluster. The lamp out indicator gives an indication to the vehicle operator when an exterior lamp has failed. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus. The lamp out indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the lamp out indicator for the following reasons: - Lamp Out Indicator Lamp-On Message - Each time the cluster receives a lamp out indicator lamp-on message from the FCM indicating that an inoperative headlamp (low or high beam), turn signal lamp, or brake lamp (excluding Center High Mounted Stop Lamp [CHMSL]) circuit has been detected with the ignition switch in the On position, the lamp out indicator is illuminated solid. The indicator remains illuminated until the cluster receives a lamp out indicator lamp-off message from the FCM or until the ignition switch is turned to the Off position, whichever occurs first. If the lamp-on message is received when the ignition is first turned to the On position, the lamp out indicator is flashed at a fast rate (1 Hertz) for about thirty seconds before illuminating solid. - Actuator Test - Each time the cluster is put through the actuator test, the lamp out indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The FCM monitors each of the headlamp, turn signal lamp, and brake lamp (except CHMSL) circuits to determine the condition of these exterior lamps. The FCM then sends the proper lamp out indicator lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the lamp out indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the exterior lighting system circuits, the FCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the lamp out indicator, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 A low fuel indicator is standard equipment on all instrument clusters. This indicator is located on the left side of the instrument cluster, to the left of the fuel gauge. The low fuel indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Fuel" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The low fuel indicator is serviced as a unit with the instrument cluster. The low fuel indicator gives an indication to the vehicle operator when the level of fuel in the fuel tank becomes low. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The low fuel indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the low fuel indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the low fuel indicator is illuminated for about two seconds as a bulb test. - Less Than Fifteen Percent Tank Full Message - Each time the cluster receives messages from the PCM or ECM indicating the percent tank full is about fifteen percent or less for ten consecutive seconds and the vehicle speed is zero, or for sixty consecutive seconds and the vehicle speed is greater than zero, the fuel gauge needle is moved to between the one-sixteenth and one-eighth graduations or below on the gauge scale, the low fuel indicator is illuminated and a single chime tone is sounded. The low fuel indicator remains illuminated until the cluster receives messages from the PCM or ECM indicating that the percent tank full is greater than about fifteen percent for ten consecutive seconds and the vehicle speed is zero, or for sixty consecutive seconds and the vehicle speed is greater than zero, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the low fuel indicator is cycled off and then on again by the appropriate percent tank full messages from the PCM or ECM. - Less Than Empty Percent Tank Full Message - Each time the cluster receives a message from the PCM or ECM indicating the percent tank full is less than empty, the low fuel indicator is illuminated immediately. This message would indicate that the fuel tank sender input to the PCM or ECM is a short circuit. - More Than Full Percent Tank Full Message - Each time the cluster receives a message from the PCM or ECM indicating the percent tank full is more than full, the low fuel indicator is illuminated immediately. This message would indicate that the fuel tank sender input to the PCM or ECM is an open circuit. - Actuator Test - Each time the cluster is put through the actuator test, the low fuel indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the fuel tank sending unit to determine the level of fuel in the fuel tank. On vehicles with a diesel engine, the ECM continually monitors the fuel tank sending unit to determine the level of fuel in the fuel tank. The PCM or ECM then sends the proper fuel level messages to the instrument cluster. For further diagnosis of the low fuel indicator or the instrument cluster circuitry that controls the LED, refer to testing. For proper diagnosis of the fuel tank sending unit, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the low fuel indicator, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation Chrysler provides no information regarding a Maintenance Required Lamp/Indicator. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. This indicator is located on the left side of the instrument cluster, to the left of the voltage gauge. The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for "Engine" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or the Engine Control Module (ECM) on vehicles with a diesel engine has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM or ECM over the Programmable Communications Interface (PCI) data bus. The MIL Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the MIL for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the indicator is illuminated for about two seconds as a bulb test. The entire bulb test is a function of the PCM or ECM. - MIL Lamp-On Message - Each time the cluster receives a MIL lamp-on message from the PCM or ECM, the indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the PCM or ECM message. For some DTC's, if a problem does not recur, the PCM or ECM will send a lamp-off message automatically. Other DTC's may require that a fault be repaired and the PCM or ECM be reset before a lamp-off message will be sent. - Communication Error - If the cluster receives no messages from the PCM or ECM for about ten seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the PCM or ECM. - Actuator Test - Each time the cluster is put through the actuator test, the MIL indicator will be turned on during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. On vehicles with a diesel engine, the ECM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM or ECM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For further diagnosis of the MIL or the instrument cluster circuitry that controls the LED, refer to testing. If the instrument cluster turns on the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the MIL, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation Odometer: Description and Operation An odometer and trip odometer are standard equipment in all instrument clusters. The odometer, trip odometer, and engine hours information are displayed BBBSB.S"" in a common electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. This VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents it from being clearly visible when it is not illuminated. The odometer, trip odometer, and engine hours information are not displayed simultaneously. The trip odometer reset switch on the instrument cluster circuit board toggles the display between odometer and trip odometer modes by depressing the odometer/trip odometer switch button that extends through the lower edge of the cluster lens, just left of the odometer VFD. When the trip odometer information is displayed, the word "TRIP" is also illuminated in the upper right corner of the VFD in a blue-green color and at the same lighting level as the trip odometer information. On all models except SRT-10, the engine hours information replaces the selected odometer or trip odometer information whenever the ignition switch is in the On position and the engine is not running. The engine hours feature is disabled on all SRT-10 models. The odometer, trip odometer, and engine hours information is stored in the instrument cluster memory. This information can be increased when the proper inputs are provided to the instrument cluster, but the information cannot be decreased. The odometer can display values up to 999,999 kilometers (999,999 miles). The odometer latches at these values, and will not roll over to zero. The trip odometer can display values up to 9,999.9 kilometers (9,999.9 miles) before it rolls over to zero. Engine hours are displayed in the format, "hr9999". The cluster will accumulate values up to 9,999 hours before the display rolls over to zero. The odometer display does not have a decimal point and will not show values less than a full unit (kilometer or mile), while the trip odometer display does have a decimal point and will show tenths of a unit (kilometer or mile). The unit of measure (kilometers or miles) for the odometer and trip odometer display is not shown in the VFD. The unit of measure for the instrument cluster odometer/trip odometer is selected at the time that it is manufactured, and cannot be changed. The odometer also has a "Rental Car" mode, which will illuminate the odometer information in the VFD whenever the driver side front door is opened with the ignition switch in the Off or Accessory positions. During daylight hours (exterior lamps are Off) the odometer VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are On), the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned On during daylight hours. The odometer/trip odometer VFD, the trip odometer switch, and the trip odometer switch button are serviced as a unit with the instrument cluster. The odometer and trip odometer give an indication to the vehicle operator of the distance the vehicle has traveled. On all models except SRT-10, the engine hours give an indication of the cumulative engine-on time. The engine hours feature is disabled on SRT-10 models. This indicator is controlled by the instrument cluster circuitry based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) or Engine Control Module (ECM) over the Programmable Communications Interface (PCI) data bus. The odometer, trip odometer and engine hours information is displayed by the instrument cluster odometer Vacuum Fluorescent Display (VFD). The odometer VFD will display the odometer information whenever the driver side front door is opened with the ignition switch in the Off or Accessory positions, and will display the last previously selected odometer or trip odometer information when the ignition switch is turned to the On or Start positions. The instrument cluster circuitry controls the VFD and provides the following features: - Odometer/Trip Odometer Display Toggling - Actuating the trip odometer reset switch button momentarily with the VFD illuminated will toggle the display between the odometer and trip odometer information. Each time the VFD is illuminated with the ignition switch in the On or Start positions, the display will automatically return to the last mode previously selected (odometer or trip odometer). - Engine Hours Display Toggling - When the trip odometer reset switch button is pressed and held for longer than about six seconds with the ignition switch in the On position and the engine speed message from the PCM is zero, the trip odometer information will be momentarily displayed, then the engine hours information will be displayed. The VFD must be displaying the odometer information when the trip odometer reset switch button is pressed in order to toggle to the engine hours display. The engine hours will remain displayed for about thirty seconds, until the engine speed message is greater than zero, or until the ignition switch is turned to the Off position, whichever occurs first. - Trip Odometer Reset - When the trip odometer reset switch button is pressed and held for longer than about two seconds with the ignition switch in the On or Start position, the trip odometer will be reset to 0.0 kilometers (miles). The VFD must be displaying the trip odometer information in order for the trip odometer information to be reset. - Communication Error - If the cluster fails to receive a distance message during normal operation, it will hold and display the last data received until the ignition switch is turned to the Off position. If the cluster does not receive a distance message within one second after the ignition switch is turned to the On position, it will display the last distance message stored in the cluster memory. If the cluster is unable to display distance information due to an error internal to the cluster, the VFD will display all dashes. - Actuator Test - Each time the cluster is put through the actuator test, the odometer VFD will display all of its segments simultaneously during the VFD portion of the test to confirm the functionality of each of the VFD segments and the cluster control circuitry. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation > Page 6988 The PCM continually monitors the vehicle speed pulse information received from the vehicle speed sensor or the Controller Anti-lock Brake (CAB) and engine speed pulse information received from the crankshaft position sensor, then sends the proper distance and engine speed messages to the instrument cluster. For further diagnosis of the odometer/trip odometer or the instrument cluster circuitry that controls these functions, refer to testing. For proper diagnosis of the vehicle speed sensor, the crankshaft position sensor, the CAB, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the odometer/trip odometer, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation An oil pressure gauge is standard equipment on all instrument clusters. The oil pressure gauge is located in the upper right quadrant of the instrument cluster, above the coolant temperature gauge. The oil pressure gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "L" (or Low) to "H" (or High) for gasoline engines except SRT-10. On SRT-10 models, the scale reads from "0" kPa to "700" kPa in markets where a metric instrument cluster is specified, or from "0" psi to "100" psi in all other markets. On vehicles with a diesel engine the scale reads from "0" kPa to "760" kPa in markets where a metric instrument cluster is specified, or from "0" psi to "110" psi in all other markets. An International Control and Display Symbol icon for "Engine Oil" is located on the cluster overlay, directly below the left end of the gauge scale. On all models except SRT-10 the oil pressure gauge graphics are black against a white field except for two red graduations at the low end of the gauge scale. On SRT-10 the gauge graphics are black against a silver field except for a single red zone at the low end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. For all models except SRT-10, each time the cluster receives a message from the PCM or ECM indicating the engine oil pressure is above about 41 kPa (6 psi) the cluster holds the gauge needle at a point near the middle increment within the normal range on the gauge scale. For SRT-10 models, each time the cluster receives a message from the PCM indicating the engine oil pressure is above about 41 kPa (6 psi) the cluster moves the gauge needle in a linear fashion to the proper relative pressure position of the gauge scale. - Engine Oil Pressure Low Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine oil pressure is below about 41 kPa (6 psi), the gauge needle is moved to the red graduations (except SRT-10) or to the red zone (SRT-10) at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the left end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine oil pressure is above about 41 kPa (6 psi), or until the ignition switch is turned to the Off position, whichever occurs first. The cluster will only turn the check gauges indicator on in response to an engine oil pressure low message if the engine speed message is greater than zero. - Communication Error - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the oil pressure gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure. On vehicles with a diesel engine, the ECM continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM or ECM then sends the proper engine oil pressure messages to the instrument cluster. If the instrument cluster turns on the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the oil pressure gauge, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Temperature Gauge > Component Information > Diagrams Gauge - Engine Oil Temperature (SRT) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Temperature Gauge > Component Information > Diagrams > Page 6995 Oil Temperature Gauge: Description and Operation An oil temperature gauge (1) is standard equipment on all SRT-10 models. This electronic, analog gauge is located in the lower end of the left A-pillar trim molding below the grab handle (2), in clear view of the vehicle operator. The gauge dial face is visible through a clear plastic lens, which is secured to the gauge housing with a silver anodized trim ring. The remainder of the gauge, including the mounting provisions and the electrical connections, are concealed behind the left A-pillar trim molding. The molded plastic housing at the rear of the gauge protects the electronic circuitry of the gauge and has two mounting studs, which are secured by nuts to a molded plastic mounting bracket screwed to the back of the A-pillar trim molding. A short pigtail wire with a connector extends from the back of the gauge housing and connects the gauge to the vehicle electrical system through a take out and connector of the instrument panel wire harness. The oil temperature gauge consists of a movable gauge needle or pointer with a 270 degree sweep that is controlled by the electronic gauge circuitry. The gauge overlay reads left-to-right from "60" to "150" with "° C" indicated directly below the low (left) end of the scale in markets where a metric instrument cluster is specified, or from "140" to "300" with "° F" indicated directly below the left end of the scale for all other markets. The text "OIL TEMP" is imprinted on the center of the gauge overlay below the hub of the gauge needle, while the text "SRT" is imprinted above the hub of the gauge needle. The gauge graphics are black against a silver field except for a single red zone at the high (right) end of the gauge scale and are clearly visible in daylight. General illumination lighting for the gauge is provided by a Light Emitting Diode (LED) that is soldered onto the gauge circuit board. The gauge overlay is a laminated plastic unit. The dark, visible, outer surface of the overlay is marked with the gauge dial face and graduations, but this layer is also translucent. The underlying layer of the overlay is opaque and allows light from the LED on the circuit board behind it to be visible through the outer layer of the overlay only through predetermined stencil-like cutouts. When illuminated from behind by the panel lamps dimmer controlled gauge lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Temperature Gauge > Component Information > Diagrams > Page 6996 The oil temperature gauge cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The gauge illumination LED unit is not available for service replacement and, if damaged or faulty, the entire gauge must be replaced. The oil temperature gauge gives an indication to the vehicle operator of the engine oil temperature. This gauge is controlled by its own internal electronic circuit board based upon a hard wired input received by the gauge from an oil temperature sensor (4) installed in a tapped hole that penetrates an oil passage on the right side of the engine block (2) just behind the oil pressure sensor (3). The oil temperature sensor is a Negative Temperature Coefficient (NTC) thermistor that changes its internal resistance with changes in temperature. The sensor has two terminals. One terminal receives a hard wired ground path through a take out and connector of the engine wire harness (1), and the second terminal provides a variable output to the gauge through the same take out and connector. As the oil temperature increases the resistance of the sensor decreases, and as the oil temperature decreases the resistance of the sensor increases. The oil temperature gauge is an air core magnetic unit. The gauge pigtail wire and connector provides the gauge electronic circuit board with a hard wired ground path, battery current through a fused ignition switch output (run-start) circuit, a Pulse Width Modulated (PWM) panel lamps dimmer input from the instrument cluster for general illumination, and the input from the oil temperature sensor. This gauge is only operational when the ignition switch is in the On or Start positions. The gauge electronic circuit board reads the input from the oil temperature sensor, then provides linear positioning of the gauge needle on the gauge scale based upon that input. The gauge electronics will move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The oil temperature gauge and the oil temperature sensor may be diagnosed using conventional diagnostic tools and methods. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Temperature Gauge > Component Information > Diagrams > Page 6997 Oil Temperature Gauge: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. The hard wired oil temperature gauge and gauge lighting circuits may be diagnosed and tested using conventional diagnostic tools and procedures. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. NOTE: When testing the oil temperature gauge by alternately opening and shorting the oil temperature sensor signal circuit, the gauge pointer may rotate in either direction (clockwise or counterclockwise) to reach the objective point on the gauge scale. This is a normal condition as the gauge electronics are programmed to move the pointer from its current position to the objective position in the direction that provides the shortest pointer travel distance. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Temperature Gauge > Component Information > Diagrams > Page 6998 Oil Temperature Gauge: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim molding (5) from the inside of the left A-pillar. 3. Remove the two nuts (2) that secure the oil temperature gauge (4) mounting studs to the mounting bracket (1) on the back of the A-pillar trim. 4. Remove the four screws (3) that secure the mounting bracket to the back of the A-pillar trim. 5. Remove the mounting bracket from the back of the A-pillar trim. 6. Push the gauge and the gauge pigtail wire (6) and connector out through the mounting hole on the face of the A-pillar trim. INSTALLATION 1. Position the oil temperature gauge (4) into the mounting hole on the face of the A-pillar trim (5). 2. Position the mounting bracket (1) to the back of the A-pillar trim with the gauge pigtail wire (6) and connector routed between the two lower mounting bracket screw bosses on the back of the A-pillar trim. 3. Install and tighten the four screws (3) that secure the mounting bracket to the back of the A-pillar trim. Tighten the screws to 1 N.m (9 in.lbs.). 4. Align and insert the two mounting studs on the back of the gauge housing through the appropriate holes in the mounting bracket. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Temperature Gauge > Component Information > Diagrams > Page 6999 5. Install and tighten the two nuts that secure the gauge mounting studs to the mounting bracket. Tighten the nuts to 0.5 N.m (5 in.lbs.). 6. Reinstall the trim molding onto the inside of the left A-pillar. 7. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Service Precautions Parking Brake Warning Lamp: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Service Precautions > Page 7003 Parking Brake Warning Lamp: Description and Operation BRAKE/PARK BRAKE INDICATOR A brake indicator is standard equipment on all instrument clusters. The brake indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The brake indicator consists of stencil-like cutouts of the word "BRAKE" and the International Control and Display Symbol icon for "Brake Failure" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "BRAKE" text and the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The brake indicator is serviced as a unit with the instrument cluster. The brake indicator gives an indication to the vehicle operator when the parking brake is applied, when there are certain brake hydraulic system malfunctions as indicated by a low brake hydraulic fluid level condition, or when the brake fluid level switch is disconnected. The brake indicator can also give an indication when certain faults are detected in the Antilock Brake System (ABS). This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Programmable Communications Interface (PCI) data bus, and a hard wired input from the park brake switch. The brake indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (RUN/START) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the brake indicator for the following reasons: Bulb Test - Each time the ignition switch is turned to the On position the brake indicator is illuminated by the instrument cluster for about two seconds as a bulb test. - Brake Lamp-On Message - Each time the cluster receives a lamp-on message from the CAB, the brake indicator will be illuminated. The CAB can also send brake lamp-on messages as feedback during ABS diagnostic procedures. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB, or until the ignition switch is turned to the Off position, whichever occurs first. - Park Brake Switch Input - Each time the cluster detects ground on the park brake switch sense circuit (park brake switch closed = park brake applied or not fully released) while the ignition switch is in the On position, the brake indicator flashes on and off. The indicator continues to flash until the park brake switch sense input to the cluster is an open circuit (park brake switch open = park brake fully released), or until the ignition switch is turned to the Off position, whichever occurs first. Actuator Test - Each time the instrument cluster is put through the actuator test, the brake indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The park brake switch on the park brake pedal mechanism provides a hard wired ground input to the instrument cluster circuitry through the park brake switch sense circuit whenever the park brake is applied or not fully released. The CAB continually monitors the ABS system circuits and sensors, including the brake fluid level switch on the brake master cylinder reservoir, to decide whether the system is in good operating condition. The CAB then sends the proper lamp-on or lamp-off messages to the instrument cluster. If the CAB sends a lamp-on message after the bulb test, it indicates that the CAB has detected a brake hydraulic system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. For further diagnosis of the brake indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster Diagnosis and Testing. The park brake switch input to the instrument cluster can be diagnosed using conventional diagnostic tools and methods. For proper diagnosis of the brake fluid level switch, the ABS, the CAB, the PCI data bus, or the electronic message inputs to the instrument cluster that control the brake indicator, a DRBIII scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Service Precautions > Page 7004 Parking Brake Warning Lamp: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE/PARK BRAKE INDICATOR The diagnosis found here addresses an inoperative brake indicator condition. If there are problems with several indicators in the instrument cluster. If the brake indicator stays on with the ignition switch in the On position and the park brake released, or comes on while driving, the brake system must be diagnosed and repaired prior to performing the following tests. (Refer to BRAKES DIAGNOSIS AND TESTING). If no brake system problem is found, the following procedures will help to locate a shorted or open circuit, or a faulty park brake switch input. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Fig.26 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 7008 Fig.27 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 7009 Switch-Parking Brake Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 7010 Parking Brake Warning Switch: Description and Operation The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the EMIC processing of the park brake switch sense input requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 7011 Parking Brake Warning Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: If the brake indicator stays on with the ignition switch in the On position and the park brake released, or comes on while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or a faulty park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 7012 Parking Brake Warning Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. INSTALLATION 1. Reach under the left end of the instrument panel to position park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 N.m (24 in.lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 7013 5. Turn the ignition switch to the On position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 A seatbelt indicator is standard equipment on all instrument clusters. The seatbelt indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The seatbelt indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Seat Belt" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The seatbelt indicator is serviced as a unit with the instrument cluster. The seatbelt indicator gives an indication to the vehicle operator of the status of the driver side front seatbelt. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hard wired input from the seatbelt switch in the driver side front seatbelt buckle through the seat belt indicator driver circuit. The seatbelt indicator also includes a programmable enhanced seatbelt reminder or "beltminder" feature that is enabled when the vehicle is shipped from the factory. This beltminder feature can be disabled and enabled by the customer using a specific programming event sequence, or by the dealer using a diagnostic scan tool. The seatbelt indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the seatbelt indicator for the following reasons: - Seatbelt Reminder Function - Each time the cluster receives a battery current input on the fused ignition switch output (run-start) circuit, the indicator will be illuminated as a seatbelt reminder for about six seconds, or until the ignition switch is turned to the Off position, whichever occurs first. This reminder function will occur regardless of the status of the seatbelt switch input to the cluster. - Driver Side Front Seatbelt Not Buckled - Beltminder Active - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the Start or On positions, the indicator will be illuminated. In addition, if the driver side front seat belt remains unbuckled about sixty seconds after the conclusion of the seatbelt reminder function with the vehicle speed greater than about 13 kilometers-per-hour (8 miles-per-hour), the seatbelt indicator will begin to cycle between flashing on and off for five seconds, then lighting solid for three seconds. The seatbelt indicator will continue to cycle between flashing and solid illumination for twelve complete cycles, until the seat belt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch is turned to the Off position, whichever occurs first. - Driver Side Front Seatbelt Not Buckled - Beltminder Inactive - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the Start or On positions, the indicator will be illuminated. The seatbelt indicator remains illuminated until the seat belt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch is turned to the Off position, whichever occurs first. - Airbag Indicator Backup - If the instrument cluster detects a fault in the airbag indicator circuit it will send a message indicating the fault to the Airbag Control Module (ACM), store a Diagnostic Trouble Code (DTC) in the cluster memory, then flash the seatbelt indicator on and off. The cluster will continue to flash the seatbelt indicator until the airbag indicator circuit fault is resolved, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the seatbelt indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The seatbelt switch is connected in series between ground and the seat belt indicator driver input to the instrument cluster. The seatbelt switch input to the instrument cluster circuitry may be diagnosed using conventional diagnostic tools and methods. For further diagnosis of the seatbelt indicator or the instrument cluster circuitry that controls the LED, refer to testing. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Service and Repair > Enhanced Seatbelt Reminder Programming Seat Belt Reminder Lamp: Service and Repair Enhanced Seatbelt Reminder Programming The seatbelt indicator also includes a programmable enhanced seatbelt reminder or "beltminder" feature that is enabled when the vehicle is shipped from the factory. This beltminder feature provides extended and modified visual seatbelt indicator and audible chime warning responses to an unbuckled driver side front seat belt. The beltminder feature may be disabled or enabled by the customer using the programming sequence that follows, or by the dealer using a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Service and Repair > Enhanced Seatbelt Reminder Programming > Page 7019 Seat Belt Reminder Lamp: Service and Repair Customer Programming Sequence NOTE: The following sequence of events must occur within sixty (60) seconds of the ignition switch being placed in the On position in order for the programming to be completed successfully. 1. With the ignition switch in any position except On or Start, buckle the driver side front seat belt. 2. Turn the ignition switch to the On position and wait for the seatbelt indicator reminder function to conclude (about six seconds). 3. Unbuckle and buckle the driver side front seat belt three or more times, ending with the belt buckled. 4. Turn the ignition switch to any position except On or Start to toggle the beltminder feature from its current setting (from active to inactive, or from inactive to active). A single chime tone will provide an audible confirmation that the programming sequence has been successfully completed. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams Dimmer Switch: Diagrams Lamp-Center Bezel Lamp CHMSL Aftermarket - 1 Way Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Description and Operation Door Switch: Description and Operation This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if faulty or damaged, the door latch unit must be replaced. The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the Electro-Mechanical Instrument Cluster (EMIC). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the PCI data bus, or the electronic messaging used to convey door ajar switch status to other modules in the vehicle. The most reliable, efficient, and accurate means to diagnose the EMIC, the PCI data bus, and both the hard wired and electronic message inputs and outputs affected by the door ajar switch inputs requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Sensor-Fuel Level Sending Unit Fuel Gauge Sender: Locations Sensor-Fuel Level Sending Unit The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Sensor-Fuel Level Sending Unit > Page 7031 Fuel Gauge Sender: Locations Fuel Pump Module The fuel pump module assembly is located on the top of the fuel tank. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7034 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7035 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7036 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7037 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7038 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7039 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7040 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7041 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7042 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7043 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7044 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7045 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7046 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7047 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7048 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7049 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7050 Fuel Gauge Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7051 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7052 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7053 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 7054 Fuel Gauge Sender: Description and Operation 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 variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit 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 diagnostic 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 7055 Fuel Gauge Sender: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation. 2. Disconnect 4-wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. Refer to Special Tools in Wiring for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4-wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/ Installation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation KEY-IN IGNITION SWITCH DESCRIPTION The key-in ignition switch is integral to the ignition switch, which is mounted on the left side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition key cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition key cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Fig.26 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 7062 Fig.27 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 7063 Switch-Parking Brake Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 7064 Parking Brake Warning Switch: Description and Operation The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the EMIC processing of the park brake switch sense input requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 7065 Parking Brake Warning Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: If the brake indicator stays on with the ignition switch in the On position and the park brake released, or comes on while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or a faulty park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the faulty park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 7066 Parking Brake Warning Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. INSTALLATION 1. Reach under the left end of the instrument panel to position park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 N.m (24 in.lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 7067 5. Turn the ignition switch to the On position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Diagrams Sensor-Water In Fuel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this model. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. The VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator VFD displays the following characters from left to right: "P," "R," "N," "D," "2," and "1". Respectively, these characters represent the park, reverse, neutral, drive, second gear, and first gear positions of the transmission gear selector lever on the steering column. The VFD illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps Off) the gear selector VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are On), the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a "Parade" mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned On during daylight hours. The gear selector indicator VFD is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission and automatic transmission model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by a dedicated Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the Off position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Programmable Communications Interface (PCI) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the gear selector indicator VFD will display all of its characters at once during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On models with a TCM, the TCM continually monitors the transmission range sensor, then sends the proper gear selector indicator position messages to the instrument cluster. On models without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. On models with a TCM, for proper diagnosis of the transmission range sensor, the TCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation Speedometer Head: Description and Operation A speedometer is standard equipment on all instrument clusters. The speedometer is located next to the tachometer, just to the right of center in the instrument cluster. The speedometer consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 210 degree primary scale on the gauge dial face. For all models except SRT-10 the speedometer reads left-to-right either from "0" to "120" mph, or from "0" to "200" km/h, depending upon the market for which the vehicle is manufactured. On SRT-10 the speedometer reads left-to-right either from "0" to "160" mph, or from "0" to "280" km/h, depending upon the market for which the vehicle is manufactured. Each version also has a secondary inner scale on the gauge dial face that provides the equivalent opposite units from the primary scale. Text appearing on the cluster overlay just below the hub of the speedometer needle abbreviates the unit of measure for the primary scale (i.e.: MPH or km/h), followed by the unit of measure for the secondary scale. The speedometer graphics for all models except SRT-10 are black (primary scale) and blue (secondary scale) against a white field. On SRT-10 the gauge graphics are black (primary scale) and gray (secondary scale) against a silver field and also includes a line of text identifying this as a "Performance Vehicle Operations" product. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black graphics appear blue-green and the blue or gray graphics appear light blue. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The speedometer is serviced as a unit with the instrument cluster. The speedometer gives an indication to the vehicle operator of the relative vehicle road speed. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus. The speedometer is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Vehicle Speed Message - Each time the cluster receives a vehicle speed message from the PCM it will calculate the correct vehicle speed reading and position the gauge needle at that relative speed position on the gauge scale. The cluster will receive a new vehicle speed message and reposition the gauge pointer accordingly about every 88 milliseconds. The gauge needle will continually be positioned at the relative vehicle speed position on the gauge scale until the vehicle stops moving, or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster fails to receive a speedometer message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the gauge needle will return to the left end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the speedometer needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the vehicle speed sensor or the Controller Anti-lock Brake (CAB) to determine the vehicle road speed. The PCM then sends the proper vehicle speed messages to the instrument cluster. For further diagnosis of the speedometer or the instrument cluster circuitry that controls the gauge, refer to testing. For proper diagnosis of the vehicle speed sensor, the CAB, the PCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the speedometer, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation Tachometer: Description and Operation A tachometer is standard equipment on all instrument clusters. The tachometer is located to the left of the speedometer, just to the left of center in the instrument cluster. The tachometer consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 210 degree scale on the gauge dial face. The tachometer reads left-to-right from "0" to "7" for gasoline engines. On vehicles with a diesel engine, the scale reads from "0" to "5". On all models except SRT-10, the text "RPM X 1000" is imprinted on the cluster overlay directly below the hub of the tachometer needle. On SRT-10 models the text "X 1000 RPM" is imprinted on the cluster overlay directly below the hub of the tachometer needle. This text identifies that each number on the tachometer scale is to be multiplied by 1000 rpm. On all models except SRT-10 the tachometer graphics are black against a white field, making them clearly visible within the instrument cluster in daylight. On SRT-10 the tachometer graphics are black against a silver field except for red graduations beginning at the "6" increment and at each 250 rpm increment to the "7" at the high end of the scale. The SRT-10 tachometer also includes the text, "Premium Unleaded Fuel Only." In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by a replaceable incandescent bulb and holder unit located on the instrument cluster electronic circuit board. The tachometer is serviced as a unit with the instrument cluster. The tachometer gives an indication to the vehicle operator of the engine speed. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The tachometer is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Speed Message - Each time the cluster receives an engine speed message from the PCM or ECM it will calculate the correct engine speed reading and position the gauge needle at that relative engine speed position on the gauge scale. The cluster will receive a new engine speed message and reposition the gauge pointer accordingly about every 88 milliseconds. The gauge needle will continually be repositioned at the relative engine speed position on the gauge scale until the engine stops running, or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster fails to receive an engine speed message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the gauge needle will return to the left end of the gauge scale. Actuator Test - Each time the cluster is put through the actuator test, the tachometer needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry On vehicles with a gasoline engine, the PCM continually monitors the crankshaft position sensor to determine the engine speed. On vehicles with a diesel engine, the ECM continually monitors the engine speed sensor to determine the engine speed. The PCM or ECM then sends the proper engine speed messages to the instrument cluster. For further diagnosis of the tachometer or the instrument cluster circuitry that controls the gauge, refer to testing. For proper diagnosis of the crankshaft position sensor, the engine speed sensor, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the tachometer, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower right quadrant of the instrument cluster, below the oil pressure gauge. The engine coolant temperature gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "C" (or Cold) to "H" (or Hot) for gasoline engines except SRT-10. On SRT-10 models, the scale reads from "60"° C to "120"° C in markets where a metric instrument cluster is specified, or from "140"° F to "260"° F in all other markets. On vehicles with a diesel engine, the scale reads from "60"° C to "120"° C in markets where a metric instrument cluster is specified, or from "140"° F to "245"° F in all other markets. An International Control and Display Symbol icon for "Engine Coolant Temperature" is located on the cluster overlay directly below the left end of the gauge scale. On all models except SRT-10 the engine coolant temperature gauge graphics are black against a white field except for two red graduations at the high end of the gauge scale. On SRT-10 the gauge graphics are black against a silver field except for a single red zone at the high end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black gauge graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives a message from the PCM or ECM indicating the engine coolant temperature is between the low end of normal [about 54° C (130° F) for gasoline engines except SRT-10, or about 60° C (140° F) for SRT-10 and diesel engines] and the high end of normal [about 122° C (252° F) for gasoline engines, about or about 116° C (240° F) for diesel engines], the gauge needle is moved to the actual relative temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives a message from the PCM or ECM indicating the engine coolant temperature is below the low end of normal [about 54° C (130° F) for gasoline engines except SRT-10, or about 60° C (140° F) for SRT-10 and diesel engines], the gauge needle is held at the graduation on the far left end of the gauge scale. The gauge needle remains at the left end of the gauge scale until the cluster receives a message from the PCM or ECM indicating that the engine temperature is above about 54° C (130° F) for gasoline engines except SRT-10, or about 60° C (140° F) for SRT-10 and diesel engines, or until the ignition switch is turned to the Off position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine coolant temperature is above about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, the gauge needle is moved into the red zone at the far right end of gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The gauge needle remains in the red zone and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine temperature is below about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled off and then on again by the appropriate engine temperature messages from the PCM or ECM. - Communication Error - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the engine coolant temperature gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. On vehicles with a diesel engine, the ECM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM or ECM then sends the proper engine coolant temperature messages to the instrument cluster. If the instrument cluster turns on the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the engine coolant temperature gauge, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > System Information > Description and Operation Tire Monitoring System: Description and Operation Chrysler provides no information on a Tire Pressure Monitoring System for this vehicle. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Upshift Indicator > Component Information > Description and Operation Upshift Indicator: Description and Operation An upshift indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with a manual transmission, or on vehicles equipped with a manual transmission but sold in a market where this is not required equipment, this indicator is electronically disabled. The upshift indicator consists of an upward pointed arrow icon, which appears on the right side of the electronic gear selector indicator Vacuum Fluorescent Display (VFD) unit. The VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The icon appears in a blue-green color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The upshift indicator is serviced as a unit with the instrument cluster. The upshift indicator gives an indication to the vehicle operator when the manual transmission should be shifted to the next highest gear in order to achieve the best fuel economy. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles with a diesel engine over the Programmable Communications Interface (PCI) data bus. The upshift indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the upshift indicator for the following reasons: - Upshift Lamp-On Message - Each time the cluster receives an upshift lamp-on message from the PCM or ECM indicating the engine speed and load conditions are right for a transmission upshift to occur, the upshift indicator is illuminated. The indicator remains illuminated until the cluster receives an upshift lamp-off message from the PCM or ECM, or until the ignition switch is turned to the Off position, whichever occurs first. The PCM or ECM will normally send an upshift lamp-off message three to five seconds after a lamp-on message, if an upshift is not performed. The indicator will then remain off until the vehicle stops accelerating and is brought back into the range of indicator operation, or until the transmission is shifted into another gear. - Actuator Test - Each time the cluster is put through the actuator test, the upshift indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the engine speed and load conditions to determine the proper fuel and ignition requirements. On vehicles with a diesel engine, the ECM continually monitors the engine speed and load conditions to determine the proper fuel requirements. The PCM or ECM then sends the proper upshift indicator lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the upshift indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the upshift indicator, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation Volt Meter Gauge: Description and Operation A voltage gauge is standard equipment on all instrument clusters. The voltage gauge is located in the upper left quadrant of the instrument cluster, above the fuel gauge. The voltage gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "L" (or Low) to "H" (or High) for gasoline engines except SRT-10. On SRT-10 models, the scale reads from "10" to "18" volts. On vehicles with a diesel engine, the scale reads from "8" to "18" volts. An International Control and Display Symbol icon for "Battery Charging Condition" is located on the cluster overlay, directly below the right end of the gauge scale. On all models except SRT-10 the voltage gauge graphics are black against a white field except for a single red graduation at each end of the gauge scale. On SRT-10 the gauge graphics are black against a silver field except for a single red graduation at the left end of the gauge scale and two red graduations at the right end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by a replaceable incandescent bulb and holder unit located on the instrument cluster electronic circuit board. The voltage gauge is serviced as a unit with the instrument cluster. The voltage gauge gives an indication to the vehicle operator of the electrical system voltage. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Programmable Communications Interface (PCI) data bus. The voltage gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the left end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - System Voltage Message - Each time the cluster receives a system voltage message from the PCM or ECM indicating the system voltage is between about 9.5 volts and about 15 volts, the gauge needle is moved to the relative voltage position on the gauge scale. - System Voltage Low (Charge Fail) Message - Each time the cluster receives three consecutive messages from the PCM or ECM indicating the electrical system voltage is less than about 9 volts (charge fail condition) or that the battery temperature sensor input is an open circuit, the gauge needle is moved to the graduation on the far left end of the gauge scale and the check gauges indicator is illuminated. The gauge needle remains at the far left end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a single message from the PCM or ECM indicating the electrical system voltage is greater than about 9.5 volts (but less than about 15.5 volts), or until the ignition switch is turned to the Off position, whichever occurs first. On vehicles equipped with the optional diesel engine, the ECM is programmed to restrict the voltage gauge needle to a position above the graduation on the far left end of the gauge scale and suppress the check engine indicator operation until after the engine intake manifold air heater has completed a pre-heat or post-heat cycle. - System Voltage High Message - On all models except SRT-10, each time the cluster receives three consecutive messages from the PCM or ECM indicating the electrical system voltage is greater than about 15.5 volts, the gauge needle is moved to the graduation on the far right end of the gauge scale and the check gauges indicator is illuminated. The gauge needle remains at the right end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating the electrical system voltage is less than about 15.0 volts (but greater than about 9.5 volts), or until the ignition switch is turned to the Off position, whichever occurs first. On SRT-10, each time the cluster receives three consecutive messages from the PCM indicating the electrical system voltage is greater than about 15.5 volts, the gauge needle is moved to the 16 volt graduation of the gauge scale and the check gauges indicator is illuminated. The gauge needle remains at or above the 16 volt graduation of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM indicating the electrical system voltage is less than about 15.0 volts (but greater than about 9.5 volts), or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster fails to receive a system voltage message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the cluster will move the gauge needle to the far left end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the voltage gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry On vehicles with a gasoline engine, the PCM continually monitors the system voltage to control the generator output. On vehicles with a diesel engine, the ECM continually monitors the system voltage to control the generator output. The PCM or ECM then sends the proper system voltage messages to the instrument cluster. For further diagnosis of the voltage gauge or the instrument cluster circuitry that controls the gauge, refer to testing. If the instrument cluster turns on the check gauges indicator due to a charge fail or voltage high condition, it may indicate that the charging system requires service. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation > Page 7092 For proper diagnosis of the charging system, the PCM, the ECM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the voltage gauge, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Diagrams Sensor-Water In Fuel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7103 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7104 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7105 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7106 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7107 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7108 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7109 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7110 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7111 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7112 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7113 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7114 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7115 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7116 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7117 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7118 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7119 Backup Lamp Switch: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7120 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7121 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7122 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7123 Backup Lamp Switch: Connector Views Switch-Back Up Lamp (Gas) Switch-Back Up Lamp (SRT M/T) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7124 Backup Lamp Switch: Electrical Diagrams Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Page 7125 Backup Lamp Switch: Description and Operation Vehicles equipped with a manual transmission have a normally open, spring-loaded plunger type back-up lamp switch. The backup lamp switch is located in a threaded hole on the side of the manual transmission housing. The backup lamp switch has a threaded body and a hex formation near the plunger end of the switch, and an integral connector at the opposite end of the switch. When installed, only the connector and the hex formation are visible on the outside of the transmission housing. Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. The TRS is described in further detail elsewhere in this service information. The backup lamp switch cannot be adjusted or repaired and, if faulty or damaged, the entire switch unit must be replaced. The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the automatic transmission. The backup lamp switch controls the flow of battery voltage to the backup lamp bulbs through an output on the back-up lamp feed circuit. The switch plunger is mechanically actuated by the gearshift mechanism within the transmission, which will depress the switch plunger and close the switch contacts whenever the reverse gear has been selected. The switch receives battery voltage through a fuse in the Integrated Power Module (IPM) on a fused ignition switch output (run) circuit whenever the ignition switch is in the On position. A take out of the engine wire harness connects the backup lamp switch to the vehicle electrical system. The backup lamp switch and circuits can be tested using conventional diagnostic tools and methods. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Page 7126 Backup Lamp Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Raise and support the vehicle. 3. Locate and disconnect the engine wire harness connector for the backup lamp switch. 4. Check for continuity between the two terminal pins in the backup lamp switch connector. a. With the gear selector lever in the Reverse position, there should be continuity. b. With the gear selector lever in any position other than Reverse, there should be no continuity. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Description and Operation Brake Lamp Relay: Description and Operation DESCRIPTION The exterior lighting system for this model include the following components: ^ Backup Lamps ^ Brake Lamps ^ Daytime Running Lamps ^ Front Fog Lamps ^ Hazard Warning Lamps ^ Headlamps ^ Park Lamps ^ Turn Signal Lamps Other components of the exterior lighting system for this model include: ^ Backup Lamp Switch ^ Brake Lamp Switch ^ Front Control Module ^ Front Fog Lamp Relay See: Maintenance/Fuses and Circuit Breakers/Relay Box ^ Hazard Switch ^ Multi-Function Switch ^ Park Lamp Relay See: Maintenance/Fuses and Circuit Breakers/Relay Box ^ Trailer Tow Connectors Some of the interior and exterior lighting functions are governed by the front control module. The headlamp, dome, and door ajar switches provide signals to the instrument cluster. The instrument cluster sends a J1850 message to the front control module to enable the necessary components for illumination. Hard wired circuitry connects the exterior lighting system components to the electrical system of the vehicle. Refer to the appropriate wiring information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations Brake Light Switch: Component Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 7135 Brake Light Switch: Connector Locations Fig.32 Steering Column Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 7136 Fig.37 Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 7137 Fig.39 Left Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7138 Brake Lamp Switch Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7139 Brake Light Switch: Description and Operation The plunger type brake lamp switch is mounted on a bracket attached to the base of the steering column, under the instrument panel. CAUTION: The switch can only be adjusted during initial installation. If the switch is not adjusted properly a new switch must be installed. The brake lamp switch is hard wired to the Center High Mount Stop Lamp (CHMSL) and also monitored by the Instrument Cluster for use by the brake lamp, speed control brake sensor circuits and electronic brake distribution (EBD). The brake lamp circuit is open until the plunger is depressed. The speed control and brake sensor circuits are closed until the plunger is depressed. When the brake lamp switch transitions, the CHMSL transitions and instrument cluster transmits a brake applied/released message on the bus. The Integrated Power Module (IPM) will then transition the brake lamps. When the brake light switch is activated, the Powertrain Control Module (PCM) receives an input indicating that the brakes are being applied. After receiving this input, the PCM maintains idle speed to a scheduled rpm through control of the Idle Air Control (IAC) motor. The brake switch input is also used to disable vent and vacuum solenoid output signals to the speed control servo. Vehicles equipped with the speed control option use a dual function brake lamp switch The PCM monitors the state of the dual function brake lamp switch. The brake switch is equipped with three sets of contacts, one normally open and the other two normally closed (brakes disengaged) The PCM sends a 12 volt signal to one of the normally closed contacts in the brake switch, which is returned to the PCM as a brake switch state signal With the contacts closed, the 12 volt signal is pulled to ground causing the signal to go low The low voltage signal, monitored by the PCM, indicates that the brakes are not applied When the brakes are applied, the contacts open, causing the PCM's output brake signal to go high, disengaging the speed control, cutting off PCM power to the speed control solenoids. The second set of normally closed contacts supplies 12 volts from the PCM any time speed control is turned on Through the brake switch, voltage is routed to the speed control servo solenoids The speed control solenoids (vacuum, vent and dump) are provided this voltage any time the speed control is ON and the brakes are disengaged. When the driver applies the brakes, the contacts open and voltage is interrupted to the solenoids The normally open contacts are fed battery voltage When the brakes are applied, battery voltage is supplied to the brake lamps. The brake lamp switch can only be adjusted once That is at the initial installation of the switch If the switch is not adjusted properly or has been removed, a new switch must be installed and adjusted. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7140 Brake Light Switch: Testing and Inspection BRAKE LAMP SWITCH The brake lamp switch can be tested with an ohm-meter The ohmmeter is used to check continuity between the pin terminals SWITCH CIRCUIT IDENTIFICATION - Terminals 1 and 2 brake lamp circuit - Terminals 3 and 4 RWAL/ABS module and Powertrain Control Module (PCM) circuit - Terminals 5 and 6 speed control circuit SWITCH CONTINUITY TEST NOTE: Disconnect switch harness before testing switch continuity With switch plunger extended, attach test leads to pins 1 and 2 Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 3 and 4 Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 5 and 6 Replace switch if meter indicates no continuity. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7141 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the switch harness 2. Press and hold the brake pedal in applied position 3. Rotate the switch counterclockwise about 30° to align the switch lock tab with the notch in bracket 4. Pull the switch rearward out of the mounting bracket and release the brake pedal INSTALLATION 1. Press and hold the brake pedal down. 2. Align the tab on the new switch with the notch in the switch bracket.Insert the switch in the bracket and turn it clockwise about 30° to lock it in place. 3. Connect the harness wires to the switch. 4. Release the brake pedal. 5. Move the release lever on the switch parallel with the connector to engage the switch plunger. The switch is now adjusted and can not be adjusted again. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Description and Operation Cargo Lamp: Description and Operation A cargo lamp indicator is standard equipment on all instrument clusters. The cargo lamp indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The cargo lamp indicator consists of a stencil-like cutout of the words "CARGO LAMP" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the "CARGO LAMP" text to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The cargo lamp indicator is serviced as a unit with the instrument cluster. The cargo lamp indicator gives an indication to the vehicle operator when the exterior cargo lamp is illuminated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, a hard wired multiplex input received by the cluster from the panel lamps dimmer switch on the headlamp dimmer switch mux circuit, and electronic unlock request messages received from the optional Remote Keyless Entry (RKE) module. The cargo lamp indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the cargo lamp indicator for the following reasons: - Cargo Lamp-On Input - Each time the cluster detects a cargo lamp-on input from the headlamp switch on the headlamp dimmer switch mux circuit, the cargo lamp and the cargo lamp indicator will be illuminated. The cargo lamp and indicator remain illuminated until the cluster receives a cargo lamp-off input from the headlamp switch, until the cluster has completed an interior lamps load shed (about five minutes), or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the cargo lamp indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The instrument cluster continually monitors the headlamp dimmer switch circuit to determine the proper interior lamps features and panel lamps illumination levels to provide. The cluster then energizes and de-energizes a low side driver circuit to control the exterior cargo lamp. Each time the instrument cluster energizes the cargo lamp driver and the ignition switch is in the On or Start positions, the cluster also turns on the cargo lamp indicator. For further diagnosis of the cargo lamp indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the cargo lamp or the headlamp switch inputs to the instrument cluster that control the cargo lamp indicator, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Description and Operation > Page 7145 Cargo Lamp: Service and Repair NOTE: The Center High Mounted Stop Lamp (CHMSL) houses three bulbs. The center bulb is the CHMSL bulb and illuminates through a red lens, while the two outboard bulbs are for the cargo lamps and illuminate through clear lenses. The bulb types and service procedures are identical for all three of these bulbs. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the two screws that secure the CHMSL to the rear cab roof header panel. 3. Pull the CHMSL lens and housing (1) away from the header panel far enough to access the lamp wiring and bulb sockets on the back of the lamp. 4. Firmly grasp the socket (3) on the back of the lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the socket and bulb straight out from the keyed opening in the housing. 6. Pull the base of the bulb (2) straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the bulb (2) with the socket (3). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of CHMSL housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Position the CHMSL into the opening in the rear cab roof header panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Description and Operation > Page 7146 7. Install and tighten the two screws (passenger side first) that secure the CHMSL to the header panel. Tighten the screws to 2 N.m (20 in.lbs.). 8. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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. Disconnect and isolate the battery negative cable. 2. Remove the CHMSL from the roof panel. 3. Turn the bulb socket 1/4 turn counterclockwise. 4. Separate the socket from the lamp. 5. Remove the bulb. INSTALLATION 1. Position the bulb in the socket and press into place. 2. Position the socket in the lamp. 3. Turn the bulb socket 1/4 turn clockwise. 4. Install the CHMSL. 5. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Clearance Lamp > Clearance Lamp Bulb > Component Information > Service and Repair Clearance Lamp Bulb: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cab clearance lamp (1) from the roof panel. 3. Pull the base of the bulb (3) straight out of the socket (2). INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the bulb (3) with the socket (2). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Reinstall the cab clearance lamp (1) onto the roof panel. 4. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Locations > Page 7159 Lamp-Glove Box Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Locations > Page 7160 Glove Box Lamp: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Reach through the window (3) in the instrument panel glove box opening (1) to access the bulb on the side of the glove box lamp and switch unit (2). 4. Pull the base of the bulb straight out of the bulb holder. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Reach through the window (3) in the instrument panel glove box opening (1) to align the base of the bulb with the bulb holder on the side of the glove box lamp and switch unit (2). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Locations > Page 7161 2. Push the bulb straight into the bulb holder until the base is firmly seated. 3. Close the glove box door. 4. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box from the instrument panel. 3. Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to access the instrument panel wire harness connector on the glove box lamp and switch. 4. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the glove box lamp and switch unit. 5. Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to depress the retaining tabs on the top and bottom of the glove box lamp and switch housing. 6. While holding the retaining tabs depressed, push the glove box lamp and switch unit out through the hole in the mounting bracket on the instrument panel glove box opening upper reinforcement. 7. Remove the glove box lamp and switch unit from the instrument panel. INSTALLATION 1. Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to feed the instrument panel wire harness connectors out through the hole in the glove box lamp and switch housing mounting bracket. 2. Position the glove box lamp and switch unit to the instrument panel. 3. Reconnect the instrument panel wire harness connector to the connector receptacle on the back of the glove box lamp and switch unit. 4. Push the glove box lamp and switch unit into the hole in the mounting bracket on the instrument panel glove box opening upper reinforcement. 5. Install the glove box onto the instrument panel. 6. Close the glove box. 7. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Description and Operation Daytime Running Lamp: Description and Operation LAMPS/LIGHTING - EXTERIOR The exterior lighting system for this model include the following components: Backup Lamps - Brake Lamps - Daytime Running Lamps - Front Fog Lamps - Hazard Warning Lamps - Headlamps - Park Lamps - Turn Signal Lamps Other components of the exterior lighting system for this model include: Backup Lamp Switch - Brake Lamp Switch - Front Control Module - Front Fog Lamp Relay - Hazard Switch - Multi-Function Switch - Park Lamp Relay - Trailer Tow Connectors Some of the interior and exterior lighting functions are governed by the front control module. The headlamp, dome, and door ajar switches provide signals to the instrument cluster. The instrument cluster sends a J1850 message to the front control module to enable the necessary components for illumination. Hard wired circuitry connects the exterior lighting system components to the electrical system of the vehicle. Refer to the appropriate wiring information. DAYTIME RUNNING LAMPS Power is reduced using pulse-width modulation to the high beams, where by the power is switched on and off rapidly instead of remaining on continuously. The duration and interval of the power pulses is programmed into the Front Control Module (FCM). See: Maintenance/Fuses and Circuit Breakers/Fuse/Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Description and Operation > Page 7168 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams Dimmer Switch: Diagrams Lamp-Center Bezel Lamp CHMSL Aftermarket - 1 Way Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair Dome Lamp Bulb: Service and Repair NOTE: There are two types of dome lamps available in this model: one with a switch (2) that is activated by depressing the lamp lens, and one without a switch. The bulb types and service procedures are identical for both of these lamps. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Insert the tip of a small flat-bladed screwdriver into the notch on one side of the dome lamp between the lens (4) and the lamp housing (1). 3. Gently pry the notched edge of the lens downward until it unsnaps from the housing. 4. Swing the notched end of the lens downward far enough to access the bulb (3). 5. Carefully unsnap the bulb from the two bulb holders within the dome lamp housing. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the ends of the bulb (3) with the two bulb holders within the dome lamp housing (1). 2. Carefully press the bulb firmly and evenly into the bulb holders until it snaps into place. 3. Swing the notched end of the lens (4) up into position against the housing, then press upward on the lens firmly and evenly until it snaps into the housing. 4. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Description and Operation Door Switch: Description and Operation This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if faulty or damaged, the door latch unit must be replaced. The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the Electro-Mechanical Instrument Cluster (EMIC). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the PCI data bus, or the electronic messaging used to convey door ajar switch status to other modules in the vehicle. The most reliable, efficient, and accurate means to diagnose the EMIC, the PCI data bus, and both the hard wired and electronic message inputs and outputs affected by the door ajar switch inputs requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair Fog/Driving Lamp Bulb: Service and Repair FOG LAMPS REMOVAL NOTE: The fog lamps are serviced from the rearward side of the front bumper. 1. Disconnect and isolate the battery negative cable. 2. Disengage fog lamp harness connector. 3. Remove the bolts attaching the fog lamp to the bumper. 4. Separate fog lamp from bumper. INSTALLATION 1. Position fog lamp in bumper. 2. Install the bolts attaching the fog lamp to the bumper. 3. Connect fog lamp harness connector. 4. Connect the battery negative cable. 5. Check for proper operation and beam alignment. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 7186 Fog/Driving Lamp Relay: Description and Operation The front fog lamp relay is located in the Power Distribution Center (PDC)See: Maintenance/Fuses and Circuit Breakers/Relay BoxApplications and ID in the engine compartment of the vehicle. The front fog lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs by five integral male spade-type terminals that extend from the bottom of the relay base. The front fog lamp relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The front fog lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the front fog lamps. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The front fog lamp relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC). The inputs and outputs of the front fog lamp relay include: - Common Feed Terminal - The common feed terminal (30) receives battery voltage at all times from a fuse in the PDC through a fused B(+) circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a front fog lamp relay control circuit. The FCM controls front fog lamp operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery voltage at all times from a fuse in the PDC through a fused B(+) circuit. - Normally Open Terminal - The normally open terminal (87) is connected to the front fog lamps through a front fog lamp relay output circuit and provides battery voltage to the front fog lamps whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is not connected in this application. The front fog lamp relay can be diagnosed using conventional diagnostic tools and methods. Refer to the appropriate wiring information for diagnosis and testing of the front fog lamp micro-relay and for complete wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 7187 Fog/Driving Lamp Relay: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. 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 cover for the Power Distribution Center (PDC). 3. Remove the front fog lamp relay by grasping it firmly and pulling it straight out from the receptacle in the PDC. INSTALLATION 1. Position the front fog lamp relay to the proper receptacle in the Power Distribution Center (PDC). 2. Align the front fog lamp relay terminals with the terminal cavities in the PDC. 3. Press firmly and evenly on the top of the front fog lamp relay until the terminals are fully seated in the PDC. 4. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Description and Operation Hazard Warning Switch: Description and Operation The hazard switch is activated by a push button located in the multifunction switch on the top of the steering column between the steering wheel and instrument cluster. The hazard warning system allows the vehicle operator to provide other vehicle operators in the near proximity an optical indication that the vehicle is disabled or an obstacle to traffic flow. The hazard warning system has battery voltage at all times, regardless of ignition position. The instrument cluster monitors the multiplexed multifunction switch operation. When the hazard warning switch is activated, the instrument cluster will send a J1850 bus message to the Front Control Module (FCM), then activate the two turn signal indicators and audible click in the instrument cluster. The FCM will then activate the necessary relays in the Power Distribution Center (PDC) to begin flashing both the front and rear turn signal indicator lamps. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the headlamp unit. 3. Separate the socket from the headlamp unit. INSTALLATION CAUTION: Do Not Touch the bulb glass with fingers or other oily surfaces. Reduced bulb life will result. 1. Install the socket into the headlamp unit. 2. Install the headlamp unit. 3. Connect the negative battery cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7199 Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7200 Left Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7201 Switch-Headlamp Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7202 Headlamp Switch: Description and Operation The multiplexed headlamp switch is located on the instrument panel. The headlamp switch controls the parking lamps, fog lamps and the headlamps. A separate switch in the module controls the interior lamps and instrument cluster illumination. This switch also contains a rheostat for controlling the illumination level of the cluster lamps. The multiplexed headlamp switch has an off, parking lamp, fog lamp and a headlamp on position. High beams are controlled by the multiplexed multifunction switch on the steering column. The fog lamps are illuminated by pulling back on the headlamp switch knob when in the parking lamp or headlamp ON position.The headlamp switch cannot be repaired. It must be replaced. The Instrument Cluster monitors the headlamp and multifunction switch operation. When the headlamp switch is rotated to the parking lamp or On position the Instrument Cluster sends a J1850 message to the Front Control Module, which is mated to the power distribution center to become the Integrated Control Module, to illuminate the appropriate bulbs. When the multifunction switch is activated to the optical horn or high beam position the Instrument Cluster illuminates the high beam indicator and sends a J1850 message to the Front Control Module to illuminate the appropriate bulbs. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7203 Headlamp Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Remove the left bezel and the headlamp switch from the instrument panel as a unit. 2. Disconnect the instrument panel wire harness connector from the back of the headlamp switch. Headlamp Switch Tests 3. Using an ohmmeter, test the resistance or continuity between the terminals of the switch as shown in the Headlamp Switch Tests table. 4. If the switch fails any of the tests, replace the faulty headlamp switch as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7204 Headlamp Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left instrument panel bezel. 3. Disconnect the harness connector. 4. Remove the screws that secure the headlamp switch to the instrument panel bezel. 5. Remove the headlamp switch from the instrument panel bezel. INSTALLATION 1. Position the headlamp switch to the left instrument panel bezel and secure with screws.Tighten the screws to 2.2 Nm (20 in. lbs.). 2. Reconnect the instrument panel wire harness connector for the headlamp switch. 3. Position the left instrument panel bezel on to the instrument panel. 4. Install the cluster bezel onto the instrument panel. 5. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Description and Operation Hi-Beam Indicator Lamp: Description and Operation A high beam indicator is standard equipment on all instrument clusters. This indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The high beam indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "High Beam" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A blue Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in blue through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The high beam indicator is serviced as a unit with the instrument cluster. The high beam indicator gives an indication to the vehicle operator whenever the headlamp high beams are illuminated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hard wired multiplex input received by the cluster from the headlamp beam select switch circuitry of the multi-function switch on the washer/beam select switch mux circuit. The high beam indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused B(+) circuit. Therefore, the LED can be illuminated regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the high beam indicator for the following reasons: High Beam Headlamps-On Input - Each time the cluster detects a high beam headlamps-on input from the headlamp beam select switch circuitry of the multi-function switch on the washer/beam select switch mux circuit, the headlamp high beams and the high beam indicator will be illuminated. The headlamp high beams and the high beam indicator remain illuminated until the cluster receives a high beam headlamps-off input from the multi-function switch, or until the exterior lamp load shedding (battery saver) timed interval expires, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the high beam indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The instrument cluster continually monitors the headlamp switch and the multi-function switch to determine the proper headlamp low beam and high beam control. The instrument cluster then sends the proper low beam and high beam lamp-on and lamp-off messages to the Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus and turns the high beam indicator on or off accordingly. For further diagnosis of the high beam indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the headlamps, or the headlamp switch and multi-function switch inputs to the instrument cluster that control the high beam indicator, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Diagrams Switch-Horn Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Diagrams > Page 7212 Horn Switch: Description and Operation The horn switch is molded into the driver airbag. The horn switch can not be serviced separately. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Diagrams > Page 7213 Horn Switch: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the horn system requires the use of a scan tool and the proper Diagnostic Procedures information. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Description and Operation Lamp Out Indicator: Description and Operation A lamp out indicator is standard equipment on all instrument clusters. The lamp out indicator consists of the words "LAMP OUT", which appear in the lower portion of the odometer/trip odometer Vacuum-Fluorescent Display (VFD) unit. The odometer/trip odometer VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the lamp out indicator from being clearly visible when it is not illuminated. The words "LAMP OUT" appear in an amber color and at the same lighting level as the odometer/trip odometer information when they are illuminated by the instrument cluster electronic circuit board. The lamp out indicator is serviced as a unit with the VFD in the instrument cluster. The lamp out indicator gives an indication to the vehicle operator when an exterior lamp has failed. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus. The lamp out indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the lamp out indicator for the following reasons: - Lamp Out Indicator Lamp-On Message - Each time the cluster receives a lamp out indicator lamp-on message from the FCM indicating that an inoperative headlamp (low or high beam), turn signal lamp, or brake lamp (excluding Center High Mounted Stop Lamp [CHMSL]) circuit has been detected with the ignition switch in the On position, the lamp out indicator is illuminated solid. The indicator remains illuminated until the cluster receives a lamp out indicator lamp-off message from the FCM or until the ignition switch is turned to the Off position, whichever occurs first. If the lamp-on message is received when the ignition is first turned to the On position, the lamp out indicator is flashed at a fast rate (1 Hertz) for about thirty seconds before illuminating solid. - Actuator Test - Each time the cluster is put through the actuator test, the lamp out indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The FCM monitors each of the headlamp, turn signal lamp, and brake lamp (except CHMSL) circuits to determine the condition of these exterior lamps. The FCM then sends the proper lamp out indicator lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the lamp out indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the exterior lighting system circuits, the FCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the lamp out indicator, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair License Plate Bulb: Service and Repair NOTE: This procedure is for pick-up models only. On cab and chassis models the license plate lamp is integral to the left rear lamp unit. The park/ brake/turn signal bulb within the left rear lamp unit provides illumination for the license plate lamp function on all cab and chassis models. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Reach under the rear bumper near the center to access the back of either of the two license plate lamp housings (3). 3. Firmly grasp the socket (2) on the back of the housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb (1) straight out from the keyed opening in the housing. 5. Pull the base of the bulb straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the bulb (1) with the license plate lamp socket (2). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the license plate lamp housing (3). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Without Sunroof Map Light Bulb: Service and Repair Without Sunroof NOTE: On vehicles equipped with an optional overhead console the standard front dome lamp is replaced by two combination dome and reading lamps that are integral to the console housing. Each of these lamps is controlled by the door ajar switches on the courtesy lamp circuit, but also are independently controlled by a switch that is activated by depressing the lamp lens. The bulb types and service procedures are identical for both of these lamps. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a small thin-bladed screwdriver, gently pry between each side of the lamp lens and the overhead console housing (1) to unsnap the pivot tabs (3) on the lens from the pivots in the lamp housing. 3. With the lens disengaged from both pivots, pull the front of the lens forward far enough to disengage the tab (2) on the rear edge of the lens from the slot in the rear of the overhead console lamp housing. 4. Remove the lens from the housing. 5. Carefully unsnap the bulb (2) from the two bulb holders (1) within the overhead console lamp housing. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Without Sunroof > Page 7226 1. Align the ends of the bulb (2) with the two bulb holders (1) within the overhead console lamp housing. 2. Carefully press the bulb firmly and evenly into the bulb holders until it snaps into place. 3. Position the lens tab (2) into the slot in the rear of the overhead console (1) lamp housing. 4. Align the pivot tabs (3) on each side of the lens with the pivots within the overhead console lamp housing. 5. Press firmly and evenly on the lens over both pivot locations until both pivot tabs snap back onto the pivots within the housing. 6. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Without Sunroof > Page 7227 Map Light Bulb: Service and Repair With Sunroof NOTE: On vehicles equipped with an optional overhead console the standard front dome lamp is replaced by two combination dome and reading lamps that are integral to the console housing. Each of these lamps is controlled by the door ajar switches on the courtesy lamp circuit, but also are independently controlled by a switch that is activated by depressing the lamp lens. The bulb types and service procedures are identical for both of these lamps. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (3) from the head-liner. 3. Firmly grasp the back of the reading lamp bulb socket (1) and unsnap it from the overhead console lamp housing. 4. Pull the socket and bulb (2) straight out from the keyed opening in the lamp housing. 5. Pull the base of the bulb straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the overhead console reading lamp bulb (2) with the socket (1). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of lamp housing in the overhead console. 4. Insert the socket and bulb into the housing and press firmly on the back of the socket until it snaps into place and is firmly seated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Without Sunroof > Page 7228 5. Reinstall the overhead console onto the headliner. 6. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Rear Fender Marker Lamp Bulb: Service and Repair Rear Fender NOTE: These lamps are used on pick-up models with dual rear wheels. A lamp with an amber lens is located on the rear fender ahead of each rear wheel opening, and a lamp with a red lens is located on the rear fender behind each rear wheel opening. The bulb types and service procedures are identical for all four of these lamps. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using hand pressure, press the rear edge of the rear fender marker lamp lens/housing (4) toward the front of the vehicle against the spring pressure of the retaining clip, then pull the rear edge of the lamp outward to disengage it from the mounting hole in the rear fender. 3. Pull the lamp out from the rear fender far enough to access the bulb socket (1) on the back of the lamp lens/housing. 4. Firmly grasp the bulb socket on the back of the lamp lens/housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the socket and bulb straight out from the keyed opening in the housing. 6. Pull the base of the bulb (3) straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the bulb (3) with the socket (1). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Be certain that a rubber O-ring seal (2) is properly installed and in good condition around the base of the bulb socket. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Rear Fender > Page 7234 4. Align the socket and bulb with the keyed opening on the back of the rear fender marker lamp lens/ housing (4). 5. Insert the socket and bulb into the housing until the socket is firmly seated. 6. Rotate the socket clockwise about 30 degrees to lock it into place. 7. Engage the front edge of the marker lamp into the front edge of the mounting hole in the rear fender. 8. Using hand pressure, press the rear edge of the marker lamp lens/housing toward the front of the vehicle against the spring pressure of the retaining clip, then push the rear edge of the lamp into the rear of the mounting hole in the rear fender. 9. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Rear Fender > Page 7235 Marker Lamp Bulb: Service and Repair Tailgate NOTE: This lamp is used on pick-up models with dual rear wheels. A lamp with a red lens and containing three bulbs is located on the outside of the tailgate below the tailgate latch release handle. The bulb types and service procedures are identical for all three of these bulbs. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the two screws that secure the outboard ends of the tailgate marker lamp lens/housing (1) to the outer tailgate panel. 3. Pull the marker lamp out from the tailgate far enough to access the sockets (2) on the back of the lamp housing. 4. Firmly grasp the marker lamp socket on the back of the lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the socket and bulb straight out from the keyed opening in the housing. 6. Pull the base of the bulb (3) straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the bulb (3) with the socket (2). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the tailgate marker lamp lens/housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Rear Fender > Page 7236 6. Position the marker lamp to the outer tailgate panel. 7. Install and tighten the two screws that secure the marker lamp lens/housing to the tailgate panel. Tighten the screws to 1 N.m (11 in.lbs.). 8. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 7241 Parking Lamp Relay: Description and Operation The park lamp relay is located in the Power Distribution Center (PDC) of the vehicle. The park lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The park lamp relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The park lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the park lamps. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The park lamp relay terminals are connected to the vehicle electrical system through a connector in the Junction Block (JB). The inputs and outputs of the headlamp low beam relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the park lamps through the park lamp relay output circuit and provides ground to the park lamps when the relay is de-energized, and battery current to the park lamps whenever the relay is energized. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a park lamp relay control circuit. The FCM controls park lamp operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current at all times from a fuse in the PDC through a fused B(+) circuit. - Normally Open Terminal - The normally open terminal (87) receives battery current at all times from a fuse in the Power Distribution Center (PDC) through a fused B(+) circuit. - Normally Closed Terminal - The normally closed terminal (87A) is connected to ground at all times. The park lamp relay can be diagnosed using conventional diagnostic tools and methods. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 7242 Parking Lamp Relay: Testing and Inspection The park lamp relay is located in the Power Distribution Center (PDC). Refer to the appropriate wiring information. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the park lamp relay from the PDC. 2. 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. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 8 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. 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, reinstall the relay and use a DRBIII(R) scan tool to perform further testing. Refer to the appropriate diagnostic information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 7243 Parking Lamp Relay: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the Power Distribution Center (PDC) cover. 3. Remove the park lamp relay by grasping it firmly and pulling it straight out from the receptacle in the PDC. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the park lamp relay to the proper receptacle in the Power Distribution Center (PDC). 2. Align the park lamp relay terminals with the terminal cavities in the PDC. 3. Press firmly and evenly on the top of the park lamp relay until the terminals are fully seated in the PDC. 4. Install the PDC cover. 5. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair Parking Light Bulb: Service and Repair REMOVAL NOTE: The front park/turn signal bulb also provides illumination for the front side marker lamp function. 1. Disconnect and isolate the battery negative cable. 2. Remove the front lamp unit (1) from the front fender. 3. Firmly grasp the park/turn signal bulb socket (2) on the back of the front lamp unit housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out from the keyed opening in the housing. 5. Pull the base of the bulb (2) straight out of the socket (1). INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. NOTE: The front park/turn signal bulb also provides illumination for the front side marker lamp function. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair > Page 7247 1. Align the base of the bulb (2) with the park/turn signal bulb socket (1). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb (2) with the keyed opening on the back of the front lamp unit housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the front lamp unit onto the front fender. 7. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Description and Operation Brake Lamp Relay: Description and Operation DESCRIPTION The exterior lighting system for this model include the following components: ^ Backup Lamps ^ Brake Lamps ^ Daytime Running Lamps ^ Front Fog Lamps ^ Hazard Warning Lamps ^ Headlamps ^ Park Lamps ^ Turn Signal Lamps Other components of the exterior lighting system for this model include: ^ Backup Lamp Switch ^ Brake Lamp Switch ^ Front Control Module ^ Front Fog Lamp Relay See: Maintenance/Fuses and Circuit Breakers/Relay Box ^ Hazard Switch ^ Multi-Function Switch ^ Park Lamp Relay See: Maintenance/Fuses and Circuit Breakers/Relay Box ^ Trailer Tow Connectors Some of the interior and exterior lighting functions are governed by the front control module. The headlamp, dome, and door ajar switches provide signals to the instrument cluster. The instrument cluster sends a J1850 message to the front control module to enable the necessary components for illumination. Hard wired circuitry connects the exterior lighting system components to the electrical system of the vehicle. Refer to the appropriate wiring information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 7255 Fog/Driving Lamp Relay: Description and Operation The front fog lamp relay is located in the Power Distribution Center (PDC)See: Maintenance/Fuses and Circuit Breakers/Relay BoxApplications and ID in the engine compartment of the vehicle. The front fog lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs by five integral male spade-type terminals that extend from the bottom of the relay base. The front fog lamp relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The front fog lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the front fog lamps. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The front fog lamp relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC). The inputs and outputs of the front fog lamp relay include: - Common Feed Terminal - The common feed terminal (30) receives battery voltage at all times from a fuse in the PDC through a fused B(+) circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a front fog lamp relay control circuit. The FCM controls front fog lamp operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery voltage at all times from a fuse in the PDC through a fused B(+) circuit. - Normally Open Terminal - The normally open terminal (87) is connected to the front fog lamps through a front fog lamp relay output circuit and provides battery voltage to the front fog lamps whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is not connected in this application. The front fog lamp relay can be diagnosed using conventional diagnostic tools and methods. Refer to the appropriate wiring information for diagnosis and testing of the front fog lamp micro-relay and for complete wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 7256 Fog/Driving Lamp Relay: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. 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 cover for the Power Distribution Center (PDC). 3. Remove the front fog lamp relay by grasping it firmly and pulling it straight out from the receptacle in the PDC. INSTALLATION 1. Position the front fog lamp relay to the proper receptacle in the Power Distribution Center (PDC). 2. Align the front fog lamp relay terminals with the terminal cavities in the PDC. 3. Press firmly and evenly on the top of the front fog lamp relay until the terminals are fully seated in the PDC. 4. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 7260 Parking Lamp Relay: Description and Operation The park lamp relay is located in the Power Distribution Center (PDC) of the vehicle. The park lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The park lamp relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The park lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the park lamps. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The park lamp relay terminals are connected to the vehicle electrical system through a connector in the Junction Block (JB). The inputs and outputs of the headlamp low beam relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the park lamps through the park lamp relay output circuit and provides ground to the park lamps when the relay is de-energized, and battery current to the park lamps whenever the relay is energized. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a park lamp relay control circuit. The FCM controls park lamp operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current at all times from a fuse in the PDC through a fused B(+) circuit. - Normally Open Terminal - The normally open terminal (87) receives battery current at all times from a fuse in the Power Distribution Center (PDC) through a fused B(+) circuit. - Normally Closed Terminal - The normally closed terminal (87A) is connected to ground at all times. The park lamp relay can be diagnosed using conventional diagnostic tools and methods. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 7261 Parking Lamp Relay: Testing and Inspection The park lamp relay is located in the Power Distribution Center (PDC). Refer to the appropriate wiring information. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the park lamp relay from the PDC. 2. 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. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 8 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. 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, reinstall the relay and use a DRBIII(R) scan tool to perform further testing. Refer to the appropriate diagnostic information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 7262 Parking Lamp Relay: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the Power Distribution Center (PDC) cover. 3. Remove the park lamp relay by grasping it firmly and pulling it straight out from the receptacle in the PDC. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the park lamp relay to the proper receptacle in the Power Distribution Center (PDC). 2. Align the park lamp relay terminals with the terminal cavities in the PDC. 3. Press firmly and evenly on the top of the park lamp relay until the terminals are fully seated in the PDC. 4. Install the PDC cover. 5. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Warnings WARNINGS 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. - 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 AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams Circuits feeding/protecting the system diagrams - System Diagrams Component Circuits that work together as a system - Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7268 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7269 Figure 1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7270 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7271 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7272 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7273 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7274 Fig.4 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, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7275 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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 Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7276 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7277 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7278 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7279 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7280 Fig.17 Heat Shrink Tube 6. 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. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7281 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7282 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7283 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7284 Backup Lamp Switch: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7285 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 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. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7286 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7287 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). 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 nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7288 Backup Lamp Switch: Connector Views Switch-Back Up Lamp (Gas) Switch-Back Up Lamp (SRT M/T) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7289 Backup Lamp Switch: Electrical Diagrams Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Page 7290 Backup Lamp Switch: Description and Operation Vehicles equipped with a manual transmission have a normally open, spring-loaded plunger type back-up lamp switch. The backup lamp switch is located in a threaded hole on the side of the manual transmission housing. The backup lamp switch has a threaded body and a hex formation near the plunger end of the switch, and an integral connector at the opposite end of the switch. When installed, only the connector and the hex formation are visible on the outside of the transmission housing. Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. The TRS is described in further detail elsewhere in this service information. The backup lamp switch cannot be adjusted or repaired and, if faulty or damaged, the entire switch unit must be replaced. The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the automatic transmission. The backup lamp switch controls the flow of battery voltage to the backup lamp bulbs through an output on the back-up lamp feed circuit. The switch plunger is mechanically actuated by the gearshift mechanism within the transmission, which will depress the switch plunger and close the switch contacts whenever the reverse gear has been selected. The switch receives battery voltage through a fuse in the Integrated Power Module (IPM) on a fused ignition switch output (run) circuit whenever the ignition switch is in the On position. A take out of the engine wire harness connects the backup lamp switch to the vehicle electrical system. The backup lamp switch and circuits can be tested using conventional diagnostic tools and methods. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Page 7291 Backup Lamp Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Raise and support the vehicle. 3. Locate and disconnect the engine wire harness connector for the backup lamp switch. 4. Check for continuity between the two terminal pins in the backup lamp switch connector. a. With the gear selector lever in the Reverse position, there should be continuity. b. With the gear selector lever in any position other than Reverse, there should be no continuity. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations Brake Light Switch: Component Locations Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 7296 Brake Light Switch: Connector Locations Fig.32 Steering Column Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 7297 Fig.37 Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 7298 Fig.39 Left Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7299 Brake Lamp Switch Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7300 Brake Light Switch: Description and Operation The plunger type brake lamp switch is mounted on a bracket attached to the base of the steering column, under the instrument panel. CAUTION: The switch can only be adjusted during initial installation. If the switch is not adjusted properly a new switch must be installed. The brake lamp switch is hard wired to the Center High Mount Stop Lamp (CHMSL) and also monitored by the Instrument Cluster for use by the brake lamp, speed control brake sensor circuits and electronic brake distribution (EBD). The brake lamp circuit is open until the plunger is depressed. The speed control and brake sensor circuits are closed until the plunger is depressed. When the brake lamp switch transitions, the CHMSL transitions and instrument cluster transmits a brake applied/released message on the bus. The Integrated Power Module (IPM) will then transition the brake lamps. When the brake light switch is activated, the Powertrain Control Module (PCM) receives an input indicating that the brakes are being applied. After receiving this input, the PCM maintains idle speed to a scheduled rpm through control of the Idle Air Control (IAC) motor. The brake switch input is also used to disable vent and vacuum solenoid output signals to the speed control servo. Vehicles equipped with the speed control option use a dual function brake lamp switch The PCM monitors the state of the dual function brake lamp switch. The brake switch is equipped with three sets of contacts, one normally open and the other two normally closed (brakes disengaged) The PCM sends a 12 volt signal to one of the normally closed contacts in the brake switch, which is returned to the PCM as a brake switch state signal With the contacts closed, the 12 volt signal is pulled to ground causing the signal to go low The low voltage signal, monitored by the PCM, indicates that the brakes are not applied When the brakes are applied, the contacts open, causing the PCM's output brake signal to go high, disengaging the speed control, cutting off PCM power to the speed control solenoids. The second set of normally closed contacts supplies 12 volts from the PCM any time speed control is turned on Through the brake switch, voltage is routed to the speed control servo solenoids The speed control solenoids (vacuum, vent and dump) are provided this voltage any time the speed control is ON and the brakes are disengaged. When the driver applies the brakes, the contacts open and voltage is interrupted to the solenoids The normally open contacts are fed battery voltage When the brakes are applied, battery voltage is supplied to the brake lamps. The brake lamp switch can only be adjusted once That is at the initial installation of the switch If the switch is not adjusted properly or has been removed, a new switch must be installed and adjusted. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7301 Brake Light Switch: Testing and Inspection BRAKE LAMP SWITCH The brake lamp switch can be tested with an ohm-meter The ohmmeter is used to check continuity between the pin terminals SWITCH CIRCUIT IDENTIFICATION - Terminals 1 and 2 brake lamp circuit - Terminals 3 and 4 RWAL/ABS module and Powertrain Control Module (PCM) circuit - Terminals 5 and 6 speed control circuit SWITCH CONTINUITY TEST NOTE: Disconnect switch harness before testing switch continuity With switch plunger extended, attach test leads to pins 1 and 2 Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 3 and 4 Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 5 and 6 Replace switch if meter indicates no continuity. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7302 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the switch harness 2. Press and hold the brake pedal in applied position 3. Rotate the switch counterclockwise about 30° to align the switch lock tab with the notch in bracket 4. Pull the switch rearward out of the mounting bracket and release the brake pedal INSTALLATION 1. Press and hold the brake pedal down. 2. Align the tab on the new switch with the notch in the switch bracket.Insert the switch in the bracket and turn it clockwise about 30° to lock it in place. 3. Connect the harness wires to the switch. 4. Release the brake pedal. 5. Move the release lever on the switch parallel with the connector to engage the switch plunger. The switch is now adjusted and can not be adjusted again. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Left Steering Column Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 7306 Switch-Multifunction Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 7307 Combination Switch: Description and Operation The multi-function switch is a resistive MUX switch that is monitored by the Instrument Cluster. The turn signals are actuated with the lever on Multi-Function Switch. The signals are automatically turned off by a canceling cam (two lobes molded to the back of the clock spring mechanism). The cam comes in contact with the cancel actuator on the turn signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. The Instrument Cluster monitors the multiplexed multifunction switch. In a turning event the Instrument Cluster senses a change in the turn signal lever and illuminates the appropriate turn signal indicator. At the same time, the Instrument Cluster will send a J1850 message on the PCI bus to the Front Control Module (FCM). The FCM will respond by activating the appropriate relay in the Power Distribution Center. A chime will sound after the turn is completed if vehicle has traveled a distance of approximately 1.0 mile and a speed of 15 mph, with the turn signal ON. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 7308 Combination Switch: Testing and Inspection To test the turn signal, headlamp beam select and optical horn portion of the multi-function switch: 1. Remove the multi-function switch. 2. Using an ohmmeter check the resistance readings between multi-function switch pins. Refer to Wiring Diagrams for proper pin numbers and the MULTI-FUNCTION SWITCH TESTS table. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 7309 Combination Switch: Service and Repair WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DISARMED. REFER TO THE ELECTRICAL RESTRAINT SYSTEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove the steering wheel and the upper and lower steering column shrouds. Refer to Steering, Column, Shroud, Removal. 3. Disconnect the wire connector from the back of the multi-function switch. 4. Remove the screws retaining the multi-function switch to the steering column adapter collar. 5. Remove the multi-function switch. 6. Remove the screws retaining the clock spring to the multifunction switch. INSTALLATION 1. Install the clock spring on the multifunction switch. 2. Position the switch on to the steering column. 3. Install the retaining screws. 4. Connect the wire harness connector. 5. Install the upper, lower steering column shrouds and the steering wheel. Refer to Steering, Column, Shroud, Installation. 6. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Description and Operation Door Switch: Description and Operation This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if faulty or damaged, the door latch unit must be replaced. The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the Electro-Mechanical Instrument Cluster (EMIC). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed and tested using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the PCI data bus, or the electronic messaging used to convey door ajar switch status to other modules in the vehicle. The most reliable, efficient, and accurate means to diagnose the EMIC, the PCI data bus, and both the hard wired and electronic message inputs and outputs affected by the door ajar switch inputs requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box from the instrument panel. 3. Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to access the instrument panel wire harness connector on the glove box lamp and switch. 4. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the glove box lamp and switch unit. 5. Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to depress the retaining tabs on the top and bottom of the glove box lamp and switch housing. 6. While holding the retaining tabs depressed, push the glove box lamp and switch unit out through the hole in the mounting bracket on the instrument panel glove box opening upper reinforcement. 7. Remove the glove box lamp and switch unit from the instrument panel. INSTALLATION 1. Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to feed the instrument panel wire harness connectors out through the hole in the glove box lamp and switch housing mounting bracket. 2. Position the glove box lamp and switch unit to the instrument panel. 3. Reconnect the instrument panel wire harness connector to the connector receptacle on the back of the glove box lamp and switch unit. 4. Push the glove box lamp and switch unit into the hole in the mounting bracket on the instrument panel glove box opening upper reinforcement. 5. Install the glove box onto the instrument panel. 6. Close the glove box. 7. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 The hazard switch is activated by a push button located in the multifunction switch on the top of the steering column between the steering wheel and instrument cluster. The hazard warning system allows the vehicle operator to provide other vehicle operators in the near proximity an optical indication that the vehicle is disabled or an obstacle to traffic flow. The hazard warning system has battery voltage at all times, regardless of ignition position. The instrument cluster monitors the multiplexed multifunction switch operation. When the hazard warning switch is activated, the instrument cluster will send a J1850 bus message to the Front Control Module (FCM), then activate the two turn signal indicators and audible click in the instrument cluster. The FCM will then activate the necessary relays in the Power Distribution Center (PDC) to begin flashing both the front and rear turn signal indicator lamps. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 7322 Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 7323 Left Instrument Panel Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 7324 Switch-Headlamp Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 7325 Headlamp Switch: Description and Operation The multiplexed headlamp switch is located on the instrument panel. The headlamp switch controls the parking lamps, fog lamps and the headlamps. A separate switch in the module controls the interior lamps and instrument cluster illumination. This switch also contains a rheostat for controlling the illumination level of the cluster lamps. The multiplexed headlamp switch has an off, parking lamp, fog lamp and a headlamp on position. High beams are controlled by the multiplexed multifunction switch on the steering column. The fog lamps are illuminated by pulling back on the headlamp switch knob when in the parking lamp or headlamp ON position.The headlamp switch cannot be repaired. It must be replaced. The Instrument Cluster monitors the headlamp and multifunction switch operation. When the headlamp switch is rotated to the parking lamp or On position the Instrument Cluster sends a J1850 message to the Front Control Module, which is mated to the power distribution center to become the Integrated Control Module, to illuminate the appropriate bulbs. When the multifunction switch is activated to the optical horn or high beam position the Instrument Cluster illuminates the high beam indicator and sends a J1850 message to the Front Control Module to illuminate the appropriate bulbs. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 7326 Headlamp Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Remove the left bezel and the headlamp switch from the instrument panel as a unit. 2. Disconnect the instrument panel wire harness connector from the back of the headlamp switch. Headlamp Switch Tests 3. Using an ohmmeter, test the resistance or continuity between the terminals of the switch as shown in the Headlamp Switch Tests table. 4. If the switch fails any of the tests, replace the faulty headlamp switch as required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 7327 Headlamp Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left instrument panel bezel. 3. Disconnect the harness connector. 4. Remove the screws that secure the headlamp switch to the instrument panel bezel. 5. Remove the headlamp switch from the instrument panel bezel. INSTALLATION 1. Position the headlamp switch to the left instrument panel bezel and secure with screws.Tighten the screws to 2.2 Nm (20 in. lbs.). 2. Reconnect the instrument panel wire harness connector for the headlamp switch. 3. Position the left instrument panel bezel on to the instrument panel. 4. Install the cluster bezel onto the instrument panel. 5. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams Switch-Horn Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 7331 Horn Switch: Description and Operation The horn switch is molded into the driver airbag. The horn switch can not be serviced separately. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 7332 Horn Switch: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the horn system requires the use of a scan tool and the proper Diagnostic Procedures information. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair Tail Light Bulb: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the tail lamp unit. 3. Remove the lamp back plate from the tail lamp unit. 4. Release the tail lamp bulb locking tabs and remove the bulb from the back plate. INSTALLATION 1. Install the tail lamp bulb into the lamp back plate. 2. Install the lamp back plate onto the tail lamp unit. 3. Install the tail lamp unit. 4. Reconnect the negative battery cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Connector Views Trailer Lamps: Connector Views Wiring-Trailer Tow 4-Way Wiring-Trailer Tow 7-Way Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Page 7341 Trailer Lamps: Description and Operation Vehicles equipped with an optional factory-installed trailer towing package have a rear body wire harness that includes an integral trailer tow wiring take out that connects to a heavy duty, sealed, 7-pin trailer tow connector located in the rear bumper. This harness includes an adapter harness that adapts the 7-pin trailer tow connector to a standard, light-duty, 4-pin trailer tow connector. Refer to the appropriate wiring information. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations Left Steering Column Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 7346 Switch-Multifunction Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 7347 Combination Switch: Description and Operation The multi-function switch is a resistive MUX switch that is monitored by the Instrument Cluster. The turn signals are actuated with the lever on Multi-Function Switch. The signals are automatically turned off by a canceling cam (two lobes molded to the back of the clock spring mechanism). The cam comes in contact with the cancel actuator on the turn signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. The Instrument Cluster monitors the multiplexed multifunction switch. In a turning event the Instrument Cluster senses a change in the turn signal lever and illuminates the appropriate turn signal indicator. At the same time, the Instrument Cluster will send a J1850 message on the PCI bus to the Front Control Module (FCM). The FCM will respond by activating the appropriate relay in the Power Distribution Center. A chime will sound after the turn is completed if vehicle has traveled a distance of approximately 1.0 mile and a speed of 15 mph, with the turn signal ON. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 7348 Combination Switch: Testing and Inspection To test the turn signal, headlamp beam select and optical horn portion of the multi-function switch: 1. Remove the multi-function switch. 2. Using an ohmmeter check the resistance readings between multi-function switch pins. Refer to Wiring Diagrams for proper pin numbers and the MULTI-FUNCTION SWITCH TESTS table. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 7349 Combination Switch: Service and Repair WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DISARMED. REFER TO THE ELECTRICAL RESTRAINT SYSTEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove the steering wheel and the upper and lower steering column shrouds. Refer to Steering, Column, Shroud, Removal. 3. Disconnect the wire connector from the back of the multi-function switch. 4. Remove the screws retaining the multi-function switch to the steering column adapter collar. 5. Remove the multi-function switch. 6. Remove the screws retaining the clock spring to the multifunction switch. INSTALLATION 1. Install the clock spring on the multifunction switch. 2. Position the switch on to the steering column. 3. Install the retaining screws. 4. Connect the wire harness connector. 5. Install the upper, lower steering column shrouds and the steering wheel. Refer to Steering, Column, Shroud, Installation. 6. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Cancel Cam > Component Information > Description and Operation Turn Signal Cancel Cam: Description and Operation The turn signal cancel cam (3) is concealed within the steering column. The turn signal cancel cam consists of two lobes on a molded plastic ring that is snapped into the lower hub of the clockspring rotor. The clock-spring mechanism provides turn signal cancellation as well as a constant electrical connection between the horn switch, driver airbag, speed control switches, and remote radio switches on the steering wheel and the instrument panel wire harness on the steering column. The housing of the clockspring (2) is secured to the multi-function switch mounting housing on the steering column and remains stationary. The rotor of the clock-spring, including the turn signal cancel cam lobes rotate with the steering wheel. The turn signal cancel cam is serviced as a unit with the clockspring and cannot be repaired. If faulty or damaged, the entire clockspring unit must be replaced. When the multi-function switch control stalk is moved to a latched turn signal position, a turn signal cancel actuator is extended from the inside surface of the switch housing toward the turn signal cancel cam. As the steering wheel is rotated to complete the turn, one of the two cam lobes will contact the actuator, automatically cancelling the turn signal event and releasing the latched multi-function switch control stalk to the neutral position. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation Turn Signal Flasher: Description and Operation Dodge Ram Trucks, 2004-2009 All, do not use a turn signal flasher relay. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Description and Operation Turn Signal Indicator: Description and Operation Two turn signal indicators, one right and one left, are standard equipment on all instrument clusters. The turn signal indicators are located near the upper edge of the instrument cluster, between the speedometer and the tachometer. Each turn signal indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Turn Warning" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents these icons from being clearly visible when they are not illuminated. A green Light Emitting Diode (LED) behind each cutout in the opaque layer of the overlay causes the icon to appear in green through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The turn signal indicators are serviced as a unit with the instrument cluster. The turn signal indicators give an indication to the vehicle operator that the turn signal (left or right indicator flashing) or hazard warning (both left and right indicators flashing) have been selected and are operating. These indicators are controlled by transistors on the instrument cluster electronic circuit board based upon the cluster programming, a hard wired multiplex input received by the cluster from the turn signal and hazard warning switch circuitry of the multi-function switch on the turn/hazard switch mux circuit, and electronic messages received from the Front Control Module (FCM) (also known as the Integrated Power Module/IPM) over the Programmable Communications Interface (PCI) data bus. Each turn signal indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused B(+) circuit. Therefore, each LED can be illuminated regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the turn signal indicators for the following reasons: - Turn Signal-On Input - Each time the cluster detects a turn signal-on input from the turn signal switch circuitry of the multi-function switch on the turn/hazard switch mux circuit, it sends the appropriate electronic turn signal switch status messages to the FCM over the PCI data bus. The FCM responds to these messages by controlling a battery voltage output and the flash rate for either the right or left turn signal lamps. The FCM also sends the appropriate electronic messages back to the EMIC to control the illumination and flash rate of the right or left turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the EMIC electronic circuit board that emulates the sound emitted by a conventional turn signal flasher. The turn signals and the turn signal indicators continue to flash on and off until the cluster receives a turn signal-off input from the multi-function switch, or until the ignition switch is turned to the Off position, whichever occurs first. - Hazard Warning-On Input - Each time the cluster detects a hazard warning-on input from the hazard warning switch circuitry of the multi-function switch on the turn/hazard switch mux circuit, it sends the appropriate electronic hazard switch status messages to the FCM over the PCI data bus. The FCM responds to these messages by controlling a battery voltage output and the flash rate for each of the right and left turn signal lamps. The FCM also sends the appropriate electronic messages back to the EMIC to control the illumination and flash rate of the right and left turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the EMIC electronic circuit board that emulates the sound emitted by a conventional hazard warning flasher. The turn signals and the turn signal indicators continue to flash on and off until the cluster receives a hazard warning-off input from the multi-function switch. - Lamp Out Mode - The instrument cluster also sends electronic turn signal on and off messages to the FCM over the PCI data bus, and the FCM flashes the appropriate exterior turn signal lamps. If the FCM detects an inoperative turn signal lamp or circuit, it increases the flash rate for the remaining operative turn signals and sends an electronic message back to the instrument cluster. The instrument cluster then increases the flash rate of the turn signal indicators) and the clicking rate of the electromechanical relay to provide an indication of the problem to the vehicle operator. - Actuator Test - Each time the cluster is put through the actuator test, the turn signal indicators will be turned on, then off again during the bulb check portion of the test to confirm the functionality of each LED and the cluster control circuitry. The instrument cluster continually monitors the multi-function switch and electronic messages from the FCM to determine the proper turn signal and hazard warning system control. For further diagnosis of the turn signal indicators or the instrument cluster circuitry that controls the indicators, refer to testing. For proper diagnosis of the turn signal and hazard warning system, the multi-function switch, the FCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the turn signal indicators, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair Turn Signal Bulb: Service and Repair REMOVAL NOTE: The front park/turn signal bulb also provides illumination for the front side marker lamp function. 1. Disconnect and isolate the battery negative cable. 2. Remove the front lamp unit (1) from the front fender. 3. Firmly grasp the park/turn signal bulb socket (2) on the back of the front lamp unit housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out from the keyed opening in the housing. 5. Pull the base of the bulb (2) straight out of the socket (1). INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. NOTE: The front park/turn signal bulb also provides illumination for the front side marker lamp function. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Page 7363 1. Align the base of the bulb (2) with the park/turn signal bulb socket (1). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb (2) with the keyed opening on the back of the front lamp unit housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the front lamp unit onto the front fender. 7. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Light Bulb > Component Information > Service and Repair Underhood Light Bulb: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Insert a small flat blade in the access slot between the lamp base and lamp lens. 3. Pry the lamp lens upward and remove the lamp lens. 4. 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. 4. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams Vanity Lamp: Diagrams Lamp-Trinity-Left (Light Package) Lamp-Vanity-Right (Light Package) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Page 7371 Vanity Lamp: Service and Repair NOTE: Vehicles equipped with optional vanity lamps have a mirror with a lamp that is integral to each sun visor. Each lamp is independently controlled by an integral switch that is automatically actuated by the mirror cover. The bulb types and service procedures are identical for both of these lamps. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Insert a small flat-bladed screwdriver on either side near the top or the bottom between the vanity lamp lens (2) and the lamp housing of the sun visor (1). 3. Carefully pry the lens outward until it unsnaps from the lamp housing. 4. Using small needle-nose pliers, carefully grasp the bulb (2) and pull the base out of the lamp socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Page 7372 1. Using small needle-nose pliers, carefully grasp the vanity lamp bulb (2) and align the base of the bulb with the socket in the lamp housing of the sun visor (1). 2. Push the bulb straight into the socket until the base is fully seated. 3. Insert one tab on the top or the bottom of the lens (2) into the appropriate slot at the top or bottom of the lamp housing. 4. Flex the lens far enough to engage the loose tab into its slot in the lamp housing. 5. Reconnect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 7378 Heated Glass Element Relay: Description and Operation The rear window defogger relay is a International Standards Organization (ISO) micro-relay Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions The ISO micro-relay terminal functions are the same as a conventional ISO relay However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The rear window defogger relay is located in the power distribution center (PDC) in the engine compartment Refer to the PDC label for rear window defogger relay identification and location. The black, molded plastic case is the most visible component of the rear window defogger relay Five male spade-type terminals extend from the bottom of the base to connect the relay to the vehicle electrical system, and the ISO designation for each terminal is molded into the base adjacent to each terminal The ISO terminal designations are as follows - 30 (Common Feed) - This terminal is connected to the movable contact point of the relay. - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The rear window defogger relay cannot be adjusted or repaired If the relay is damaged or faulty, it must be replaced. The rear window defogger relay is an electromechanical switch that uses a low current input from the integrated power module (IPM) to control the high current output to the rear window defogger grid The movable common feed contact point is held against the fixed normally closed contact point by spring pressure When the relay coil is energized, an electromagnetic field is produced by the coil windings This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point The resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear window defogger relay terminals are connected to the vehicle electrical system through a receptacle in the IPM The inputs and outputs of the rear window defogger relay include: - The common feed terminal (30) receives a battery current input from fuse 27 (15 amp) in the IPM through a fused B(+) circuit at all times - The coil ground terminal (87) receives a ground input from the A/C-heater control when the A/Cheater control electronically pulls the control circuit to ground - The coil battery terminal (85) receives a battery current input from fuse 36 (10 amp) in the IPM through a fused B(+) circuit only when the ignition switch is in the Run position - The normally open terminal (86) provides a battery current output to the rear window defogger and heated power mirrors (when equipped) through the relay output circuit only when the rear window defogger relay coil is energized - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the rear window defogger relay coil is de-energized The rear window defogger relay cannot be repaired and, if faulty or damaged, it must be replaced Refer to the appropriate wiring information for diagnosis and testing of the micro-relay and for complete rear window defogger system wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 7379 Heated Glass Element Relay: Service and Repair REMOVAL. 1. Disconnect and isolate the negative battery cable. 2. Remove the cover from the integrated power module (IPM). 3. Refer to the fuse and relay layout map on the inner surface of the IPM cover for rear window defogger relay identification and location. 4. Remove the rear window defogger relay from the IPM. INSTALLATION 1. Refer to the fuse and relay layout map on the inner surface of the integrated power module (IPM) for rear window defogger relay identification and location. 2. Position the rear window defogger relay into the proper receptacle in the IPM. 3. Align the rear window defogger relay terminals with the terminal cavities in the IPM receptacle. 4. Push down firmly on the rear window defogger relay until the terminals are fully seated in the terminal cavities in the IPM receptacle. 5. Install the cover onto the IPM. 6. Reconnect the negative battery cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Description and Operation Heated Glass Element Switch: Description and Operation The rear window defogger switch is integrated into the A/C-heater control mounted in the center of the instrument panel. The rear window defogger switch and the rear window defogger LED indicator cannot be repaired and, if faulty or damaged, the A/C-heater control must be replaced. An LED indicator will illuminate when the rear window defogger switch is activated. The switch energizes the timing circuit integral to the A/C-heater control which then activates the rear window defogger relay. The rear window defogger relay controls the current to flow to the grids of the rear window defogger. The rear window defogger system will operate for approximately ten minutes or until the rear window defogger switch or ignition switch is turned off. The rear window defogger switch cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Rear Defogger Relay > Component Information > Description and Operation Rear Defogger Relay: Description and Operation The rear window defogger relay is a International Standards Organization (ISO) micro-relay Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions The ISO micro-relay terminal functions are the same as a conventional ISO relay However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The rear window defogger relay is located in the power distribution center (PDC) in the engine compartment Refer to the PDC label for rear window defogger relay identification and location. The black, molded plastic case is the most visible component of the rear window defogger relay Five male spade-type terminals extend from the bottom of the base to connect the relay to the vehicle electrical system, and the ISO designation for each terminal is molded into the base adjacent to each terminal The ISO terminal designations are as follows - 30 (Common Feed) - This terminal is connected to the movable contact point of the relay. - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The rear window defogger relay cannot be adjusted or repaired If the relay is damaged or faulty, it must be replaced. The rear window defogger relay is an electromechanical switch that uses a low current input from the integrated power module (IPM) to control the high current output to the rear window defogger grid The movable common feed contact point is held against the fixed normally closed contact point by spring pressure When the relay coil is energized, an electromagnetic field is produced by the coil windings This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point The resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear window defogger relay terminals are connected to the vehicle electrical system through a receptacle in the IPM The inputs and outputs of the rear window defogger relay include: - The common feed terminal (30) receives a battery current input from fuse 27 (15 amp) in the IPM through a fused B(+) circuit at all times - The coil ground terminal (87) receives a ground input from the A/C-heater control when the A/Cheater control electronically pulls the control circuit to ground - The coil battery terminal (85) receives a battery current input from fuse 36 (10 amp) in the IPM through a fused B(+) circuit only when the ignition switch is in the Run position - The normally open terminal (86) provides a battery current output to the rear window defogger and heated power mirrors (when equipped) through the relay output circuit only when the rear window defogger relay coil is energized - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the rear window defogger relay coil is de-energized The rear window defogger relay cannot be repaired and, if faulty or damaged, it must be replaced Refer to the appropriate wiring information for diagnosis and testing of the micro-relay and for complete rear window defogger system wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 7391 Heated Glass Element Relay: Description and Operation The rear window defogger relay is a International Standards Organization (ISO) micro-relay Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions The ISO micro-relay terminal functions are the same as a conventional ISO relay However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The rear window defogger relay is located in the power distribution center (PDC) in the engine compartment Refer to the PDC label for rear window defogger relay identification and location. The black, molded plastic case is the most visible component of the rear window defogger relay Five male spade-type terminals extend from the bottom of the base to connect the relay to the vehicle electrical system, and the ISO designation for each terminal is molded into the base adjacent to each terminal The ISO terminal designations are as follows - 30 (Common Feed) - This terminal is connected to the movable contact point of the relay. - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The rear window defogger relay cannot be adjusted or repaired If the relay is damaged or faulty, it must be replaced. The rear window defogger relay is an electromechanical switch that uses a low current input from the integrated power module (IPM) to control the high current output to the rear window defogger grid The movable common feed contact point is held against the fixed normally closed contact point by spring pressure When the relay coil is energized, an electromagnetic field is produced by the coil windings This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point The resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear window defogger relay terminals are connected to the vehicle electrical system through a receptacle in the IPM The inputs and outputs of the rear window defogger relay include: - The common feed terminal (30) receives a battery current input from fuse 27 (15 amp) in the IPM through a fused B(+) circuit at all times - The coil ground terminal (87) receives a ground input from the A/C-heater control when the A/Cheater control electronically pulls the control circuit to ground - The coil battery terminal (85) receives a battery current input from fuse 36 (10 amp) in the IPM through a fused B(+) circuit only when the ignition switch is in the Run position - The normally open terminal (86) provides a battery current output to the rear window defogger and heated power mirrors (when equipped) through the relay output circuit only when the rear window defogger relay coil is energized - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the rear window defogger relay coil is de-energized The rear window defogger relay cannot be repaired and, if faulty or damaged, it must be replaced Refer to the appropriate wiring information for diagnosis and testing of the micro-relay and for complete rear window defogger system wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 7392 Heated Glass Element Relay: Service and Repair REMOVAL. 1. Disconnect and isolate the negative battery cable. 2. Remove the cover from the integrated power module (IPM). 3. Refer to the fuse and relay layout map on the inner surface of the IPM cover for rear window defogger relay identification and location. 4. Remove the rear window defogger relay from the IPM. INSTALLATION 1. Refer to the fuse and relay layout map on the inner surface of the integrated power module (IPM) for rear window defogger relay identification and location. 2. Position the rear window defogger relay into the proper receptacle in the IPM. 3. Align the rear window defogger relay terminals with the terminal cavities in the IPM receptacle. 4. Push down firmly on the rear window defogger relay until the terminals are fully seated in the terminal cavities in the IPM receptacle. 5. Install the cover onto the IPM. 6. Reconnect the negative battery cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Description and Operation Rear Defogger Relay: Description and Operation The rear window defogger relay is a International Standards Organization (ISO) micro-relay Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions The ISO micro-relay terminal functions are the same as a conventional ISO relay However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The rear window defogger relay is located in the power distribution center (PDC) in the engine compartment Refer to the PDC label for rear window defogger relay identification and location. The black, molded plastic case is the most visible component of the rear window defogger relay Five male spade-type terminals extend from the bottom of the base to connect the relay to the vehicle electrical system, and the ISO designation for each terminal is molded into the base adjacent to each terminal The ISO terminal designations are as follows - 30 (Common Feed) - This terminal is connected to the movable contact point of the relay. - 85 (Coil Ground) - This terminal is connected to the ground feed side of the relay control coil. - 86 (Coil Battery) - This terminal is connected to the battery feed side of the relay control coil. - 87 (Normally Open) - This terminal is connected to the normally open fixed contact point of the relay. - 87A (Normally Closed) - This terminal is connected to the normally closed fixed contact point of the relay. The rear window defogger relay cannot be adjusted or repaired If the relay is damaged or faulty, it must be replaced. The rear window defogger relay is an electromechanical switch that uses a low current input from the integrated power module (IPM) to control the high current output to the rear window defogger grid The movable common feed contact point is held against the fixed normally closed contact point by spring pressure When the relay coil is energized, an electromagnetic field is produced by the coil windings This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point The resistor or diode is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear window defogger relay terminals are connected to the vehicle electrical system through a receptacle in the IPM The inputs and outputs of the rear window defogger relay include: - The common feed terminal (30) receives a battery current input from fuse 27 (15 amp) in the IPM through a fused B(+) circuit at all times - The coil ground terminal (87) receives a ground input from the A/C-heater control when the A/Cheater control electronically pulls the control circuit to ground - The coil battery terminal (85) receives a battery current input from fuse 36 (10 amp) in the IPM through a fused B(+) circuit only when the ignition switch is in the Run position - The normally open terminal (86) provides a battery current output to the rear window defogger and heated power mirrors (when equipped) through the relay output circuit only when the rear window defogger relay coil is energized - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the rear window defogger relay coil is de-energized The rear window defogger relay cannot be repaired and, if faulty or damaged, it must be replaced Refer to the appropriate wiring information for diagnosis and testing of the micro-relay and for complete rear window defogger system wiring diagrams. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation Heated Glass Element Switch: Description and Operation The rear window defogger switch is integrated into the A/C-heater control mounted in the center of the instrument panel. The rear window defogger switch and the rear window defogger LED indicator cannot be repaired and, if faulty or damaged, the A/C-heater control must be replaced. An LED indicator will illuminate when the rear window defogger switch is activated. The switch energizes the timing circuit integral to the A/C-heater control which then activates the rear window defogger relay. The rear window defogger relay controls the current to flow to the grids of the rear window defogger. The rear window defogger system will operate for approximately ten minutes or until the rear window defogger switch or ignition switch is turned off. The rear window defogger switch cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Left Front Door Premium Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 7403 Right Front Door Premium Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 7404 Left Rear Door (Right Side Similar) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 7405 Power Window Switch: Diagrams Switch-Power Window-Left Rear Switch-Power Window-Passenger Switch-Power Window-Right Rear Switch-Window/Door Lock Driver C1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 7406 Switch-Window/Door Lock Driver C1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 7407 Power Window Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative, refer to testing. If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED(s) is faulty and must be replaced. For complete circuit diagrams, 1. Check the fuse in the Integrated Power Module (IPM) and the circuit breaker located near the park brake pedal. If OK, go to Step 2. If not OK, replace the faulty fuse or circuit breaker. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the Integrated Power Module (IPM). If OK, turn the ignition switch to the Off position and go to Step 3. If not OK, check circuit breaker and repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors). The drivers door switch is included with the window/lock switch. Unplug the wire harness connector from the switch unit. Power Window Switch Continuity Chart 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the Off, Up and Down switch positions. If OK, refer to testing. If not OK, replace the faulty switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 7408 Power Window Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams Circuit Breaker - Power Window Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations Power Window Motor: Locations Left Front Door Premium Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Page 7416 Right Front Door Premium Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Page 7417 Left Rear Door (Right Side Similar) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Page 7418 Power Window Motor: Diagrams Motor-Power Window-Driver Motor-Power Window-Left Rear Motor-Power Window-Passenger Motor-Power Window-Right Rear Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations Power Window Switch: Locations Left Front Door Premium Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 7422 Right Front Door Premium Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 7423 Left Rear Door (Right Side Similar) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 7424 Power Window Switch: Diagrams Switch-Power Window-Left Rear Switch-Power Window-Passenger Switch-Power Window-Right Rear Switch-Window/Door Lock Driver C1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 7425 Switch-Window/Door Lock Driver C1 Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 7426 Power Window Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative, refer to testing. If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED(s) is faulty and must be replaced. For complete circuit diagrams, 1. Check the fuse in the Integrated Power Module (IPM) and the circuit breaker located near the park brake pedal. If OK, go to Step 2. If not OK, replace the faulty fuse or circuit breaker. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the Integrated Power Module (IPM). If OK, turn the ignition switch to the Off position and go to Step 3. If not OK, check circuit breaker and repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors). The drivers door switch is included with the window/lock switch. Unplug the wire harness connector from the switch unit. Power Window Switch Continuity Chart 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the Off, Up and Down switch positions. If OK, refer to testing. If not OK, replace the faulty switch. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 7427 Power Window Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite Back Window Glass: Service and Repair Backlite BACKLITE REMOVAL CAUTION: It is difficult to salvage the backlite during the removal operation. The backlite is part of the structural support for the roof. The urethane bonding used to secure the glass to the fence is difficult to cut or clean from any surface. Since the molding is set in urethane, it is unlikely it would be salvaged. Before removing the backlite, check the availability from the parts supplier. NOTE: The backlite is attached to the window frame with urethane adhesive. The urethane adhesive is applied cold and seals the surface area between the window opening and the glass. The primer adheres the urethane adhesive to the backlite. 1. Roll down door glass. 2. Remove headliner (9). 3. On standard cab models remove the upper b-pillar trim (5), Refer to Trim Panel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite > Page 7433 4. On quad cab models remove the upper c-pillar trim (5), Refer to Trim Panel. 5. Bend backlite retaining tab (2) inward against glass. 6. Disconnect the rear window defogger electrical connector (if equipped). 7. Using a suitable pneumatic knife from inside the vehicle, cut urethane holding backlite frame to opening fence. 8. Separate glass (1) from vehicle. INSTALLATION 1. Clean urethane adhesive from around backlite opening fence. 2. If necessary, apply black-out primer to outer edge of replacement backlite frame (1). 3. If black-out primer was pre-applied on backlite, clean bonding surface with Isopropyl alcohol and clean lint free cloth. Allow 3 minutes for drying time. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite > Page 7434 4. Apply black-out primer to backlite opening fence. 5. Apply a 13 mm (0.5 in.) bead of urethane (4) around the perimeter of the window frame bonding surface (1). 6. Set glass (1) on lower fence and move glass forward into opening. 7. Firmly push glass (1) against rear window glass opening fence. 8. Bend tabs around edges of backlite opening fence to retain glass. 9. Clean excess urethane from exterior with MOPAR(R), Super Clean or equivalent. 10. Allow urethane to cure at least 24 hours (full cure is 72 hours). 11. Water test to verify repair before returning vehicle to service. 12. Connect the rear window defogger electrical connector, if equipped. 13. On standard cab models, install the upper b-pillar trim (5). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite > Page 7435 14. On quad cab models, install the upper c-pillar trim (5). 15. Install the headliner (9). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite > Page 7436 Back Window Glass: Service and Repair Backlite Vent Glass BACKLITE VENT GLASS REMOVAL 1. Slide the upper run channel (1) out of the window frame (2). 2. Slide the vent glass (3) upward to remove from the lower window frame (2). 3. Lower the glass (3) out of the upper window frame (2) and remove. INSTALLATION 1. Slide the vent glass (3) upper edge into window frame (2) and insert the lower edge into the lower molding. 2. Position the upper run channel (1) into the window frame (2) and slide it into place. 3. Verify vent glass (3) operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Molding FRONT DOOR OUTER BELT MOLDING REMOVAL 1. Remove the screw (4) and separate the belt molding (1) from the door (5) flange from the back to the front. INSTALLATION 1. Position the belt molding (1) onto the door (5) flange and seat fully. 2. Install the screw (4). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7442 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove the door glass. 2. Separate the front door glass run weatherstrip (2) out of the door frame (5) and remove through the window opening. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7443 NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the front door glass run weatherstrip (2) into the door (5) through the window opening. 2. Position the weatherstrip into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip between the corners and then down the sides firmly. 4. Install the door glass. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7444 Front Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL FRONT-ALL MODELS 1. Raise the window glass to the full up position and remove the window regulator. 2. Loosen the two bolts (2 and 3) that secure the front glass run channel (1) to the door (5). 3. Slide the front glass run channel upward and disengage it from the door. 4. Remove the front glass run channel from the door through the door panel opening (4). 5. If required, remove the weatherstrip from the front glass run channel. REAR-QUAD CAB 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the lower bolt (1) that secures the rear glass run channel (3) to the door. 3. Loosen the upper bolt (4) that secures the rear glass run channel to the door. 4. Slide the rear glass run channel upward and disengage the upper screw from the door. 5. Remove the rear glass run channel from the door through the door panel opening (2). 6. If required, remove the weatherstrip from the rear glass run channel. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7445 REAR-STANDARD CAB 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1) that secure the rear glass run channel (2) to the door. 3. Remove the rear glass run channel from the door through the door panel opening (3). 4. If required, remove the weatherstrip from the rear glass run channel. INSTALLATION FRONT-ALL MODELS 1. If removed, install the weatherstrip onto the front glass run channel (1). 2. Position the front glass run channel into the door (5) through the door panel opening (4). 3. Engage the two bolts (2 and 3) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. REAR-QUAD CAB Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7446 1. If removed, install the weatherstrip onto the rear glass run channel (3). 2. Position the rear glass run channel into the door through the door panel opening (2). 3. Engage the upper bolt (4) that secures the rear glass run channel to the door. 4. Install the lower bolt (1) that secures the rear glass run channel to the door. Tighten both the upper and lower bolts to 10 N.m (89 in.lbs.). 5. Install the window regulator and verify correct window operation. REAR-STANDARD CAB 1. If removed, install the weatherstrip onto the rear glass run channel (2). 2. Position the rear glass run channel into the door through the door panel opening (3). 3. Install the two bolts (1) that secure the rear glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7447 Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Molding FRONT DOOR INNER BELT MOLDING REMOVAL 1. Remove the door trim panel (3). 2. Separate the belt molding (1) from the door (3) mounting flange from the back to the front. INSTALLATION 1. Position the belt molding (1) and seat onto the door (3) mounting flange fully. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7448 2. Install the door trim panel (3). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel Rear Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL FRONT 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1) that secure the front glass run channel (2) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the front glass run channel. Mega Cab Models 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1 & 3) that secure the front glass run channel (2) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the front glass run channel. REAR Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7454 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (2) that secure the rear glass run channel (1) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the rear glass run channel. INSTALLATION FRONT 1. If removed, install the weatherstrip onto the front glass run channel (2). 2. Position the front glass run channel into the door through the door panel opening. 3. Install the two bolts (1) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Mega Cab Models Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7455 1. If removed, install the weatherstrip onto the front glass run channel (2). 2. Position the front glass run channel into the door through the door panel opening. 3. Install the two bolts (1 & 3) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. REAR 1. If removed, install the weatherstrip onto the rear glass run channel (1). 2. Position the rear glass run channel into the door through the door panel opening. 3. Install the two bolts (2) that secure the rear glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7456 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Molding REAR DOOR OUTER BELT MOLDING REMOVAL 1. Remove the screw (3) and separate the belt molding (1) from the door (2) flange from the back to the front. INSTALLATION 1. Position the belt molding (1) onto the door (2) flange and seat fully. 2. Install the screw (3). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7457 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Lower the glass. 2. Separate the rear door glass run weatherstrip (5) out of the door frame (2) and remove through the window opening. INSTALLATION NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the rear door glass run weatherstrip (5) into the door (2) through the window opening. 2. Position the weatherstrip (5) into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip (5) between the corners and then down the sides firmly. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7458 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Molding REAR DOOR INNER BELT MOLDING REMOVAL 1. Remove the door trim panel (5). 2. Separate the belt molding (2) from the rear door mounting flange from the back to the front. INSTALLATION 1. Position the belt molding (2) and seat onto the rear door mounting flange fully. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7459 2. Install the door trim panel (5). Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Back Window Regulator > Component Information > Service and Repair Back Window Regulator: Service and Repair BACKLITE VENT GLASS-REGULATOR REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the rear seats. 3. Remove the rear cab back panel, Refer to Trim Panel. 4. Remove the two mounting bolts (1). 5. Disconnect the electrical connector to the power motor. 6. Separate the cable housings from the glass track (1). 7. Disconnect the cable ends from the vent glass (2). 8. Separate the support clips (5) and remove the regulator assembly (3). INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Back Window Regulator > Component Information > Service and Repair > Page 7464 1. Connect the cable ends to the vent glass (2). 2. Install the cable housings into the glass tracks (1). 3. Fasten the support clips (5). 4. Install the 2 mounting bolts (1). 5. Install the rear cab back panel. 6. Install the rear seats. 7. Connect the battery negative cable. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures Front Door Window Regulator: Procedures REMOVAL 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 8. Remove the bolt (5) that secures the window regulator to the door and loosen the other two regulator bolts (7). 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (6). INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7469 1. Connect the door wire harness (6) to the window regulator (4) and install the regulator through the opening in the door (2). 2. Engage the two regulator bolts (7) to the door. 3. Install the bolt (5) that secure the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (2) to the position shown. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7470 Front Door Window Regulator: Removal and Replacement Window Regulator-Power WINDOW REGULATOR-POWER REMOVAL 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Front Door Panel. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 8. Remove the bolt (5) that secures the window regulator to the door and loosen the other two regulator bolts (7). 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (6). INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7471 1. Connect the door wire harness (6) to the window regulator (4) and install the regulator through the opening in the door (2). 2. Engage the two regulator bolts (7) to the door. 3. Install the bolt (5) that secure the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (2) to the position shown. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Window Regulator-Manual WINDOW REGULATOR-MANUAL REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7472 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Front Door Panel. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 7. Remove the two bolts (5) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7473 1. Install the window regulator (4) through the opening in the door (2). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolt (5) that secure the window regulator to the door and tighten all four regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (2) to the position shown and remove the manual window crank. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Install the waterdam. 9. Install the inner belt molding. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures Rear Door Window Regulator: Procedures REMOVAL 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (4) and the sight window (5) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (5) and remove the two nuts (3) that secure the regulator stabilizer (4) to the door (1). 7. Remove the two bolts (2) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7478 1. Install the window regulator (5) through the opening in the door (1). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolts (2) that secure the window regulator to the door and tighten all four regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (4) onto the door and install the two nuts (3). Tighten the nuts to 10 N·m (89 in. lbs.). 5. Raise the window regulator (3) to the position shown and remove the manual window crank. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Install the waterdam. 9. Install the inner belt molding. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7479 Rear Door Window Regulator: Removal and Replacement Window Regulator-Power WINDOW REGULATOR-POWER REMOVAL 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Rear Door Panel. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (5) and the sight window (4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (2) and remove the two nuts that secure the regulator stabilizer to the door. 8. Remove the lower bolt (1) that secures the window regulator to the door and loosen the other two regulator bolts. 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (3). INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7480 1. Connect the door wire harness (3) to the window regulator (2) and install the regulator through the opening in the door. 2. Engage the two upper regulator bolts (1) to the door. 3. Install the lower regulator bolt that secures the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer into the door and install the two nuts. Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (3) to the position shown. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator (3) through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Window Regulator-Manual WINDOW REGULATOR-MANUAL REMOVAL Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7481 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Rear Door Panel. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (5) and the sight window (4) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (5) and remove the two nuts (3) that secure the regulator stabilizer (4) to the door (1). 7. Remove the two bolts (2) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7482 1. Install the window regulator (5) through the opening in the door (1). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolts (2) that secure the window regulator to the door and tighten all four regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (4) onto the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (3) to the position shown and remove the manual window crank. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Install the waterdam. 9. Install the inner belt molding . Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest for Window Track: > 23-029-04 > Aug > 04 > Body - Front Door Power Window Binding/Slow Operation Window Track: Customer Interest Body - Front Door Power Window Binding/Slow Operation NUMBER: 23-029-04 GROUP: Body DATE: August 2, 2004 SUBJECT: Front Power Window Binds OVERVIEW: This bulletin involves lubricating the window channel and installing a spacer under the outside mirror. MODELS: 2004 (DR) Ram Truck NOTE: This bulletin applies to vehicles equipped with trailer tow mirrors, sales code GPD or GPG. SYMPTOM/CONDITION: Vehicles equipped with trailer tow mirrors may experience the power window on the front door binding or slow to operate. DIAGNOSIS: Operate the both front power windows. If a binding condition is present in either window, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Separate the door trim panel from the door, leaving the wiring attached. 2. Lubricate the window run channels with MOPAR Silicone Spray Lube, p/n 04318070 or equivalent. 3. Separate the outside mirror from the door, leaving the wiring attached. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest for Window Track: > 23-029-04 > Aug > 04 > Body - Front Door Power Window Binding/Slow Operation > Page 7491 4. Install the mirror with washer, p/n 06100876, positioned over the lower rear stud on the mirror (Fig. 1). The washer should sit between the gasket and the body of the mirror. Tighten the nuts to 7 Nm (60 in. lbs.). 5. Install the door trim panel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Track: > 23-029-04 > Aug > 04 > Body - Front Door Power Window Binding/Slow Operation Window Track: All Technical Service Bulletins Body - Front Door Power Window Binding/Slow Operation NUMBER: 23-029-04 GROUP: Body DATE: August 2, 2004 SUBJECT: Front Power Window Binds OVERVIEW: This bulletin involves lubricating the window channel and installing a spacer under the outside mirror. MODELS: 2004 (DR) Ram Truck NOTE: This bulletin applies to vehicles equipped with trailer tow mirrors, sales code GPD or GPG. SYMPTOM/CONDITION: Vehicles equipped with trailer tow mirrors may experience the power window on the front door binding or slow to operate. DIAGNOSIS: Operate the both front power windows. If a binding condition is present in either window, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Separate the door trim panel from the door, leaving the wiring attached. 2. Lubricate the window run channels with MOPAR Silicone Spray Lube, p/n 04318070 or equivalent. 3. Separate the outside mirror from the door, leaving the wiring attached. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Track: > 23-029-04 > Aug > 04 > Body - Front Door Power Window Binding/Slow Operation > Page 7497 4. Install the mirror with washer, p/n 06100876, positioned over the lower rear stud on the mirror (Fig. 1). The washer should sit between the gasket and the body of the mirror. Tighten the nuts to 7 Nm (60 in. lbs.). 5. Install the door trim panel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions Windshield: Service Precautions WARNING WINDSHIELD SAFETY PRECAUTIONS Do not operate the vehicle within 24 hours of windshield installation. It takes at least 24 hours for urethane adhesive to cure. If it is not cured, the windshield may not perform properly in an accident. - Urethane adhesives are applied as a system. Use glass cleaner, glass prep solvent, glass primer, PVC (vinyl) primer and pinch weld (fence) primer provided by the adhesive manufacturer. If not, structural integrity could be compromised. - DaimlerChrysler does not recommend glass adhesive by brand. Technicians should review product labels and technical data sheets, and use only adhesives that their manufactures warranty and will restore a vehicle to the requirements of fmvss 212. Technicians should also insure that primers and cleaners are compatible with the particular adhesive used. - Be sure to refer to the urethane manufacturer's directions for curing time specifications and do not use adhesive after its expiration date. - Vapors that are emitted from the urethane adhesive or primer could cause personal injury or death. Use them in a well-ventilated area. - Skin contact with urethane adhesive should be avoided. Personal injury or death may result. - Always wear eye and hand protection when working with glass. Protect all painted and trimmed surfaces from coming in contact with urethane or primers. Be careful not to damage painted surfaces when removing moldings or cutting urethane around windshield . Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 7501 Windshield: Service and Repair REMOVAL 1. Remove inside rear view mirror (3). 2. Remove cowl grille (2). 3. Remove the a-pillar weatherstrip retainer (1), Refer to Weatherstrip. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 7502 4. Remove the a-pillar trim panels (2), Refer to Trim Panel. 5. Remove the headliner (9) and from the inside of the vehicle, cut the upper urethane bonding from around windshield upper edge using a suitable sharp cold knife (C-4849). A pneumatic cutting device can be used but is not recommended. 6. From the outside of the vehicle, cut urethane bonding from the remaining sides of the windshield using a suitable sharp cold knife (C-4849). A pneumatic cutting device can be used but is not recommended. 7. Separate windshield from vehicle. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 7503 WARNING: Allow the urethane at least 24 hours to cure before returning the vehicle to use. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing windshield. This is to avoid pressurizing the passenger compartment if a door is slammed before the urethane is cured. The potential for water leaks can result. The windshield fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. 1. Place replacement windshield (1) into windshield opening and position glass in the center of the opening against the support spacers (3). Mark the outside surface of the glass at the support spacers (3) with a grease pencil or pieces of masking tape and ink pen to use as a reference (2) for installation. Remove replacement windshield from windshield opening. 2. Position the windshield (1) inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. By 4 in. By 20 in.) blocks (3), placed parallel 75 cm (2.5 ft.) apart. 3. Clean inside of windshield with MOPAR(R) Glass Cleaner and lint-free cloth. 4. Apply clear glass primer 25 mm (1 in.) wide around perimeter of windshield and wipe with a new clean and dry lint-free cloth. 5. Apply black-out primer onto the glass using the windshield molding as a guide. The primer should be 15 mm (5/8 in.) wide on the top and sides of the glass and 25 mm (1 in.) on the bottom of windshield. Allow at least three minutes drying time. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 7504 6. Locate NEW support spacers (3) on support brackets and adjust to lowest height. 7. Position seven new foam spacers (4 and 3) on the inside surface of the windshield, flush with the lower and side edges. 8. Position three new foam spacers (1) on the inside surface of the windshield, at a minimum distance of 3 mm (0.12 in.) from the top edge of the windshield. 9. The urethane bead should be shaped in a triangular cross-section, this can be achieved by notching the tip of the applicator. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 7505 10. Apply a 13 mm (1/2 in.) high and 10 mm (3/8 in.) wide bead of urethane around the perimeter of windshield (2). At the top, apply the bead 7 mm (1/4 in.) inboard from the glass edge. On the other three sides apply the bead 14 mm (0.55 in.) inboard from the glass edge. 11. Install the a-pillar trim (2). 12. With the aid of a helper, position the windshield (2) over the windshield opening. Align the reference marks at the bottom of the windshield to the support spacers (3). 13. Slowly lower windshield glass (2) to the fence opening guiding the lower corners into proper position. Beginning at the bottom and continuing to the top, push glass (2) onto fence along the A-Pillars. Push windshield (2) inward to the fence at the bottom corners. 14. Push windshield (2) upward, setting the windshield to roof gap to 1.5 mm (0.06 in.) to 3 mm (0.12 in.) and ratchet up the adjustable support Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 7506 brackets. 15. Using clean water, lightly mist the support spacers (3). 16. Clean excess urethane from exterior with MOPAR(R) Super Clean or equivalent. 17. Install cowl grille (2). 18. Install rear view mirror support bracket (4). 19. Install rear view mirror (3). 20. Install the a-pillar weatherstrip retainer (1). 21. After urethane has cured, remove tape strips and water test windshield to verify repair. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Description and Operation Check Valve: Description and Operation A single washer system check valve is standard equipment on this model, and is installed in the washer system plumbing. The check valve is integral to the washer nozzle plumbing eye fitting (2) located in the cowl plenum area beneath the cowl plenum cover/grille panel near the base of the windshield. The check valve consists of a molded plastic body with a raised arrowhead (4) molded into its center section that indicates the direction of the flow through the valve, and three barbed hose nipples (1 and 3) formed in a eye configuration on the outside circumference of the center section of the valve body. The check valve cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The check valve provides more than one function in this application. It serves as a eye connector fitting between the engine compartment and washer nozzle sections of the washer supply hose. It prevents washer fluid from draining out of the washer supply hoses back to the washer reservoir. This drain-back would result in a lengthy delay from when the washer switch is actuated until washer fluid was dispensed through the washer nozzles, because the washer pump would have to refill the washer plumbing from the reservoir to the nozzles. Such a drain-back condition could also result in water, dirt, or other outside contaminants being siphoned into the washer system through the washer nozzle orifice. This water could subsequently freeze and plug the nozzle, while other contaminants could interfere with proper nozzle operation and cause improper nozzle spray patterns. In addition, the check valve prevents washer fluid from siphoning through the washer nozzles after the washer system is turned Off. When the washer pump pressurizes and pumps washer fluid from the reservoir through the washer plumbing, the fluid pressure (5) unseats a diaphragm (3) from over a sump well within the valve by overriding the pressure applied to a piston (2) by a spring (1). With the diaphragm unseated, washer fluid is allowed to flow toward the two washer nozzles (4). When the washer pump stops operating, the spring pressure on the piston seats the diaphragm over the sump well in the valve and fluid flow in either direction within the washer plumbing is prevented. The check valve cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Description and Operation > Page 7511 Check Valve: Service and Repair REMOVAL 1. Remove both wiper arms from the wiper pivots. 2. Unlatch and open the hood. 3. Remove the cowl plenum cover/grille panel from over the cowl plenum. 4. From the underside of the cowl plenum cover/grille panel (5), disconnect the cowl plenum (4) and washer nozzle (1 and 6) hoses from the three barbed nipples of the check valve (2). 5. Remove the check valve from the underside of the cowl plenum cover/grille panel. INSTALLATION 1. Position the check valve (2) to the underside of the cowl plenum cover/grille panel (5). Be certain that the flow direction arrow molded into the check valve body is oriented towards the washer nozzles. 2. From the underside of the cowl plenum cover/grille panel, reconnect the cowl plenum (4) and washer nozzle (1 and 6) hoses to the three barbed nipples of the check valve. 3. Reinstall the cowl plenum cover/grille panel over the cowl plenum. 4. Close and latch the hood. 5. Reinstall both wiper arms onto the wiper pivots. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Left Rear Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 7516 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > Wiper High/Low Relay Wiper Relay: Description and Operation Wiper High/Low Relay The wiper high/low relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper high/low relay is located in the Power Distribution Center (PDC)/Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The wiper high/low relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The wiper high/low relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper high/low relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC)/Integrated Power Module (IPM). The inputs and outputs of the wiper high/low relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the output of the wiper on/off relay at all times through the wiper on/off relay output circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper high/low relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current when the ignition switch is in the On or Accessory positions from a fuse in the PDC/IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) is connected to the high speed brush of the wiper motor through a wiper high/low relay high speed output circuit, and is connected to the high speed brush whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to the low speed brush of the wiper motor through a wiper high/low relay low speed output circuit, and is connected to the low speed brush whenever the relay is de-energized. The wiper high/low relay can be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the ElectroMechanical Instrument Cluster (EMIC), the FCM, or the electronic message inputs to or outputs from the EMIC and the FCM that control the operation of the wiper high/low relay. The most reliable, efficient, and accurate means to diagnose the wiper high/low relay, the EMIC, the FCM, or the electronic message inputs and outputs related to the wiper high/low relay operation requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > Wiper High/Low Relay > Page 7522 Wiper Relay: Description and Operation Wiper On/Off Relay The wiper on/off relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper on/off relay is located in the Power Distribution Center (PDC)/Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The wiper on/off relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The wiper on/off relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper on/off relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC)/Integrated Power Module (IPM). The inputs and outputs of the wiper on/off relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the common feed terminal of the wiper high/low relay at all times through the wiper on/off relay output circuit. Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper on/off relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current at all times from a fuse in the PDC/IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit, and provides battery current to the wiper on/off relay output circuit whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to ground at all times through a take out of the left headlamp and dash wire harness with an eyelet terminal connector that is secured by a screw to the front end sheet metal, and is connected to the wiper on/off relay output circuit whenever the relay is de-energized. The wiper on/off relay may be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the ElectroMechanical Instrument Cluster (EMIC), the FCM, or the electronic message inputs to or outputs from the EMIC and the FCM that control the operation of the wiper on/off relay. The most reliable, efficient, and accurate means to diagnose the wiper on/off relay, the EMIC, the FCM, or the electronic message inputs and outputs related to the wiper on/off relay operation requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Left Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7527 Left Front Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7528 Integrated Power Module And Fan Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7529 Sensor-Washer Fluid Level Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7530 Washer Fluid Level Switch: Description and Operation The washer fluid level switch is a single pole, single throw reed-type switch mounted on the side of the washer reservoir (4) in the engine compartment. Only the molded plastic switch mounting flange (1) and the integral connector receptacle (8) are visible when the switch is installed in the reservoir. A short nipple formation (2) extends from the inner surface of the switch mounting flange, and a barb on the nipple is pressed through a rubber grommet seal (5) installed in the mounting hole of the reservoir. A small, molded plastic float (3) has two pivot pins (6) near its center that are snapped into two receptacles near the ends of two stanchions that extend toward the float from the nipple formation. A small magnet (7) is secured within the end of the float nearest the nipple, and a reed switch is concealed within the nipple. A diagnostic resistor is connected between the two switch terminals within the switch mounting flange. The washer fluid level switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. The washer fluid level switch uses a pivoting, oblong float to monitor the level of the washer fluid in the washer reservoir. The float contains a small magnet. When the float pivots, the proximity of this magnet to a stationary reed switch within the nipple formation of the switch changes. When the fluid level in the washer reservoir is at or above the float level, the float moves to a vertical position, the influence of the float magnetic field is removed from the reed switch, and the normally open reed switch contacts open. When the fluid level in the washer reservoir falls below the level of the pivoting float, the float moves to a horizontal position, the influence of the float magnetic field is applied to the reed switch, and the contacts of the normally open reed switch close. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the right (except SRT-10 and diesel engines) or left (SRT-10 and diesel engines only) headlamp and dash wire harness. The switch is connected in series between a clean ground output of the Front Control Module (FCM) on a sensor return circuit and the washer fluid switch sense input to the FCM. When the switch closes, the FCM senses the ground on the washer fluid switch sense circuit. The FCM is programmed to respond to this input by sending an electronic washer fluid indicator lamp-on message to the instrument cluster over the Programmable Communications Interface (PCI) data bus. The instrument cluster responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the instrument cluster, the FCM, or the electronic message inputs to or outputs from the instrument cluster and the FCM that control the operation of the washer fluid visual and/or audible indicators. The most reliable, efficient, and accurate means to diagnose the washer fluid level indicator, the instrument cluster, the FCM, or the electronic message inputs and outputs related to the washer fluid indicator requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7531 Washer Fluid Level Switch: Service and Repair REMOVAL NOTE: The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the washer hose (4) from the barbed outlet nipple of the washer pump/motor unit (3) and allow the washer fluid to drain into a clean container for reuse. 4. Disconnect the left headlamp and dash wire harness (1) connector for the washer fluid level switch (5) from the switch connector receptacle. NOTE: The pivoting float of the washer fluid level switch must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and in an upright position, the pivoting float will orient itself to the horizontal position when the switch connector receptacle is pointed straight upwards. 5. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the washer reservoir sump (2). Care must be taken not to damage the reservoir. 6. Remove the washer fluid level switch from the washer reservoir. 7. Remove the rubber grommet seal from the washer fluid level switch mounting hole in the washer reservoir and discard. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7532 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the washer reservoir (2). Always use a new rubber grommet seal on the reservoir. 2. Insert the float of the washer fluid level switch (5) through the rubber grommet seal and into the washer reservoir. The connector receptacle of the washer fluid level switch should be pointed upward. 3. Using hand pressure, press firmly and evenly on the washer fluid level switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Reconnect the left headlamp and dash wire harness (1) connector for the washer fluid level switch to the switch connector receptacle. 5. Reconnect the removed washer hose (4) to the barbed outlet nipple of the washer pump/motor unit (3). 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. 8. Close and latch the hood. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation Washer Fluid Level Indicator: Description and Operation A washer fluid indicator is standard equipment on all instrument clusters. The washer fluid indicator consists of the text "LOW WASH", which appears in the lower portion of the odometer Vacuum-Fluorescent Display (VFD) unit. The odometer VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The "LOW WASH" text appears in an amber color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The washer fluid indicator is serviced as a unit with the VFD in the instrument cluster. The washer fluid indicator gives an indication to the vehicle operator that the fluid level in the washer reservoir is low. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) (also known as the Integrated Power Module/IPM or Power Distribution Center/PDC) over the Programmable Communications Interface (PCI) data bus. The washer fluid indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is switched to ground by the instrument cluster circuitry. The instrument cluster will turn on the washer fluid indicator for the following reasons: - Washer Fluid Indicator Lamp-On Message - Each time the cluster receives a washer fluid indicator lamp-on message from the FCM indicating that a low washer condition has been detected for sixty consecutive seconds, the washer fluid indicator is illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a washer fluid indicator lamp-off message for sixty consecutive seconds from the FCM or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the washer fluid indicator is cycled off and then on again by the appropriate washer fluid lamp messages from the FCM. - Actuator Test - Each time the cluster is put through the actuator test, the washer fluid indicator will be turned on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The FCM continually monitors the washer fluid level switch in the washer reservoir to determine the level of the washer fluid. The FCM then sends the proper washer fluid indicator lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the washer fluid indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the washer fluid level switch, the FCM, the PCI data bus, or the electronic message inputs to the instrument cluster that control the washer fluid indicator, a diagnostic scan tool is required. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Left Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7539 Left Front Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7540 Integrated Power Module And Fan Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7541 Sensor-Washer Fluid Level Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7542 Washer Fluid Level Switch: Description and Operation The washer fluid level switch is a single pole, single throw reed-type switch mounted on the side of the washer reservoir (4) in the engine compartment. Only the molded plastic switch mounting flange (1) and the integral connector receptacle (8) are visible when the switch is installed in the reservoir. A short nipple formation (2) extends from the inner surface of the switch mounting flange, and a barb on the nipple is pressed through a rubber grommet seal (5) installed in the mounting hole of the reservoir. A small, molded plastic float (3) has two pivot pins (6) near its center that are snapped into two receptacles near the ends of two stanchions that extend toward the float from the nipple formation. A small magnet (7) is secured within the end of the float nearest the nipple, and a reed switch is concealed within the nipple. A diagnostic resistor is connected between the two switch terminals within the switch mounting flange. The washer fluid level switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. The washer fluid level switch uses a pivoting, oblong float to monitor the level of the washer fluid in the washer reservoir. The float contains a small magnet. When the float pivots, the proximity of this magnet to a stationary reed switch within the nipple formation of the switch changes. When the fluid level in the washer reservoir is at or above the float level, the float moves to a vertical position, the influence of the float magnetic field is removed from the reed switch, and the normally open reed switch contacts open. When the fluid level in the washer reservoir falls below the level of the pivoting float, the float moves to a horizontal position, the influence of the float magnetic field is applied to the reed switch, and the contacts of the normally open reed switch close. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the right (except SRT-10 and diesel engines) or left (SRT-10 and diesel engines only) headlamp and dash wire harness. The switch is connected in series between a clean ground output of the Front Control Module (FCM) on a sensor return circuit and the washer fluid switch sense input to the FCM. When the switch closes, the FCM senses the ground on the washer fluid switch sense circuit. The FCM is programmed to respond to this input by sending an electronic washer fluid indicator lamp-on message to the instrument cluster over the Programmable Communications Interface (PCI) data bus. The instrument cluster responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the instrument cluster, the FCM, or the electronic message inputs to or outputs from the instrument cluster and the FCM that control the operation of the washer fluid visual and/or audible indicators. The most reliable, efficient, and accurate means to diagnose the washer fluid level indicator, the instrument cluster, the FCM, or the electronic message inputs and outputs related to the washer fluid indicator requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7543 Washer Fluid Level Switch: Service and Repair REMOVAL NOTE: The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the washer hose (4) from the barbed outlet nipple of the washer pump/motor unit (3) and allow the washer fluid to drain into a clean container for reuse. 4. Disconnect the left headlamp and dash wire harness (1) connector for the washer fluid level switch (5) from the switch connector receptacle. NOTE: The pivoting float of the washer fluid level switch must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and in an upright position, the pivoting float will orient itself to the horizontal position when the switch connector receptacle is pointed straight upwards. 5. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the washer reservoir sump (2). Care must be taken not to damage the reservoir. 6. Remove the washer fluid level switch from the washer reservoir. 7. Remove the rubber grommet seal from the washer fluid level switch mounting hole in the washer reservoir and discard. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7544 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the washer reservoir (2). Always use a new rubber grommet seal on the reservoir. 2. Insert the float of the washer fluid level switch (5) through the rubber grommet seal and into the washer reservoir. The connector receptacle of the washer fluid level switch should be pointed upward. 3. Using hand pressure, press firmly and evenly on the washer fluid level switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Reconnect the left headlamp and dash wire harness (1) connector for the washer fluid level switch to the switch connector receptacle. 5. Reconnect the removed washer hose (4) to the barbed outlet nipple of the washer pump/motor unit (3). 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. 8. Close and latch the hood. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Description and Operation Windshield Washer Hose: Description and Operation The washer plumbing consists of a small diameter rubber reservoir washer hose that is routed from the barbed outlet nipple of the electric washer pump/motor unit on the washer reservoir through a trough molded into the back of the reservoir above the washer pump to the engine compartment washer hose to the right side of the engine cooling module. On SRT-10 models or those equipped with an optional diesel engine, the reservoir washer hose is routed through routing clips on the top of the radiator fan shroud from the washer reservoir on the left side of the radiator to the engine compartment washer hose on the right side of the radiator. The engine compartment washer hose is contained within the right headlamp and dash wire harness (2), which is routed through the engine compartment along the top of the right front fender wheel house to the dash panel. This hose is connected to the washer reservoir washer hose at one end (5) and to the cowl plenum washer hose at the other end (3) with molded plastic in-line fittings that have a barbed nipple on each end. The cowl plenum washer hose (4) is routed from the engine compartment into the cowl plenum area through a trough formation located near the right end of the cowl plenum cover/grille panel. The cowl plenum washer hose is connected to the washer system check valve/eye fitting on the underside of the cowl plenum cover/grille panel. The cowl plenum washer hose and the two washer nozzle hoses are routed through integral routing clips on the underside of the cowl plenum cover/grille panel. The cowl plenum washer hose is connected to one nipple on the eye fitting and the two washer nozzle hoses are connected to the other two nipples. The washer nozzle hoses are then routed along the underside of the cowl plenum cover/grille panel to the two washer nozzles. Washer hose is available for service only as roll stock, which must then be cut to length. The molded plastic washer hose fittings cannot be repaired. If these fittings are faulty or damaged, they must be replaced. Washer fluid in the washer reservoir is pressurized and fed by the washer pump/motor through the washer system plumbing and fittings to the two washer nozzles. Whenever routing the washer hose or a wire harness containing a washer hose, it must be routed away from hot, sharp, or moving parts; and, sharp bends that might pinch the hose must be avoided. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams Pump-Washer-Windshield Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Page 7551 Windshield Washer Pump: Description and Operation The washer pump/motor unit (1) is located on the rearward facing surface of the washer reservoir, in the right (except SRT-10 and diesel) or left (SRT-10 and diesel only) front corner of the engine compartment. A small permanently lubricated and sealed electric motor is coupled to the rotor-type washer pump. A seal flange with a barbed inlet nipple (6) on the pump housing passes through a rubber grommet seal installed in a dedicated mounting hole of the washer reservoir. A removable molded plastic filter screen (7) inserted into the inlet nipple prevents most debris from entering the pump housing. When the pump is installed in the reservoir a barbed outlet nipple (5) on the pump housing connects the unit to the washer system through a short washer reservoir hose. The washer pump/motor unit is retained on the reservoir by the interference fit between the barbed pump inlet nipple and the grommet seal, which is a light press fit. The top of the washer pump is also secured to the washer reservoir by the use of a snap post (2) on the motor housing and a snap post receptacle molded into the reservoir that allows for mounting of the washer pump without the use of fasteners. An integral connector receptacle (3) on the top of the motor housing connects the unit to the vehicle electrical system. The washer pump/motor unit cannot be repaired. If faulty or damaged, the entire washer pump/motor unit must be replaced. The washer pump/motor unit features a small Direct Current (DC) electric motor. The motor is connected to the vehicle electrical system through a single take out and two-cavity connector of the right (except SRT-10 and diesel) or left (SRT-10 and diesel only) headlamp and dash wire harness. The motor is grounded at all times through another take out of the right (except SRT-10 and diesel) or left (SRT-10 and diesel only) headlamp and dash wire harness. On models except SRT-10 or diesel, a single eyelet terminal connector is secured by a nut to a ground stud located on the right front fender inner shield in the engine compartment. On SRT-10 or diesel models, an eyelet terminal connector is secured by a ground screw to the left front fender inner shield in the engine compartment. The motor receives battery current on a washer pump/motor control circuit. The washer pump/motor control circuit is energized through a high side driver within the Front Control Module (FCM) whenever the FCM receives an electronic message requesting washer system operation from the ElectroMechanical Instrument Cluster (EMIC) over the Programmable Communications Interface (PCI) data bus. The EMIC monitors a resistor multiplexed hard wired input from the momentary washer switch contacts within the multi-function switch on the steering column to determine when it should issue the electronic message requesting washer system operation. Washer fluid is gravity-fed from the washer reservoir to the inlet side of the washer pump. When the pump motor is energized, the motor spins the rotor within the washer pump. The spinning pump rotor pressurizes the washer fluid and forces it through the pump outlet nipple, the washer plumbing, and the washer nozzles onto the windshield glass. The washer pump/motor unit may be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the FCM, the PCI data bus or the electronic messages used to control the operation of the washer pump/motor unit. The most reliable, efficient, and accurate means to diagnose the washer pump/motor unit, the EMIC, the FCM, the PCI data bus, and the electronic messages for washer pump/motor unit control requires the use of a diagnostic scan tool. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Page 7552 Windshield Washer Pump: Service and Repair REMOVAL NOTE: The washer pump/motor unit can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the washer hose from the barbed outlet nipple (8) of the washer pump/motor unit and allow the washer fluid to drain into a clean container for reuse. 4. Disconnect the left headlamp and dash wire harness connector for the washer pump/motor unit from the motor connector receptacle (1). 5. Firmly grasp the top of the washer pump/motor housing. 6. Pull lightly outward on the top of the washer pump/ motor housing away from the washer reservoir (6) far enough to disengage the snap post (2) on the top of the motor from the receptacle (3) in the reservoir. 7. Pull the washer pump/motor unit straight out from the washer reservoir far enough to disengage the barbed pump inlet nipple (7) from the rubber grommet seal (4) in the reservoir. 8. Remove the washer pump/motor unit from behind the washer reservoir. 9. Remove the rubber grommet seal from the washer reservoir and discard. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Page 7553 1. Install a new rubber grommet seal (4) into the washer pump mounting hole in the washer reservoir (6). Always use a new rubber grommet seal on the reservoir. 2. Position the barbed inlet nipple (7) of the washer pump to the rubber grommet seal in the washer reservoir. 3. Using hand pressure, press on the washer pump/ motor unit firmly and evenly until the barbed inlet nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Align the washer pump/motor snap post (2) on the top of the motor housing with the snap post receptacle (3) in the washer reservoir. 5. Using hand pressure, press firmly and evenly on the top of washer pump/motor unit until the snap post snaps into the washer reservoir receptacle. 6. Reconnect the washer reservoir hose to the barbed outlet nipple (8) of the washer pump. 7. Reconnect the left headlamp and dash wire harness connector for the washer pump/motor unit to the motor connector receptacle (1). 8. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 9. Reconnect the battery negative cable. 10. Close and latch the hood. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation Windshield Washer Reservoir: Description and Operation Except on SRT-10 and diesel models, the molded plastic washer fluid reservoir (1) is integral to the engine coolant overflow bottle (4) located on the right rearward facing surface of the engine cooling module shroud in the right front corner of the engine compartment. On SRT-10 and diesel models, the molded plastic washer fluid reservoir is separate from the engine coolant overflow bottle and is mounted on the rearward facing surface of the left vertical member of the radiator support in the engine compartment. These reservoirs are constructed of a translucent plastic that allows the fluid level to be inspected without removing the reservoir caps. A round bright yellow plastic cap (2) with a rubber seal snaps over the open end of the washer reservoir filler neck and can be easily distinguished from the coolant overflow bottle cap (3) by an International Control and Display Symbol icon for "Windshield Washer" and the text "Washer Fluid Only" molded into it. The cap hinges on and is secured to a molded-in hook formation on the top of the reservoir just behind the filler neck when it is removed for inspecting or adjusting the fluid level in the reservoir. Except on SRT-10 and diesel models, the washer reservoir is secured to the cooling module radiator shroud with two integral tabs at the bottom, and through two integral mounting brackets with two screws at the top. The two bottom tabs are inserted into two slots near the bottom of the shroud, while the two screws secure the mounting brackets to integral mounting points near the top of the shroud. On SRT-10 and diesel models, the washer reservoir is secured with two screws through integral mounting brackets to the left vertical member of the radiator support. There are separate, dedicated holes on the lower rearward facing side of either reservoir provided for the mounting of the washer/pump motor unit (6) and the washer fluid level switch (5). A snap post receptacle for the washer pump and a routing trough for the washer hose are molded into both reservoirs to allow for mounting of the washer pump/ motor unit without the use of fasteners. Except on SRT-10 and diesel models, the washer reservoir is serviced only as a unit with the engine coolant reserve bottle. A washer reservoir cannot be repaired and, if faulty or damaged, the unit must be replaced. The washer pump/motor unit, the washer fluid level switch, their rubber grommet seals, as well as the reservoir filler cap are each available for individual service replacement. The washer fluid reservoir provides a secure, on-vehicle storage location for a large reserve of washer fluid for operation of the washer system. The washer reservoir filler neck provides a clearly marked and readily accessible point from which to add washer fluid to the reservoir. The washer/pump motor unit is located in a sump area near the bottom of the reservoir to be certain that washer fluid will be available to the pump as the fluid level in the reservoir becomes depleted. The washer fluid level switch is mounted just above the washer pump inlet nipple in the sump area of the reservoir so that there will be adequate warning to the vehicle operator that the washer fluid level is low, well before the washer system will no longer operate. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation > Page 7557 Windshield Washer Reservoir: Service and Repair REMOVAL 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. Disengage the reservoir washer hose (4) from the integral routing clips on the top of the radiator fan shroud. 4. Disconnect the reservoir washer hose from the barbed nipple of the inline fitting at the engine compartment washer hose in the right headlamp and dash wire harness and allow the washer fluid to drain from the reservoir into a clean container for reuse. 5. Disconnect the left headlamp and dash wire harness (1) connector for the washer fluid level switch from the switch connector receptacle (5). 6. Disconnect the left headlamp and dash wire harness connector for the washer pump/motor unit from the motor connector receptacle (3). 7. Remove the two screws (3) that secure the washer reservoir (4) to the left vertical member of the radiator support (2). 8. Remove the washer reservoir from the left side of the engine compartment. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation > Page 7558 1. Position the washer reservoir (4) to the left vertical member of the radiator support (2) on the left side of the engine compartment. 2. Install and tighten the two screws (3) that secure the washer reservoir to the radiator support. Tighten the screws to 10 N.m (85 in.lbs.). 3. Reconnect the left headlamp and dash wire harness (1) connector for the washer pump/motor unit to the motor connector receptacle (3). 4. Reconnect the left headlamp and dash wire harness connector for the washer fluid level switch to the switch connector receptacle (5). 5. Reconnect the reservoir washer hose (4) to the barbed nipple of the inline fitting at the engine compartment washer hose in the right headlamp and dash wire harness. 6. Engage the reservoir washer hose into the integral routing clips on the top of the radiator fan shroud. 7. Refill the washer reservoir (2) with the washer fluid drained from the reservoir during the removal procedure. 8. Reconnect the battery negative cable. 9. Close and latch the hood. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation Windshield Washer Spray Nozzle: Description and Operation The fluidic washer nozzles (1) are constructed of molded plastic. Each nozzle has two integral latches (2) and an anti-rotation tab (4) that secure them in dedicated holes in the cowl plenum cover/grille panel located near the base of the windshield The domed upper surface of the washer nozzle is visible on the top of the plenum cover/grille panel, and the nozzle orifice (5) is oriented towards the windshield glass. The washer plumbing fittings (3) for the washer nozzles extend below the cowl plenum cover/grille panel. The cowl plenum cover/grille panel must be removed from the vehicle to access the nozzles for service. The washer nozzles cannot be adjusted or repaired. If faulty or damaged, they must be replaced. The two washer nozzles are designed to dispense washer fluid into the wiper pattern area on the outside of the windshield glass. Pressurized washer fluid is fed to each nozzle from the washer reservoir by the washer pump/ motor unit through a single hose, which is attached to a barbed nipple on each washer nozzle below the cowl plenum cover/grille panel. A fluidic matrix within the washer nozzle causes the pressurized washer fluid to be emitted from the nozzle orifice as an oscillating stream to more effectively cover a larger area of the glass to be cleaned. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Page 7562 Windshield Washer Spray Nozzle: Service and Repair REMOVAL 1. Remove both wiper arms from the wiper pivots. 2. Unlatch and open the hood. 3. Remove the cowl plenum cover/grille panel from over the cowl plenum. 4. From the underside of the cowl plenum cover/grille panel (1), disconnect the washer nozzle hose from the barbed nipple (3) of the washer nozzle. 5. From the underside of the cowl plenum cover/grille panel, release the integral latch features (2) of the washer nozzle and push the nozzle out through the mounting hole toward the top side of the cowl plenum cover/grille panel. 6. Remove the washer nozzle from the top of the cowl plenum cover/grille panel. INSTALLATION 1. From the top of the cowl plenum cover/grille panel, position the nipple end of the washer nozzle through the mounting hole and engage the anti-rotation tabs (2 and 4) of the nozzle into the anti-rotation notches in the mounting hole. 2. Using hand pressure, push firmly and evenly on the top of the washer nozzle until the integral latch features (6) lock into place on the underside of the cowl plenum cover/grille panel (1). 3. From the underside of the cowl plenum cover/grille panel, reconnect the washer hose to the barbed nipple (3) of the washer nozzle. 4. Reinstall the washer nozzle hose into its routing clips on the underside of the cowl plenum cover/ grille panel. 5. Reinstall the cowl plenum cover/grille panel over the cowl plenum. 6. Close and latch the hood. 7. Reinstall both wiper arms onto the wiper pivots. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation Wiper Arm: Description and Operation The wiper arms are the rigid members located between the wiper pivots protruding from the cowl plenum cover/grille panel near the base of the windshield and the wiper blades on the windshield glass. These wiper arms feature an over-center hinge that allows easy access to the windshield glass for cleaning. The wiper arms each have a die cast metal pivot end (3) with a large internally serrated socket formation at one end. A key (4) within the socket formation indexes the wiper arm to a keyway in the pivot shaft to provide wiper alignment, and a spring-loaded latch (5) on the underside of the pivot end locks the unit to the pivot shaft when it is fully installed. The right and left wiper arms for this model are not interchangeable, as the right wiper arm is slightly longer than the left one. The wide end of a tapered, stamped steel channel (8) hinges on and is secured with a hinge pin (6) to the blade end of both the right and left wiper arm pivot ends. One end of a long, rigid, stamped steel strap (2), with a small hole near its pivot end, is riveted and crimped within the narrow end of the stamped steel channel. The tip of the wiper blade end of this strap is bent back under itself to form a small hook (1). Concealed within the stamped steel channel, one end of a long spring (7) is engaged with a wire hook on the underside of the die cast pivot end, while the other end of the spring is hooked through the small hole in the steel strap. The entire wiper arm has a satin black finish applied to all of its visible surfaces. A wiper arm cannot be adjusted or repaired. If damaged or faulty, the entire wiper arm unit must be replaced. The wiper arms are designed to mechanically transmit the motion from the wiper pivots to the wiper blades. The wiper arm must be properly indexed to the wiper pivot in order to maintain the proper wiper blade travel on the glass. The serrated and keyed socket formation in the wiper arm pivot end interlocks with the serrations and keyway on the outer circumference of the wiper pivot shaft, providing positive engagement and alignment of this connection. The latch positively locks the wiper arm to the wiper pivot shaft when the arm is fully installed. The spring-loaded wiper arm hinge controls the down-force applied through the tip of the wiper arm to the wiper blade on the glass. The hook formation on the tip of the wiper arm provides a cradle for securing and latching the wiper blade pivot block to the wiper arm. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation > Page 7566 Wiper Arm: Service and Repair REMOVAL 1. Lift the wiper arm to its over-center position to hold the wiper blade off of the glass and relieve the spring tension on the wiper arm to wiper pivot shaft connection. 2. Pull the latch (2) on the pivot end (1) of the wiper arm outward. 3. Using a slight rocking action, disengage and remove the wiper arm pivot end from the wiper pivot shaft. INSTALLATION NOTE: The right and left wiper arms are not interchangeable. The right wiper arm is slightly longer than the left. Be certain that each wiper arm is installed on the proper wiper pivot. 1. Place the wiper arm hinge in its over-center position prior to attempting installation. 2. The wiper arms are indexed to the wiper pivot shafts with integral keys in the wiper arm pivot ends (1) and keyways in the wiper pivot shafts. Align the key of the wiper arm to the keyway on the wiper pivot shaft. 3. Once the wiper blade is aligned, push the pivot of the wiper arm down firmly and evenly over the wiper pivot shaft until it is fully engaged. When the wiper arm is fully engaged on the wiper pivot, the spring-loaded latch (2) will snap back into place against the wiper arm pivot end. 4. Gently lower the wiper arm until the wiper blade is in position on the windshield glass. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) 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 Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 7580 Wiper Blade: Description and Operation Each wiper blade is secured by an integral latching pivot block (3) to the hook formation on the tip of each wiper arm, and rests on the glass near the base of the windshield when the wipers are not in operation. The wiper blade consists of the following components: - Superstructure (1) - The superstructure includes several stamped steel bridges and links with claw formations that grip the wiper blade element. Also included in this unit is the latching, molded plastic pivot block that secures the superstructure to the wiper arm. All of the metal components of the wiper blade have a satin black finish applied. - Element (2) - The wiper element or squeegee is the resilient rubber member of the wiper blade that contacts the glass. - Flexor (7) - The flexor is a rigid metal component running along the length of each side of the wiper element where it is gripped by the claws (6) of the superstructure. All models have two 60.00 centimeter (23.62 inch) long wiper blades with non-replaceable rubber elements (squeegees). The wiper blades cannot be adjusted or repaired. If faulty, worn, or damaged the entire wiper blade unit must be replaced. The wiper blades are moved back and forth across the glass by the wiper arms when the wipers are being operated. The wiper blade superstructure is the flexible frame that grips the wiper blade element and evenly distributes the force of the spring-loaded wiper arm along the length of the element. The combination of the wiper arm force and the flexibility of the superstructure makes the element conform to and maintain proper contact with the glass, even as the blade is moved over the varied curvature that may be encountered across the glass surface. The wiper element flexor provides the claws of the blade superstructure with a rigid, yet flexible component on the element which can be gripped. The rubber element is designed to be stiff enough to maintain an even cleaning edge as it is drawn across the glass, yet resilient enough to conform to the glass surface and flip from one cleaning edge to the other each time the wiper blade changes directions. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 7581 Wiper Blade: Service and Repair REMOVAL CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. NOTE: The notched end of the wiper element flexor should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. 1. Lift the wiper arm (2) to raise the wiper blade and element (6) off of the glass, until the wiper arm hinge is in its over-center position. 2. To remove the blade from the arm, depress the latch release tab (4) on the pivot block (3) under the tip of the arm and slide the blade away from the tip towards the pivot end of the arm far enough to disengage the pivot block from the hook formation (5) on the end of the arm. 3. Extract the hook formation on the tip of the wiper arm through the opening in the wiper blade superstructure (1) just ahead of the pivot block. 4. Gently lower the tip of the wiper arm onto the glass. INSTALLATION CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. NOTE: The notched end of the wiper element flexor should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. 1. Lift the wiper arm (2) off of the windshield glass, until the wiper arm hinge is in its over-center position. 2. Position the wiper blade near the hook formation (5) on the tip of the arm with the notched end of the wiper element flexor oriented towards the end of the wiper arm that is nearest to the wiper pivot. 3. Insert the hook formation on the tip of the arm through the opening in the blade superstructure (1) ahead of the pivot block (3) far enough to engage the pivot block into the hook. 4. Slide the pivot block up into the hook formation on the tip of the wiper arm until the latch release tab (4) snaps into its locked position. Latch engagement will be accompanied by an audible click. 5. Gently lower the wiper blade and element (6) onto the glass. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Left Rear Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 7585 Left Side Engine Compartment Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Connector Views Motor-Windshield Wiper Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 7590 Wiper Motor: Description and Operation The wiper module is secured with screws through three rubber grommet-type insulators (5) to the cowl plenum panel. The module is concealed beneath the molded plastic cowl plenum cover/grille panel between the base of the windshield and the rear edge of the hood panel. The ends of the pivot shafts protruding through openings in the cowl plenum cover/grille panel to drive the wiper arms and blades are the only visible components of the wiper module. The wiper module consists of the following major components: - Bracket - The wiper module bracket consists of a long tubular steel main member (2) that has a die cast pivot bracket (1) at each end to which the two wiper pivots are secured. A stamped steel clamp secures the center of the tubular member to the die cast bracket integral to the wiper motor with two screws. - Crank Arm (10) - The wiper motor crank arm is a stamped steel unit with a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a ball stud secured to the drive end. Linkage (2) - Two stamped steel drive links connect the wiper motor crank arm to the wiper pivot lever arms. The left side drive link has a plastic socket-type bushing (6) on each end. The right side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The socket-type bushing on one end of each drive link is snap-fit over the ball stud on the lever arm (8) of its respective pivot. The right side drive link sleeve-type bushing end is then fit over the motor crank arm ball stud, and the other socket-type bushing of the left side drive link is snap-fit over the exposed end of the wiper motor crank arm ball stud. - Motor (11) - The wiper motor features an integral die cast bracket to which the wiper module bracket is secured with a stamped steel clamp and two screws near the top and which has a single rubber insulated mounting ear at the bottom. This die casting also serves as the wiper motor transmission housing from which the wiper motor output shaft exits. A nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal automatic resetting circuit breaker. - Pivots (2) - The two front wiper pivots are secured within the die cast pivot brackets on the outboard ends of the wiper module main member. The lever arms that extend from the center of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fastened each has a serrated driver with a keyway. The lower ends of the pivot shafts are installed through lubricated bushings in the pivot brackets and are secured with snap rings. The wiper module cannot be adjusted or repaired. If any component of the module is faulty or damaged, the entire wiper module unit must be replaced. The wiper module operation is controlled by the battery current inputs received by the wiper motor through the wiper on/off and wiper high/low relays. The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately opens and closes the wiper park switch sense circuit to ground, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned Off, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 7591 Wiper Motor: Service and Repair REMOVAL 1. Remove both wiper arms (4) from the wiper pivots. 2. Unlatch and open the hood. 3. Disconnect and isolate the battery negative cable. 4. Remove the cowl plenum cover/grille panel (5) from over the cowl plenum (8). 5. Disconnect the left headlamp and dash wire harness connector (7) for the wiper motor from the motor pigtail wire connector. 6. Remove the two screws (9) that secure the wiper module (6) to the top of the cowl plenum panel at the pivot brackets. 7. Remove the screw that secures the wiper module to the bottom of the cowl plenum panel. 8. Remove the wiper module from the cowl plenum panel as a unit. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 7592 1. Position the wiper module (6) into the cowl plenum (8) as a unit. 2. Install the two screws (9) that secure the wiper module to the top of the cowl plenum panel at the pivot brackets. Tighten the screw on the driver side, followed by the screw on the passenger side. Tighten the screws to 8 N.m (75 in.lbs.). 3. Install and tighten the screw that secures the wiper module to the bottom of the cowl plenum panel. Tighten the screw to 8 N.m (75 in.lbs.). 4. Reconnect the left headlamp and dash wire harness connector (7) for the wiper motor to the motor pigtail wire connector. 5. Reinstall the cowl plenum cover/grille panel (5) over the cowl plenum. 6. Reconnect the battery negative cable. 7. Close and latch the hood. 8. Reinstall both wiper arms (4) onto the wiper pivots. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Description and Operation Wiper Motor Linkage: Description and Operation The wiper module is secured with screws through three rubber grommet-type insulators (5) to the cowl plenum panel. The module is concealed beneath the molded plastic cowl plenum cover/grille panel between the base of the windshield and the rear edge of the hood panel. The ends of the pivot shafts protruding through openings in the cowl plenum cover/grille panel to drive the wiper arms and blades are the only visible components of the wiper module. The wiper module consists of the following major components: - Bracket - The wiper module bracket consists of a long tubular steel main member (2) that has a die cast pivot bracket (1) at each end to which the two wiper pivots are secured. A stamped steel clamp secures the center of the tubular member to the die cast bracket integral to the wiper motor with two screws. - Crank Arm (10) - The wiper motor crank arm is a stamped steel unit with a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a ball stud secured to the drive end. Linkage (2) - Two stamped steel drive links connect the wiper motor crank arm to the wiper pivot lever arms. The left side drive link has a plastic socket-type bushing (6) on each end. The right side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The socket-type bushing on one end of each drive link is snap-fit over the ball stud on the lever arm (8) of its respective pivot. The right side drive link sleeve-type bushing end is then fit over the motor crank arm ball stud, and the other socket-type bushing of the left side drive link is snap-fit over the exposed end of the wiper motor crank arm ball stud. - Motor (11) - The wiper motor features an integral die cast bracket to which the wiper module bracket is secured with a stamped steel clamp and two screws near the top and which has a single rubber insulated mounting ear at the bottom. This die casting also serves as the wiper motor transmission housing from which the wiper motor output shaft exits. A nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal automatic resetting circuit breaker. - Pivots (2) - The two front wiper pivots are secured within the die cast pivot brackets on the outboard ends of the wiper module main member. The lever arms that extend from the center of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fastened each has a serrated driver with a keyway. The lower ends of the pivot shafts are installed through lubricated bushings in the pivot brackets and are secured with snap rings. The wiper module cannot be adjusted or repaired. If any component of the module is faulty or damaged, the entire wiper module unit must be replaced. The wiper module operation is controlled by the battery current inputs received by the wiper motor through the wiper on/off and wiper high/low relays. The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately opens and closes the wiper park switch sense circuit to ground, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned Off, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Description and Operation > Page 7596 Wiper Motor Linkage: Service and Repair REMOVAL 1. Remove both wiper arms (4) from the wiper pivots. 2. Unlatch and open the hood. 3. Disconnect and isolate the battery negative cable. 4. Remove the cowl plenum cover/grille panel (5) from over the cowl plenum (8). 5. Disconnect the left headlamp and dash wire harness connector (7) for the wiper motor from the motor pigtail wire connector. 6. Remove the two screws (9) that secure the wiper module (6) to the top of the cowl plenum panel at the pivot brackets. 7. Remove the screw that secures the wiper module to the bottom of the cowl plenum panel. 8. Remove the wiper module from the cowl plenum panel as a unit. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Description and Operation > Page 7597 1. Position the wiper module (6) into the cowl plenum (8) as a unit. 2. Install the two screws (9) that secure the wiper module to the top of the cowl plenum panel at the pivot brackets. Tighten the screw on the driver side, followed by the screw on the passenger side. Tighten the screws to 8 N.m (75 in.lbs.). 3. Install and tighten the screw that secures the wiper module to the bottom of the cowl plenum panel. Tighten the screw to 8 N.m (75 in.lbs.). 4. Reconnect the left headlamp and dash wire harness connector (7) for the wiper motor to the motor pigtail wire connector. 5. Reinstall the cowl plenum cover/grille panel (5) over the cowl plenum. 6. Reconnect the battery negative cable. 7. Close and latch the hood. 8. Reinstall both wiper arms (4) onto the wiper pivots. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Description and Operation Wiper Pivot: Description and Operation The wiper module is secured with screws through three rubber grommet-type insulators (5) to the cowl plenum panel. The module is concealed beneath the molded plastic cowl plenum cover/grille panel between the base of the windshield and the rear edge of the hood panel. The ends of the pivot shafts protruding through openings in the cowl plenum cover/grille panel to drive the wiper arms and blades are the only visible components of the wiper module. The wiper module consists of the following major components: - Bracket - The wiper module bracket consists of a long tubular steel main member (2) that has a die cast pivot bracket (1) at each end to which the two wiper pivots are secured. A stamped steel clamp secures the center of the tubular member to the die cast bracket integral to the wiper motor with two screws. - Crank Arm (10) - The wiper motor crank arm is a stamped steel unit with a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a ball stud secured to the drive end. Linkage (2) - Two stamped steel drive links connect the wiper motor crank arm to the wiper pivot lever arms. The left side drive link has a plastic socket-type bushing (6) on each end. The right side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The socket-type bushing on one end of each drive link is snap-fit over the ball stud on the lever arm (8) of its respective pivot. The right side drive link sleeve-type bushing end is then fit over the motor crank arm ball stud, and the other socket-type bushing of the left side drive link is snap-fit over the exposed end of the wiper motor crank arm ball stud. - Motor (11) - The wiper motor features an integral die cast bracket to which the wiper module bracket is secured with a stamped steel clamp and two screws near the top and which has a single rubber insulated mounting ear at the bottom. This die casting also serves as the wiper motor transmission housing from which the wiper motor output shaft exits. A nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal automatic resetting circuit breaker. - Pivots (2) - The two front wiper pivots are secured within the die cast pivot brackets on the outboard ends of the wiper module main member. The lever arms that extend from the center of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fastened each has a serrated driver with a keyway. The lower ends of the pivot shafts are installed through lubricated bushings in the pivot brackets and are secured with snap rings. The wiper module cannot be adjusted or repaired. If any component of the module is faulty or damaged, the entire wiper module unit must be replaced. The wiper module operation is controlled by the battery current inputs received by the wiper motor through the wiper on/off and wiper high/low relays. The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately opens and closes the wiper park switch sense circuit to ground, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned Off, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Description and Operation > Page 7601 Wiper Pivot: Service and Repair REMOVAL 1. Remove both wiper arms (4) from the wiper pivots. 2. Unlatch and open the hood. 3. Disconnect and isolate the battery negative cable. 4. Remove the cowl plenum cover/grille panel (5) from over the cowl plenum (8). 5. Disconnect the left headlamp and dash wire harness connector (7) for the wiper motor from the motor pigtail wire connector. 6. Remove the two screws (9) that secure the wiper module (6) to the top of the cowl plenum panel at the pivot brackets. 7. Remove the screw that secures the wiper module to the bottom of the cowl plenum panel. 8. Remove the wiper module from the cowl plenum panel as a unit. INSTALLATION Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Description and Operation > Page 7602 1. Position the wiper module (6) into the cowl plenum (8) as a unit. 2. Install the two screws (9) that secure the wiper module to the top of the cowl plenum panel at the pivot brackets. Tighten the screw on the driver side, followed by the screw on the passenger side. Tighten the screws to 8 N.m (75 in.lbs.). 3. Install and tighten the screw that secures the wiper module to the bottom of the cowl plenum panel. Tighten the screw to 8 N.m (75 in.lbs.). 4. Reconnect the left headlamp and dash wire harness connector (7) for the wiper motor to the motor pigtail wire connector. 5. Reinstall the cowl plenum cover/grille panel (5) over the cowl plenum. 6. Reconnect the battery negative cable. 7. Close and latch the hood. 8. Reinstall both wiper arms (4) onto the wiper pivots. Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Module - Integrated Power (Front View) Dodge Ram Srt-10 Pickup Workshop Manual (V10-505 8.3L (2004)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > Wiper High/Low Relay Wiper Relay: Description and Operation Wiper High/Low Relay The wiper high/low relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper high/low relay is located in the Power Distribution Center (PDC)/Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The wiper high/low relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The wiper high/low relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper high/low relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC)/Integrated Power Module (IPM). The inputs and outputs of the wiper high/low relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the output of the wiper on/off relay at all times through the wiper on/off relay output circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper high/low relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current when the ignition switch is in the On or Accessory positions from a fuse in the PDC/IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) is connected to the high speed brush of the wiper motor through a wiper high/low relay high speed output circuit, and is connected to the high speed brush whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to the low speed brush of the wiper motor through a wiper high/low relay low speed output circuit, and is connected to the low speed brush whenever the relay is de-energized. The wiper high/low relay can be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the ElectroMechanical Instrument Cluster (EMIC), the FCM, or the electronic message inputs to or outputs from the EMIC and the FCM that control the operation of the wiper high/low relay. The most reliable, efficient, and accurate means to diagnose the wiper high/low relay, the EMIC, the FCM, or the electronic message inputs and outputs related to the wiper high/low relay operation requires the use of a diagnostic scan tool.