Dodge Ram 3500 Van Workshop Manual (V8-360 5.9L VIN 5 Magnum (1998) )

Factory Workshop Manual
Make
Dodge
Model
Ram 3500 Van
Engine and year
V8-360 5.9L VIN 5 Magnum (1998)
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This manual was submitted by

Anonymous
Date
1st January 2018
Dodge Ram 3500 Van Workshop Manual (V8-360 5.9L VIN 5 Magnum (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Service and Repair
Keyless Entry Module: Service and Repair
A power lock and Remote Keyless Entry (RKE) module is only used on high-line versions of this
vehicle that are not equipped with the optional Vehicle Theft Security System (VTSS). Models
equipped with the optional VTSS have the power lock and RKE functions controlled by the Central
Timer Module (CTM). See Power Lock System and Remote Keyless Entry System in the General
Information for more information.
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE

ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the engine cover from
the passenger compartment.
Power Lock And Remote Keyless Entry Module Remove/Install
3. Remove the two screws that secure the power lock and RKE module to the inboard side of the
left center instrument panel support. 4. Pull the power lock and RKE module away from its
mounting location far enough to access and unplug the two wire harness connectors. 5. Remove
the power lock and RKE module from the instrument panel. 6. Reverse the removal procedures to
install. Tighten the mounting screws to 3.3 N.m (30 in. lbs.).
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Service and Repair

INJURY.
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Testing and Inspection
Power Door Lock Control Module: Testing and Inspection
The power lock and Remote Keyless Entry (RKE) module is used on models that are not equipped
with the optional Vehicle Theft Security System (VTSS).
1. Check the fused B(+) fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted
circuit or component as required and replace the
faulty fuse.
2. Check for battery voltage at the fused B(+) fuse in the junction block. If OK, go to Step 4. If not
OK, repair the open circuit to the Power
Distribution Center (PDC) as required.
3. Check the fused ignition switch output fuse in the junction block. If OK, go to Step 5. If not OK,
rep air the shorted circuit or component as
required and replace the faulty fuse.
4. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch
output fuse in the junction block. If OK, turn the
ignition switch to the Off position and go to Step 6. If not OK, repair the open circuit to the ignition
switch as required.
5. Disconnect and isolate the battery negative cable. Access and unplug the power lock and RKE
module wire harness connectors. See Power Lock
and Remote Keyless Entry Module in the Removal and Installation for the procedures.
6. Check the wire harness connectors and the receptacles in the power lock and RKE module for
loose, corroded, or damaged terminals and pins. If
OK, go to Step 8. If not OK, repair the connections as required.
7. Probe the ground circuit cavity in the black power lock and RKE module wire harness connector
and check for continuity to a good ground. There
should be continuity. If OK, go to Step 9. If not OK, repair the open circuit to ground as required.
8. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity in
the black power lock and RKE module wire
harness connector. If OK, go to Step 10. If not OK, repair the open circuit to the fuse in the junction
block as required.
9. Probe the door lock switch output (lock) circuit cavity in the black power lock and RKE module
wire harness connector and check for battery
voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 11. If not OK,
repair the open circuit from either or both power lock switch(s) to the power lock and RKE module
as required.
10. Probe the door lock switch output (unlock) circuit cavity in the black power lock and RKE
module wire harness connector and check for battery
voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 12. If not
OK, repair the open circuit from either or both power lock switch(s) to the power lock and RKE
module as required.
11. Check for continuity between the door jamb switch sense circuit cavity of the black power lock
and RKE module wire harness connector and a
good ground. There should be no continuity with both the side and the rear cargo doors closed,
and there should be continuity with any of the side or rear cargo doors opened. Test each of the
side and the rear doors. If OK, go to Step 13. If not OK, repair the open circuit to the door jamb
switch(s) or replace the faulty door jamb switch(s) as required.
output circuit cavity in the blue power lock and
RKE module wire harness connector. If OK, turn the ignition switch to the Off position and go to
Step 14. If not OK, repair the open circuit to the fuse in the junction block as required.
13. Plug the wire harness connectors back into the power lock and RKE module. Back probe the
door latch switch sense circuit cavity of the black
power lock and RKE module wire harness connector and check for continuity to a good ground.
There should be no continuity. Press and release the Unlock button of the RKE transmitter. There
should now be continuity for about thirty seconds. If OK, go to Step 15. If not OK, replace the faulty
power lock and RKE module.
14. Back probe the door lock driver circuit cavity in the black power lock and RKE module wire
harness connector and check for battery voltage as
the power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of
the RKE transmitter. If OK, go to Step 16. If not OK using the power lock switch, but OK with the
RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE
transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter in the
Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the
faulty power lock and RKE module.
15. Still back probing the door lock driver circuit cavity in the black power lock and RKE module
wire harness connector, open the side or rear cargo
door. Move the power lock switch to the Lock position or press the Lock button of the RKE
transmitter. Now close all of the doors. Within five seconds of the last door closing, there should be
battery voltage on the door lock driver circuit. If OK, go to Step 17. If not OK, replace the faulty
16. Back probe the door unlock driver circuit cavity in the black power lock and RKE module wire
the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button
of the RKE transmitter. If OK, see Power Lock Motor in the Diagnosis and Testing. If not OK using
the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis
and Testing. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote
Keyless Entry Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the
RKE transmitter, replace the faulty power lock and RKE module.
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Testing and Inspection > Page 14
Power Door Lock Control Module: Service and Repair

INJURY.
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring
Corrosion
Technical Service Bulletin # D20 Date: 040901
Recall - ABS Wiring Corrosion
September 2004
Dealer Service Instructions for:
Safety Recall D20 - ABS Wiring Corrosion
Models
1998-2003 (AB) Dodge Ram Van/Wagon
NOTE:
This recall applies only to the above vehicles equipped with a 4-wheel Anti-lock Brake System
(ABS) (sales code BGK).
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process.
Subject
Electrolyte (battery acid) from aftermarket batteries may leak onto an Antilock Brake System (ABS)
wiring connector on about 43,000 of the above vehicles. This may cause the wiring to corrode and
short circuit, which can result in an underhood fire.
Repair
All vehicles must have a revised battery tray installed that will protect the ABS control module
wiring harness connector from future electrolyte leakage. A cowl seal extension must also be
installed on all vehicles to redirect any water draining from the windshield away from the battery.
The ABS control module wiring harness and connector must be inspected for electrolyte damage
and repaired if necessary.
Corrosion > Page 24
Parts Information
Completion Reporting and Reimbursement

Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim
Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to
record recall service completions and provide dealer payments.
Corrosion > Page 25
Use one of the labor operation numbers and time allowances shown.
Add the cost of the recall parts package plus applicable dealer allowance to your claim.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing instructions.
Parts Return
Not required.
Dealer Notification and Vehicle list
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this
recall in the near future.
Vehicle Lists, Global Recall System, VIP and Dealer Follow Up
All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS)
and Vehicle Information Plus (VIP) for dealer inquiry as needed.
Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification
letter.
GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's
name, address and phone number are listed if known. Completed vehicles are removed from GRS
within several days of repair claim submission.
To use this system, click on the "Service" tab and then click on "Global Recall System." Your
dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at
recall launch, those with a phone number, city, zip code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery.
Dealers should also use the VIN list to follow up with all owners to schedule appointments for this
repair.
Recall VIN lists may contain confidential, restricted owner name and address information that was
obtained from the Department of Motor Vehicles of various states. Use of this information is
permitted for this recall only and is strictly prohibited from all other use.
Owner Notification and Service Scheduling
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A generic copy of the owner letter is included.
Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our
records if applicable.
Corrosion > Page 26
Additional Information
If you have any questions or need assistance in completing this action, please contact your Service
and Parts District Manager.
Customer Services Field Operations DaimlerChrysler Corporation
A. Install Cowl Seal Extension
1. Open the hood.
2. Using Mopar glass cleaner and a shop cloth, clean the plastic cowl panel where the cowl seal
ends on the driver's side of the vehicle (Figure 1).
3. Test fit the cowl seal extension. Cut the cowl seal extension length so that the seal stops at the
end of the plastic cowl panel (Figure 1).
4. Insert the cowl seal connector halfway into the cowl seal extension (Figure 2).
5. Remove the protective plastic covering from the glue strip on the cowl seal extension.
6. Install the cowl seal extension connector into the original cowl seal end and firmly press the seal
against the plastic cowl panel (Figure 2).
Corrosion > Page 27
7. Continue with Section B. Inspect ABS Control Module Wiring Harness Connector.
B. Inspect ABS Control Module Wiring Harness Connector
1. Turn the ignition switch to the "Off" position. Be certain that all electrical accessories are turned
off.
2. Loosen the battery negative cable clamp pinch-bolt hex nut.
3. Disconnect the battery negative cable terminal clamp from the battery negative terminal post. If
necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Figure
3).
4. Loosen the battery positive cable terminal clamp pinch-bolt hex nut.
5. Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If
3).
6. Remove the two nuts with washers that secure the battery hold down strap to the threaded end
of the J-bolt and the long stud (Figure 4).
7. Remove the battery hold down strap from the top of the battery (Figure 4).
8. Remove the J-bolt from the holes in the battery tray support on the inboard side of the battery
tray (Figure 4).
9. Carefully remove the battery from the battery tray.

Corrosion > Page 28
WARNING:
Wear a suitable pair of rubber gloves when removing the battery. Safety glasses should also be
worn.
10. Remove the three screws that secure the bottom of the battery tray to the battery tray support
(Figure 5).
11. Remove the two screws that secure the outboard side of the battery tray to the left cowl side
panel (Figure 5).
12. Lift the battery tray slightly and disconnect the battery temperature sensor electrical connector.
13. Remove the battery tray and the drain tube from the vehicle as an assembly (Figure 5).
14. In the area below the battery location, inspect the front (large) wiring harness connector on the
ABS control module for acid damage, by spraying the connector and surrounding area with the
provided Electrolyte Detection and Neutralizing Spray (Figure 6).
> If the spray remains an orange color, there is no electrolyte (battery acid) on the ABS control
module wiring harness connector. Continue with Section E - Battery Tray Installation.
Corrosion > Page 29
> If the spray turns a purple color, continue with Step 15 of this procedure.
15. Disconnect the large ABS control module wiring harness connector from the ABS control
module by first sliding the red lock tab forward. Then push down on the black release tab while
pulling the connector from the module (Figure 7).
16. Inspect the large ABS control module wiring harness connector:
a. If a heat damaged (melted) connector is found, replace the wiring harness connector. Continue
with Section C - ABS Control Module Wiring Harness Connector Replacement.
If no heat damage is found continue with inspection Step b.
b. Inspect the wire side and the terminal side of the large ABS control module wiring harness
connector for green colored corrosion. If green colored corrosion is found in one or more of the
connector cavities continue with Section C - ABS Control Module Wiring Harness Connector
Replacement. If no green colored corrosion is found, continue with inspection Step c.
c. Looking into the terminal side of the large ABS control module wiring harness connector, inspect
the metal terminals for a dull finish or discoloration. If a dull finish or discoloration is found, continue
with Section C - ABS Control Module Wiring Harness Connector Replacement because the original
connector housing wire weather seals have been damaged. If no dull or discolored terminals are
found continue with Section E - Battery Tray Installation.
C. ABS Control Module Wiring Harness Connector Replacement
NOTE:
Only ABS control module wiring harness connectors with heat damage (melted), green wire
terminals or dull/discolored terminals, as determined by the inspection in Section B, require
replacement.
Corrosion > Page 30
1. Remove the secondary terminal lock from the original ABS control module wiring harness
connector housing (Figure 8).
2. Some models may have two empty wire cavities in the ABS control module wiring harness
connector housing. Insert the gray wire cavity plugs supplied with the repair kit into the correct
cavities of the new ABS control module wiring harness connector.
3. The ABS control module wiring harness connector terminals that do not have heat damage,
green corrosion or are only dull or discolored can be transferred to the new connector using the
following process:
a. From the terminal side of the connector, insert a small pick into the connector next to the
terminal and push on the terminal release arm while pulling on the wire.
CAUTION:
Remove only one wire from the original connector at a time and note which connector cavity the
wire is to be transfer into.
b. Using the electrolyte detection and neutralizing spray, lightly spray the removed wire until the
spray remains an orange color. This may require two or three applications.
c. Using compressed air, carefully dry the terminal and wire.
d. Insert the terminal into the proper connector cavity of the new connector housing.
e. Repeat Steps a. through d. on all wires that need to be transferred to the new connector
housing.
4. The ABS control module wiring harness connector terminals with heat damage and/or green
corrosion must be replaced using the following process:
a. Cut off the wire one inch back from the original ABS connector.
b. Remove one-half (1/2) inch (13 mm) of insulation from the wire on the harness that needs to be
spliced.
c. Cut the replacement wire supplied in the connector repair kit to the required length. Then remove
one-half (1/2) inch (13 mm) of insulation from the wire.
d. Place a piece of sealant lined heat shrink tubing on one side of the wire.
Corrosion > Page 31
e. Place the strands of wire overlapping each other inside of the brass splice band (Figure 9).
f. Using crimp tool (Mopar P/N 05019912AA), crimp the brass splice band and wires together
(Figure 10).
g. Solder the connection together using rosin core type solder. DO NOT use acid core solder.
CAUTION:
All splices must be properly soldered. Failure to properly solder these wiring connectors can cause
the ABS to become inoperative in the future.
h. Center the shrink tubing over the splice joint. Using a heat gun, heat the surface of the shrink
tubing until the shrink tubing is tightly sealed and sealant comes out of both ends of the shrink
tubing (Figure 11).
5. After all of the terminals have been transferred or replaced, install the blue secondary terminal
lock into the ABS control module wiring harness connector (Figure 8).
Corrosion > Page 32
6. Using a small mirror (Snap-on GA295 or equivalent), inspect the ABS control module connector
pins for green corrosion and the connector housing for heat damage (Figure 12).
> ABS control module connectors found with green corroded pins continue with Section D - ABS
Control Module Replacement.
> ABS control module connector housings found with heat damage continue with Section D - ABS
> ABS control module connectors found without heat damage or green corroded pins continue with
Section E - Battery Tray Installation.
D. ABS Control Module Replacement
NOTE:
Only ABS control modules with a heat damaged (melted) connector or green corroded connector
pins, as determined by the inspection in Section B and C, require replacement. Very few vehicles
are expected to require ABS control module replacement.
1. Disconnect the small ABS control module wiring connector from the ABS control module (Figure
13).
2. Remove the four mounting screws on the ABS control module (Figure 13).
3. Lift the module from the ABS hydraulic control unit and disconnect the solenoid connector
located on the bottom side of the ABS control module.
4. Remove the ABS control module from the vehicle and discard.
5. Using a clean shop towel, clean the ABS control module mounting surface on the ABS hydraulic
control unit.
6. Connect the solenoid connector to the new ABS control module and then place the module into
position on the ABS hydraulic control unit.
Corrosion > Page 33
7. Install the four ABS control module mounting screws. Tighten the screws to 39 in. lbs (4.4 N.m).
8. Continue with Section E - Battery Tray Installation.
E. Battery Tray Installation
1. If disconnected, spray the ABS control module connector and the ABS control module wiring
harness connector with Electrolyte Detection and Neutralizing spray to ensure that all traces of acid
have been neutralized.
NOTE:
When the spray remains an orange color, any remaining battery acid has been neutralized.
2. Using compressed air, carefully blow out the connector until completely dry.
3. If previously disconnected, connect the large and/or small wiring harness connectors to the ABS
control module.
4. Transfer the battery temperature sensor from the old battery tray to the new battery tray (Figure
14). Then discard the old battery tray.
5. Place a small bead of RTV silicone rubber adhesive (P/N 04883971) onto the base of the new
drain tube grommet.
6. Snap the new drain tube into position on the new battery tray (Figure 14).
7. While installing the new battery tray into position, route the drain tube through the original hole in
the fender panel (Figure 15) and connect the battery temperature sensor electrical connector.
8. Install the battery tray mounting bolts. Tighten the bolts to 95 in. lbs. (10.7 N.m).
Corrosion > Page 34
9. Install the battery onto the new battery tray.
10. Install the "J" hook and battery hold down bracket.
11. Install the battery hold down retaining nuts. Tighten the nuts to 24 in. lbs. (2.7 N.m).
12. Connect the positive battery cable to the positive battery post. Tighten the retaining nut to 70 in.
lbs. (7.9 N.m).
13. Connect the negative battery cable to the negative battery post. Tighten the retaining nut to 70
in. lbs. (7.9 N.m).
14. From inside the left wheel well housing, secure the battery tray drain tube to the frame rail
bracket with the provided plastic tie strap (Figure 16).
15. If the ABS control module was replaced, connect the DRB III scan tool to the vehicle and
program the rear axle ratio and tire size into the new control module.
Corrosion > Page 35
Control Module > Component Information > Technical Service Bulletins > Recalls: > NHTSA04V185000 > Apr > 04 > Recall
04V185000: ABS Control Module Corrosion
Electronic Brake Control Module: Recalls Recall 04V185000: ABS Control Module Corrosion
DEFECT: On some van and wagon model vehicles equipped with 4-wheel antilock brake systems
(ABS), aftermarket batteries may leak electrolyte onto the ABS control module connector, which
can compromise the sealing integrity of the connector. This may allow development of a short
circuit in the connector, which could eventually lead to a fire.
REMEDY: Dealers will inspect the ABS control module connector for electrolyte damage and
replace the connector as necessary. The manufacturer has not yet provided an owner notification
for this campaign. Owners may contact DaimlerChrysler at 1-800-853-1403.
Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-002-02 > Jan > 02 > Rear
Axle - Vehicle Speed Is Inaccurate
Electronic Brake Control Module: Customer Interest Rear Axle - Vehicle Speed Is Inaccurate
NUMBER: 18-002-02
GROUP: Vehicle Performance
DATE: January 21, 2002
THE MDS2(R) MUST BE OPERATING WITH CIS CD2094 OR HIGHER, AVAILABLE OCTOBER
29, 2001. THE DRBIII(R) MUST BE AT LEVEL 52.5 OR LATER.
SUBJECT: Pinion Factor Recalibration
MODELS:
1998-2002 AB Ram Van
NOTE:
THIS BULLETIN APPLIES TO ALL 1998 - 2002 (AB) RAM VANS EQUIPPED WITH THE 9.25
REAR AXLE.
DISCUSSION:
Owners of 1998 - 2002 (AB) Ram Vans equipped with the 9.25 rear axle may complain that vehicle
speed is inaccurate. It may be that past service on the rear axle has caused the calibration to
change. Accurate calibration can be restored by reprogramming the applicable module, (ABS)
Antilock Brake System or (RWAL) Rear Wheel Antilock, using the DRBI III(R).
NOTE:
THE DRBIII(R) MUST BE AT LEVEL 52.5 OR HIGHER AND THE MDSII(R) AT CD 2094 OR
HIGHER TO PERFORM THE REPROGRAMMING.
POLICY: Information Only

Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic
Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion
September 2004
Models
NOTE:
IMPORTANT:
Subject
Repair
Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 50
Parts Information

NOTE:
Parts Return
Not required.
letter.
repair.
1. Open the hood.
off.
3).
3).
tray (Figure 4).

WARNING:
worn.
(Figure 5).
panel (Figure 5).
NOTE:
replacement.
following process:
CAUTION:
housing.
spliced.
(Figure 10).
CAUTION:
tubing (Figure 11).
NOTE:
13).
control unit.
NOTE:
control module.
drain tube grommet.
lbs. (7.9 N.m).
in. lbs. (7.9 N.m).
Brake Control Module: > NHTSA04V185000 > Apr > 04 > Recall 04V185000: ABS Control Module Corrosion
Electronic Brake Control Module: All Technical Service Bulletins Recall 04V185000: ABS Control
Module Corrosion
Brake Control Module: > 18-002-02 > Jan > 02 > Rear Axle - Vehicle Speed Is Inaccurate
Electronic Brake Control Module: All Technical Service Bulletins Rear Axle - Vehicle Speed Is
Inaccurate
NUMBER: 18-002-02
MODELS:
NOTE:
REAR AXLE.
DISCUSSION:
NOTE:

Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake
Control Module: > 18-002-02 > Jan > 02 > Rear Axle - Vehicle Speed Is Inaccurate
Inaccurate
NUMBER: 18-002-02
MODELS:
NOTE:
REAR AXLE.
DISCUSSION:
NOTE:

Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion
September 2004
Models
NOTE:
IMPORTANT:
Subject
Repair
Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 80
Parts Information

NOTE:
Parts Return
Not required.
letter.
repair.
1. Open the hood.
off.
3).
3).
tray (Figure 4).

WARNING:
worn.
(Figure 5).
panel (Figure 5).
NOTE:
replacement.
following process:
CAUTION:
housing.
spliced.
(Figure 10).
CAUTION:
tubing (Figure 11).
NOTE:
13).
control unit.
NOTE:
control module.
drain tube grommet.
lbs. (7.9 N.m).
in. lbs. (7.9 N.m).
Control Module: > NHTSA04V185000 > Apr > 04 > Recall 04V185000: ABS Control Module Corrosion
Module Corrosion
Control Module > Component Information > Specifications > With RWAL Brakes
Electronic Brake Control Module: Specifications With RWAL Brakes
Mounting Screws .................................................................................................................................

....................................................... 4 Nm (36 ft. lbs.)
Control Module > Component Information > Specifications > With RWAL Brakes > Page 98
Electronic Brake Control Module: Specifications With 4-Wheel Antilock Brakes
Screws .................................................................................................................................................
................................................. 4.4 Nm (39 inch lbs.)
Control Module > Component Information > Locations > EBC 2
Control Module > Component Information > Locations > EBC 2 > Page 101
Control Module > Component Information > Description and Operation > Kelsey-Hayes EBC Controller Antilock Brake
(CAB)
Electronic Brake Control Module: Description and Operation Kelsey-Hayes EBC Controller Antilock
Brake (CAB)
The CAB is mounted under the hood, separately from the valve body, and has a microprocessor
and circuits that:
- monitor the brake switch input to tell whether or not to prepare for possible antilock braking
- monitor the wheel speed sensor inputs to determine when a rear wheel is tending to lock up.
- operate the integral control unit assembly during antilock braking based on comparing the speed
sensor to information programmed in memory
- detect ABS system related problems and take diagnostic action
The CAB will disable antilock control and set a hard ignition latched trouble code if it detects one of
the following conditions with itself:
- (71) RAM Read/Write
- (72) ROM Checksum
- (73) Watchdog
(CAB) > Page 104
Electronic Brake Control Module: Description and Operation Kelsey-Hayes EBC 325 Controller
Antilock Brake (CAB)
The CAB is mounted directly to the hydraulic control unit and includes a microprocessor and six
solenoids that control brake pressure during antilock braking. The CAB also has circuits that
monitor the following:
- Brake switch input is monitored to determine whether or not to prepare for possible antilock
braking.
- Wheel speed sensors are monitored to determine when a wheel is tending to lock up. The CAB
will operate the valves in the ECU to control braking pressure during antilock braking.
(CAB) > Page 105
Electronic Brake Control Module: Description and Operation With Four Wheel Antilock Brakes
CAB/HCU
The Controller Antilock Brake (CAB) is mounted on the top of the hydraulic control unit.
The CAB operates the ABS system and is separate from other vehicle electrical circuits. CAB
voltage source is through the ignition switch in the RUN position.
The CAB contains dual microprocessors. A logic block in each microprocessor receives identical
sensor signals. These signals are processed and compared simultaneously.
The CAB contains a self check program that illuminates the ABS warning light when a system fault
is detected. Faults are stored in a diagnostic program memory and are accessible with the DRB
scan tool.
ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50
times. Stored faults are not erased if the battery is disconnected.
NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be
programed into the new CAB.
(CAB) > Page 106
Electronic Brake Control Module: Description and Operation With Rear Wheel Antilock Brakes
GENERAL INFORMATION
RWAL Controller Antilock Brake (CAB)
The Controller Antilock Brakes (CAB) is a microprocessor which handles testing, monitoring and
controlling the ABS brake system operation. The CAB functions are: -
Perform self-test diagnostics.
- Monitors the RWAL brake system for proper operation.
- Controls the RWAL valve solenoids.
SYSTEM SELF-TEST
When the ignition switch is turned-on the microprocessor RAM and ROM are tested. If an error
occurs during the test a Diagnostic Trouble Code (DTC) will be set into the RAM memory. However
it is possible the DTC will not be stored in memory if the error has occurred in the RAM module
were the DTC's are stored. Also it is possible a DTC may not be stored if the error has occurred in
the ROM which signals the RAM to store the DTC.
CAB INPUTS
The CAB continuously monitors the speed of the differential ring gear by monitoring signals
generated by the rear wheel speed sensor. The CAB determines a wheel locking tendency when it
recognizes the ring gear decelerating too rapidly. The CAB monitors the following inputs to
determine when a wheel locking tendency may exists: -
Rear Wheel Speed Sensor
- Brake Lamp Switch
- Brake Warning Lamp Switch
- Reset Switch
- 4WD Switch (If equipped)
CAB OUTPUTS
The CAB controls the following outputs for antilock braking and brake warning information: -
RWAL Valve
- ABS Warning Lamp
- Brake Warning Lamp

Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System
Electronic Brake Control Module: Service and Repair Four Wheel Antilock Brake System
NOTE: If the Controller Antilock Brake (CAB) needs to be replaced, the rear axle type and tire
revolutions per mile must be programed into the new CAB.
REMOVAL
1. Disconnect battery cables and remove the battery. 2. Remove the power distribution center. 3.
Remove the battery and power distribution center mount. 4. Remove the washer reservoir
mounting screws. 5. Lift up the reservoir and disconnect the pump motor connector and pump
hose. 6. Remove the reservoir from the engine compartment.
Harness Connector Locks
7. Push the harness connector locks to release the locks, then remove the connectors from the
CAB.
Pump Motor Connector
8. Disconnect the pump motor connector.

Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 109
Controller Mounting Screws
9. Remove screws attaching CAB to the Hydraulic Control Unit (HCU).
10. Remove the CAB.
INSTALLATION
1. Place the CAB onto the HCU.
NOTE: Insure the CAB seal is in position before installation.
2. Install the mounting screws and tighten to 4.4 Nm (39 inch lbs.). 3. Connect the pump motor
harness. 4. Connect the harnesses to the CAB and lock the connectors. 5. Install the reservoir in
the engine compartment. Connect the pump motor connector and pump hose. 6. Install the washer
reservoir mounting screws. 7. Install the battery and power distribution center mount. 8. Install the
power distribution center. 9. Install the battery and battery cables.
Electronic Brake Control Module: Service and Repair Rear Wheel Antilock Brake System
REMOVAL
1. Remove the washer reservoir mounting screws. 2. Lift up the reservoir and disconnect the pump
motor connector and pump hose. 3. Remove the reservoir from the engine compartment. 4.
Disconnect battery cables and remove the battery. 5. Remove the power distribution center. 6.
Remove the battery and power distribution center mount. 7. Remove the RWAL valve harness. 8.
Pull up on the CAB harness connector lock release and remove the connector from the controller.
9. Remove controller mounting screws and remove controller.
INSTALLATION
1. Position the controller on the mounting bracket and install the mounting screws. 2. Install the
CAB harness connector into the controller and push down on the connector lock. 3. Install the
RWAL valve harness connector into controller. 4. Install the battery and power distribution center
mount. 5. Install the power distribution center. 6. Install the battery and battery cables. 7. Install the
reservoir in the engine compartment. Connect the pump motor connector and pump hose. 8. Install
the washer reservoir mounting screws.
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations
8w-10-2
Information > Description and Operation > Blower Motor Relay
Blower Motor Relay: Description and Operation Blower Motor Relay
SYSTEM OPERATION
Front
The front blower motor relay is a International Standards Organization (ISO)-type relay. The relay
is a electromechanical device that switches battery current from a fuse in the Power Distribution
Center (PDC) directly to the blower motor. The relay is energized when the relay coil is provided a
voltage signal by the ignition switch. This arrangement reduces the amount of battery current that
must flow through the ignition switch.
The blower motor relay control circuit is protected by a fuse located in the junction block. When the
relay is de-energized, the blower motor receives no battery current. See Blower Motor Relay in the
Diagnosis and Testing for more information.
The front blower motor relay is located in the PDC in the engine compartment. Refer to the PDC
label for blower motor relay identification and location.
The blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced.
Rear
The blower motor relay for the optional rear heater-A/C unit is a International Standards
Organization (ISO)-type relay. The relay is a electromechanical device that switches battery current
from a fuse in the Power Distribution Center (PDC) directly to the blower motor. The relay is
energized when the relay coil is provided a voltage signal by the ignition switch. This arrangement
reduces the amount of battery current that must flow through the ignition switch.
The rear blower motor relay is located in a connector that is secured to the back of the rear
heater-A/C unit housing in the passenger compartment. See Blower Motor Relay - Rear in the
Removal and Installation for rear blower motor relay identification and location.
Information > Description and Operation > Blower Motor Relay > Page 117
Blower Motor Relay: Description and Operation High Speed Blower Motor Relay
SYSTEM OPERATION
Front
The front blower motor electrical circuit uses a high speed blower motor relay. The high speed
blower motor relay is a International Standards Organization (1S0)-type relay The relay is a
electromechanical device that switches the blower motor to ground, bypassing the remainder of the
blower motor feed circuit.
The high speed blower motor relay is energized when the relay coil is provided a ground signal by
the blower motor switch, and a battery feed from the ignition switch. When the relay is
de-energized, the front blower motor ground feed is routed through the front blower motor switch
and the blower motor resistor. See High Speed Blower Motor Relay in the Diagnosis and Testing
for more information.
The front high speed blower motor relay is located in the engine compartment, on a bracket that is
secured under one of the screws for the top cover on the inboard side of the heater-A/C housing.
The high speed blower motor relay cannot be repaired and, if faulty or damaged, it must be
replaced.
Rear
The optional rear heater-A/C unit blower motor electrical circuit uses a high speed blower motor
relay The high speed blower motor relay is a International Standards Organization (IS0)-type relay
The relay is a electromechanical device that switches the blower motor to ground, bypassing the
remainder of the blower motor feed circuit.
de-energized, the rear blower motor ground feed is routed through the rear blower motor switch
The rear high speed blower motor relay is located in a connector that is secured to the back of the
rear heater-A/C unit housing in the passenger compartment. See High Speed Blower Motor Relay
Rear in the Removal and Installation for rear high speed blower motor relay identification and
location.
The rear high speed blower motor relay cannot be repaired and, if faulty or damaged, it must be
replaced.
Information > Testing and Inspection > Blower Motor Relay
Blower Motor Relay: Testing and Inspection Blower Motor Relay
Blower Motor Relay
Relay Test
The blower motor relays used for the front heater-only or heater-A/C systems and for the optional
rear heater-A/C unit can be tested in the same manner. The front blower motor relay is located in
the Power Distribution Center (PDC). The rear blower motor relay is located in a connector that is
attached to the back of the rear heater-A/C unit. See Blower Motor Relay in the Removal and
Installation for the procedures to remove the relay, to perform the following tests:
1. A relay in the de-energized position should have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK,
go to Step 3. If not OK, replace the faulty relay
2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to

Step 4. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There
should now be continuity between terminals 30 and 87, and no continuity between terminals 87A
and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty
relay.
Relay Circuit Test
1. The relay common feed terminal cavity (30) is connected to fused battery feed directly from a
fuse in the Power Distribution Center (PDC), and
should be hot at all times. Check for battery voltage at the PDC cavity for relay terminal 30. If OK,
go to Step 3. If not OK repair the open circuit to the PDC fuse as required.
2. The relay normally closed terminal cavity (87A) is not used for this application. Go to Step 4. 3.
The relay normally open terminal cavity (87) is connected to the blower motor. When the relay is
energized, terminal 87 is connected to terminal
30 and provides full battery current to the blower motor feed circuit. There should be continuity
between the PDC cavity for terminal 87 and the blower motor relay output circuit cavity of the
blower motor wire harness connector at all times. If OK, go to Step 5. If not OK, repair the open
circuit to the blower motor as required.
4. The coil battery terminal cavity (86) is connected to the ignition switch. When the ignition switch
is placed in the On position, fused ignition
switch output is directed from a fuse in the junction block to the relay electromagnetic coil to
energize the relay. There should be battery voltage at the PDC cavity for relay terminal 86 with the
ignition switch in the On position. If OK, go to Step 6. If not OK, repair the open circuit to the
junction block fuse as required.
5. The coil ground terminal cavity (85) is connected to ground. This terminal supplies the ground for
the relay electromagnetic coil. There should be
continuity between the PDC cavity for relay terminal 85 and a good ground at all times. If not OK,
repair the open circuit as required.
Information > Testing and Inspection > Blower Motor Relay > Page 120
Blower Motor Relay: Testing and Inspection High Speed Blower Motor Relay
Blower Motor Relay
Relay Test
The high speed blower motor relays used for the front heater-only or heater-A/C systems and for
the optional rear heater-A/C unit can be tested in the same manner. The front high speed blower
motor relay is located in the engine compartment on a bracket mounted to the inboard side of the
heater-A/C housing. The rear high speed blower motor relay is located in a connector that is
Installation procedures to remove the relay, to perform the following tests: 1. A relay in the
de-energized position should have continuity between terminals 87A and 30, and no continuity
between terminals 87 and 30. If OK,
go to Step 3. If not OK, replace the faulty relay.

relay.
Relay Circuit Test
1. The relay common feed terminal cavity (30) is connected to the ground side of the front or rear
blower motor. There should be continuity between
the ground circuit cavity of the front or rear blower motor wire harness connector and the wire
harness connector cavity for relay terminal 30 at all times. If OK, go to Step 3. If not OK, repair the
open circuit to the front or rear blower motor as required.
The relay normally open terminal cavity (87) is connected to ground. When the relay is energized,
terminal 87 is connected to terminal 30 and
provides a direct path to ground for the front or rear blower motor. There should be continuity
between the wire harness connector cavity for relay terminal 87 and ground at all times. If OK, go
to Step 5. If not OK, repair the open circuit to ground as required.
energize the relay. There should be battery voltage at the wire harness connector cavity for relay
terminal 86 with the ignition switch in the On position. If OK, go to Step 6. If not OK, repair the open
circuit to the junction block fuse as required.
5. The coil ground terminal cavity (85) is connected to the high speed output circuit terminal of the
front or rear blower motor switch. This terminal
supplies the ground for the relay electromagnetic coil. There should be continuity between the wire
harness connector cavity for relay terminal 85 and the high speed output circuit terminal of the front
or rear blower motor switch at all times. If not OK, repair the open circuit to the front or rear blower
motor switch as required.
Information > Testing and Inspection > Page 121
Blower Motor Relay: Service and Repair
Front
1. Disconnect and isolate the battery negative cable.
Power Distribution Center
2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC
for blower motor relay identification and location. 4. Unplug the blower motor relay from the PDC. 5.
Install the blower motor relay by aligning the relay terminals with the cavities in the PDC and
pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable.
8. Test the relay operation.
Rear
The rear blower motor relay is used only on models with the optional rear heater-A/C unit. 1.
Disconnect and isolate the battery negative cable. 2. Remove the cover from the rear heater-A/C
unit.
Rear Blower Motor Relay Remove/Install
3. Unplug the blower motor relay from the inboard relay wire harness connector, which is secured
to the rear of the rear heater-A/C unit. 4. Install the blower motor relay by aligning the relay
terminals with the cavities in the wire harness connector and pushing the relay firmly into
place.
5. Reinstall the cover for the rear heater-A/C unit. 6. Connect the battery negative cable. 7. Test the
relay operation.
High Speed Blower Motor Relay
Front 1. Disconnect and isolate the battery negative cable.

Front High Speed Blower Motor Relay Remove/Install
2. The high speed blower motor relay is retained by a snap fit to the blade of the mounting bracket
on the inboard side of the heater-A/C housing.
Unsnap the relay from the mounting bracket by sliding it downwards.
3. Unplug the wire harness connector from the high speed blower motor relay. 4. Install the high
speed blower motor relay by aligning the relay terminals with the cavities in the relay wire harness
connector and pushing the relay
firmly into place.
5. Slide the molded receptacle on the high speed blower motor relay case back onto the blade of
the mounting bracket until it snaps into place. 6. Connect the battery negative cable. 7. Test the
relay operation.
Rear
The rear high speed blower motor resistor is used only on models with the optional rear heater-A/C
unit. 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the rear
heater-A/C unit.
Rear High Speed Blower Motor Relay Remove/Install
3. Unplug the high speed blower motor relay from the outboard relay wire harness connector,
which is secured to the rear of the rear heater-A/C unit. 4. Install the high speed blower motor relay
by aligning the relay terminals with the cavities in the wire harness connector and pushing the relay
firmly into place.
relay operation.
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Component Locations
Compressor Clutch Relay: Component Locations
8w-10-2
Information > Locations > Component Locations > Page 127
A/C Compressor Clutch Relay Connector, PDC.


Information > Locations > Page 129
Compressor Clutch Relay: Description and Operation
SYSTEM OPERATION
The compressor clutch relay is a International Standards Organization (ISO) micro-relay The
terminal designations and functions are the same as a conventional ISO relay. However, the
micro-relay terminal orientation (footprint) is different, the current capacity is lower, and the relay
case dimensions are smaller than those of the conventional ISO relay
The compressor clutch relay is a electromechanical device that switches battery current to the
compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the
relay. The PCM responds to inputs from the heater-A/C mode control switch, the low pressure
cut-off switch, the high pressure cut-off switch, and the fin sensing cycling clutch switch. See
Compressor Clutch Relay in the Diagnosis and Testing for more information.
The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine
compartment. Refer to the PDC label for relay identification and location.
The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced.
Compressor Clutch Relay: Testing and Inspection
Relay Test
Compressor Clutch Relay
The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC
label for relay identification and location. Remove the relay from the PDC to perform the following
tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30,
and no continuity between terminals 87 and 30. If OK,

and 30. If OK, see Relay Circuit Test. If not OK, replace the faulty relay.
Relay Circuit Test
1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be
battery voltage at the cavity for relay terminal 30
at all times. If OK, go to Step 3. If not OK, repair the open circuit to the fuse in the PDC as required.
2. The relay normally closed terminal (87A) is not used in this application. Go to Step 4. 3. The
relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should
be continuity between this cavity and the
A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness
connector. If OK, go to Step 5. If not OK, repair the open circuit as required.
4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start)
circuit. There should be battery voltage at the cavity
for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 6. If not OK, repair
the open circuit to the fuse in the junction block as required.
5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module
(PCM). There should be continuity between
this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness
connector C (gray) at all times. If not OK, repair the open circuit as required.
Compressor Clutch Relay: Service and Repair
REMOVAL AND INSTALLATION
1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the Power
Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay
identification and location. 4. Unplug the compressor clutch relay from the PDC. 5. Install the
compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the
relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the
relay operation.
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions
Audible Warning Device Control Module: Diagram Information and Instructions
Introduction
8w-01-002
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 137
8w-01-003
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Circuit Identification Code Chart

All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: -
In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.

- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC

TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE

CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
8w-01-006
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the Component Location group to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.

Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)

Terminal Removal
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Terminal/Connector Repair-Thomas and Betts Connectors
Thomas And Betts Connector Lock Release Tabs
3. Push in the two lock tabs on the side of the connector.
Removing Wire Terminal
4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire
and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or
replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the
connector.
Single Lock Tab
8. Push in the single lock tab on the side of the connector.
Wiring Repair
Wire Repair
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
Special Tools
Probing Tool Package 6807

Terminal Pick 6680
Terminal Removing Tool 6932

Audible Warning Device Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation

Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.

Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,

CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Audible Warning Device Control Module: Electrical Diagrams
8w-45-2
8w-45-3
8w-45-4
8w-45-5
8w-45-6
NOTE: To view Diagrams referred to in these diagrams SEE Complete Body and Chassis
Diagrams.. See: Diagrams/Electrical Diagrams/Diagrams By Group Number
Control Module > Component Information > Diagrams > Page 160
Audible Warning Device Control Module: Description and Operation
SYSTEM OPERATION
A Central Timer Module (CTM) is used on this vehicle when it is equipped with the optional Vehicle
Theft Security System (VTSS). In addition to serving as the security system module, the CTM
combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated
entry module, and a Remote Keyless Entry (RKE) module in a single unit.
The CTM is also able to control and integrate many of the additional electronic functions and
features included on models with this option. The CTM contains a central processing unit and
interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus
network. The CCD data bus network allows the sharing of sensor information. This helps to reduce
wire harness complexity, reduce internal controller hardware, and reduce component sensor
current loads. At the same time, this system provides increased reliability, enhanced diagnostics,
and allows the addition of many new feature capabilities.
The horn relay is one of the outputs that the CTM can control. The CTM is programmed to energize
or de-energize the horn relay in response to certain inputs from the Vehicle Theft Security System
(VTSS) and the Remote Keyless Entry (RKE) system. Refer to Body and Frame/Locks/Power
Locks Systems for more information on the RKE system. Refer to Accessories and Optional
Equipment/Antitheft and Alarm Systems/Vehicle Theft/Security Systems for more information on
the VTSS.
The CTM is mounted under the instrument panel, to the inboard side of the left center instrument
panel support. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument
Panel/Central Timer Module Replacement
For diagnosis of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic
Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be
replaced.
The CTM controls features and functions of the power lock, illuminated entry, and Remote Keyless
Entry (RKE) systems. The CTM receives hard wired inputs from the power lock switches, CCD
message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and
coded radio frequency inputs from the RKE transmitters. In response to those and many other
inputs, the internal programming of the CTM sends the proper outputs to control the power lock
motors, the headlamp and horn relays, and the courtesy lamps.
The RKE receiver within the CTM has a memory function to retain the vehicle access codes of at
least one, but no more than four RKE transmitters. The receiver is designed to retain the
transmitter codes in memory, even if the battery is disconnected.
Some of the features and functions of the power lock, illuminated entry and RKE systems made
possible because of the communication of the CTM on the CCD data bus network include: -
A door-lock inhibit feature which prevents the power lock system from being energized with a
power door lock switch if the key is in the ignition and/or the headlamps are on. However, the locks
can still be operated manually, with a key, or energized with the REE transmitter.
- A delay lock feature. With the delay lock feature, if a side or rear door is still open when a lock
request is received by the CTM, the module will automatically cycle all of the power lock motors to
lock five seconds after the doors are closed.
- An enhanced accident response feature will unlock all doors, then prevent the power door lock
system from locking the doors for a predetermined time interval, after receiving a CCD message
from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature
will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if
the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course,
these responses are dependent upon functional battery power and wiring circuitry following the
impact.
- Rolling door locks is a programmable feature of the power lock system. This feature will
automatically lock all of the doors and the liftgate after the vehicle reaches a speed of about 24
kilometers-per- hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is
opened, then closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour).
- A programmable feature of the RKE system is the enabling or disabling of the horn chirp following
activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the
horn chirp duration (twenty or forty milliseconds) can be selected.
panel support. Refer to Central Timer Module Replacement.
The programmable features of the CTM can be enabled or disabled using the DRB scan tool as
described in the proper Diagnostic Procedures. For diagnosis of the CTM or the CCD data bus, a
DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be
repaired and, if faulty or damaged, it must be replaced.
network.
The CCD data bus network allows the sharing of sensor information. This helps to reduce wire
harness complexity, reduce internal controller
hardware, and reduce component sensor current loads. At the same time, this system provides
increased reliability, enhanced diagnostics, and allows the addition of many new feature
capabilities.
One of the features that the CTM supports and controls is the Vehicle Theft Security System
(VTSS). In the VTSS, the CTM receives hard--wired inputs from the door ajar, front door lock
cylinder, and ignition switches. The programming in the CTM allows it to process the information
from these inputs and send control outputs to energize or de-energize the headlamp (or security)
relay, horn relay; and the security lamp. The CTM also sends CCD data bus messages to the
Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS.
The CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry
(RKE) systems, which are integrated into the arming, disarming, and triggering function; of the
VTSS.
panel support. Refer to Instrument Panel, Gauges and Warning Indicators/Audible Warning Device
Control Module/
Central Timer Module Replacement.
Audible Warning Device Control Module: Testing and Inspection
NOTE: The following tests may not prove conclusive in the diagnosis of the Central Timer Module
(CTM). The most reliable, efficient, and accurate means to diagnose the CTM requires the use of a
DRB scan tool.
The CTM is used on models that are equipped with the optional Vehicle Theft Security System
(VTSS).
If the problem being diagnosed involves only the RKE horn chirp feature, see Horn Relay in the
Diagnosis and Testing. If the relay checks OK; or if the problem being diagnosed involves the
rolling door locks, door lock inhibit, or enhanced accident response features, further diagnosis of
the CTM should be performed using a DRB scan tool.
faulty fuse.
repair the shorted circuit or component as
switch as required.
5. Disconnect and isolate the battery negative cable. Access and unplug the CTM wire harness
connectors. Refer to Instrument Panel, Gauges and
Warning Indicators/Audible Warning Device Control Module/Central Timer Module Replacement.
6. Check the wire harness connectors and the receptacles in the CTM for loose, corroded, or
damaged terminals and pins. If OK, go to Step 8. If not
OK, repair the connections as required.
7. Probe the ground circuit cavity in the 14-way CTM wire harness connector and check for
continuity to a good ground. Repeat the check between
the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each
case, there should be continuity If OK, go to Step 9. If not OK, repair the open circuit(s) to ground
as required.
the 14-way CTM wire harness connector. If OK,
go to Step 10. If not OK, repair the open circuit to the fuse in the junction block as required.
9. Probe the door lock switch output (lock) circuit cavity in the 18-way CTM wire harness connector
and check for battery voltage as you actuate
each power lock switch to the Lock position. If OK, go to Step 11. If not OK, repair the open circuit
from either or both power lock switch(s) to the CTM as required.
10. Probe the door lock switch output (unlock) circuit cavity in the 18-way CTM wire harness
connector and check for battery voltage as you actuate
each power lock switch to the Unlock position. If OK, go to Step 12. If not OK, repair the open
circuit from either or both power lock switch(s) to the CTM as required.
11. Disconnect and isolate the battery negative cable. Reinstall the wire harness connectors to the
CTM. Connect the battery negative cable. Back
probe the door lock driver circuit cavity in the 18-way CTM wire harness connector and check for
battery voltage as the power lock switch is moved to the Lock position. Repeat the test pressing the
Lock button of the Remote Keyless Entry (RKE) transmitter. If OK, go to Step 13. If not OK using
Keyless Entry transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the
RKE transmitter, replace the faulty CTM.
12. Still back probing the door lock driver circuit cavity in the 18-way CTM wire harness connector,
open the side or rear cargo door. Move the power
lock switch to the Lock position or press the Lock button of the RKE transmitter. Now close all of
the doors. Within five seconds of the last door closing, there should be battery voltage on the door
lock driver circuit. If OK, go to Step 14. If not OK, replace the faulty CTM.
13. Back probe the door unlock driver circuit cavity of the 18-way CTM wire harness connector and
check for battery voltage as the power lock
switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE
transmitter If OK. see Power Lock Motor in the Diagnosis and Testing. If not OK using the power
lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing.
If not OK using the RKE transmitter but OK with the power lock switch, see Remote Keyless Entry
Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE
transmitter, replace the faulty CTM.
Audible Warning Device Control Module: Service and Repair
A Central Timer Module (CTM) is only used on high-line versions of this vehicle that are also
equipped with the Vehicle Theft Security System (VTSS). See Central Timer Module in the General
information.
Before replacing a CTM, use a DRB scan tool to determine the current settings for tile CTM
programmable features. These settings should be duplicated in the replacement CTM using the
DRB scan tool, before returning the vehicle to service.

INJURY.
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Remove the engine cover from the
passenger compartment.
Central Timer Module Remove/Install
3. Remove the three screws that secure the CTM to the inboard side of the left center instrument
panel support. 4. Pull the CTM away from its mounting location far enough to access and unplug
the two wire harness connectors. 5. Remove the CTM from the instrument panel. 6. Reverse the
removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.).
NOTE: If a new Central Timer Module is installed, the programmable features must be enabled and
or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic
Procedures to perform these operations.
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Service and Repair
Daytime Running Lamp Control Unit: Service and Repair
Daytime Running Light Module
The headlamps on vehicles sold in Canada will illuminate when the vehicle is started. The lamps
illuminate at less than 50% of normal intensity. To disable the DRLM, set park bake.
REMOVAL The Daytime Running Light Module (DRLM) is mounted in the engine compartment on
the bottom of the cowl plenum next to the windshield wiper motor. 1. Remove the bolts holding the
(DRLM) and bracket to the vehicle. 2. Disconnect the electrical connector.
INSTALLATION 1. Connect the electrical connector. 2. Install the bolts holding the (DRLM) and
bracket to the vehicle.
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay >
Component Information > Diagrams
VTSS Headlamp Relay Connector

Component Information > Diagrams > Page 171
Headlamp Relay: Description and Operation
SYSTEM OPERATION
The headlamp (or security) relay is a International Standards Organization (ISO) micro-relay The
micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay
The headlamp relay is a electromechanical device that switches battery current to the headlamps
when the high-line Central Timer Module (CTM) grounds the relay coil. See Headlamp Relay in the
The headlamp relay is located in a connector that is taped back to the headlamp switch takeout of
the instrument panel wire harness in the passenger compartment. To service the headlamp relay
remove the headlamp switch mounting screws and pull the switch and wire harness out from the
instrument panel far enough to access the relay and connector.
The headlamp relay cannot be repaired and, if faulty or damaged, it must be replaced.
Headlamp Relay: Service and Repair
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAGS BEFORE

INJURY.
Headlamp Relay Remove/Install
1. Disconnect and isolate the battery negative cable. 2. Remove the headlamp switch from the
instrument panel, but do not unplug the wire harness connectors. Refer to Lighting and
Horns/Headlamp
Switch Replacement.
3. Pull the headlamp switch out from the instrument panel far enough to access the headlamp
relay, which is taped to the headlamp switch takeout of
the instrument panel wire harness.
4. Remove the tape that secures the headlamp relay and its connector to the wire harness. 5.
Unplug the headlamp relay from its wire harness connector. 6. Install the headlamp relay by
aligning the relay terminals with the cavities in the wire harness connector and pushing the relay
firmly into place. 7. Tape the headlamp relay and its connector back to the wire harness. 8.
Reinstall the headlamp switch in the instrument panel. Refer to Lighting and Horns/Headlamp
Switch Replacement. 9. Connect the battery negative cable.

Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Description and Operation
Horn Relay: Description and Operation
SYSTEM OPERATION
The horn relay is a International Standards Organization (ISO) micro-relay. The terminal
designations and functions are the same as a conventional ISO relay. However, the micro-relay
terminal orientation (or footprint) is different, current capacity is lower, and the relay case
dimensions are smaller than those of the conventional ISO relay.
The horn relay is a electromechanical device that switches battery current to the horn when the
horn switch grounds the relay coil. See Horn Relay in the Diagnosis and Testing for more
information.
The horn relay is located in the junction block, which is located on the driver side end of the
instrument panel in the passenger compaftment.
If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by
removing the horn relay from the junction block until further diagnosis is completed.
The horn relay cannot be repaired and, if faulty or damaged, it must be replaced.
The horn relay is a component of the Remote Key-less Entry (RKE) system only on vehicles
equipped with the optional Vehicle Theft Security System (VTSS). The horn relay is a International
Standards Organization (ISO) micro-relay. The terminal designations and functions are the same
as a conventional ISO relay However, the micro-relay terminal orientation (or footprint) is different,
current capacity is lower, and the relay case dimensions are smaller than those of the conventional
ISO relay
horn switch or the Central Timer Module (CTM) grounds the relay coil. See Horn Relay in the
instrument panel in the passenger compartment. If a problem is encountered with a continuously
sounding horn, it can usually be quickly resolved by removing the horn relay from the junction block
until further diagnosis is completed.
Information > Description and Operation > Page 176
Horn Relay: Testing and Inspection

INJURY.
Relay Test
Horn Relay
The horn relay is located in the junction block in the passenger compartment. Remove the horn
relay from the junction block to perform the following tests: 1. A relay in the de-energized position
should have continuity between terminals 87A and 30, and no continuity between terminals 87 and
30. if OK,
2. Resistance between terminals 85 and 86 electromagnet. should be 75 - 5 Ohms. If OK, go to

relay.
Relay Circuit Test 1. The relay common feed terminal cavity 30. is connected to battery voltage and
should be hot at all times. If OK, go to Step 3. If not OK, repair the
open circuit to the PDC fuse as required.
2. The relay normally closed terminal 87A. is connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 4. 3. The relay normally open terminal 87. is
connected to the common feed terminal 30. in the energized position. This terminal supplies battery
voltage to the horns. There should be continuity between the cavity for relay terminal 87 and the
horn relay output circuit cavity of each horn wire harness connector at all times. If OK, go to Step 5.
If not OK, repair the open circuit to the horns. as required.
4. The coil battery terminal 86. is connected to the electromagnet in the relay. It is connected to
battery voltage and should be hot at all times. Check
for battery voltage at the cavity for relay terminal 86. If OK, go to Step 6. If not OK, repair the open
circuit to the fuse in the PDC as required.
5. The coil ground terminal 85. is connected to the electromagnet in the relay It is grounded
through the horn switch when the horn switch is
depressed. On vehicles equipped with the Vehicle Theft Security System VTSS., the horn relay coil
ground terminal can also be grounded by the Central Timer Module CTM. in response to certain
inputs related to the VTSS or Remote Keyless Entry (RKE). system. Check for continuity to ground
at the cavity for relay terminal 85. There should be continuity with the horn switch depressed, and
no continuity with the horn switch released. If not OK, see Horn Switch in the Diagnosis and
Testing.

INJURY.
relay from the junction block to perform the following tests:

and 30. If OK, test the relay circuits. If not OK, replace the faulty relay.
Horn Relay: Service and Repair
1. Disconnect and isolate the battery negative cable. 2. Remove the end cap from the driver side
end of the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument
Panel/Instrument Panel End Cap Replacement.
Junction Block
3. Unplug the horn relay from the junction block. 4. Install the horn relay by aligning the relay
terminals with the cavities in the junction block and pushing the relay firmly into place. 5. Connect
the battery negative cable. 6. Test the relay operation. 7. Reinstall the end cap on the instrument
panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument
Panel End
Cap Replacement.
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations
Power Distribution Center, Battery, Windshield Washer Reservoir

Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules -
Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations
Module Locations
Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations >
Page 188
Central Timer Module

Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions
Body Control Module: Diagram Information and Instructions
Introduction
8w-01-002
Instructions > Page 191
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

Body Control Module: Diagnostic Aids
position
problem
Testing For Voltage
Testing For Voltage


Probing Tool
Body Control Module: Connector Views

CTM Connector
CTM Connector
Body Control Module: Electrical Diagrams
Vehicle Communications
Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Central
Timer Module Description
Body Control Module: Description and Operation Central Timer Module Description
The AB HIGH LINE utilize a Central Timer Module (CTM). The Base AB RAM VAN will not be
addressed in this manual. For concerns about the Base AB VAN, please refer to the appropriate
service and repair article. The CTM performs most of the typical functions a Body Control Module
would perform.
The CTM provides the following features:
- Remote Keyless Entry (RKE)
- Chime
- Courtesy Lamp controls/Illuminated Entry
- Power Door Locks WIRKE
- Speed Sensitive Intermittent Wipers
- Enhanced Accident Response
- Vehicle Theft Security System (VTSS)
The module is located on the left center instrument panel support. It contains a white 18-way and a
green 14-way connector.
Timer Module Description > Page 214
Body Control Module: Description and Operation System Description and Functional Operation
The body system on the 1998 AB HIGH LINE consists of three modules that communicate over the
CCD bus (Chrysler Collision Detection multiplex system). There are two additional modules, the
Powertrain Control Module (PCM) and the Controller Anti-Lock Brake (CAB) that are not part of the
body system, but do utilize the CCD bus for communication. The CAB also utilizes the bus for
diagnostics. The PCM sends and receives messages on the CCD bus, however diagnostics are
performed through the Serial Communication Interface of SCI, the same as previous years. All of
the information about the functioning of all the system is organized, controlled, and communicated
by the CCD bus, which is described in Section 3 (CCD Bus) of this general information section.
Through the CCD bus, information about the operation of vehicle components and circuits is
relayed quickly to the appropriate module(s). All modules receive all the information transmitted on
the bus even though a module may not require all the information to perform it's function. It will only
respond to messages "addressed" to it through a binary coding process. This method of data
transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring
harnesses.
Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component
Tests and General Diagnostics
Body Control Module: Component Tests and General Diagnostics
Identification of Systems
The vehicle Systems that are part of the "body" system are:
- Airbag System (ACM)
- Central Timer Module (CTM)
- Instrument Cluster (MIC)
- Vehicle Communication
Diagnostic Strategies
Diagnosis of the central timer module (CTM) is done in six basic steps:
- verification of complaint
- verification of any related symptoms
- symptom analysis
- problem isolation
- repair of isolated problem verification of proper operation

Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM
Technical Service Bulletin # 831 Date: 990601
Recall - Reprogram PCM
June 1999
California Emissions Recall No. 831 Reprogram Powertrain Control Module
Models
1998 (DN) Dodge Durango (with a 5.9L engine and automatic transmission)
(AB) Dodge Ram Van/Wagon (with a 5.9L engine and automatic transmission)
(ZJ) Jeep(R) Grand Cherokee (with a 5. 9L engine and automatic transmission)
(AN) Dodge Dakota (with 5.2L engine and manual transmission or 5.9L engine and automatic
transmission)
(BR/BE)Dodge Ram Pickup (with a 5.2L engine and manual transmission, 5.9L engine and
automatic transmission or 8.0L engine)
NOTE:
This recall applies only to certain vehicles equipped with a California emission control system
(sales code NAE) built through April 30, 1998 (MDH 0430XX).
Subject
The On-Board Diagnostic (OBD) system on about 18,000 of the above vehicles may not detect
evaporative emissions purge system malfunctions as required by California Emission Regulations.
Repair
The Powertrain Control Module (PCM) must be reprogrammed (flashed).
Parts Information
Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street
address) will receive enough Authorized Software Update labels and Authorized Modifications
labels to service about 25% of those vehicles. Additional labels may be ordered as needed.
Each vehicle requires application of the following labels:
Part Number Description
04669020 Authorized Software Update Label
04275086 Authorized Modifications Label
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims
submitted will be used by DaimlerChrysler to record recall service completions and provide dealer
payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
PCM Update Previously Performed 08831181 0.2 hours

Reprogram Powertrain Control Module 08831182 0.5 hours
Add the cost of the labels plus applicable dealer allowance to your claim.
NOTE:
Parts Return
Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 225
Not Applicable
Dealer Notification and Vehicle List
additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this
recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current
dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is
arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are
also listed. The lists are for dealer reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall
implementation for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The
customer name, address and phone number are listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "0RD831".
A copy of the owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and
recall are identified on the form for owner or dealer reference as needed.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the
pre-addressed Owner Notification Form or describe the reason on a postcard and mail to:
DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan
48326-2757
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
Service Procedure
The DRB III(R) with either MDS1 or MDS2 is required to perform this repair.
^ If using the MDS1 and DRB III, the MDS must be operating at release 21 or higher and TIL CD
release 1184 or higher must be installed.
^ If using the MDS2 and DRB III, the system must be operating at CIS CD2034 or higher.
Using the MDS1
1. Connect the MDS1 (Mopar Diagnostic System) and the DRB III (Scan Tool) to the vehicle and
power them up.
2. Use the arrow keys and select # 2 - CONNECT TO MDS1 OR MDS2 on the DRB III MAIN
MENU screen.
3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III UPDATE on the DRB III MAIN
MENU.
4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU.
5. Use the arrow keys and select VEHICLE CONTROLLER REPROGRAMMING on the MDS1,
then press NEXT MENU.
6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING
MDS1 AND DRB III on the MDS1, then press NEXT MENU.
7. FOLLOW THE STEPS PRESENTED ON THE MDS1 and DRB III that will allow the DRB III to
obtain the current part number of the PCM.
8. The MDS1 will display the part number of the PCM on the vehicle and the appropriate
replacement part number(s). Press NEXT MENU to begin programming.
9. The MDS and DRB III will prompt the operator for any action needed during the remainder of the
programming process.
NOTE:
If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES
AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously
installed authorized software update label) matches the part number displayed on the MDS and
then continue with Step C.
Using the MDS2

1. Log onto the MDS2 system.
2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and
switch the IGNITION KEY TO "ON".
3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III MAIN MENU
SCREEN.
4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU
SCREEN.
NOTE:
Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN
FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a
MDS2 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to
begin the session.
5. Push the FLASH TAB on the MDS2.
6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2.
Press the "OK" button.
NOTE:
If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information
Box will appear that says "Part number (updated part number is displayed) is up to date and does
not require any new updates." Verify that the part number of the PCM (or previously installed
authorized software update label) matches the part number displayed on the MDS. Press the "OK"
button, then continue with Step C.
7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE
CONTROLLER SOFTWARE.
8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the
reprogramming process.
B. Install Authorized Software Update Label
Fig. 1
Type or print (with a ballpoint pen) the necessary information on the "Authorized Software Update"
label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label.
C. Install the Authorized Modifications Label
Fig. 2
Type or print (with a ballpoint pen) the necessary information shown in Figure 2 onto the
Authorized Modifications Label. Then attach the label near the VECI label.
D. Complete Proof of Correction Form For California Residents
This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement
Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053)
and supply it to vehicle owners residing in the state of California for proof that this recall has been
performed when they renew the vehicle registration.
Owner Letter
EMISSIONS RECALL TO REPROGRAM YOUR VEHICLE'S POWERTRAIN CONTROL MODULE
Dear DaimlerChrysler Vehicle Owner:
DaimlerChrysler has determined that some 1998 Dodge Dakota, Durango, Ram Van/Wagon, Ram
Truck, and Jeep(R) Grand Cherokee vehicles, equipped with a V-8 or V-10 engine, may be in
violation of California Emissions Regulations.
The problem is...
The On-Board Diagnostic (OBD) system on your vehicle (identified on the enclosed form) may not
detect evaporative emissions purge system malfunctions as required by California Emissions
Regulations. As a result, the OBD system on your vehicle may not illuminate the "Check Engine"
light if the evaporative emissions purge system malfunctions. This could cause your vehicle to emit
hydrocarbon levels above the limits that were established to protect the public health from the
dangers of air pollution.
Hydrocarbons (unburned fuel) combined with oxides of nitrogen, in the presence of sunlight, can
cause the formation of ozone. These pollutants are the primary components of smog.
What DaimlerChrysler and your dealer will do...
DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will
reprogram your vehicle's powertrain control module. The work will take about 1/2 hour to complete.
However, additional time may be necessary depending on how dealer appointments are scheduled
and processed.
What you must do...
^ Simply contact your dealer right away to schedule a service appointment.
^ Bring the enclosed Owner Notification form with you to your dealer. It identifies the required
service to the dealer.
If you live in California and don't get this done...
The State of California requires the completion of emission recall repairs prior to vehicle
registration renewal. In addition, the State requires that every vehicle must pass an emission test
(SMOG Check) every two years and before it is sold. Without the free service we are providing,
your vehicle may be more likely to fail this test and require that you make costly repairs.
How the state knows that the recall has been performed...
State of California regulations require DaimlerChrysler to provide the Department of Motor Vehicles
with a record of all vehicles that have not had the recall service performed. If you live in the state of
California and your vehicle is not on this list, the state will know that the recall has been completed.
Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the
recall service is completed. Be sure to save this form since the California Department of Motor
Vehicles may require that you supply it as proof of recall completion.
If you need help...
If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer
Assistance Center, toll free, at 1-800-992-1997. A representative will assist you in getting your
vehicle repaired.
In order to ensure your full protection under the emission warranty provisions, it is recommended
that you have your vehicle serviced as soon as possible. Failure to do so could be determined as
lack of proper maintenance of your vehicle.
We are sorry for any inconvenience but trust you understand our interest in clean air and your
continued satisfaction with our products. Thank you for your attention to this important matter.
Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 >
Engine Controls/Charging System - Manual Updates
Powertrain Control Module: All Technical Service Bulletins Engine Controls/Charging System -
Manual Updates
NUMBER: 26-08-99F
GROUP: Miscellaneous
DATE: August, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1998-2.5L, 3.9L, 5.2L, 5.9L, 8.0 SFI/Mechanically Injected Diesel Diagnostic Manual -
Publication Number 81-699-97027
DESCRIPTION OF CHANGES
Revisions to the Charging System Low Test

Engine Controls/Charging System - Manual Updates > Page 233
71
Revision to the 5.2/5.9L PCM Wiring Schematic
744
Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 831 > Jun > 99 > Recall -
Reprogram PCM
June 1999
Models
transmission)
NOTE:
Subject
Repair
Parts Information
payments.
Number Allowance

NOTE:
Parts Return
Reprogram PCM > Page 239
Not Applicable
48326-2757
Service Office.
Service Procedure
Using the MDS1
power them up.
MENU screen.
MENU.
NOTE:
Using the MDS2

SCREEN.
SCREEN.
NOTE:
begin the session.
NOTE:
Fig. 1
Fig. 2
Owner Letter
The problem is...
and processed.
What you must do...
If you need help...
vehicle repaired.
Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun > 98 >
Powertrain Control Module - Service Precaution
Powertrain Control Module: All Technical Service Bulletins Powertrain Control Module - Service
Precaution
NO: 18-21-98
DATE: Jun. 5, 1998
SUBJECT:
Powertrain Control Module (PCM) Service Caution
MODELS:
1996 - 1998 (AB) Ram Van
1996 - 1998 (AN) Dakota
1996 - 1998 (BR/BE) Ram Truck
1998 (DN) Durango
1997 - 1998 (TJ) Wrangler
1996-1998 (XJ) Cherokee
1996-1998 (ZJ) Grand Cherokee
1996 - 1998 (ZG) Grand Cherokee (European Market)
DISCUSSION:
Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF"
position for a minimum of 5 seconds before connector removal.
It has been found under certain key "ON" or momentary key "OFF" conditions, when the black
connector is unplugged, the PCM may attempt to write information to the EEPROM processor
within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero)
volts. The result will prevent the charging system from charging the battery.
If this occurs, the only correction is PCM replacement.

Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 >
Engine Controls/Fuel System - Service Manual Revisions
Powertrain Control Module: All Technical Service Bulletins Engine Controls/Fuel System - Service
Manual Revisions
NUMBER: 26-12-97H
DATE: December, 1997
Models: 1998 2.5L, 3.9L, 5.2L, 8.0L Powertrain Diagnostic Manual - Publication Number -
81-699-97027
Revisions to the "No Cam Signal at PCM" test

Engine Controls/Fuel System - Service Manual Revisions > Page 250
29
56
58
Revision to the "Fuel Level Sending Unit" test
412
Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine
Controls/Charging System - Manual Updates
Manual Updates
NUMBER: 26-08-99F
DATE: August, 1999

Controls/Charging System - Manual Updates > Page 259
71
744
Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun > 98 > Powertrain
Control Module - Service Precaution
Precaution
NO: 18-21-98
DATE: Jun. 5, 1998
SUBJECT:
MODELS:
1996 - 1998 (AB) Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
DISCUSSION:

Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine
Controls/Fuel System - Service Manual Revisions
Manual Revisions
NUMBER: 26-12-97H
81-699-97027

Controls/Fuel System - Service Manual Revisions > Page 269
29
56
58
412
Technical Service Bulletins > Page 273
Powertrain Control Module: Specifications
Mounting Screws 1 Nm
Powertrain Control Module: Locations
Fig 1 Powertrain Control Module
The Powertrain Control Module (PCM) is located under the hood; mounted to the cowling, near the
wiper motor.
Diagrams > Diagram Information and Instructions
Powertrain Control Module: Diagram Information and Instructions
Introduction
8w-01-002
Diagrams > Diagram Information and Instructions > Page 277
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

Powertrain Control Module: Diagnostic Aids
position
problem
Testing For Voltage
Testing For Voltage


Probing Tool
Powertrain Control Module
Diagrams > Page 296
Powertrain Control Module: Description and Operation
SYSTEM OPERATION
Powertrain Control Module (PCM)
The Powertrain Control Module (PCM) is located in the engine compartment. The ignition system is
controlled by the PCM.
NOTE: Base ignition timing by rotation of distributor is not adjustable.
The PCM opens and closes the ignition coil ground circuit to operate the ignition coil. This is done
to adjust ignition timing, both initial (base) and advance, and for changing engine operating
conditions. The amount of electronic spark advance provided by the PCM is determined by five
input factors: engine coolant temperature, engine rpm, intake manifold temperature, manifold
absolute pressure and throttle position.
Service and Repair > Module Replacement
Powertrain Control Module: Service and Repair Module Replacement
REMOVAL
1. Disconnect the negative battery cable at battery. 2. Carefully unplug the three 32-way
connectors from PCM. 3. Remove three Powertrain Control Module (PCM) mounting bolts and
remove PCM from vehicle.
INSTALLATION
1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 4 N.m (35 in. lbs.). 3. Check pin
connectors in the PCM and the three 32-way connectors for corrosion or damage. Repair as
necessary 4. Install three 32-way connectors. 5. Install battery cable.
Service and Repair > Module Replacement > Page 299
Powertrain Control Module: Service and Repair A Note About PCM Replacement
Important Note:
If the Powertrain Control Module has been changed and the correct VIN and mileage have not
been programmed, a DTC will be set in the ABS, Airbag and SKIM modules. In addition, if the
vehicle is equipped with a Sentry Key Immobilizer Module (SKIM), Secret Key data must be
updated to enable starting.
For ABS and Airbag Systems: 1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS
and Airbag modules.
For SKIM Theft Alarm: 1. Connect the DRB to the data link connector. 2. Go to Engine, Misc. and
place the SKIM in secured access mode, by using the appropriate PIN code for this vehicle. 3.
Select Update the Secret Key data, data will be transferred from the SKIM to the PCM (this is
required to allow the vehicle to start with the new
PCM).
4. If three attempts are made to enter secured access mode using an incorrect PIN, secured
access mode will be locked out for one hour. To exit this
lock out mode, leave the ignition key in the Run/Start position for one hour. Ensure all accessories
are turned off. Also monitor the battery state and connect a battery charger if necessary.
Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Automatic Shut Down (ASD) Relay: Locations
Auto Shutdown Relay Connector, Power Distribution Center

Component Information > Locations > Page 303
8w-10-2

Automatic Shut Down (ASD) Relay: Description and Operation
SYSTEM OPERATION
As one of its functions, the (ASD) relay will supply battery voltage to the ignition coil. The ground
circuit for the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM regulates
ASD relay operation by switching the ground circuit on-and-off.
Automatic Shut Down (ASD) Relay: Testing and Inspection
Fig. 24 Asd And Fuel Pump Relay Terminals
The relay terminal numbers can be found on the bottom of the relay:
- Terminal number 30 is connected to battery voltage and can be switched or B+ (hot) at all times.
- The center terminal number 87A is connected (a circuit is formed) to terminal 30 in the
de-energized (normally OFF) position.
- Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON)

position. Terminal number 87 then supplies battery voltage to the component being operated.
- Terminal number 86 is connected to a switched (+) power source.
- Terminal number 85 is grounded by the Powertrain Control Module (PCM).
TESTING
1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between
terminals 85 and 86.
- Resistance value (ohms) should be 75 +/- 5 ohms for resistor equipped relays.
3. Connect the ohmmeter between terminals number 87A and 30.
- Continuity should be present at this time.
4. Connect the ohmmeter between terminals number 87 and 30.
- Continuity should not be present at this time.

5. Use a set of jumper wires (16 gauge or smaller).
- Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12
volt power source.
6. Attach the other jumper wire to the positive side (+) of a 12V power source.
- Do not connect this jumper wire to relay at this time.
CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to
ohmmeter may result.
7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay.
- Continuity should now be present between terminals number 87 and 30.
- Continuity should not be present between terminals number 87A and 30.
8. Disconnect jumper wires from relay and 12 volt power source.
If continuity or resistance tests did not pass, replace relay.

Automatic Shut Down (ASD) Relay: Service and Repair
Fig 2 Power Distribution Center
The Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). The PDC
is located in the engine compartment. Refer to label on PDC cover for relay location.
REMOVAL
1. Remove the PDC coven 2. Remove the relay by lifting straight up.
INSTALLATION
1. Check condition of relay terminals at PDC for corrosion or damage.
- Also check the heights of relay terminal pins at PDC.
- Pin height should be same for all pins.
- Repair as necessary before installing relay.
2. Push the relay into the connector. 3. Install the relay cover.
Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Fuel Pump Relay: Locations
Fuel Pump Relay Connector, PDC

Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 312
8w-10-2

Fuel Pump Relay: Service and Repair

Power Distribution Center -- Under The Hood, Near The Brake Master Cylinder
The fuel pump and automatic shutdown (ASD) relays are located in the Power Distribution Center
(PDC). The PDC is located in the engine compartment in front of the brake master cylinder. Refer
to label on PDC cover for relay location. Check the terminals in the PDC relay connector for
corrosion or damage before installation.
Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >

8w-10-2

SYSTEM OPERATION

TESTING

volt power source.

REMOVAL
INSTALLATION
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 816 > Feb > 99 > Recall -
Airbag Electronic Control Module
Recall - Airbag Electronic Control Module
February 1999
Safety Recall No. 816
Models
1998 (AB) Dodge Ram Vans and Wagons
NOTE:
This recall applies only to vehicles built through June 5, 1998 (MDH 060517).
IMPORTANT:
Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to
complete this recall service on these vehicles before retail delivery. Dealers should also consider
this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for
service as determined by using the DIAL VIP System.
Subject If an object impacts the airbag electronic control module (AECM) on about 46,000 of the
above vehicles, the module may inadvertently deploy both airbags. Inadvertent airbag deployment
can injure a front seat occupant.
Repair
The AECM must be replaced and a protective cover must be installed over the new AECM.
CCF18160 AECM Package
Each package contains the following components:
Quantity Description
1 AECM
1 AECM Cover
3 Screws - AECM-to-Floor Pan
Each dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street
address), will receive enough AECM Packages to service about 25% of those vehicles.
Claims for vehicles that have been serviced, must be submitted on the DIAL System. Claims
payments.
Use the following labor operation number and time allowance:
Number Allowance
Replace AECM and install cover 08816182 0.4 hours

NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section for complete recall
claim processing instructions
Parts Return
Not required.
Dealer Notification & Vehicle List

Airbag Electronic Control Module > Page 333
additional copies will be sent through the CMMS and the "TIL" will be updated to include this recall
in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at
the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in
Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed.
The lists are for dealer reference in arranging for service of involved vehicles
customer name, address and phone number is listed if known. Completed vehicles are removed
the "ENTER FUNCTION" prompt, then type "ORD816".
recall are identified on the form for owner or dealer reference as needed,
If a vehicle is not available for service, let us know by filling out the pre-addressed Vehicle
Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and
mail to:
DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive Last Auburn Hills, Michigan
48326-2757
Service Office.
Service Procedure
1. With the ignition key in the OFF position, disconnect the battery.
Note:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
2. Using a trim panel removal tool, remove the push-in fasteners that attach the seat riser trim
shield to the rear of the driver's seat riser (if equipped) (Figure 1). Set the trim shield aside.
3. Remove the power seat wiring harness connector from the front riser crossmember and then
disconnect the connector (if equipped) (Figure 2).
4. Remove the nuts that attach the driver's seat riser to the floor pan (Figure 2).
5. Remove the driver's seat assembly from the vehicle.
6. Disconnect the airbag electronic control module (AECM) wiring connector.
7. Remove the three (3) screws that attach the AECM to the floor pan mounting bracket (Figure 3).
Discard the screws.
8. Remove the AECM. Destroy the old AECM connector pins and then discard the old AECM.
9. Install the supplied AECM. Position the AECM on the floor pan mounting bracket with the arrow
on the housing pointing forward (Figure 3).
10. Install the three provided AECM mounting screws. Tighten the screws to 105 in-lbs (11.8 N.m).
11. Connect the AECM wiring connector. Make sure that the connector latches are fully engaged.
12. Clean the floor pan area around the AECM.
13. Remove the "peel and stick" backing paper from the adhesive strips on the provided AECM
cover.
14. Install the cover over the AECM. Press down firmly to ensure that the adhesive strips are
securely attached to the floor pan (Figure 4).
Note:
Position the cover so that the vehicle wiring harnesses are routed through the cover openings.
Ensure that the power seat wiring harness is not trapped under the cover.
15. Install the driver's seat assembly into the vehicle.
16. Install the nuts that attach the driver's seat riser to the floor (Figure 2). Tighten the nuts to 55
ft-lbs (75 N.m).
17. Connect the power driver seat wiring harness connector and attach it to the front riser
crossmember (if equipped) (Figure 2).
18. Attach the riser trim shield to the rear of the driver's seat riser with the push-in fasteners (if
equipped) (Figure 1).
19. Turn the ignition switch to the "RUN" position.
20. Connect the negative battery cable.
21. From outside the vehicle, turn the ignition switch to the "OFF" position for about 10 seconds
and then turn it back to the "RUN" position.
22. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light, or lights and stays on, there is a system malfunction. Refer
to the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
Owner Letter
SAFETY RECALL TO REPLACE YOUR VEHICLE'S AIRBAG ELECTRONIC CONTROL MODULE
Dear Ram Van or Wagon Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
DaimlerChrysler Corporation has determined that a defect, which relates to motor vehicle safety,
exists in some 1998 Dodge Ram Vans and Wagons.
The problem is...
If an object impacts the airbag electronic control module (AECM) under the driver's seat of your
Ram van or wagon (identified on the enclosed form), the module may inadvertently deploy both
airbags. Inadvertent airbag deployment can injure a front seat occupant.
replace the AECM and install a protective cover over it. The work will take about one hour to
complete. However, additional time may be necessary depending on how dealer appointments are
scheduled and processed.
What you must do to ensure your safety...
^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold
the parts for your vehicle or to order them before your appointment.
^ Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required
If you need help...
If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Center,
toll free, at 1-800-992-1997.
A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to
remedy this defect without charge and within a reasonable time, you may submit a written
complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street,
S.W., Washington, DC 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393.
Washington, DC area residents may call 1-202-366-0123.
We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for
your attention to this important matter.
816
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 816 >
Feb > 99 > Recall - Airbag Electronic Control Module
February 1999
Models
NOTE:
IMPORTANT:
Repair
1 AECM
1 AECM Cover
payments.
Number Allowance

NOTE:
Parts Return
Not required.

Feb > 99 > Recall - Airbag Electronic Control Module > Page 342
mail to:
48326-2757
Service Office.
Service Procedure
Note:
service procedure.
Discard the screws.
cover.
Note:
ft-lbs (75 N.m).
and then go out.
NOTE:
Owner Letter
Vehicle Safety Act.
The problem is...
If you need help...
toll free, at 1-800-992-1997.
816
Component Information > Technical Service Bulletins > Page 346
Air Bag Control Module: Locations

Module Locations
Air Bag Control Module

Air Bag Control Module: Diagrams

ACM Connector
ACM Connector
Air Bag Control Module: Description and Operation
SYSTEM OPERATION
The Airbag Control Module (ACM) is secured to a bracket on the floor panel underneath the driver
side front seat in the passenger compartment of the vehicle. The ACM contains a microprocessor
that contains the airbag system logic, the impact sensor, and an energy storage capacitor. The
ACM system logic includes On-Board Diagnostics (OBD) capability, and communicates with the
instrument cluster circuitry on the Chrysler Collision Detection (CCD) data bus to control the airbag
indicator lamp.
The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical
circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends
messages to the instrument cluster on the CCD data bus to turn on the airbag indicator lamp. A
pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration
rate signaled by the impact sensor indicates an impact that is severe enough to require airbag
system protection. When the programmed conditions are met, the ACM sends an electrical signal
to deploy the air-bag system components.
Only one impact sensor is used in this airbag system. The impact sensor is an accelerometer that
senses the rate of vehicle deceleration, which provides verification of the direction and severity of
an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit
with the ACM.
The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical
energy to deploy the airbags for up to one second following a battery disconnect or failure during
an impact. The purpose of the capacitor is to provide airbag system protection in a severe
secondary impact, if the initial impact has damaged or disconnected the battery, but was not
severe enough to deploy the airbags.
The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced.
Air Bag Control Module: Service and Repair
WARNING:
- THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE
SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY
AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT
PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR
TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO
DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
- NEVER STRIKE OR KICK THE AIR BAG CONTROL MODULE, AS IT CAN DAMAGE THE
IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS
ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND
REPLACED WITH A NEW UNIT. ALWAYS REINSTALL THE AIRBAG CONTROL MODULE
PROTECTIVE COVER.
1. Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two
minutes for the system capacitor to discharge
before further service.
2. Reach under the driver side front seat to access and unplug the wire harness connector from the
Air-Bag Control Module (ACM).
Airbag Control Module Remove/Install

3. Remove the three screws that secure the ACM to the mounting bracket on the floor panel under
the driver seat. 4. Remove the ACM from the floor panel mounting bracket. 5. When installing the
ACM, position the unit with the arrow on the ACM housing pointing forward. 6. Secure the ACM to
the floor panel mounting bracket with the three mounting screws. Tighten the mounting screws to
11.8 N.m (105 in. lbs.). 7. Plug in the wire harness connector to the ACM. Be certain that the
connector latches are fully engaged. 8. Do not connect the battery negative cable at this time. See
Airbag System in the Diagnosis and Testing.
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Starter Relay: Locations
8w-10-2
Starter Relay Connector, PDC


Starter Relay: Description and Operation
SYSTEM OPERATION
The starter relay is a International Standards Organization (ISO) micro-relay. The terminal
designations and functions are the same as a conventional ISO relay However, the micro-relay
terminal orientation (or footprint) is different, the current capacity is lower, and the relay case
dimensions are smaller than those of the conventional ISO relay
The starter relay is a electromechanical device that switches battery current to the pull-in coil of the
starter solenoid when the ignition switch is turned to the Start position. See Starter Relay/Testing
and Inspection/Procedures.
The starter relay is located in the Power Distribution Center (PDC), in the engine compartment.
Refer to the PDC label for relay identification and location.
The starter relay cannot be repaired and, if faulty or damaged, it must be replaced.
Starter Relay: Service and Repair
for starter relay identification and location. 4. Unplug the starter relay from the PDC. 5. Install the
starter relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly
into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay
operation.
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set
Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set
NUMBER: 21-04-00
GROUP: Transmission
DATE: June 3O, 2000
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30,
1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS.
SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too
High
OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain
Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and
99Cal14).
MODELS:
**1996** - 1999 (AB) Ram Van
**1996** - 1999 (AN) Dakota
**1996** - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
**1997** - 1999 (TJ) Wrangler
**1996** 1999 (XJ) Cherokee
**1996** - 1998 (ZJ) Grand Cherokee
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC

TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX).
SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble
Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle
operator may experience slower than normal vehicle accelerations because the transmission may
have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode
may last until the vehicle owner cycles the ignition key. The technician may not detect a problem
with the automatic transmission during a diagnostic test or test drive.
The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the
result of a new valve body machining process, which entered into production January 1, 1998. This
condition will occur most often with vehicles that were built between January 1, 1998 and
December 18, 1998.
Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the
transmission assembly is replaced with components built after January 1, 1998.
DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB
III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission
systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record
them on the repair order and repair as necessary before proceeding further with this bulletin. If no
DTC's are present, and the above symptom has been experienced, perform the Repair Procedure.
NOTE:
WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF
THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION
LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS
NECESSARY.
PARTS REQUIRED:
1 04669020 Label, Authorized Software Update
1 04275086 Label, Authorized Modification
EQUIPMENT REQUIRED:
1 CH6000 Scan Tool (DRB III(R))
1 CH7035 General Purpose Interface Bus Cable (GPIB)

Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 368
1 CH7000/7001 J1962 Cable
1 MDS2
NOTE:
THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN
USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061
OR HIGHER.
REPAIR PROCEDURE:
2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON".
3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU
SCREEN.
4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU
SCREEN.
NOTE:
ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE
"CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY
THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2
SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO
BEGIN SESSION.
5. Select the FLASH tab on the MDS2.
NOTE:
IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO
UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT
IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN.
IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER
VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION.
7. Select the new software part number with the light pen and click UPDATE CONTROLLER
SOFTWARE.
8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of
the reprogramming process.
NOTE:
DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER

MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S
MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF
COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL
MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE
VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER
MODULES HAVE HAD THEIR FAULTS ERASED.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI label (Figure 2).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-19-42-99 0.5 Hrs.
FAILURE CODE: FM - Flash Module

Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set
Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set
NUMBER: 21-04-00
GROUP: Transmission
DATE: June 3O, 2000
High
99Cal14).
MODELS:
**1996** - 1999 (AB) Ram Van
**1996** - 1999 (AN) Dakota
**1996** - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
**1997** - 1999 (TJ) Wrangler
**1996** 1999 (XJ) Cherokee
NOTE:

December 18, 1998.
NOTE:
NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:

Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 375
1 CH7000/7001 J1962 Cable
1 MDS2
NOTE:
OR HIGHER.
REPAIR PROCEDURE:
SCREEN.
SCREEN.
NOTE:
BEGIN SESSION.
NOTE:
SOFTWARE.
NOTE:

NOTE:
TIME ALLOWANCE:

Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 377
Control Module: Description and Operation
This vehicle does not have a Transmission Control Module. Transmission control is accomplished
through the Engine Control Module or Powertrain Control Module.
Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations
Transmission Control System Relay: Locations
Transmission Control Relay Connector, PDC

Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 381
8w-10-2
Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 382

Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Description and Operation
Wiper Control Module: Description and Operation
SYSTEM OPERATION
Intermittent Wipe Module An intermittent wipe module is used on vehicles that are not equipped
with the optional Vehicle Theft Security System (VTSS). In addition to low and high speed, the
intermittent wipe system has a delay mode. Electronic circuitry within the intermittent wipe module
is used to accomplish the wiper delay mode. The delay time selected by the driver has a range of
from about one-half second to about fourteen seconds.
The driver selects the length of the delay by placing the wiper (multi-function) switch knob in one of
five different intermittent wipe detent positions. One of the detent positions sends a battery voltage
signal to the intermittent wipe module, while the other four positions use resistors to provide
progressively lower voltage signals to the module. If the washer knob is depressed while the wiper
switch is in the Off position, the intermittent wipe module will operate the wiper motor for
approximately two wipes and automatically turn off the motor.
The intermittent wipe module is snap-fit onto a single blade-type mounting bracket located on the
instrument panel reinforcement above the glove box opening. The intermittent wipe module cannot
be repaired and, if faulty or damaged, it must be replaced.
Module > Component Information > Description and Operation > Page 387
Wiper Control Module: Testing and Inspection
Intermittent Wiper Module Testing The intermittent wipe module is used on vehicles that are not
equipped with the Vehicle Theft Security System (VTSS). See Wiper System in the Diagnosis and
Testing before performing the following tests. If the problem being diagnosed involves only some of
the intermittent wipe delay positions, see Wiper Switch and Washer Switch in the Diagnosis and
Testing. If the problem being diagnosed involves all of the intermittent wipe delay positions,
proceed with the following tests.

INJURY.
1. Disconnect and isolate the battery negative cable. Access and unplug the intermittent wipe
module wire harness connector. Check for continuity
between the ground circuit cavity of the intermittent wipe module wire harness connector and a
good ground. If OK, go to Step 3. If not OK, repair the open circuit to ground as required.
2. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery
voltage at the fused ignition switch output circuit
of the intermittent wipe module wire harness connector. If OK, go to Step 4. If not OK, repair the
open circuit to the fuse in the junction block as required.
3. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable.
Unplug the wire harness connector from the wiper
motor Check for continuity between the wiper park switch sense circuit (VS) cavities of the
intermittent wipe module wire harness connector and the wiper motor wire harness connector.
There should be continuity. If OK, go to Step 5. If not OK, repair the open circuit as required.
4. Unplug the steering column wire harness connector. Check for continuity between the wiper park
switch sense circuit (V7) cavities of the
intermittent wipe module wire harness connector and the instrument panel half of the steering
column wire harness connector. There should be continuity. If OK, go to Step 6. If not OK, repair
the open circuit as required.
5. Check for continuity between the wiper switch mode signal circuit cavities of the intermittent wipe
module wire harness connector and the
instrument panel half of the steering column wire harness connector. There should be continuity. If
OK, go to Step 7. If not OK, repair the open circuit as required.
6. Check for continuity between the wiper switch delay output circuit cavities of the intermittent wipe
7. Test the multi-function switch continuity. See Wiper Switch and Washer Switch in the Diagnosis
and Testing. If the switch tests OK, replace the
faulty intermittent wipe module.

Module > Component Information > Description and Operation > Page 388
Wiper Control Module: Service and Repair
Intermittent Wipe Module Replacement
REMOVAL
An intermittent wipe module is used on vehicles that are not equipped with the optional Vehicle
Theft Security System (VTSS). See Intermittent Wipe Module and Central Timer Module in the
Description and Operation for more information.

INJURY.
1. Disconnect and isolate the battery negative cable. 2. Roll down the glove box from the
instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument
Panel/Glove Box - Roll
Down Replacement.
Instermittent Wiper Module Remove/Install
3. Reach through and above the glove box opening to access the intermittent wipe module. Push
the module towards the front of the vehicle to
disengage the snap-fit slot on the intermittent wipe module from the slide tab of the mounting
bracket on the instrument panel armature.
4. Lower the intermittent wipe module into the instrument panel glove box opening far enough to
access and unplug the wire harness connector. 5. Reverse the removal procedures to install.
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Wiper Relay: Diagrams
Intermittent Wiper Relay Connector

Wiper Relay: Description and Operation
SYSTEM OPERATION
An intermittent wipe relay is used on models that are equipped with the optional Vehicle Theft
Security System (VTSS). The intermittent wipe relay is a International Standards Organization
(ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO
relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is
lower, and the relay case dimensions are smaller than those of the conventional ISO relay.
The intermittent wipe relay is a electromechanical device that switches battery current to the
windshield wiper motor when the relay coil is grounded by the Central Timer Module (CTM) in
response to inputs from the windshield wiper (multi-function) switch. See Intermittent Wipe Relay in
the Diagnosis.
The intermittent wipe relay is located in a connector that is taped back to the instrument panel wire
harness above the inboard side of the glove box opening. The intermittent wipe relay cannot be
Wiper Relay: Testing and Inspection
The intermittent wipe relay is used on vehicles that are equipped with the Vehicle Theft Security
System (VTSS). See Wiper System in the Diagnosis and Testing before performing the following
tests. If the problem being diagnosed involves only some of the intermittent wipe delay positions,
see Wiper Switch and Washer Switch in the Diagnosis and Testing. If the problem being diagnosed
involves all of the intermittent wipe delay positions, proceed with the following tests.

INJURY.
Relay Test
Instrument Wipe Relay
harness above the inboard side of the glove box opening in the passenger compartment. Remove
the intermittent wipe relay from its wire harness connector as described Replacement to perform
the following tests: 1. A relay in the de-energized position should have continuity between terminals
87A and 30, and no continuity between terminals 87 and 30. If OK,

relay.
Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the wiper
(multi-function) switch. There should be continuity between the cavity for
relay terminal 30 and the two washer switch output (V11A and V11B) circuit cavities in the
instrument panel half of the steering column wire harness connector at all times. If OK, go to Step
3. If not OK, repair the open circuit(s) to the wiper (mufti-function) switch as a required.
2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized
position. There should be continuity between the cavity
for relay terminal 87A and the wiper park switch sense circuit cavities of the wiper motor wire
harness connector and the 14-way Central Timer Module (CTM) wire harness connector at all
times. If OK, go to Step 4. If not OK, repair the open circuit(s) to the wiper motor and CTM as
required.
3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the
energized position. There should be battery voltage at
the cavity for relay terminal 87 with the ignition switch in the On or Accessory positions. If OK, go to
4. The coil battery terminal (86) is connected to the electromagnet in the relay There should be
battery voltage at the cavity for relay terminal 86 with
the ignition switch in the On or Accessory positions. If OK, go to Step 6. If not OK, repair the open
circuit to the fuse in the junction block as required.
5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded by
the CTM to energize the relay and cycle the wiper
motor. a Check for continuity between the cavity for relay terminal 85 and the intermittent wiper
relay control circuit cavity of the 14-way CTM wire harness connector. There should be continuity If
OK, use a DRB scan tool and the proper Diagnostic Procedures for diagnosis of the CTM. If not
OK, repair the open circuit to the CTM as required.
Wiper Relay: Service and Repair
Intermittent Wipe Relay Replacement An intermittent wipe relay is used on vehicles that are
equipped with the optional Vehicle Theft Security System (VTSS). See Intermittent Wipe Relay and
Central Timer Module in the Description and Operation for more information.

INJURY.
Down Replacement.
Intermittent Wipe Relay Remove/Install
3. Reach through and above the inboard side of the glove box opening to access the intermittent
wipe relay. Remove the tape that secures the relay
and its connector to the wire harness near the instrument panel armature.
4. Lower the intermittent wipe relay into the instrument panel glove box opening far enough to
access and unplug the relay from its wire harness
connector.
5. Install the intermittent wipe relay by aligning the relay terminals with the cavities in the wire
harness connector and pushing the relay firmly into
place.
6. Tape the intermittent wipe relay and its wire harness connector back to the wire harness. 7.
Reinstall the glove box in the instrument panel. Refer to Instrument Panel, Gauges and Warning
Indicators/Instrument Panel/Glove Box - Roll
Down Replacement.
8. Connect the battery negative cable. 9. Test the relay operation.

Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door
Sensor/Switch (For Alarm) > Component Information > Diagrams
Door Disarm Switch Connector

Sensor/Switch (For Alarm) > Component Information > Diagrams > Page 400
Door Sensor/Switch (For Alarm): Description and Operation
SYSTEM OPERATION
Door Ajar Switch The door ajar switches are integra to the door latches on each front door. The
door ajar switches for the side and rear doors are mounted to the door opening pillars. Each of
these switches close a path to ground for the Central Timer Module (CTM) when a door is opened,
and open the ground path when a door is closed.
The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit (front
doors) or door ajar switch unit (side or rear doors) must be replaced.
Sensor/Switch (For Alarm) > Component Information > Diagrams > Page 401
Door Sensor/Switch (For Alarm): Service and Repair
REMOVAL
Front Door The front door ajar switches are integral to the front door latch unit. If a front door ajar
switch is faulty or damaged, the entire front door latch unit must be replaced.
Side Or Rear Door 1.
Disconnect and isolate the battery negative cable.
Door Ajar Switch Remove/Install - Side Or Rear Door
2. Unscrew the door ajar switch from the pillar.
3. Pull the door ajar switch away from the pillar far enough to access and unplug the two wire
harness connectors from the switch.
4. Remove the door ajar switch from the vehicle.
5. Reverse the removal procedures to install. Tighten the switch to 5.6 N.m (50 in. lbs.).
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock
Cylinder Switch > Component Information > Description and Operation
Lock Cylinder Switch: Description and Operation
SYSTEM OPERATION
The door lock cylinder switches are mounted to the back of the key lock cylinder inside each front
door. They are normally-open momentary witches that close to ground only when the lock cylinder
is rotated to the unlock position.
The door lock cylinder switches cannot be repaired and, if faulty or damaged, they must be
replaced.
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock
Cylinder Switch > Component Information > Description and Operation > Page 405
Lock Cylinder Switch: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of
the front door.
Door Lock Cylinder Switch Remove/Install
3. Unplug the door lock cylinder switch wire harness connector. 4. Disengage the door lock cylinder
switch from the back of the front door lock cylinder 5. Disengage the retainers that secure the door
lock cylinder switch wire harness to the inner door panel. 6. Remove the door lock cylinder switch
from the door. 7. Reverse the removal procedures to install.
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch
> Component Information > Diagrams
Power Door Lock Switch Connector

> Component Information > Diagrams > Page 410
Power Door Lock Switch: Description and Operation
SYSTEM OPERATION
The power locks can be controlled by a two-way switch mounted in a bezel on the mirror flag bezel
trim of each front door. The power lock switch controls the battery feeds to the lock and unlock
sense inputs of the power lock and Remote Keyless Entry (RKE) module or the Central Timer
Module (CTM). The relays that are integral to the power lock and REE module or the CTM then
direct the correct battery and ground feeds to the power lock motors.
The power lock switches cannot be repaired and, if faulty or damaged, the switches must be
replaced.
Power Door Lock Switch: Testing and Inspection
1. Check the fuse in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or
component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the
junction block. If OK, go to Step 4. If not OK, repair the open circuit to the Power Distribution
Center
(PDC) as required.
3. Disconnect and isolate the battery negative cable. Unplug the wire harness connector from the
power lock switch. 4. Connect the battery negative cable. Check for battery voltage at the fused
B(+) circuit cavity of the power lock switch wire harness connector. If
OK, go to Step 6. If not OK, repair the open circuit to the junction block as required.
Power Lock Switch Continuity
5. Test the power lock switch continuity See the Power Lock Switch Continuity chart to determine if
the continuity is correct in the Of,, Lock and
Unlock switch positions. If OK, repair the door lock switch output (lock and/or unlock) circuit(s) from
the power lock switch wire harness connector to the power lock and Remote Keyless Entry (RKE)
module or to the Central Timer Module (CTM) as required. If not OK, replace the faulty switch.
Power Door Lock Switch: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Remove the mirror flag bezel from the
inside of the front door.
Power Lock Switch Remove/Install
3. From the back side of the mirror flag bezel, remove the screws that secure the power window
and power lock switch and mounting plate unit to the
mirror flag bezel.
4. Remove the power window and power lock switch and mounting plate unit from the mirror flag
bezel. 5. With a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power
lock switch receptacle on the back of the switch mounting
plate and pull the switch out of the receptacle.
6. Reverse the removal procedures to install. Be certain that both of the switch snap retainers in
the receptacle on the back of the switch mounting
plate are fully engaged. Tighten the mounting screws to 2.2 N.m (20 in. lbs.).
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Description and Operation
Power Mirror Switch: Description and Operation
SYSTEM OPERATION
Power Mirror Switch Both the right and left power outside mirrors are controlled by a single
multi-function switch unit located on and mounted to the upper flag area of the driver side door trim
panel. The switch knob is rotated clockwise (right mirror control), or counterclockwise (left mirror
control) to select the mirror to be adjusted. The switch knob is then moved in a joystick fashion to
control movement of the selected mirror up, down, right, or left.
The power mirror switch cannot be repaired and, if faulty or damaged, it must be replaced. The
power mirror switch knob is available for service replacement.
Component Information > Description and Operation > Page 416
Power Mirror Switch: Service and Repair
REMOVAL
Power Mirror Switch Knob Remove/Install
2. Pull the power mirror switch control knob rearward to remove it from the switch stem.
Power Mirror Switch Nut
3. Remove the nut that secures the power mirror switch to the driver side door trim pane). 4.
Remove the mirror flag bezel from the inside of the front door.
Power Mirror Switch Remove/Install
5. Unplug the power mirror switch wire harness connector. 6. Remove the power mirror switch from
the back of the door mirror flag bezel. 7. Reverse the removal procedures to install.
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Power Seat Switch: Description and Operation
SYSTEM OPERATION
Power Seat Switch The power seat can be adjusted in six different ways using the power seat
switch. The switch is located in a bezel on the lower inboard side of the seat cushion frame. on the
power seat switch functions and the seat adjusting procedures.
The individual switches in the power seat switch unit cannot be repaired. If one switch is damaged
or faulty, the entire power seat switch unit must be replaced.
Power Seat Switch: Testing and Inspection
1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the
seat cushion. See Power Seat Switch Replacement.
Power Seat Switch Continuity
3. Use an ohmmeter to test the continuity of the switches in each position. See the Power Seat
Switch Continuity chart. If OK, see Power Seat
Adjuster and Motors in the Diagnosis and Testing. If not OK, replace the faulty switch module.
Power Seat Switch: Service and Repair
REMOVAL
1. Remove the driver side front seat from the power seat adjuster and motors unit. See Power Seat
Adjuster and Motors Replacement.
Power Seat Switch And Bezel Remove/Install
2. Remove the two screws that secure the power seat switch and bezel unit to the seat from the
inside of the seat cushion frame. 3. Pull the power seat switch and bezel unit out from the outside
of the seat cushion frame far enough to access the wire harness connector. 4. Using a trim stick or
another suitable wide flat-bladed tool, gently pry the locking tabs of the power seat switch unit away
from the wire harness
connector and carefully unplug the switch from the connector.
5. Remove the two screws that secure the power seat switch unit to the back of the switch bezel. 6.
Remove the power seat switch from the bezel. 7. Reverse the removal procedures to install.
Tighten the mounting screws to 2.2 N.m (20 in. lbs.).
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > 4WD Switch >
4WD Switch: Description and Operation
Vehicles equipped with four wheel drive (4WD) have an indicator switch mounted on the front axle
assembly. This switch is closed to ground when the transfer case is shifted to four wheel drive
mode and the engine is running on some vehicles. While in four wheel drive, the front and rear
axles will operate together. With this input, the CAB is able to modify its operation to allow for 4WD
operation. Should a need for antilock operation occur while in four wheel drive, the CAB will extend
the amount of allowable dump cycles.
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking
Sensor/Switch > Component Information > Description and Operation
Braking Sensor/Switch: Description and Operation
An input from this switch prepares the CAB for a possible antilock stop.
The antilock system uses an input signal from the brake pedal activated switch. When the driver
applies the brake pedal, the circuit voltage is 12 volts. A released brake pedal will close the switch
circuit and provide O volts. This signal tells the CAB that the pedal is depressed
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Specifications > With Four Wheel Antilock Brakes
Wheel Speed Sensor: Specifications
Front Bolt 11 ft.lb
Rear Bolt 18 ft.lb

Sensor > Component Information > Specifications > With Four Wheel Antilock Brakes > Page 434
Mounting Bolt 18 ft.lb

Sensor > Component Information > Locations > Component Locations
Wheel Speed Sensor: Component Locations
Sensor > Component Information > Locations > Component Locations > Page 437
Wheel Speed Sensor: Connector Locations
Sensor > Component Information > Diagrams > Front
Wheel Speed Sensor: Diagrams Front
Sensor > Component Information > Diagrams > Front > Page 441
Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes
Wheel Speed Sensor: Description and Operation Four Wheel Antilock Brakes
OPERATION
The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front steering
knuckles. The third sensor is mounted on top of the rear axle differential housing. The sensor is a
magnet coil that is mounted over a tone wheel front/exciter ring rear with an air gap between them.
The sensors measure the wheel speed by monitoring the rotation of the tone wheels front/exciter
ring rear. As the teeth of the tone wheels front/exciter ring rear move through the magnetic field of
the sensor an AC voltage is generated. This signal frequency increases or decreases proportionally
to the speed of the wheel. The Controller Antilock Brake (CAB) monitors these signals for changes
in wheel deceleration. If the CAB detects a sudden wheel or wheels deceleration within a
predetermined amount the CAB will activate the ABS system.
CIRCUIT OPERATION
The all wheel Anti-Lock Brake System (ABS) uses three wheel speed sensors; a single sensor for
both rear wheels and individual sensors for the front wheels. The single sensor used for the rear
wheels mounts on the top of the rear axle differential housing. Each sensor converts wheel speed
into an electrical signal that is transmitted to the Controller Anti-Lock Brakes (CAB). A pair of
twisted wires connect to each sensor and provide signals to the CAB.
Circuits B6 and B7 provide signals to the CAB from the right front wheel speed sensor. Circuit B6,
which provides the LOW signal, connects to cavity 15 of the CAB. Circuit B7 connects to cavity 2 of
the CAB and provides the HIGH signal.
Circuits B8 and B9 provide signals to the CAB from the left front wheel speed sensor. Circuit B8,
which provides the LOW signal, connects to cavity 16 of the CAB. Circuit B9 connects to cavity 3
and provides the HIGH signal.
Circuit B114 connects to cavity 14 of the CAB and to circuit B2 of the rear wheel speed sensor
harness at the sensor connector. Circuit B113 connects to cavity 1 of the CAB and to circuit B1 at
the rear wheel speed sensor harness connector. Circuit B114 provides the rear wheel speed
sensor LOW input while circuit B113 provides the HIGH input.
Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 444
Wheel Speed Sensor: Description and Operation Kelsey-Hayes Antilock Brake Systems
The EBC 325 ABS system uses one wheel speed sensor on each front wheel, and one speed
sensor mounted in the rear axle for the rear wheels.
The RWAL II uses only one speed sensor mounted in the rear axle for the rear wheels.
The sensor measures the wheel speed by monitoring a rotating tone wheel. The signal generated
by the sensor and tone wheel is transmitted to the CAB.
Each sensor has:
- a metal tone wheel with teeth on its outside diameter
- a magnetic/coil pick-up (speed sensor) that is mounted to a fixed component
- an air gap between the tone wheel and the speed sensor assembly
As the teeth of the tone wheel move through the magnetic field of the sensor, an AC voltage is
generated. This signal frequency increases or decreases proportionally to the speed of the wheel.
The CAB monitors this signal to check for a sudden change in single or multiple wheel
decelerations. If the deceleration of one or more wheels is not within a predetermined amount, the
antilock module takes control.
Diagnostically, the coil of wheel speed sensors have different amounts of resistance based upon
the sensor type. When measured across the connector two terminals, the resistance should be:
AN, DN, BE and BR:
4x4 front sensors 945-1155 ohms
AB, AN and DN:
BE and BR:
AB, AN, DN, BE and BR:
All rear sensors 1600-2300 ohms
NOTE: For all resistance ranges add 30% to the value for extreme heat, subtract 30% for extreme
cold.)
The rear wheel speed sensor used on all vehicles have the same resistance value, but there are
two different sensors. Therefore, it is important to replace the rear wheel speed sensor with the
proper part.
On a EBC 325 system each front wheel speed is monitored through the speed sensor mounted at
the wheel end of the hub. On a EBC 325 and RWAL II system the rear wheel speed is monitored
through the speed sensor mounted in the rear axle assembly.
The CAB will disable antilock control, illuminate the ABS warning light circuit via COD, and store
trouble codes if it detects a problem with any or all of the wheel speed sensors:
- incorrect circuit resistance when checked with no vehicle movement
- incorrect sensor output during vehicle movement

- erratic sensor output during vehicle movement
Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brakes
The rear wheel speed sensor is mounted on the top of the rear axle differential. The sensor
converts wheel speed into an electrical signal that is transmitted to the Rear Wheel Anti-Lock
(RWAL) control module.
Circuits B113 and B114, a pair of twisted wires connect to the sensor and provide signals to the
RWAL control module. These circuits also connect to the rolls test connector used only during
manufacture of the vehicle.
Circuit B113 connects to cavity 14 of the RWAL control module and to circuit B1 of the wheel
speed sensor harness. Circuit B114 connects to cavity 13 of the RWAL control module and circuit
B2 of the sensor harness.
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement
Front
REMOVAL
1. Raise and support vehicle. 2. Disconnect speed sensor from the main harness.
Wheel Speed Sensor
3. Remove sensor mounting bolt from the steering knuckle. 4. Remove the sensor from the
steering knuckle.
INSTALLATION
CAUTION: A special bolt is used to attach the sensor. Use only a factory replacement bolt.
1. Install the sensor into the steering knuckle. 2. Install mounting bolt and tighten to 15 Nm (11 ft.
lbs.). 3. Connect sensor wire to main harness and ensure wire is routed away from hot or moving
components. 4. Remove supports and lower vehicle.
With Rear Wheel Antilock Brakes
REMOVAL
1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the
sensor stud.
Rear Speed Sensor Mounting

Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 448
3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from
differential housing. 5. Disconnect sensor wire harness and remove sensor.
INSTALLATION
1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring
connector. 2. Install 0-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install
sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (18 ft. lbs.). 6. Install the
brake line on the sensor stud and install the nut. 7. Lower vehicle.
With Four Wheel Antilock Brakes
REMOVAL
1. Raise and support vehicle.
2. Disconnect wire from rear sensor on axle housing. 3. Remove sensor and bracket mounting bolt
and remove sensor and bracket.
INSTALLATION
1. Secure sensor wire to rear brake hose with clips provided. 2. Install sensor and mounting
bracket in axle housing. Install mounting bolt and tighten to 24 Nm (18 ft. lbs.). 3. Connect wire to
sensor and secure wire to mounting bracket. 4. Remove support and lower vehicle.
Wheel Speed Sensor: Service and Repair Tone Wheel Replacement
Front Tone Wheel
Tone Wheel
The tone wheel for the front speed sensor is located on the rotor hub. The tone wheel is not a
serviceable component. The complete rotor and hub assembly will have to be replaced if the tone
wheel is damaged.
Rear Tone Wheel
The toothed exciter ring is press-fitted onto the differential carrier next to the final drive ring gear in
the differential case. If the ring is damaged, refer to Transmission and Drivetrain for service
procedures.
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical
Service Bulletins > Engine Controls - ECT Sensor Test revisions
Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls -
ECT Sensor Test revisions
NUMBER: 26-11-97F
DATE: November, 1997
Models: 1998 2.5L/4.0L/5.2L/5.9L SFI Engine Diagnostic Manual - Publication Number

81-699-97019
Revisions to the ECT sensor voltage too high test

Service Bulletins > Engine Controls - ECT Sensor Test revisions > Page 456
165
Service Bulletins > Page 457
Coolant Temperature Sensor/Switch (For Computer): Specifications
Torque 11 Nm
Coolant Temperature Sensor/Switch (For Computer): Locations
Generator, A/C Compressor, Elec.CONN, Engine Coolant Temperature Sensor

Engine Coolant Temperature Sensor

Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to DRB
scan tool and appropriate Powertrain Diagnostics Procedures. To test the sensor only, refer to the
following:
1. Vehicles equipped with air conditioning:
a. Disconnect the negative battery cable at battery. b. Remove Jeep/Truck Engine Controller
(JTEC) mounting bolts and remove JTEC. Do not disconnect three 32-way connectors from JTEC.
Fig. 66 Engine Coolant Temperature Sensor
2. Disconnect wire harness connector from coolant temperature sensor. 3. Engines with air
conditioning:
- When removing the connector from sensor, do not pull directly on wiring harness.
- Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long).
- Place the hook part of tool under the connector for removal.
- The connector is snapped onto the sensor.
- It is not equipped with a lock type tab.

Sensor Resistance (OHMS) - Coolant Temperature Sensor/Intake Air Temperature Sensor
4. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter.
- The resistance (as measured across the sensor terminals) should be as shown in the chart.
- Replace the sensor if it is not within the range of resistance specified in the chart.
5. Test continuity of the wire harness between the JTEC wire harness connector and the coolant
sensor connector terminals.
- Refer to Diagrams/connector Views.
- Repair the wire harness if an open circuit is indicated.
6. After tests are completed, connect electrical connector to sensor.
- The sensor connector is symmetrical (not indexed).
- It can be installed to the sensor in either direction.

Coolant Temperature Sensor/Switch (For Computer): Service and Repair
REMOVAL
WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING

SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING COOLANT TEMPERATURE
SENSOR.
Engine Coolant Temperature Sensor Location
The engine coolant temperature sensor is installed into a water jacket at front of intake manifold
near rear of generator.
1. Disconnect negative battery cable at battery. 2. Place a small mirror above sensor connector. 3.
Disconnect electrical connector from sensor. When removing connector from sensor, do not pull
directly on wiring harness. Fabricate an L-shaped
hook tool from a coat hanger (approximately eight inches long). Place hook part of tool under
connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock
type tab.
4. Partially drain cooling system. 5. Remove sensor from intake manifold.
INSTALLATION
1. Install sensor into intake manifold. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Connect electrical
connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the
sensor in either direction. 4. Replace any lost engine coolant. 5. Connect negative battery cable at
battery.
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations

Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Mounting Screws, Speed Control Switches

Speed Control Switch Connector

Cruise Control Switch: Description and Operation
SYSTEM OPERATION
Two separate speed control switch modules are mounted on the steering wheel to the left and right
side of the driver's airbag module. Within the two switch modules, five momentary contact
switches, supporting seven different speed control functions are used. The outputs from these
switches are filtered into one input. The Powertrain Control Module (PCM) determines which output
has been applied through resistive multiplexing. The input circuit voltage is measured by the PCM
to determine which switch function has been selected.
A speed control indicator lamp, located on the instrument panel cluster is energized by the PCM via
the CCD Bus. This occurs when speed control system power has been turned ON, and the engine
is running.
The two switch modules are labeled: ON/OFF, SET, RESUME/ACCEL, CANCEL and COAST.
Refer to the owner's manual for more information on speed control switch functions and setting
procedures. The individual switches cannot be repaired. If one individual switch fails, the switch
module must be replaced.
Cruise Control Switch: Testing and Inspection
For complete speed control system diagnosis, refer to the appropriate Powertrain Diagnostic
Procedures. To test each of the speed control switches only, refer to the following:
WARNING: BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL ANY AIRBAG

SYSTEM OR RELATED STEERING WHEEL AND STEERING COLUMN COMPONENTS, YOU
MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE.
WAIT 2 MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM
SERVICE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND
POSSIBLE PERSONAL INJURY.
1. Disconnect negative battery cable. Wait 2 minutes for airbag system capacitor to discharge. 2.
Remove the two speed control switch modules from steering wheel. Refer to the
removal/installation section for procedures.
Speed Control Switch Continuity (Typical Switch Shown)
3. Check continuity of each individual speed control switch module as shown in chart. If OK,
reinstall switch. If not OK, replace switch module
assembly.
Cruise Control Switch: Service and Repair
REMOVAL
WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR

INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY.
THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO
MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM
SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT
AND POSSIBLE INJURY.
1. Disconnect and isolate negative battery cable. 2. Remove airbag module. Refer to airbags
Speed Control Switches
3. Remove switch-to-steering wheel mounting screws. 4. Remove switch. 5. Remove electrical

connector at switch.
INSTALLATION
1. Install electrical connector to switch. 2. Install switch and mounting screws. 3. Tighten screws to
1.5 N.m (14 in. lbs.) torque. 4. Install airbag module. Refer to airbags for procedures. 5. Connect
negative battery cable.
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed
Sensor/Transducer - Cruise Control > Component Information > Description and Operation
Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation
VEHICLE SPEED AND DISTANCE-PCM INPUT
The Vehicle Speed Sensor (VSS) is no longer used for any Dodge truck in the 1998 model year.
Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. See:
Sensors and Switches - Brakes and Traction Control/Wheel Speed Sensor The sensor is mounted
to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer.
A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle
speed and distance covered. The PCM will then determine strategies for fuel system and speed
control system operation.
Sensor/Transducer - Cruise Control > Component Information > Service and Repair > With Four Wheel Antilock Brakes
Vehicle Speed Sensor/Transducer - Cruise Control: Service and Repair With Four Wheel Antilock
Brakes
REMOVAL
INSTALLATION
Sensor/Transducer - Cruise Control > Component Information > Service and Repair > With Four Wheel Antilock Brakes >
Page 479
Vehicle Speed Sensor/Transducer - Cruise Control: Service and Repair With Rear Wheel Antilock
Brakes
REMOVAL
sensor stud.
INSTALLATION
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Oil Pressure Sender: Locations
Transmission Wiring, Camshaft Position Connector, Distributor, Oilpressure Sending Unit/switch

Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component
Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions
Oil Pressure Sensor: Technical Service Bulletins Engine Controls/Fuel System - Manual Revisions
NUMBER: 26-01-99C
DATE: January, 1999
Models: 1998 Powertrain 2.5L. 3.9L, 5.2L, 5.9L, 8.0 SFI, Mechanical Injected Diesel Diagnostic
Manual - Publication Number 81-699-97027
Revision to the Table of Contents

Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 489
vi
Revision to the Trouble Code Test menu

538
Revision to the Oil Pressure Sensor test
589, 589A through 589F

589
589A
589B
589C
589D
589E
589F
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Blower Motor Switch: Description and Operation
SYSTEM OPERATION
Front
The front blower motor is controlled by a four position rotary-type blower motor switch, mounted in
the heater-only or heater-A/C control panel. The switch allows the selection of one of four blower
motor speeds, but can only be turned off by selecting the Off position with the heater-A/C mode
control switch knob.
The blower motor switch directs the blower motor ground path from the mode control switch to the
blower motor resistor, or directly to ground through the high speed blower motor relay, as required
to achieve the selected blower motor speed.
The front blower motor switch cannot be repaired and, if faulty or damaged, the entire heater-only
or heater-A/C control unit must be replaced. The blower motor switch knob is serviced separately
Rear
The optional rear heater-A/C unit blower motor is controlled by a four position rotary-type blower
motor switch, mounted in the accessory switch plate located to the right of the heater-A/C control
on the instrument panel. The switch allows the selection of one of three blower motor speeds and
an Off position.
The rear blower motor switch directs the blower motor ground path to the blower motor resistor, or
directly to ground through the high speed blower motor relay as required to achieve the selected
blower motor speed.
The rear blower motor switch cannot be repaired and, if faulty or damaged, it must be replaced.
The rear blower motor switch knob is serviced separately The rear blower motor switch also has a
replaceable incandescent-type illumination lamp bulb.
Blower Motor Switch: Testing and Inspection
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIR-BAGS BEFORE

COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
Front 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative
cable. Remove the heater-A/C control from the instrument
panel. See Heater-A/C Control Replacement for the procedures. Check for continuity between the
ground circuit (Z1V) cavity of the heater-A/C mode control wire harness connector and a good
ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground
as required.
2. With the heater-A/C control wire harness connector unplugged, place the heater-A/C mode
control switch knob in any position except the Off
position. Check for continuity between the two ground circuit terminals in the mode switch
receptacle of the heater-A/C control. There should be continuity. If OK, go to Step 4. If not OK,
replace the faulty heater-A/C control unit.
3. Check for continuity between the ground circuit (C 72) cavities of the heater-A/C mode control
wire harness connector and the heater-A/C blower
speed switch wire harness connector. There should be continuity. If OK, go to Step 5. If not OK,
4. Check for continuity between the ground circuit (C 72) terminal and each of the blower motor
driver circuit terminals in the blower speed switch
receptacle of the heater-A/C control as you move the blower motor switch knob to each of the four
speed positions. There should be continuity at each driver circuit terminal in only one blower motor
switch speed position. If OK, test and repair the blower driver circuits between the heater-A/C
control blower speed switch wire harness connector and the front blower motor resistor or the front
high speed blower motor relay as required. If not OK, replace the faulty heater-A/C control unit.
Rear 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative
cable. Remove the accessory switch plate from the
instrument panel. Refer to Accessory Switch Plate in the Removal and Installation Instrument
Panel, Gauges and Warning Indicators/Instrument Panel for the procedures. Check for continuity
between the ground circuit cavity of the rear blower motor switch wire harness connector and a
good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to
ground as required.
2. With the rear blower motor switch wire harness connector unplugged, place the rear blower
motor switch knob in any position except the Off
position. Check for continuity between the ground circuit terminal and each of the blower motor
driver circuit terminals of the rear blower motor switch as you move the blower motor switch knob
to each of the three speed positions. There should be continuity at each driver circuit terminal in
only one blower motor switch speed position. If OK, test and repair the rear blower driver circuits
between the rear blower motor switch wire harness connector and the rear blower motor resistor or
the rear high speed blower motor relay as required. If not OK, replace the faulty rear blower motor
switch.
Blower Motor Switch: Service and Repair
The rear blower motor switch is used only on models with the optional rear heater-A/C unit.
REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the accessory switch
plate from the instrument panel. Refer to Accessory Switch Plate in the Removal and Installation
Instrument Panel,
Gauges and Warning Indicators/Instrument Panel procedures.
Rear Blower Motor Remove/Install
3. Rotate the illumination lamp socket counterclockwise to disengage it from the back of the switch
housing. 4. Pull the knob off of the blower motor switch stem from the front of the accessory switch
plate. 5. With a small thin-bladed screwdriver, gently pry the sides of the accessory switch plate to
release the two snap clips on each side of the rear
blower motor switch housing.
6. Remove the rear blower motor switch from the back of the accessory switch plate.
INSTALLATION 1. Position the rear blower motor switch on the back of the accessory switch plate.
2. Firmly and evenly press the rear blower motor switch into the back of the accessory switch plate
until it snaps into place. Be certain that all of the
switch snap clip retainers are fully engaged.
3. Reinstall the knob onto the rear blower motor switch stem from the front of the accessory switch
plate. Be certain to index the flat on the switch
stem with the flat in the hub of the knob.
4. Reinstall the illumination lamp socket to the back of the rear blower motor switch housing. 5.
Reinstall the accessory switch plate in the instrument panel. Refer to Accessory Switch Plate in the
Removal and Installation Instrument Panel,
6. Connect the battery negative cable.

Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Description and Operation
High Pressure Sensor / Switch: Description and Operation
SYSTEM OPERATION
High Pressure Cut-Off Switch The high pressure cut-off switch is located on the discharge line near
the condenser. The switch is screwed onto a fitting that contains a Schrader-type valve, which
allows the switch to be serviced without discharging the refrigerant system. The discharge line
fitting is equipped with an 0-ring to seal the switch connection.
The high pressure cut-off switch is connected in series electrically with the low pressure cut-off
switch between the fin sensing cycling clutch switch and the Powertrain Control Module (PCM).
The switch contacts open and close causing the PCM to turn the compressor clutch on and off.
This prevents compressor operation when the discharge line pressure approaches high levels.
The high pressure cut-off switch contacts are open when the discharge line pressure rises above
about 3100 to 3375 kPa (450 to 490 psi). The switch contacts will close when the discharge line
pressure drops to about 1860 to 2275 kPa (270 to 330 psi).
The high pressure cut-off switch is a factory-calibrated unit. The switch cannot be adjusted or
Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Page 508
High Pressure Sensor / Switch: Testing and Inspection
Before performing diagnosis of the high pressure cut-off switch, verify that the refrigerant system
has the correct refrigerant charge. See Refrigerant System Charge in the Service Procedures.
1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from
the high pressure cut-off switch on the refrigerant system fitting. 3. Check for continuity between
the two terminals of the high pressure cut-off switch. There should be continuity. If OK, test and
repair the A/C
switch sense circuit as required. If not OK, replace the faulty switch.
High Pressure Sensor / Switch: Service and Repair
REMOVAL
High Pressure Cut-Off Switch Removed/Install
the high pressure cut-off switch, which is mounted to a fitting on the discharge line between the
compressor and the condenser inlet.
3. Unscrew the high pressure cut-off switch from the discharge line fitting. 4. Remove the high
pressure cut-off switch from the vehicle. 5. Remove the 0-ring seal from the discharge line fitting
and discard.
INSTALLATION
1. Lubricate a new 0-ring seal with clean refrigerant oil and install it on the discharge line fitting.
Use only the specified 0-rings as they are made of a
special material for the R-134a system. Use only refrigerant oil of the type recommended for the
compressor in the vehicle.
2. Install and tighten the high pressure cut-off switch on the discharge line fitting. Tighten the switch
to 7.5 N.m (5.5 ft. lbs.). 3. Plug the wire harness connector into the high pressure cut-off switch. 4.
Connect the battery negative cable.
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams
8w-80-4
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 513
Low Pressure Sensor / Switch: Description and Operation
SYSTEM OPERATION
Fin Sensing Cycling Clutch Switch
Fin Sensing Cycling Clutch Switch The fin sensing cycling clutch switch is used on this model to
signal the Powertrain Control Module (PCM) to cycle the compressor clutch on arid off in order to
control the evaporator temperature. Controlling the evaporator temperature prevents condensate
water on the evaporator fins from freezing and obstructing air conditioning system air flow.
The fin sensing cycling clutch switch consists of a probe and a switch unit. The probe, which is a
Negative Temperature Coefficient (NTC) thermistor in a capillary tube, is inserted between the front
evaporator coil fins to monitor evaporator temperature. The switch unit contains internal control
logic that monitors the input from the probe in order to switch an internal transistor that controls the
output to the PCM. when the fin sensing cycling clutch switch sees a temperature input below
about 1.60 °C (350 °F), it signals the PCM to cycle the compressor off. When the temperature input
reaches above about 3.90 °C (390 °F), the switch signals the PCM to cycle the compressor back
on.
The fin sensing cycling clutch switch can be accessed for service by removing the screws and
carefully lifting the front of the top cover up from the heater-A/C housing. The fin sensing cycling
clutch switch is a sealed unit and cannot be adjusted or repaired. If faulty or damaged, the switch
must be replaced.
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Testing and Inspection > Fin Sensing
Cycling Clutch Switch
Low Pressure Sensor / Switch: Testing and Inspection Fin Sensing Cycling Clutch Switch
Before testing the fin sensing cycling clutch switch, verity that the refrigerant system has the correct
refrigerant charge. Also check that both the low and high pressure cut-off switches are functional,
and confirm that the compressor clutch is operational. Use a volt/ohmmeter to test the switch.
1. Turn the ignition switch in the On position. Place the heater-A/C mode control switch in any A/C
position. Check for battery voltage at the fused
ignition switch output (run/start) circuit cavity of the fill sensing cycling clutch switch wire harness
connector. If OK, go to Step 3. If not OK, repair the open circuit to the fuse in the junction block as
required.
2. With the ambient temperature between 20 to 30° C (68 to 900 F), start the engine and run the air
conditioning system. The compressor clutch
should cycle on and off two to three times per minute. If the clutch fails to cycle at this rate in these
temperatures, replace the faulty fin sensing cycling clutch switch.
NOTE: If the ambient temperature is above 32° C (90° F) the compressor clutch may stay engaged
and not cycle due to the high heat load. This condition is normal.
Cycling Clutch Switch > Page 516
Low Pressure Sensor / Switch: Testing and Inspection Low Pressure Cut-Off Switch
Before performing diagnosis of the low pressure cut-off switch, remember that lower ambient
temperatures, below about -1° C (30° F), during cold weather will open the switch contacts and
prevent compressor operation due to the pressure/temperature relationship of the refrigerant.
Also verify that the refrigerant system has the correct refrigerant charge. See Refrigerant System
Charge in the Service Procedures.
1. Disconnect and isolate the battery negative cable. 2. Unplug the low pressure cut-off switch wire
harness connector from the switch on the suction line jumper fitting. 3. Install a jumper wire
between the two cavities of the low pressure cut-off switch wire harness connector. 4. Connect a
manifold gauge set to the refrigerant system service ports. See Refrigerant System Service
Equipment and Refrigerant System Service
Ports.
5. Connect the battery negative cable. 6. Place the heater-A/C mode control switch knob in any
A/C position and start the engine. 7. Check for continuity between the two terminals of the low
pressure cut-off switch. There should be continuity with a suction pressure (low side)
reading of 103 to 172 kPa (15 to 25 psi) or above, arid no continuity with a suction pressure
reading of 48 to 90 kPa (7 to 13 psi) or below. If OK, test and repair the A/C switch sense circuit as
required. If not OK, replace the faulty switch.
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Fin Sensing
Cycling Clutch Switch Replacement
Low Pressure Sensor / Switch: Service and Repair Fin Sensing Cycling Clutch Switch
Replacement
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Remove the screws that secure the top
cover of the heater-A/C housing to the housing. 3. Unplug the wire harness connector from the fin
sensing cycling clutch switch.
Fin Sensing Cycling Clutch Switch Remove/Install
4. Carefully lift the front of the heater-A/C housing top cover far enough to access and remove the
fin sensing cycling clutch switch probe from the
evaporator coil fins.
INSTALLATION
1. Carefully lift the heater-A/C housing top cover far enough to insert the fin sensing cycling clutch
switch probe into the same hole between the
evaporator coil fins from which it was removed.
2. Position the grommet on the fin sensing cycling clutch switch wire harness into the notch on the
front edge of the lower heater-A/C housing. 3. Secure the top cover to the heater-A/C housing with
the mounting screws. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). 4. Plug in the fin
sensing cycling clutch switch wire harness connector. 5. Connect the battery negative cable.
Cycling Clutch Switch Replacement > Page 519
Low Pressure Sensor / Switch: Service and Repair Low Pressure Cut-Out Switch Replacement
REMOVAL
Low Pressure Cut-Off Switch Remove/Install
2. Unplug the wire harness connector from the low pressure cut-off switch on the suction line
jumper near the filter-drier. 3. Unscrew the low pressure cut-off switch from the fitting on the suction
line jumper. 4. Remove the 0-ring seal from the suction line jumper fitting and discard.
INSTALLATION
1. Lubricate a new 0-ring seal with clean refrigerant oil and install it on the suction line jumper
fitting. Use only the specified 0-rings as they are
made of a special material for the R-134a system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
2. Install and tighten the low pressure cut-off switch on the suction line jumper fitting. Tighten the
switch to 4 N.m (2.9 ft. lbs.). 3. Plug the wire harness connector into the low pressure cut-off
switch. 4. Connect the battery negative cable.
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >
Door Switch: Diagrams
Left Front Door Ajar Switch Connector
Right Front Door Ajar Switch Connector
Auxiliary Door Switch Connector

Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch >

Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions
Fuel Gauge Sender: Technical Service Bulletins Engine Controls/Fuel System - Service Manual
Revisions
NUMBER: 26-12-97H
81-699-97027

Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions > Page
529
29
530
56
531
58
532
412
Fuel Gauge Sender: Description and Operation
DESCRIPTION
The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The
sending unit consists of a float, an arm, and a vanable resistor (track). The resistor track is used to
send electrical signals to the Powertrain Control Module (PCM) for fuel gauge operation and for
OBD II emission requirements.
OPERATION
For fuel gauge operation: As fuel level increases, the float and arm move up. This decreases the
sending unit resistance, causing the fuel gauge to read full. As fuel level decreases, the float and
arm move down. This increases the sending unit resistance causing the fuel gauge to read empty.
After this fuel level signal is sent to the PCM, the PCM will transmit the data across the CCD bus
circuits to the instrument panel. Here it is translated into the appropriate fuel gauge level reading.
For OBD II emission monitor requirements: A voltage signal is sent from the resistor track on the
sending unit to the PCM to indicate fuel level. The purpose of this feature is to prevent the OBD II
system from recording/setting false misfire and fuel system monitor trouble codes. The feature is
activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If
equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if
the fuel level in the tank is more than approximately 85 percent of its rated capacity.
Fuel Gauge Sender: Testing and Inspection
The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down,
electrical resistance will change. To test the gauge sending unit only, it must be removed from
vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal Installation
for procedures.
Measure the resistance across the sending unit terminals. -
With float in up position, resistance should be 20 ohms ± 6 ohms.
- With float in down position, resistance should be 220 ± 6 ohms.

Fuel Gauge Sender: Service and Repair
Fig 30 Fuel Gauge Sending Unit Location
The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel
pump module. The fuel pump module is located on top of fuel tank.
REMOVAL
1. Remove fuel tank. 2. Remove fuel pump module. 3. Carefully separate the lower section of
pump module from upper section by releasing three module lock tabs. Take care not to stretch
plastic fuel
line within module.
4. Unplug 6-way electrical connector. 5. Disconnect 2 sending unit wires at 6-way connector. Note
location of wires within 6-way connector.
Fig 31 Fuel Gauge Sending Lock Tab/Tracks
6. The sending unit is retained to pump module with a small lock tab and notch. Carefully pry up on
lock tab to release from notch while sliding
sending unit downward on tracks for removal. Note wire routing while removing unit from module.
INSTALLATION
1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps
into notch. 3. Connect 2 sending unit wires into 6-way connector. 4. Connect 6-way electrical
connector to module. 5. Carefully connect lower section of pump module to upper section (3 tabs
lock upper section to lower section). 6. Install fuel pump module. 7. Install fuel tank.
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Brake Lamp Switch

Component Information > Description and Operation > General Information
Brake Light Switch: Description and Operation General Information
SYSTEM OPERATION
Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is
mounted on the brake pedal mounting bracket under the instrument panel. The PCM monitors the
state of the dual function stop lamp switch.
Component Information > Description and Operation > General Information > Page 543
Brake Light Switch: Description and Operation Switch With RWAL System
The primary function of the switch,is to turn on the stop lamps during braking. The switch is also
used to send signals to components that must know when the brakes are applied, such as the
Powertrain Control Module (PCM), which uses the signal to cancel speed control. The Controller
Antilock Brake (CAB) uses the brake switch signal to monitor brake pedal application. When the
switch contacts open (brakes applied), the CAB receives the brake applied signal. The CAB then
monitors the ABS system to anticipate the need for an ABS stop.
Brake Light Switch: Testing and Inspection
GENERAL INFORMATION
Stop lamp switch operation can be tested with an ohmmeter. The ohmmeter is used to check
continuity between the pin terminals at different plunger positions.
NOTE: The switch wire harness must be disconnected before testing switch continuity.
SWITCH CIRCUIT IDENTIFICATION
Stop Lamp Switch Terminal Identification
- Terminals 1 and 2 are for the RWAL/ABS module and Powertrain Control Module (PCM) circuit.
- Terminals 5 and 6 are for the stop lamp circuit.
- Terminals 3 and 4 are for the speed control circuit.
SWITCH CONTINUITY TEST
1. Check continuity between terminal pins 5 and 6 as follows:
a. Pull plunger all the way out to fully extended position. b. Attach test leads to pins 5 and 6 and
note ohmmeter reading. c. If continuity exists, proceed to next test. Replace switch if meter
indicates lack of continuity (shorted or open).
2. Check continuity between terminal pins 1 and 2 and pins 3 and 4 as follows:
a. Push switch plunger inward to fully retracted position. b. Attach test leads to pins 1 and 2 and
note ohmmeter reading. c. If continuity exists, switch is OK. Replace switch if meter indicates lack
of continuity (switch is open).
Brake Light Switch: Adjustments
The switch can be adjusted by lightly pulling the brake pedal rearward against the internal booster
stop. This will set the switch plunger to the proper position.
CAUTION: Do not use excessive force to pull the pedal rearward. Excessive force will damage
switch.
Brake Light Switch: Service and Repair
REMOVAL
1. Remove lower column cover. 2. Remove the Data Link Connector, hood release lever and park
brake release lever from the knee blocker. 3. Remove the knee blocker for access to switch. 4.
Press and hold brake pedal in applied position.
Stop Lamp Switch Mounting
5. Rotate stop lamp switch counterclockwise about 1/16 turn to unlock switch. Then pull switch
straight out of mounting bracket and release brake
pedal.
6. If switch is to be tested or replaced, disconnect wire harness and remove switch from vehicle.
INSTALLATION
1. Pull switch plunger all the way out. Then push plunger 4 notches inward to preset position.
Plunger length out of housing will be approximately 14
mm (0.55 inch).
2. Plug wire harness connector into switch. 3. Press and hold brake pedal in applied position. 4.
Align switch locking collar index in switch bracket. Then insert switch straight into bracket. 5. Turn
switch clockwise about 1/16 turn to lock it in position. 6. Release brake pedal. 7. Lightly pull brake
pedal rearward against internal stop in booster.
CAUTION: Do not use excessive force to move the pedal rearward for switch adjustment.
Excessive force will damage the switch.
8. Install the knee blocker. 9. Install the Data Link Connector, hood release lever and park brake
release lever to the knee blocker.
10. Install lower column cover.

Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >

Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >

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

INJURY.
1. Disconnect and isolate the battery negative cable. 2. Open the glove box. 3. Reach through and
above the instrument panel glove box opening upper reinforcement to depress the retaining tabs
on the top and bottom of the
glove box lamp and switch housing.
Glove Box Lamp And Switch Remove/Install
4. While holding the retaining tabs depressed, push the glove box lamp and switch unit out through
the hole in the mounting tab on the upper
instrument panel glove box opening.
5. Pull the glove box lamp and switch out through the mounting tab far enough to access and
unplug the two wire harness connectors. 6. Reverse the removal procedures to install.
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch
> Component Information > Description and Operation
Hazard Warning Switch: Description and Operation
SYSTEM OPERATION
Multi-Function Switch
The turn signal and hazard warning switches are integral to the multi-function switch assembly,
which is secured to the left side of the steering column. A switch stalk that extends from the left
side of the multi-function switch is moved up or down to activate the right or left turn signals,
respectively A latching push-button that extends upward from the multi-function switch and through
the top of the upper steering column shroud is used to control the hazard warning system.
The multi-function switch also contains circuitry for the following functions: -
Headlamp beam selection
- Headlamp optical horn
- Horn contact and circuit
- Windshield wipers
- Windshield washers.
The information contained addresses only the multi-function switch turn signal and hazard warning
switches. For information relative to the other circuits and switches that are integral to the
multi-function switch. However, the turn signal and hazard warning switches cannot be repaired. If
these switches or any other circuit of the multi-function switch is faulty or damaged, the entire
multi-function switch assembly must be replaced.
> Component Information > Description and Operation > Page 557
Hazard Warning Switch: Testing and Inspection
The turn signal switch and the hazard warning switch are integral to the multi-function switch. See
Turn Signal and Hazard Warning Systems in the Diagnosis and Testing before testing the
multi-function switch.

INJURY.
1. Disconnect and isolate the battery negative cable. Unplug the steering column wire harness
connector.
Turn Signal Switch And Hazard Warning Switch Continuity
2. Using an ohmmeter, perform the switch continuity checks at the steering column half of the
steering column wire harness connector terminals as
shown in the Turn Signal Switch and Hazard Warning Switch Continuity chart.
3. If the turn signal switch or hazard warning switch fails any of the continuity checks, repair the
open circuit in the steering column wire harness or
replace the faulty multi-function switch assembly as required. If the switches are OK, repair the
lighting circuits as required.
Hazard Warning Switch: Service and Repair
REMOVAL

INJURY.
1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from
the steering wheel. Refer to Airbag Module in the Removal and Installation for the procedures. 3. if
the vehicle is equipped with the optional vehicle speed control, unplug the wire harness connectors
from the speed control switches in the
steering wheel.
4. Remove the nut that secures the steering wheel to the steering column upper shaft. 5. Remove
the steering wheel with a steering wheel puller (Special Tool C-3428-B). 6. Remove the knee
blocker from the instrument panel. Refer to Instrument Panel, Gauges and Warning
Indicators/Instrument Panel/Knee
Diverter/Knee Blocker Replacement.
7. If the vehicle is so equipped, remove the tilt steering column lever by grasping the lever firmly
and pulling it sharply away from the column.
Lower Steering Column Shroud Screws
8. Remove the two screws from the bottom of the lower steering column shroud that secure it to the
upper shroud. 9. Unsnap the front and both sides of the lower shroud from the upper shroud.
Lower Steering Column Shroud Remove/Install
10. Tilt the lower shroud downward and slide it back to disengage the hooks from the pivots on the
upper shroud.
Upper Steering Column Shroud Remove/Install
11. Remove the two screws that secure the upper shroud to the steering column. 12. Remove the
upper shroud from the steering column.
Steering Column Tie-Wraps
13. Remove the two lower wire harness tie wraps. 14. Remove the screw from the center of the
steering column wire harness connector and unplug the two halves of the connector. 15.
Disengage the two multi-function switch wire harness connectors (one 17-way and one 13-way)
from the steering column wire harness insulator.
Multi-Function Switch Remove/Install
16. Remove the two screws that secure the multi-function switch to the steering column. 17.
Remove the multi-function switch from the steering column. 18. Reverse the removal procedures to
install. During installation, check that the following procedures are accomplished:
- Tighten the multi-function switch mounting screws to 6 N.m (53 in. lbs.).
- Be certain that the new wire harness tie-wraps are installed in the same positions as those that
were removed.
- Be certain that the steering column wire harnesses are routed so that they will not be pinched or
stretched.
- Be certain that the upper shroud spacer mounting stud is fully seated to the mounting boss on the
inside of the shroud.
- Tighten the upper shroud mounting screws to 1.4 N.m (12 in. lbs.).
- Tighten the lower shroud mounting screws to 3.4 N.m (30 in. lbs.).
- Be certain to index the alignment splines in the hub of the steering wheel with the splines on the
upper steering column shaft.
- Be certain to route the wire harnesses from the clockspring between the steering wheel back trim
cover and the steering wheel armature.
- Tighten the steering wheel nut to 61 N.m (45 ft. lbs.).

Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Headlamp Switch: Diagrams

Headlamp Switch Connector
Headlamp Switch Ground Connector

Headlamp Switch: Testing and Inspection
Headlamp Diagnosis
When a vehicle experiences problems with the headlamp system, verify the condition of the battery
connections, charging system, headlamp bulbs, wire connectors, relay, high beam dimmer switch
and headlamp switch.
Always begin any diagnosis by testing all of the fuses and circuit breakers in the system.
Conventional and halogen headlamps are interchangeable. It is recommended that they not be
intermixed on a given vehicle.
Headlamp Switch: Service and Repair
WARNING:
- ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE ATTEMPTING

ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT
IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
- IF THE HEADLAMP SWITCH WAS ON, WAIT FIVE MINUTES TO ALLOW THE CERAMIC
DIMMER RESISTOR TO COOL. IF THE CERAMIC DIMMER RESISTOR IS NOT ALLOWED TO
COOL, IT CAN BURN YOUR FINGERS.
1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the
instrument panel. See Cluster Bezel Replacement for the procedures. 3. Remove the three screws
that secure the headlamp switch bezel to the instrument panel.
Headlamp Switch And Bezel Remove/Install
4. Pull the headlamp switch and bezel out from the instrument panel far enough to access and
unplug the wire harness connectors. 5. Pull the headlamp switch control knob out to the On
position stop. 6. Depress the headlamp switch knob and shaft release button on the top of the
switch. 7. While holding the release button depressed, pull the knob and shaft out of the headlamp
switch. 8. Remove the spanner nut that secures the headlamp switch bezel and mounting bracket
to the switch. 9. Remove the headlamp switch bezel and mounting bracket from the switch.
10. Reverse the removal procedures to install. Tighten the headlamp switch and bezel mounting
screws to 2.2 N.m (20 in. lbs.).
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Horn Switch: Locations
A center-blow, resistive membrane-type horn switch is installed on the back side of the driver side
airbag module trim cover in the center of the steering wheel. When the center area of the airbag
trim cover is depressed, the horn switch completes a curcuit to ground for the coil side of the horn
relay. The steering wheel and steering column must be properly grounded for the horn switch to
function.
The horn switch is only serviced as a part of the airbag module trim cover. If the horn switch should
fail, or if the airbag is deployed, the airbag module trim cover and horn switch must be replaced as
a unit.
Horn Switch: Description and Operation
SYSTEM OPERATION
trim cover is depressed, the horn switch completes a circuit to ground for the coil side of the horn
function.
a unit.
Horn Switch: Testing and Inspection

INJURY.
1. Disconnect and isolate the battery negative cable. Remove the steering column opening cover
and knee blocker from the instrument panel. 2. Check for continuity between the metal steering
column jacket and a good ground. There should be continuity. If OK, go to Step 4. If not OK,
refer to Steering and Suspension/Steering Column.
3. Remove the driver side airbag module from the steering wheel. Refer to Airbag Module in Air
Bags and Seat Belts/Air Bags for the procedures.
Unplug the horn switch wire harness connector from the air-bag module.
4. Unplug the horn relay from the junction block. Check for continuity between the steering column
half of the horn switch feed wire harness
connector and a good ground. There should be no continuity If OK, go to Step 6. If not OK, see
Horn Contact in the Diagnosis and Testing.
5. Check for continuity between the steering column half of the horn switch feed wire harness
connector and the horn relay control circuit cavity for
the horn relay in the PDC. There should be continuity If OK, go to Step 7. If not OK, see Horn
Tower in the Diagnosis and Testing.
6. Check for continuity between the horn switch feed wire and the horn switch ground wire on the
airbag module. There should be no continuity. If
OK, go to Step 8. If not OK, replace the faulty horn switch.
7. Depress the center of the airbag module trim cover and check for continuity between the horn
switch feed wire and the horn switch ground wire on
the airbag module. There should now be continuity If not OK, replace the faulty horn switch.
Component Information > Service and Repair > Driver Side Airbag Trim Cover and Horn Switch
Horn Switch: Service and Repair Driver Side Airbag Trim Cover and Horn Switch
REMOVAL
WARNING:
- THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE

ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING
WHEEL, STEERING COLUMN OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST
DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM
SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO
DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
- THE HORN SWITCH IS INTEGRAL TO THE AIRBAG MODULE TRIM COVER. SERVICE OF
THIS COMPONENT SHOULD BE PERFORMED ONLY BY CHRYSLER-TRAINED AND
AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER
PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN
ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
1. Disconnect and isolate the battery negative cable. If the airbag module has not been deployed,
wait two minutes for the system capacitor to
discharge before further service.
2. Remove the driver side airbag module from the steering wheel. See Airbag Module - Driver Side
in the Replacement.
Airbag Trim Cover Retainer Nuts Remove/Install
3. Remove the four nuts that secure the upper and lower trim cover retainers to the studs on the
airbag housing.
Airbag Trim Cover Retainers Remove/Install
4. Remove the upper and lower trim cover retainers from the airbag housing studs. 5. Remove the
horn switch ground wire eyelet from the airbag housing stud.
Component Information > Service and Repair > Driver Side Airbag Trim Cover and Horn Switch > Page 573
Airbag Trim Cover Remove/Install
6. Disengage the six trim cover locking blocks from the lip around the outside edge of the airbag
housing and remove the housing from the cover.
WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING
THE DRIVER SIDE AIRBAG MODULE, OR BECOMING ENTRAPPED BETWEEN THE DRIVER
SIDE AIRBAG MODULE TRIM COVER AND THE DRIVER SIDE AIRBAG MODULE. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG
DEPLOYMENT.
7. When installing the trim cover and horn switch, be certain that the locking blocks are fully
engaged on the lip of the airbag housing.
Driver Side Airbag Trim Cover Locking Blocks Engaged
8. When installing the upper and lower trim cover retainers, be certain that the tabs on each
retainer are engaged in the retainer slots of the trim
cover.
9. Install and tighten the trim cover retainer nuts to 10 N.m (90 in. lbs.).
10. Reverse the remaining removal procedures to complete the installation, but do not connect the
battery negative cable at this time. See Airbag
System in the Diagnosis and Testing.

Component Information > Service and Repair > Driver Side Airbag Trim Cover and Horn Switch > Page 574
Horn Switch: Service and Repair Horn Switch
WARNING: ON VEHICLES EQUIPPED WITH A DRIVER SIDE AIRBAG, THE HORN SWITCH IS
INTEGRAL TO THE AIRBAG MODULE TRIM COVER. SERVICE OF THIS COMPONENT
SHOULD BE PERFORMED ONLY BY CHRYSLER-TRAINED AND AUTHORIZED DEALER
SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW
THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REFER TO DRIVER
SIDE AIR-BAG TRIM COVER AND HORN SWITCH IN THE REMOVAL AND INSTALLATION
SECTION OF AIRBAG FOR THE SERVICE PROCEDURES
.
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch >
Courtesy Lamp Defeat Switch Connector

Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Turn Signal Switch: Description and Operation
SYSTEM OPERATION
- Windshield wipers
Turn Signal Switch: Testing and Inspection
Turn Signal Switch and Hazard Warning Switch The turn signal switch and the hazard warning
switch are integral to the multi-function switch. See Turn Signal and Hazard Warning Systems in
the Diagnosis and Testing before testing the multi-function switch.

INJURY.
connector.
Turn Signal Switch: Service and Repair
REMOVAL

INJURY.
steering wheel.
upper shroud.
were removed.
stretched.

Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations
Battery Tray, Battery Tempt Sensor, Engine Wiring Harness, Sensor Harness
Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page
590
Battery Temperature Sensor Connector

591
Battery Temperature Sensor: Service Precautions
WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY
DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN
REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN
.
592
Battery Temperature Sensor: Description and Operation
SYSTEM OPERATION
The battery temperature sensor is used to determine the battery temperature and control battery
charging rate. This temperature data, along with data from monitored line voltage, is used by the
PCM to vary the battery charging rate System voltage will be higher at colder temperatures and is
gradually reduced at warmer temperatures.
Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and
Inspection > Testing
Battery Temperature Sensor: Testing and Inspection Testing
To perform a complete test of this sensor and its circuitry. refer to the appropriate Powertrain
Diagnostic Procedures. To test the sensor only, refer to the following:
Battery Temperature Sensor
1. The sensor is located under the battery and is attached to the battery tray. A two-wire pig-tail
harness is attached directly to the sensor. The
opposite end of this harness connects the sensor to the engine wiring harness.
2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to
the wire terminals of the pigtail harness. 4. At room temperature of 25° C (75-80° F), an ohmmeter
reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the
specification, replace the sensor
Inspection > Page 595
Battery Temperature Sensor: Service and Repair
Battery Temperature Sensor Location
The battery temperature sensor is located under vehicle battery and is attached to a mounting hole
on battery tray.
REMOVAL
1. Remove battery. Refer to Starting and Charging/Battery 2. Disconnect sensor pigtail harness
from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole.
INSTALLATION
1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray.
2. Connect pigtail harness. 3. Install battery. Refer to Starting and Charging/Battery
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations
Camshaft Position Sensor: Locations
Camshaft Position Sensor
The Camshaft Position (CMP) Sensor is mounted in the distributor housing.

Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 599
Camshaft Position Sensor Connector

Camshaft Position Sensor: Description and Operation
SYSTEM OPERATION
The camshaft position sensor is located in the distributor on all engines.
The sensor contains a hall effect device called a sync signal generator to generate a fuel sync
signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The
pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction
with the crankshaft position sensor to differentiate between fuel injection and spark events. It is
also used to synchronize the fuel injectors with their respective cylinders.
When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following
occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync
signal of approximately 5 volts.
When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following
occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts.
Camshaft Position Sensor: Testing and Inspection
Camshaft Position Sensor - Typical
To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain
Diagnostics Procedures service. To test the sensor only, refer to the following:
For this test, an analog (non-digital) voltmeter is needed. Do not remove the distributor connector
from the distributor. Using small paper clips, insert them into the backside of the distributor wire
harness connector to make contact with the terminals. Be sure that the connector is not damaged
when inserting the paper clips. Attach voltmeter leads to these paper clips.
1. Remove engine cover. 2. Connect the positive (+) voltmeter lead into the sensor output wire.
This is at done the distributor wire harness connector. For wire identification. 3. Connect the
negative (-) voltmeter lead into the ground wire. For wire identification. 4. Set the voltmeter to the
15 Volt DC scale. 5. Remove distributor cap from distributor (two screws). Rotate (crank) the
engine until the distributor rotor is pointed towards the rear of vehicle.
The movable pulse ring should now be within the sensor pickup.
6. Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. 7. If voltage is
not present, check the voltmeter leads for a good connection. 8. If voltage is still not present, check
for voltage at the supply wire. For wire identification. 9. If 5 volts is not present at supply wire,
check for voltage at PCM 32-way connector (cavity A-17). Leave the PCM connector connected for
this
test.
10. If voltage is still not present, perform vehicle test using the DRB scan tool. 11. If voltage is
present at cavity A-17, but not at the supply wire:
a. Check continuity between the supply wire. This is checked between the distributor connector and
cavity A-17 at the PCM. If continuity is not
present, repair the harness as necessary
b. Check for continuity between the camshaft position sensor output wire and cavity A-18 at the
PCM. If continuity is not present, repair the
harness as necessary
c. Check for continuity between the ground circuit wire at the distributor connector and ground. If
continuity is not present, repair the harness as
necessary.
12. While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle
should fluctuate between 0 and 5 volts while the
engine is cranking. This verifies that the camshaft position sensor in the distributor is operating
properly and a sync pulse signal is being generated. If sync pulse signal is not present,
replacement of the camshaft position sensor is necessary.
Camshaft Position Sensor: Service and Repair
The camshaft position sensor is located in the distributor.
REMOVAL
Distributor removal is not necessary to remove camshaft position sensor. 1. Remove engine cover.
2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws).
4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5.
Remove distributor rotor from distributor shaft.
Crankshaft Position Sensor
6. Lift the camshaft position sensor assembly from the distributor housing.
INSTALLATION
1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2.
Connect wiring harness. 3. Install rotor. 4. Install distributor cap. Tighten mounting screws. 5. Install
engine cover.
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > Engine Controls - ECT Sensor Test revisions
NUMBER: 26-11-97F

81-699-97019

Information > Technical Service Bulletins > Engine Controls - ECT Sensor Test revisions > Page 607
165
Information > Technical Service Bulletins > Page 608
Torque 11 Nm


following:
conditioning:


REMOVAL

SENSOR.
type tab.
INSTALLATION
battery.
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Mounting Bolts 8 Nm
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications >
Page 617
Crankshaft Position Sensor: Locations
Fig. 25 Crankshaft Position Sensor - Typical
The sensor is located on the top of cylinder block near the rear of right cylinder head.
Page 618
Crankshaft Position Sensor Connector

Page 619
Crankshaft Position Sensor: Description and Operation
SYSTEM OPERATION
Sensor Operation
Engine speed and crankshaft position are provided through the crankshaft position sensor. The
sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM
interprets the sensor input to determine the crankshaft position. The PCM then uses this position,
along with other inputs, to determine injector sequence and ignition timing.
The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel
within a certain distance from it.
On this engines, the flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its
outer edge.
The notches cause a pulse to be generated when they pass under the sensor. The pulses are the
input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines.
The engine will not operate if the PCM does not receive a crankshaft position sensor input.
Page 620
Crankshaft Position Sensor: Testing and Inspection
To perform a complete test of this sensor and its circuitry, refer to the DRB scan tool. Also refer to
the appropriate Powertrain Diagnostics Procedures.
Page 621
Crankshaft Position Sensor: Service and Repair
REMOVAL
Crankshaft Position Sensor - Typical
The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. 1. Remove
engine cover. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3.
Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine.
INSTALLATION
1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 N.m (70
in.lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install engine cover.
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications
Intake Air Temperature Sensor: Specifications IAT Sensor
IAT Sensor
Torque 28 Nm
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications >
Page 625
Intake Air Temperature Sensor: Locations
Intake Manifold Air TEMPT Sensor, Electrical CONN

Page 626
Intake Air TEMPT Sensor CONN

Page 627
Intake Air Temperature Sensor: Testing and Inspection
Fig. 69 Intake Manifold Air Temperature Sensor
1. Disconnect the wire harness connector from the intake manifold air temperature sensor.
2. Test the resistance of the sensor with an input impedance (digital) volt-ohmmeter. Refer to the
Coolant Temperature sensor/Intake Air
Temperature sensor resistance chart. Replace the sensor if it is not within the range of resistance
specified in the chart.
3. Test the resistance of the wire harness. Do this between the Powertrain Control Module (PCM)
wire harness connector A-15 and the sensor
connector terminal. Also check between PCM connector A-4 to the sensor connector terminal.
Repair the wire harness as necessary if the resistance is greater than 1 ohm.
Page 628
Intake Air Temperature Sensor: Service and Repair
Fig 57 Air Temperature Sensor
REMOVAL
1. Disconnect electrical connector at sensor. 2. Remove sensor from intake manifold.
INSTALLATION
1. Install sensor to intake manifold. Tighten to 28 N.m (20 ft. lbs.) torque. 2. Install electrical
connector.
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
Manifold Pressure/Vacuum Sensor: Specifications
> Page 632
Manifold Pressure/Vacuum Sensor: Locations
Fig. 15 MAP And Throttle Position Sensor Location - Typical
Map Sensor, Idle Air Control Motor, Throttle Position Sensor

> Page 633
Map Sensor Connector

> Page 634
Manifold Pressure/Vacuum Sensor: Testing and Inspection
Fig 57 Manifold Absolute Pressure Sensor
1. Inspect the rubber L-shaped fitting from the Manifold Absolute Pressure (MAP) sensor to the
throttle body. Repair as necessary.
CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the
test meter probes.
Fig 58 Rubber L-Shaped Fitting -- MAP Sensor-to-Throttle Body

> Page 635
Fig 33 MAP Sensor Connector Terminals -- Typical
2. Test the MAP sensor output voltage at the MAP sensor connector between terminals A and B.
With the ignition switch ON and the engine OFF,
output voltage should be 4-to-5 volts. The voltage should drop to 1.5-to-2.1 volts with a hot, neutral
idle speed condition.
3. Test Powertrain Control Module (PCM) cavity A-27 for the same voltage described above to
verify the wire harness condition. Repair as
necessary.
4. Test MAP sensor supply voltage at sensor connector between terminals A and C with the
ignition ON. The voltage should be approximately 5
volts (+/- 0.5V). Five volts (+/- 0.5V) should also be at cavity A-17 of the PCM wire harness
connector. Repair or replace the wire harness as necessary
5. Test the MAP sensor ground circuit at sensor connector terminal-A and PCM connector A-4.
Repair the wire harness if necessary.
> Page 636
Manifold Pressure/Vacuum Sensor: Service and Repair
Fig 86 MAP Sensor Location
The Manifold Absolute Pressure (MAP) sensor is located on the front of the throttle body. An
L-shaped rubber fitting is used to connect the MAP sensor to throttle body.
NOTE: The throttle body must be removed from the intake manifold for MAP sensor removal.
REMOVAL
1. Remove air cleaner assembly. 2. Remove throttle body. 3. Remove two MAP sensor mounting
bolts (screws). 4. While removing MAP sensor, slide the vacuum rubber L-shaped fitting from the
throttle body 5. Remove rubber L-shaped fitting from MAP sensor.
Fig 87 MAP Sensor L-Shaped Rubber Fitting
INSTALLATION
1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding
rubber fitting over throttle body vacuum nipple. 3. Install MAP sensor mounting bolts (screws).
Tighten screws to 3 N.m (25 in. lbs.) torque. 4. Install throttle body. 5. Install air cleaner.
Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins
> Engine Controls/Fuel System - Manual Revisions
NUMBER: 26-01-99C
DATE: January, 1999

> Engine Controls/Fuel System - Manual Revisions > Page 641
vi
538

589
589A
589B
589C
589D
589E
589F
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications
Oxygen Sensor: Specifications
Torque 30 Nm
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor
Bank Locations
Oxygen Sensor: Locations Oxygen Sensor Bank Locations

Bank Locations > Page 655
JTEC O2 Sensor Location
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 656
Oxygen Sensor Connector

Oxygen Sensor: Application and ID

Oxygen Sensor: Testing and Inspection
Fig 6 Heated Oxygen Sensors
The upstream O2S sensor is located on the inlet end of the catalytic converter.
The downstream O2S sensor is located on the outlet end of the catalytic converter.
Each O2S heating element can be tested with an ohmmeter as follows:
Disconnect the O2S sensor connector. Connect the ohmmeter test leads across the white wire
terminals of the sensor connector. Resistance should be between 4 and 7 ohms. Replace the
sensor if the ohmmeter displays an infinity (open) reading.
Oxygen Sensor: Service and Repair
NOTE: The O2S sensors are located at the inlet and outlet ends of the catalytic converter.
WARNING: The exhaust manifold, exhaust pipes and catalytic converter become very hot during
engine operation. Allow engine to cool before removing oxygen sensor.
REMOVAL
1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor.
CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going
into sensor.
3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for
removal and installation.
NOTE: Threads of new oxygen sensors are factory coated with anti-seize compound to aid in
removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor.
INSTALLATION
1. Install the O2S sensor. Tighten to 30 N.m (22 ft. lbs.) torque. 2. Connect the O2S sensor wire
connector. 3. Lower the vehicle.
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Fuel System/Engine Controls - Manual Revisions
Throttle Position Sensor: Technical Service Bulletins Fuel System/Engine Controls - Manual
Revisions
NUMBER: 26-02-99A
DATE: February, 1999
Models: 1998 Diagnostic Manual - Publication Number 81-699-97019
Revision to the Diagnostic Trouble Codes

Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 664
45
46
47
Revision to the Throttle Position Sensor connector pin outs
152
156
Revision to the Fuel System Rich test
316
Revisions to the Throttle Position sensor
620
622
Bulletins > Page 672
Throttle Position Sensor: Specifications
Throttle Position Sensor: Locations
Map Sensor Throttle Position Sensor, Idle Air Control Motor, Throttle Position Sensor
Throttle Position Sensor Connector

Throttle Position Sensor: Testing and Inspection
The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of
the TPS is the output terminal.
With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of
the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT).
- At idle, TPS output voltage should should be greater than 0.350 millivolts and less than 900
millivolts.
- At wide open throttle, TPS output voltage must be less than 4.5 volts.
- The output voltage should increase gradually as the throttle plate is slowly opened from idle to
WOT.
NOTE: For additional testing information and circuit diagnosis see Computers and Control
Systems/System Diagnosis/Procedures/Diagnostic Charts.
Throttle Position Sensor: Service and Repair
Fig 80 TPS Mounting Bolts
REMOVAL
1. Remove air intake tube at throttle body 2. Disconnect Throttle Position Sensor (TPS) electrical
connector. 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body
Fig. 81 Installation
INSTALLATION
The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be
installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with
the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when
rotated.
1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 N.m (60 in. lbs.) torque. 3. Manually
operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS
electrical connector to TPS. 5. Install air intake tube.
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations
Locations > Page 680
Transmission Position Switch/Sensor: Service and Repair
Park/Neutral Position Switch
1. Raise vehicle and position drain pan under switch.
2. Disconnect switch wires.
3. Remove switch from case.
4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are
centered in switch opening in case.
5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque.
6. Test continuity of new switch with 12V test lamp.
7. Connect switch wires and lower vehicle.
8. Top off transmission fluid level.

Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
Introduction
8w-01-002
Information and Instructions > Page 685
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

Vehicle Speed Sensor: Diagnostic Aids
position
problem
Testing For Voltage
Testing For Voltage


Probing Tool
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 703
Vehicle Speed Sensor: Description and Operation
Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. See:
Sensors and Switches - Brakes and Traction Control/Wheel Speed Sensor The sensor is mounted
to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer.
A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle
speed and distance covered. The PCM will then determine strategies for fuel system and speed
control system operation.
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > With
Four Wheel Antilock Brakes
Vehicle Speed Sensor: Service and Repair With Four Wheel Antilock Brakes
REMOVAL
INSTALLATION
Four Wheel Antilock Brakes > Page 706
Vehicle Speed Sensor: Service and Repair With Rear Wheel Antilock Brakes
REMOVAL
sensor stud.
INSTALLATION
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Revisions
NUMBER: 26-02-99A

45
46
47
152
156
316
620
622

millivolts.
WOT.
REMOVAL
INSTALLATION
rotated.
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations

Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 729

SYSTEM OPERATION
this
test.
necessary.
REMOVAL
INSTALLATION
engine cover.
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications
Mounting Bolts 8 Nm
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 736

SYSTEM OPERATION
Sensor Operation
outer edge.
REMOVAL
INSTALLATION
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and
Operation
Ignition Switch Lock Cylinder: Description and Operation
SYSTEM OPERATION
The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition
switch module. For electrical diagnosis of the Key-In-Switch, For removal/installation of either the
key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Replacement.
On vehicles equipped with an automatic transmission and a steering column mounted shifter, an
interlock device is located within the steering column. This interlock device is used to lock the
transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY
position. The interlock device within the steering column is not serviceable. If repair is necessary,
the steering column assembly must be replaced.
On vehicles equipped with an automatic transmission and a floor mounted shifter, a cable connects
the interlock device within the steering column assembly, to the transmission floor shift lever. This
interlock device is used to lock the transmission shifter in the PARK position when the key is in the
LOCKED or ACCESSORY position. The interlock device within the steering column is not
serviceable. If repair is necessary, the steering column assembly must be replaced. The shifter
interlock cable can be adjusted or replaced.
Operation > Page 745
Ignition Switch Lock Cylinder: Service and Repair
REMOVAL
1. Disconnect negative battery cable from battery. 2. Place shifter in PARK position. 3. Remove
tilt-wheel lever (pulls out).
Lower Shroud Screws
4. Remove 2 lower shroud screws (size T25).
Shroud Pivot Point
5. Upper and lower shrouds are snapped together at sides. Pivot points for lower and upper
shrouds is at rear of shrouds. Lower shroud is hooked to
pins on upper shroud. Tilt lower shroud down for removal.

Upper Shroud Screws
6. Remove 2 upper shroud screws (size T5) and remove upper shroud from steering column. 7. If
removing key lock cylinder only, proceed to next step. If removing ignition switch, proceed to
IGNITION SWITCH REMOVAL. 8. KEY LOCK CYLINDER REMOVAL: Ignition key must be in key
cylinder for cylinder removal.
a. Rotate and hold key in START position.
Lock Cylinder Retainer Pin Access Hole
b. Position a 1/16" pin punch into lock cylinder retainer pin access hole. c. Press in on pin punch to
release lock cylinder retainer pin while releasing key to RUN position. d. Pull lock cylinder out for
removal.
9. IGNITION SWITCH REMOVAL: Key lock cylinder removal is not necessary for ignition switch
removal.
Installing Lock Cylinder To Column
Removing/Installing Alarm Switch
a. Remove alarm switch. Alarm switch is located at right/upper side of steering column. Press on
retaining clip with a small screwdriver while
rotating switch 1/4 turn for removal.
b. Remove knee blocker below steering column. Refer to Knee Blocker in Instrument Panel
Gauges And Warning Indicator. c. Note position of wiring harnesses and all tie wraps between
ignition switch and 4 way connector at lower part of steering column. when
installing ignition switch/wire harness assembly, the harnesses must be correctly routed with tie
wraps in correct position to prevent damage to harness.
d. If equipped with overdrive (OD) transmission, unclip OD wire harness at ignition switch. e. Cut
necessary tie wraps.
Ignition Switch Mounting Screws
f. Remove 2 ignition switch mounting screws (size T4) and separate switch at steering column.
Separating 48-Way Connectors At Lower Part Of Column
g. Separate steering column 48-way electrical connectors by removing one fastener (bolt). The
48-way connector is located near lower part of
steering column. This 48-way connector contains 48 different pin-outs including 3 different
connectors: a 17-way for the multi-function switch; a 13-way for the multi-function switch; and an
18-way for the ignition switch.
h. Separate 17-way multi-function switch connector from 18-way ignition switch connector.
Steering Column 48-Way Connector (Male C0nnector To Column Shown)
i. Separate 13-way multi-function switch connector from 18-way ignition switch connector.
j. Separate multi-function switch wire harnesses from ignition switch wiring harness.
k. Remove wiring harness and ignition switch as an assembly from steering column.
INSTALLATION
1. KEY LOCK CYLINDER INSTALLATION:
a. Place key into lock cylinder. b. Place key lock cylinder into steering column by aligning
positioning tab on lock cylinder to positioning slot on steering column. Locking tab
should also be aligned to locking tab slot.
c. Press on lock cylinder until retaining pin engages. d. Rotate key to OFF position. e. Check for
proper retention of lock cylinder by attempting to pull out on lock cylinder.
2. IGNITION SWITCH INSTALLATION:
a. Position switch and wire harness assembly to steering column. b. Install switch screws and
tighten to 1.4 N.m (12 in. lbs.) torque. c. Carefully route ignition switch wire harness down to bottom
of steering column. d. If equipped with overdrive (OD) transmission, clip OD wire harness to ignition
switch. e. Route alarm switch wire harness around ignition switch. f.
Attach alarm switch to steering column by rotating and snapping into position).
g. Attach 13-way multi-function switch connector to ignition switch 18-way connector. h. Attach
17-way multi-function switch connector to ignition switch 18-way connector. i.
Attach both 48-way electrical connectors together (1 bolt). Tighten bolt to 7 N.m (62 in. lbs.) torque.
j. Install new tie wraps in their previously noted positions.
k. If equipped with a tilt steering wheel, operate tilt mechanism while observing wiring harnesses for
binding. Correct binding if necessary. l.
Operate shift lever while observing wiring harnesses for binding. Correct binding if necessary.
3. A 2-5/8" long plastic spacer is attached to inside of upper shroud. Before positioning shroud to
column, verify spacer is tightened to upper shroud. 4. Position upper shroud to steering column. 5.
Install 2 upper shroud screws. 6. Position rubber shields for shift lever and multi-function switch into
upper shroud. 7. Position lower shroud hooks into pins on upper shroud. 8. Snap lower shroud to
upper shroud. 9. Install 2 lower shroud screws.
10. Install tilt-wheel lever (snaps in). 11. Shifter should lock in PARK position when key is in LOCK
position. Shifter should unlock when key rotated to ON position. 12. Check for proper operation of
ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 13. Steering wheel
should lock when key is in LOCK position. Rotate steering wheel to verify Steering wheel should
unlock when key is rotated to ON
position.
14. Connect negative battery cable to battery.

Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches
Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches
NUMBER: 08-025-01
GROUP: Electrical
DATE: Nov. 23, 2001
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED

NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN
THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS,
PARTS, AND 2001 MODEL YEAR PROCEDURES.
NOTE:
THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS.
SUBJECT: Airbag On-Off Switches
MODELS:
1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - **2001** (AB) Ram Van/Wagon
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) Lebaron Coupe/Convertible
1994 - **2001** (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1991 - 1995 (AS) Town & Country/Caravan Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - **2001** (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - **2001** (DN) Durango
1995 - 2000 (FJ) Avenger/Sebring/Talon
1995 - 2000 (JA) Breeze/Cirrus/Stratus
**2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - **2001** (PL) Neon
1997 (PR) Prowler

**2001 (PT) PT Cruiser**
**2001** (RS) Town & Country/Caravan/Voyager

Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 755
1996 - 1997 (SR) Viper
**2001 - 2002 (ST) Sebring Coupe/Stratus Coupe**
1997 - 2001** (TJ) Wrangler
1999 - **2001** (WJ) Grand Cherokee
1997 - **2001** (XJ) Cherokee
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY

TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A
CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE
WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR
PART WARRANTY.
NOTE:
**SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE

OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS
DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.**
DISCUSSION:
DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed
above. The switches are packaged in a kit containing all necessary parts (except as indicated) and
a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule,
consumers will be authorized for on-off switches by claiming they meet any of several criteria.
Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA
authorization letter. For more information concerning the authorization process and/or the
authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you
(dealer) to install these switches when the customer is interested in doing so and has the
necessary NHTSA authorization.
NOTE:
FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001
CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS
REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG
SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE
CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE
AIRBAG KIT.
**FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS,

AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N
05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE
NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.**
PARTS REQUIRED:
NOTE:
SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE
COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES.
DEACTIVATION/DOCUMENTATION PROCEDURE:
1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner
must present to you an "Authorization Form" from the U.S. Department of Transportation National
Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle
identification number. The authorization applies only to the vehicle identified and not to other
vehicles that the owner may have~
2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release
Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on
your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner.
3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making
copies for the owner's and your records.
NOTE:
ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG
OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE.

Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch
Availibility
NO: 08-17-98 Rev. C
GROUP: Electrical
DATE: Dec. 30, 1998
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM

AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED

SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL
MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
**1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan**
1995 - **1999** (AB) Ram Van/Wagon
**1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon**
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/Convertible
1994 -**1999** (AN) Dakota
1991 - 1995 (AS) Town & Country/Caravan/Voyager
**1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue**
1994 - **1999** (BR) Ram Pickup
**1995 - 1996 (B7) Stealth**
1998 - **1999** (DN) Durango
**1995 - 1999 (FJ) Avenger/Sebring/Talon**
1995 - **1999** (JA) Breeze/Cirrus/Stratus
1996 - **1999** (JX) Sebring Convertible
1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - **1999** (NS) Town & Country/Caravan/ Voyager
1995 - **1999** (PL) Neon
1996 - 1997 (SR) Viper
1997 - **1999** (TJ) Wrangler

1997 - **1999** (XJ) Cherokee
NOTE:

PART WARRANTY.
DISCUSSION:
above. Other applicable passenger vehicles will be announced as soon as the switches are
available. The switches are packaged in a kit containing all necessary parts (except as indicated)
and a detailed instruction sheet.
Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for
on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be
installed without the vehicle owner presenting the NHTSA authorization letter. For more information
concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety
Hotline at 1-800-424-9393.
We encourage you (dealer) to install these switches when the customer is interested in doing so
and has the necessary NHTSA authorization.
PARTS REQUIRED:
NOTE:
vehicles that the owner may have.
Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for
your records and make a copy for the vehicle owner.
NOTE:
Switch > Component Information > Locations > Component Locations
Passenger Airbag Switch

Switch > Component Information > Locations > Component Locations > Page 770
Passenger Side Airbag On/Off Switch Remove/Install

Switch > Component Information > Locations > Page 771
Air Bag Deactivation Switch: Diagrams
Passenger Airbag Switch Connector

Switch > Component Information > Locations > Page 772
Air Bag Deactivation Switch: Service and Repair
REMOVAL
WARNING: THE AIR BAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT.

BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED
STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU
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.

2. Remove the accessory switch plate from the instrument panel. Refer to Instrument Panel,
Gauges and Warning Indicators/Instrument
Panel/Accessory Switch Plate Replacement.
3. Remove the two screws that secure the passenger airbag disarm switch to the back of the
accessory switch plate. 4. Remove the passenger airbag disarm switch from the accessory switch
plate. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in.
lbs.). 6. Do not connect the battery negative cable at this time. See Airbag System in the Diagnosis
and Testing.
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature
Sensor > Component Information > Locations
Sensor > Component Information > Locations > Page 777

.
SYSTEM OPERATION
Sensor > Component Information > Testing and Inspection > Testing
Sensor > Component Information > Testing and Inspection > Page 782
on battery tray.
REMOVAL
INSTALLATION
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Description and Operation
SYSTEM OPERATION
Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 787
REMOVAL
Lower Shroud Screws
Shroud Pivot Point

Upper Shroud Screws
removal.
removal.
INSTALLATION
position.

Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Specifications
Neutral Safety Switch: Specifications
Switch, Park/Neutral ............................................................................................................................

..................................................... 34 Nm (25 ft. lbs.)
Switch > Component Information > Specifications > Page 795
Solenoid Case Connector, Park/Neutral Position Switch Connector

Park/Neutral Position Switch Connector

Switch > Component Information > Service and Repair > 32RH Transmission
Neutral Safety Switch: Service and Repair 32RH Transmission
REMOVAL
1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch
from case.
INSTALLATION
centered in switch opening in case. 2. Install new seal on switch and install switch in case. Tighten
switch to 34 Nm (25 ft. lbs.) torque. 3. Test continuity of new switch with 12V test lamp. 4. Connect
switch wires and lower vehicle. 5. Top off transmission fluid level.
Switch > Component Information > Service and Repair > 32RH Transmission > Page 799
Neutral Safety Switch: Service and Repair 46RE Transmission
REMOVAL
from case.
INSTALLATION
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer
Interest: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm
Fluid Pressure Sensor/Switch: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm
NO: 18-19-98
GROUP: Driveability
DATE: Apr. 10, 1998
SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration
MODELS: 1996 - 1998
(AB) Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
1996 - 1998 (ZJ) Grand Cherokee
1996 - 1998 (ZG) Grand Cherokee (International Markets)
NOTE:
THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX)
EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION.
SYMPTOM/CONDITION:
Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking
occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel
shut off rev limit before the transmission can shift into the next higher gear and is most likely to
occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower
on MAX etc.). During high current demands, the generator may emit electrical noise that can affect
the transmission governor pressure sensor output. If this occurs, the transmission may not shift
properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel
shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced
between the 1-2 shift.
DIAGNOSIS:
Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual,
verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes
(DTC's) are present, record them on the repair order and repair as necessary before proceeding
further with this bulletin.
NOTE:
ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD

OBEYING ALL POSTED SPEED LIMITS AND LAWS.
Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with
WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev
limiter before the 2-3 or 1-2 shift is made.
If the bucking condition is experienced at approximately 5300 RPM before making the appropriate
upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the
electrical loads on and off a second time. If the bucking occurs with the electrical loads on and
does not occur with the loads off, perform the Repair Procedure.
PARTS REQUIRED:
1 56041403AA Sensor, Governor Pressure
REPAIR PROCEDURE:
This bulletin involves installing a newly designed governor pressure sensor.

Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer
Interest: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 810
1. Following the procedures in the applicable service manual, replace the governor pressure
sensor with p/n 56041403AA (Figure 1).
2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following
the applicable service manual procedure.
TIME ALLOWANCE: Labor Operation No:
21-96-06-90 1.1 Hrs.
FAILURE CODE: P8 - New Part

Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm
Fluid Pressure Sensor/Switch: All Technical Service Bulletins A/T - Engine Bucking/Surging at
5,300 Rpm
NO: 18-19-98
GROUP: Driveability
DATE: Apr. 10, 1998
MODELS: 1996 - 1998
(AB) Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
NOTE:

PARTS REQUIRED:
REPAIR PROCEDURE:

Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 816
21-96-06-90 1.1 Hrs.

Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Fluid Pressure Sensor/Switch: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set
NUMBER: 21-04-00
GROUP: Transmission
DATE: June 3O, 2000
High
99Cal14).
MODELS:
**1996** - 1999 (AB) Ram Van
**1996** - 1999 (AN) Dakota
**1996** - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
**1997** - 1999 (TJ) Wrangler
**1996** 1999 (XJ) Cherokee
NOTE:

December 18, 1998.
NOTE:
NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:

Service Bulletins for Fluid Pressure Sensor/Switch: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 822
1 CH7000/7001 J1962 Cable
1 MDS2
NOTE:
OR HIGHER.
REPAIR PROCEDURE:
SCREEN.
SCREEN.
NOTE:
BEGIN SESSION.
NOTE:
SOFTWARE.
NOTE:

NOTE:
TIME ALLOWANCE:

1 CH7000/7001 J1962 Cable
1 MDS2
NOTE:
OR HIGHER.
REPAIR PROCEDURE:
SCREEN.
SCREEN.
NOTE:
BEGIN SESSION.
NOTE:
SOFTWARE.
NOTE:

NOTE:
TIME ALLOWANCE:

Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 834

Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation
Transmission Speed Sensor: Description and Operation
TRANSMISSION SPEED SENSOR
Transmission Output Speed Sensor
The speed sensor is located in the overdrive gear case. The sensor is positioned over the park
gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by
the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are
sent to the transmission control module for processing. The rear wheel speed sensor also serves
as a backup for the transmission speed sensor. Signals from this sensor are shared with the
powertrain control module. See: Sensors and Switches - Brakes and Traction Control/Wheel Speed
Sensor
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations
Transmission Temperature Sensor/Switch: Locations
Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid,

Governor
The transmission temperature sensor is located in the transmission solenoid assembly in the valve
body. The governor pressure sender and the transmission fluid temperature thermistor are
separate sensors in the same component. This component is attached to the governor body in the
solenoid assembly of the valve body.
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch
Power Window Switch: Description and Operation
SYSTEM OPERATION
The power windows are controlled by two-way momentary switches mounted in the mirror flag
bezel on the trim panel of each front door. A second power window switch on the driver side bezel
allows the driver to control the passenger side window. The power windows will only operate when
the ignition switch is in the On position.
The power window switches control the battery and ground feeds to the power window motors. The
passenger side power window switch receives a ground feed through the driver side power window
switch for operating the passenger side power window motor.
The power window switches cannot be repaired and, if faulty or damaged, they must be replaced.
Power Window Switch: Testing and Inspection
Before you proceed with this diagnosis, confirm proper circuit breaker operation. See Circuit
Breaker in the Diagnosis and Testing.
1. Remove the power window switch from the mirror flag bezel. See Power Window Switch
Replacement. Carefully separate the wire harness
connector from the switch body.
Left Side Switch Continuity
Power Window Switch Continuity - Passenger Side
2. Check the switch continuity in each position, as shown in the charts. If OK, see Power Window
Motor in the Diagnosis and Testing. If not OK,
replace the faulty power window switch unit.

Power Window Switch: Service and Repair
REMOVAL
Power Window Switch Remove/Install
mirror flag bezel.
window switch receptacle on the back of the switch
mounting plate and pull the switch out of the receptacle.
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Description and Operation
Washer Fluid Level Switch: Description and Operation
SYSTEM OPERATION
Washer Fluid Level Sensor The washer fluid level sensor is mounted near the bottom of the
rearward facing side of the washer reservoir. A barbed nipple on the sensor is press-fit into a
rubber grommet seal installed in the mounting hole on the reservoir.
When the fluid level in the washer reservoir falls below the travel limit of the float, the internal
switch contacts of the sensor close. Refer to Instrument Panel, Gauges and Warning
Indicators/Instrument Panel/Low Washer Fluid Warning Lamp.
The washer fluid level sensor cannot be repaired. If faulty or damaged, the sensor unit must be
replaced.
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Description and Operation > Page 851
Washer Fluid Level Switch: Service and Repair
REMOVAL
1. Remove the washer reservoir from the engine compartment. See Washer Reservoir
Replacement.
NOTE: The pivoting float of the washer fluid sensor must be in a horizontal position within the
reservoir in order to be removed. With the reservoir empty and held in an upright position, the
pivoting float will orient itself to the horizontal position when the sensor connector is pointed straight
downwards.
2. Using a trim stick or another suitable wide flat-bladed tool, gently pry the washer fluid level
sensor out of the rubber grommet seal. Care must be
taken not to damage the reservoir.
3. Remove the rubber grommet seal from the reservoir and discard. 4. Reverse the removal
procedures to install. Always use a new rubber grommet seal on the reservoir.
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Description and Operation
Windshield Washer Switch: Description and Operation
SYSTEM OPERATION
The windshield wiper and washer switches are integral to the multi-function switch assembly, which
is secured to the left side of the steering column. A knob on the end of the multi-function switch
stalk is rotated to select the desired wiper speed or intermittent wipe delay interval. A paddle near
the end of the switch stalk is rotated toward the instrument panel to activate the washer system.
Turn signals
- Hazard warning
- Headlamp beam selection
- Horn contact and circuit.
The information contained addresses only the multi-function switch windshield wiper and washer
multi-function switch. However, the windshield wiper and washer switches cannot be repaired. If
multi-function switch assembly must be replaced. Refer to Turn Signal Switch and Hazard Warning
Switch Replacement.
Washer Switch > Component Information > Description and Operation > Page 855
Windshield Washer Switch: Testing and Inspection
The wiper switch and washer switch are integral to the multi-function switch. See Wiper System
and/or Washer System in the Diagnosis and Testing
WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIRBAGS BEFORE

INJURY.
connector.
Wiper Switch And Washer Switch Continuity
shown in the Wiper Switch and Washer Switch Continuity chart.
3. If the wiper switch or the washer switch fails any of the continuity checks, repair the open circuit
in the steering column wire harness or replace the
faulty multi-function switch assembly as required. Refer to Lighting and Horns/Turn Signal/Turn
Signal Switch and Hazard Warning Switch Replacement for the multi-function switch service
procedures. If the switches are OK, repair the wiper system and/or washer system wire harness
circuits as required.
Washer Switch > Component Information > Description and Operation > Page 856
Windshield Washer Switch: Service and Repair
The wiper switch and washer switch are integral to the multi-function switch, which is installed on
the left side of the steering column. If the wiper switch or the washer switch is faulty or damaged,
the multi-function switch assembly must be replaced. Refer to Lighting and Horns/Turn Signal
Switch and Hazard Warning Switch Replacement.
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch
Wiper Switch: Description and Operation
SYSTEM OPERATION
Turn signals
- Hazard warning
Switch Replacement.
Wiper Switch: Testing and Inspection

INJURY.
connector.
Wiper Switch: Service and Repair
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer
Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair
Technical Service Bulletin # 19-002-01A Date: 010928
Steering/Suspension - Wander Diagnosis/Repair
NUMBER: 19-002-01 REV. A
GROUP: Steering
DATE: Sept. 28, 2001

SEPTEMBER 14, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISES
THE PART DESCRIPTIONS FOR THE SHOCK ABSORBERS AND SPRINGS WHICH WERE
REVERSED AND CORRECTS A LABOR OPERATION NUMBER. THE CHANGES ARE
HIGHLIGHTED WITH **ASTERISKS**.
SUBJECT: Steering Wander Diagnosis
OVERVIEW: This bulletin provides a diagnostic procedure for steering sensitivity.
MODELS:
1998 - 2001 (AB) Ram Van/Wagon
NOTE:
THIS BULLETIN APPLIES TO 3500 (8700 LB. GVW & 9200 LB. GVW) SERIES VEHICLES.
SYMPTOM/CONDITION:
Steering Sensitivity/Wander Diagnosis is the diagnosis of a condition where slight steering

corrections are necessary to be able to keep the vehicle moving in a straight line. Steering
sensitivity/wander can be attributed to a number of different conditions, including but not limited to
the following:
^ Non-factory installed options.
^ Tires or wheels of different size.
^ Aftermarket tires and wheels.
^ Tires that have a belt that has shifted.
^ Incorrect tire pressure.

^ A vehicle that is carrying excess added weight (above manufactures front and/or rear AWR).
^ Steering and/or suspension components that are worn, damaged or out of adjustment.
^ Wheel bearings that are loose, worn, or damaged.
^ A vehicle that is not within alignment specifications.
NOTE:
CERTAIN CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS, CROSSWIND, ETC.),
MAY CONTRIBUTE TO STEERING WANDER.
The following Steering Wander Diagnosis was developed to ensure that the vehicle and its steering
system components are functioning as designed and are not the root cause of steering wander.
Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 871
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
Diagnosis/Repair Procedures
1. Verity that the vehicle is not equipped with non-factory installed options, or equipment that may
cause the vehicle to wander. Equipment such as heavy tool boxes or hardware may cause the
vehicle to exceed the front or rear Gross Axle Weight Rating (GAWR).
2. Inspect the front suspension components including wheel bearings, for any signs of wear or
damage. Make any repairs necessary.
NOTE:
MOST AIR LEVELING SYSTEMS DESIGNED FOR THE RAM VAN/WAGON SHOULD NOT
CAUSE STEERING WANDER. HOWEVER, THE AIR LEVELING SYSTEM MAY BE INSTALLED
ON THE VEHICLE TO ADJUST VEHICLE ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN
AIR LEVELING SYSTEM, ENSURE THE SYSTEM IS INFLATED TO THE MANUFACTURERS
SPECIFICATIONS PRIOR TO PROCEEDING.
3. Lubricate all front steering and suspension system components.
4. Inspect the condition and size of all tire and wheel assemblies. Tires that are worn or damaged
and/or wheels that are of a different size and/or offset than recommended, may cause the vehicle
to wander. Any tires or wheels which exhibit the conditions stated above should be replaced before
continuing with the diagnosis.
5. Inflate the tires to 65 psi. - front and 80 psi. - rear

NOTE:
-IMPORTANT- TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD

SPECIFICATION WHEN PERFORMING STEERING WANDER DIAGNOSIS, HOWEVER,
HEAVILY LOADED VEHICLES SUCH AS MOTOR HOMES OR CONVERSION VANS, OR
VEHICLES USED FOR SHUTTLE SERVICES WHICH ARE OFTEN FILLED WITH PASSENGERS
WILL REQUIRE ADDITIONAL PRESSURE. HEAVILY LOADED VEHICLES SHOULD BE RUN
WITH TIRE PRESSURES OF 65 PSI. - FRONT AND 80 PSI. REAR TO ENHANCE STEERING
PERFORMANCE. THIS INCREASE IN TIRE PRESSURE ALONE MAY BE ALL THAT IS
REQUIRED TO CORRECT THE CONDITION.
6. Validate the customer's concern by test driving the vehicle on a smooth highway, free of road
crown, ruts, speed bumps, or potholes. Drive the vehicle at speeds between 80 - 113 km/h (50 - 70
mph), preferably without crosswind conditions. If crosswind conditions are prevalent, drive the
vehicle in both directions relative to the crosswind. Return the vehicle to the customer if the
steering wander condition has been repaired. If the vehicle still exhibits a steering wander
condition, proceed to the steering gear replacement procedure.
NOTE:
VEHICLES THAT DO NOT EXHIBIT A STEERING WANDER CONDITION DURING THE ROAD
TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-6, OR THE CONDITION
MAY HAVE BEEN CAUSED BY ROAD OR WEATHER CONDITIONS (E.G. WIND, HIGH ROAD
CROWN, GROOVED ROADS, ETC.).
^ WHEEL BEARING ADJUSTMENT
1. Verify the front wheel bearing end play. If the end play is above the specification, complete the
following repair procedure
NOTE:
The end play should be 0.25-0.076 mm (0.001-0.003 in.).
2. Remove the dust cover, nut lock and cotter pin. Tighten the nut to 54 N.m (40 ft. lb. to preload
the bearing while rotating the hub/rotor. Stop hub/rotor and loosen the nut to completely release
bearing preload torque. Tighten the nut to 3 N.m (25 in. lb.). Install the nut lock and a new cotter
pin.
3. Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap
with lubricant. Install the cap.
STEERING GEAR REPLACEMENT
NOTE:
INSPECT THE BAR CODE LABEL ON THE STEERING GEAR AND NOTE THE PART NUMBER.
IF THE PART NUMBER IS 52039231 AD OR 52039231AE (14:1 RATIO) THE VEHICLE WILL
REQUIRE STEERING GEAR REPLACEMENT. IF THE PART NUMBER IS 52039231AB OR
52039231AC (16-13:1 VARIABLE RATIO), STEERING GEAR REPLACEMENT IS NOT
REQUIRED. MOST 1998 AND SOME EARLY 1999 VEHICLES WILL BE EQUIPPED WITH THE
16-13 :1 VARIABLE RATIO GEAR.
1. Using the procedures outlined in the appropriate service manual, remove the steering gear and
install the new steering gear, P/N 52013456AA.
NOTE:
MAKE SURE TO FILL THE STEERING SYSTEM WITH FLUID (P/N 04883077) AND PURGE ALL
AIR FROM THE SYSTEM AS OUTLINED IN THE APPROPRIATE SERVICE MANUAL.
^ REAR SPRINGS AND SHOCK ABSORBERS REPLACEMENT (8700 LB. GVW ONLY)
NOTE:
THE REAR SPRINGS AND SHOCK ABSORBERS ON THE 8700 LB. GVW VEHICLES WILL
REQUIRE UPGRADING TO THE COMPONENTS USED ON THE 9200 LB. GVW VEHICLES.
INSTALLATION OF THE UPGRADED SPRINGS AND SHOCKS IS NOT REQUIRED ON 9200 LB.
GVW VEHICLES. FOR 9200 LB. GVW VEHICLES, PROCEED TO THE WHEEL ALIGNMENT.
CAUTION:
THE REAR OF THE VEHICLE MUST BE LIFTED USING A HOIST. THE LIFT MUST BE PLACED
UNDER THE FRAME RAIL CROSSMEMBER LOCATED AFT OF THE REAR AXLE. USE CARE
TO AVOID BENDING THE SIDE RAIL FLANGE.
1. Raise the vehicle on a hoist and inspect the rear springs and shock absorbers. The heavy duty
spring part number is **52106156AD**. The heavy duty shock part number is **52106320AC**. It
the part numbers on the components differ from these numbers, they must be replaced.
2. Using the procedures outlined in the appropriate service manual, remove the rear springs and
shock absorbers. Install new springs, p/n **52106156AD** and new shock absorbers, p/n
**52106320A0 **
WHEEL ALIGNMENT
NOTE:
IF THE VEHICLE IS EQUIPPED WITH A REAR SUSPENSION AIR LEVELING SYSTEM,

ENSURE THAT THE SYSTEM IS DEFLATED PRIOR TO PERFORMING A WHEEL ALIGNMENT.
3. Perform the Pre-Alignment inspection as identified in Group 02, Service Procedures, of the
appropriate Ram Van/Wagon Service Manual or the service information provided in the MDS2. Any
worn steering and/or suspension component must be replaced prior to performing an alignment.
4. Perform a wheel alignment on the vehicle. Refer to the procedures identified in the appropriate
Ram Van/Wagon Service Manual or the service information provided in the MDS2, Group 02,
Service Procedures, Wheel Alignment. Adjust any front alignment angle not within specifications.
Refer to the following chart for proper alignment specifications.
NOTE:
FOR VEHICLES EQUIPPED WITH THE REAR SUSPENSION AIR LEVELING SYSTEM,
ENSURE THAT THE SYSTEM IS RE-INFLATED TO THE MANUFACTURERS RECOMMENDED
AIR PRESSURE AFTER THE ALIGNMENT IS COMPLETED.
NOTE:
THE SPECIFICATIONS IN THE SERVICE MANUAL MAY BE DIFFERENT FROM THAT ON THIS
TECHNICAL SERVICE BULLETIN. THE SPECIFICATIONS IN THIS BULLETIN SHOULD BE
USED ANYTIME WHEEL ALIGNMENTS ARE PERFORMED ON SUBJECT MODEL RAM
VAN/WAGONS.
CAUTION:
ENSURE THERE IS PROPER CLEARANCE BETWEEN THE UPPER CONTROL ARM AND
REAR A/C LINES (IF EQUIPPED). ADJUST THE LINES AS NECESSARY.
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
Service Bulletins for Alignment: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 879
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:

NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised
Alignment: All Technical Service Bulletins Steering Wander - Diagnosis and Correction Revised
NUMBER: 19-07-00
GROUP: Steering
DATE: September 22, 2000
OVERVIEW: This bulletin provides a diagnostic procedure for steering wander.
MODELS: 1998-2001 (AB) Ram Van/Wagon
SYMPTOM/CONDITION: Steering Wander Diagnosis is the diagnosis of a condition where slight

steering corrections are necessary to be able to keep the vehicle moving in a straight line.
Steering wander can be created by a number of different conditions including but not limited to the
following:
^ Aftermarket wheels.
^ A vehicle that is carrying extra added weight (e.g. tool boxes).
^ Steering and/or suspension components that are worn or damaged.
NOTE:
UNDER CERTAIN ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED ROADS,
CROSSWIND, ETC.), MAY CONTRIBUTE TO STEERING WANDER.
DIAGNOSIS:
1. Verify that the vehicle is not equipped with non-factory installed options or equipment that may
cause the vehicle to wander such as heavy toolboxes or hardware that may cause the vehicle to
exceed the front or rear Gross Axle Weight Rating (GAWR).
and/or wheels that are of a different size and/or offset than recommended may cause the vehicle to
wander and should be replaced before continuing with the diagnosis.
3. Inflate all tires to the pressure specified in the Tire Inflation Pressure sheet (located in the glove
box).
NOTE:
TIRE PRESSURES ARE NORMALLY SET TO THE LIGHT LOAD SPECIFICATION WHEN
PERFORMING STEERING WANDER DIAGNOSIS BUT, ONLY IF THE VEHICLE IS AT CURB
OR LIGHT LOAD CONDITIONS.
mph), preferably without cross wind conditions. If crosswind conditions are prevalent, drive the
vehicle in both directions relative to the crosswind. Proceed to the next step if the vehicle exhibits a
steering wander condition.
NOTE:
TEST MAY HAVE HAD THE CONDITION CORRECTED WITH STEPS 1-3 OR THE CONDITION
MAY HAVE BEEN CAUSED BY ROAD CONDITIONS (E.G. HIGH ROAD CROWN, GROOVED
ROADS, ETC.).
5. Raise the vehicle on an appropriate lift.

Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised > Page 886
6. Secure a dial indicator to the lower control arm. Position the dial indicator so that the tip of the
indicator contacts the inside face of the rotor (Figure 1).
7. Place your hands at the top and bottom of the tire/wheel assembly and push the tire/wheel
assembly inboard (Figure 2). Zero the dial indicator. With your hands at the top and bottom of the
tire/wheel assembly, pull the tire/wheel assembly outboard (Figure 3). Record the dial indicator
reading. Perform this procedure on both front wheel bearings and proceed to the next step if the
wheel bearing endplay exceeds 0.025 - 0.076 mm (0.001 - 0.003 in.). Proceed to Step 9 if
wheel-bearing endplay on both front wheel bearings are within specifications.
NOTE:
WHEEL BEARING INSPECTION AND ADJUSTMENT IS ONLY REQUIRED ON WHEEL

BEARINGS EXCEEDING 0.025 - 0.076 MM (0.001 - 0.003 IN.) ENDPLAY.
8. Remove the wheel bearing protective end cap, cotter pin, nut lock, nut, and washer from the
spindle. Inspect the wheel bearings. If it is determined that wheel bearing replacement is
necessary, refer to the appropriate Ram Van/Wagon Service Manual, Group 02, Wheel Bearings,
for removal and installation information. Reinstall the wheel bearings, washer, and adjustment nut if
the wheel bearings pass the inspection.
9. Using a torque wrench, tighten the wheel bearing adjustment nut to 54 N.m (40 ft. lbs.) while
rotating the tire/wheel assembly. Stop the wheel from rotating and loosen the nut. Using the
procedure identified in Steps 6 and 7 to measure endplay, adjust the front wheel bearing endplay
until 0.025 - 0.076 mm (0.001 - 0.003 in.) endplay has been achieved. Install the nut lock and a
new cotter pin.
appropriate Ram Van/Wagon Service Manual. Any worn steering and/or suspension component
must be replaced prior to performing an alignment.
Ram Van/Wagon Service Manual, Group 02, Service Procedures, Wheel Alignment. Adjust any
front alignment angle not within specifications. Refer to the chart for proper alignment
specifications.
NOTE:
VAN/WAGONS.

Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other
Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised
NUMBER: 19-07-00
GROUP: Steering

following:
NOTE:
DIAGNOSIS:
box).
NOTE:
NOTE:
ROADS, ETC.).

NOTE:

new cotter pin.
specifications.
NOTE:
VAN/WAGONS.

Service Bulletins for Alignment: > Page 895
Alignment: By Symptom
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:
NOTE:
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
CAUSE STEERING WANDER. HOWEVER,
THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE
ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE
SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO
PROCEEDING.
NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
GROUP: Steering

OVERVIEW:
This bulletin provides a diagnostic procedure for steering sensitivity.
MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:
NOTE:
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:
NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 906
Alignment: Specifications
CASTER:
Preferred ..............................................................................................................................................
...................................................................... +2.5° Range .................................................................
..................................................................................................................................................... ±
1.50° Maximum Right/Left Difference ..................................................................................................
............................................................................. 1.25°
CAMBER:
Preferred ..............................................................................................................................................
........................................................................... 0° Range .................................................................
....................................................................................................................................................... ±
0.6° Maximum Right/Left Difference ....................................................................................................
................................................................................ 0°
TOTAL TOE-IN:
Preferred ..............................................................................................................................................
........................................................................... 0° Range .................................................................
..................................................................................................................................................... ±
............................................................................. 0.05°
THRUST ANGLE
Preferred ..............................................................................................................................................
........................................................................... 0° Range .................................................................
....................................................................................................................................................... ±
0.4°
Alignment: Description and Operation
GENERAL INFORMATION
Wheel Alignment Measurements
Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The
positioning is accomplished through suspension and steering linkage adjustments. An alignment is
considered essential for efficient steering, good directional stability and to minimize tire wear. The
most important measurements of an alignment are caster, camber and toe.
Caster - is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the
knuckle forward provides negative caster. Tilting the top of the knuckle rearward provides positive
caster. Positive caster promotes directional stability. This angle enables the front wheels to return
to a straight ahead position after turns.
Camber - is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the
top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides
positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire.
Toe - is the difference between the leading inside edges and trailing inside edges of the front tires.
Uneven wheel toe position cause's unstable steering, uneven tire near and steering wheel
off-center. The wheel toe position is the final front wheel alignment adjustment.
Thrust Angle - is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust
angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged
component(s) must be replaced to correct the thrust angle.
Alignment: Testing and Inspection
PRE-ALIGNMENT INSPECTION
Before starting wheel alignment, the following inspection and necessary corrections must be
completed. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for
wear or adjustment. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4.
Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5.
Inspect suspension components for wear and noise.
Alignment: Service and Repair
GENERAL INFORMATION
The front wheel alignment angles should be set to preferred specifications. This will prevent
abnormal tire tread wear.
Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each
bumper at the center and jounce the vehicle up and down several times. Always release the
bumper in the down position.
CAMBER AND CASTER
Camber and caster angle adjustments involve repositioning the upper suspension arm pivot bar.
Alignment adjustments are accomplished by changing the position of the pivot bar.
Adjuster Tool 8199, or equivalent is used to adjust the camber and caster angles.
Tools Attached To Frame
1. Clamp the tool on the upper suspension arm frame bracket. Use the two clamp bolts to attach
the tool to the bracket. 2. With the adjustment tools installed, loosen both upper suspension arm
bolts completely. 3. Tighten or loosen the tool adjustment bolts to move the upper suspension arm
inward or outward to obtain the proper camber and caster
angles.
Caster: Move the rear position of the pivot bar in or out. This will change the caster angle
significantly and camber angle only slightly. To retain the camber while adjusting caster, move the
rear pivot bar in or out. Move the forward pivot very slightly in the opposite direction.
NOTE: For example, to increase a positive caster angle move the rear position of the pivot bar
inward. Move the front of pivot bar outward until the original camber angle is obtained.
Camber: Move the forward position of the pivot bar in or out. This will change the camber angle
significantly and caster angle only slightly. The camber angle should be adjusted to the service
specifications. Tighten the pivot bar bolts to 298 Nm (220 ft. lbs.).
TOE POSITION
The wheel toe position is the final adjustment procedure. 1. Secure the steering wheel with the
front wheels in the straight ahead position. For power steering vehicles, start the engine before
straightening
the wheels.
2. Loosen the tie rod adjustment sleeve clamp bolts.
3. Adjust the wheel toe position by rotating the tie rod adjustment sleeve. 4. Position the adjustment
sleeve clamps so the ends are not located at the sleeve slot. Tighten the tie rod sleeve clamps to:
- Standard Duty: 23 Nm (17 ft. lbs.)
- Heavy Duty: 35 Nm (26 ft. lbs.)
Ensure the clamp bolts are located at the underside of the sleeve.
5. Verify camber, caster and toe position.

Adjuster, Caster & Camber 8119

Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage
Fuel Pressure: Technical Service Bulletins Fuel Pressure Gauge Adapter - Usage
NO: 14-03-98
GROUP: Fuel DATE: May 1, 1998
SUBJECT: Fuel Pressure Gauge Adapter Usage
MODELS: 1996 - 1998 (AB)
Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
1996 - 1998 (XJ) Cherokee
DISCUSSION:
Currently, four different fuel pressure adapters are required, depending on application, to attach a
fuel gauge for pressure testing. The matrix lists the adapter part numbers and their application.

Information > Specifications > Pressure, Vacuum and Temperature Specifications
Fuel Pressure: Pressure, Vacuum and Temperature Specifications
Fuel Pressure
Engine at curb idle ...............................................................................................................................

........................................ 339 ± 34 kPa (49.2 ± 5 psi)
Pressure Leakdown (fuel pump not engaged)

................................................................................................................. Not fall below 30 psi for 5
minutes
Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 919
Fuel Pressure: Capacity Specifications
NOTE: Before performing this test, verify fuel pump pressure by performing the Fuel Pump
Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test.
1. Release fuel system pressure.
- Refer to the Fuel Pressure Release Procedure.
2. Disconnect the fuel supply line at fuel rail.
- Some engines may require air cleaner housing removal before line disconnection.
3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or
6539) into disconnected fuel supply line.
- Insert other end of Adaptor Tool hose into a graduated container.
4. Remove the fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool
and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7
seconds.
- Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump
module reservoir may run empty.
a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap
opening, check for a kinked/damaged fuel
supply line somewhere between fuel rail and fuel pump module.
b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel
pressure regulator. -
The filter/regulator may be serviced separately on certain applications.
- Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information.
c. If both fuel pressure and capacity are low, replace fuel pump module assembly. -
Refer to Fuel Pump Module Removal/Installation.

Information > System Diagnosis > Fuel Pressure Leak Down Test
Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down Test
Fig 9 Connecting Adaptor Tool -- Typical
Fig. 8 Installing Adapter Tool And Pressure Gauge
NOTE: Use this test in conjunction with the Fuel Pump Pressure Test and Fuel Pump Capacity
Test.
Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent
fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is
not operational. It is also used to keep the fuel supply line full of gasoline when pump is not
operational.
After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid
gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure
that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the
electric fuel pump is activated, fuel pressure should immediately rise to specification.
Abnormally long periods of cranking to restart a hot engine that has been shut down for a short
period of time may be caused by: -
Fuel pressure bleeding past a fuel injector(s).
- Fuel pressure bleeding past the check valve in the fuel pump module.
1. Disconnect the fuel inlet line at fuel rail.
- On some engines, air cleaner housing removal may be necessary before fuel line disconnection.
2. Connect the appropriate Fuel Line Pressure Test Adapter Tool (number 6539, 6631, 6541 or
6923) between the disconnected fuel line and fuel rail
(Fig. 9) or (Fig. 10).
3. Connect the 0-414 kPa (0-60 psi) fuel pressure test gauge (from Gauge Set 5069) to the test
port on the appropriate Adaptor Tool.
- The fittings on both tools must be in good condition and free from any small leaks before
performing the proceeding test.
4. Start engine and bring to normal operating temperature.

Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 922
5. Observe test gauge. Normal operating pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5
psi). 6. Shut engine off. 7. Pressure should not fall below 30 psi for five minutes. 8. If pressure falls
below 30 psi, it must be determined if a fuel injector, the check valve within the fuel pump module,
or a fuel tube/line is leaking. 9. Again, start engine and bring to normal operating temperature.
10. Shut engine off. 11. Testing for fuel injector or fuel rail leakage:
- Clamp off the rubber hose portion of Adaptor Tool between the fuel rail and the test port "T" on
Adapter Tool.
- If pressure now holds at or above 30 psi, a fuel injector or the fuel rail is leaking.
12. Testing for fuel pump check valve, filter/regulator check valve or fuel tube/line leakage:
- Clamp off the rubber hose portion of Adaptor Tool between the vehicle fuel line and test port "T"
on Adapter Tool.
- If pressure now holds at or above 30 psi, a leak may be found at a fuel tube/line.
- If no leaks are found at fuel tubes or lines, one of the check valves in either the electric fuel pump
or filter/ regulator may be leaking.
NOTE: A quick loss of pressure usually indicates a defective check valve in the filter/regulator. A
slow loss of pressure usually indicates a defective check valve in the electric fuel pump.
The electric fuel pump is not serviced separately -- Replace the fuel pump module assembly. The
filter/ regulator may be replaced separately on certain applications. Refer to Fuel Filter/Fuel
Pressure Regulator Removal/installation for additional information.
Fuel Pressure: Testing and Inspection Fuel Pressure Test
Fuel Pressure Test Gauge
NOTE: Use this test in conjunction with the Fuel Pump Capacity Test, Fuel Pressure Leak Down
Test, fuel pump amperage test.
fuel flow hack into the tank and to maintain fuel supply line pressure (engine warm) when pump is
operational. After the vehicle has cooled down fuel pressure may drop to 0 psi (cold fluid
contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel
injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal
condition. When the electric fuel pump is activated, fuel pressure should immediately rise to
specification.
All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure
regulator. The fuel pressure regulator is not controlled by engine vacuum.
WARNING: The fuel system is under constant fuel pressure even with the engine off. Before
disconnecting fuel line at fuel rail, this pressure must be released. Refer to the fuel system
pressure release procedure.
NOTE: To perform this test you will need to remove the engine cover.
1. Remove the protective cap at the fuel rail test port. Connect the 0-414 kPa (0-60 psi) fuel
pressure gauge (from gauge set 5069) to the test port
pressure fitting on the fuel rail.
2. Start and warm the engine and note pressure gauge reading. Fuel pressure should be 3.39 kPa
+/- 34 kPa (49.2 psi +/- 5 psi) at idle. 3. If engine runs but pressure is below 44.2 psi, check for a
kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not
kinked, replace fuel pump module assembly. Refer to Fuel Pump Removal/Installation.
4. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is
defective. Replace fuel filter/fuel pressure regulator.
Certain filter/regulators may be serviced separately and some require the replacement of the fuel
pump module assembly Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for more
information.
Fuel Pressure: Testing and Inspection Fuel Pump Amperage Test
This amperage (current draw) test is to be done in conjunction with the Fuel Pump Pressure Test,
Fuel Pump Capacity Test and Fuel Pressure Leak Down Test. Before performing the amperage
test, be sure the temperature of the fuel tank is above 50° F (10° C).
The DRB Scan Tool along with the DRB Low Current Shunt (LCS) adapter and its test leads will be
used to check fuel pump amperage specifications.
Low Current Shunt Adapter
1. Obtain LCS adapter. 2. Plug cable from LCS adapter into DRB scan tool at SET 1 receptacle. 3.
Plug DRB into vehicle 16-way connector (data link connector). 4. Connect (-) and (+) test cable
leads into LCS adapter receptacles. Use 10 amp (10A +) receptacle and common (-) receptacles.
5. Gain access to MAIN MENU on DRB screen. 6. Press DVOM button on DRB. 7. Using left/right
arrow keys, highlight CHANNEL 1 function on DRB screen. 8. Press ENTER three times. 9. Using
up/down arrow keys, highlight RANGE on DRB screen (screen will default to 2 amp scale).
10. Press ENTER to change 2 amp scale to 10 amp scale. This step must be done to prevent
damage to DRB scan tool or LCS adapter (blown fuse). 11. Remove cover from Power Distribution
Center (PDC). 12. Remove fuel pump relay from PDC. Refer to label on PDC cover for relay
location.
WARNING: BEFORE PROCEEDING TO NEXT STEP, NOTE THE FUEL PUMP WILL BE
ACTIVATED AND SYSTEM PRESSURE WILL BE PRESENT. THIS WILL OCCUR AFTER
CONNECTING TEST LEADS FROM LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES. THE
FUEL PUMP WILL OPERATE EVEN WITH IGNITION KEY IN OFF POSITION. BEFORE
ATTACHING TEST LEADS, BE SURE ALL FUEL LINES AND FUEL SYSTEM COMPONENTS
ARE CONNECTED.
CAUTION: To prevent possible damage to the vehicle electrical system and LCS adapter, the test
leads must be connected into relay cavities exactly as shown in following steps. Depending upon
vehicle model, year or engine configuration, three different types of relays may be used: Type-1,
type-2 and type-3.
Starter Relay
13 If equipped with type-1 relay, attach test leads from LCS adapter into PDC relay cavities number
30 and 87. For location of these cavities, refer to
numbers stamped to bottom of relay.
Type-2 Relay
14. If equipped with type-2 relay, attach test leads from LCS adapter into PDC relay cavities
number 30 and 87. For location of these cavities, refer to
Type-3 Relay
16. When LCS adapter test leads are attached into relay cavities, fuel pump will be activated.
Determine fuel pump amperage on DRB screen.
Amperage should be below 10.0 amps. If amperage is below 10.0 amps, and specifications for the
Fuel Pump Pressure, Fuel Pump Capacity and Fuel Pressure Leak Down tests were met, the fuel
pump module is OK.
17. If amperage is more than 10.0 amps, replace fuel pump module assembly The electric fuel
pump is not serviced separately.
18. Disconnect test leads from relay cavities immediately after testing.
Fuel Pressure: Testing and Inspection Fuel Pump Capacity Test
seconds.

Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System
Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions
Air/Fuel Mixture: Technical Service Bulletins Fuel System/Engine Controls - Manual Revisions
NUMBER: 26-02-99A

Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 932
45
46
47

152
156

316

620
622
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information
> Specifications
Idle Speed: Specifications
Minimum Air Flow Idle .........................................................................................................................

......................................................... 500 to 900 rpm
Note: Idle speed range achieved through Minimum Air Flow Idle Test
> Specifications > Page 943
Idle Speed: Testing and Inspection
The following test procedure has been developed to check throttle body calibrations for correct idle
conditions. The procedure should be used to diagnose the throttle body for conditions that may
cause idle problems. This procedure should be used only after normal diagnostic procedures have
failed to produce results that indicate a throttle body related problem. Be sure to check for proper
operation of the idle air control motor before performing this test.
Fig. 73 Fixed Orifice Tool
A special fixed orifice tool (number 6714) must be used for the following test.
1. Start the engine and bring to operating temperature. Be sure all accessories are off before
performing this test. 2. Shut off the engine and remove the air cleaner element housing.
Fig. 74 Install Orifice Tool
3. Disconnect the vacuum line at the PCV valve. 4. Install the 0.185 inch orifice tool (number 6714)
into the disconnected vacuum line in place of the PCV valve.
Fig. 75 Idle Purge Line

5. Disconnect the idle purge vacuum line from fitting at throttle body This vacuum line is located on
the front of throttle body next to the MAP
sensor. Cap the fitting at throttle body after vacuum line has been removed.
6. Connect the DRB scan tool to the 16-way data link connector. This connector is located under
the instrument panel to the left of the steering
column.
7. Start the engine. 8. Using the DRB scan tool, scroll through the menus as follows:
select-System, select-Engine, select-Fuel and Ignition, select-Actuator Tests, select
Engine rpm and select-Minimum Air Flow.
9. The DRB scan tool will count down to stabilize the idle rpm and display the minimum air flow idle
rpm. The idle rpm should be between 500 and
900 rpm. If the idle speed is outside of these specifications, replace the throttle body.
10. Disconnect the DRB scan tool from the vehicle. 11. Remove cap from idle purge fitting at
throttle body and install vacuum line. 12. Remove orifice tool and connect vacuum line to PCV
valve. 13. Install air cleaner element housing.
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component
Information > Service and Repair
Air Cleaner Housing: Service and Repair
Fig 52 Air Cleaner Components -- Typical
REMOVAL
1. From engine compartment, remove plastic air intake tube at front of air cleaner housing. Tube
snaps onto air cleaner housing. 2. Remove engine cover. 3. Pull crankcase breather/filter (straight
up) from engine valve cover. 4. Remove wing nut and remove air cleaner assembly from throttle
body.
INSTALLATION
1. Position air cleaner housing to throttle body. 2. If housing-to-throttle body mounting stud is being
installed, tighten to 10 N.m (90 in. lbs.) torque. 3. Tighten wingnut to 1.5 N.m (15 in. lbs.) torque. 4.
Push crankcase breather/filter into valve cover. 5. Install plastic air intake tube to housing. 6. Install
engine cover.
AIR CLEANER ELEMENT
Housing removal is not necessary for element (filter) replacement.
REMOVAL
1. Remove engine cover. 2. Remove wingnut and remove cover from housing. 3. Remove air
cleaner element from housing. 4. Clean inside of housing before replacing element.
INSTALLATION
1. Install element into housing. 2. Install housing cover to housing. 3. Install wingnut. 4. Install
engine cover.
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair
Fuel Pressure Release: Service and Repair
NOTE: Use following procedure if fuel rail is or is not equipped with fuel pressure test port.
1. Remove fuel fill cap. 2. The fuel filler tube contains a spring-loaded flap (door) located below fuel
fill cap. The flap is used as a secondary way of sealing fuel tank if fuel
fill cap has not been properly tightened. It is part of EVAP monitor system when vehicle is equipped
with a Leak Detection Pump (LDP). The vehicle may be equipped with flap installed into fuel filler
tube even though vehicle is not equipped with LDP and EVAP monitor system. Place a nonmetallic
object into fuel fill tube and press on flap to relieve any tank pressure.
3. Remove Fuel Pump relay from Power Distribution Center (PDC). For location of relay, refer to
label on underside of PDC cover. 4. Start and run engine until it stalls. 5. Attempt restarting engine
until it will no longer run. 6. Turn ignition key to OFF position.
CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail.
Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a
cylinder chamber.
7. Unplug connector from any injector. 8. Attach one end of a jumper wire with alligator clips (18
gauge or smaller) to either injector terminal. 9. Connect other end of jumper wire to positive side of
battery.
10. Connect one end of a second jumper wire to remaining injector terminal.
CAUTION: Powering an injector for more than a few seconds will permanently damage the injector.
11. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a
few seconds. 12. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 13.
Disconnect quick-connect fitting at fuel rail. 14. Return fuel pump relay to PDC. 15. One or more
Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay
removal. The DRB scan tool must
be used to erase a DTC.

Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One
Cylinder > Component Information > Locations
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System -
Cross Fire/Ignition Wire Induction
Technical Service Bulletin # 18-48-98 Date: 981230
Ignition System - Cross Fire/Ignition Wire Induction
NO: 18-48-98
DATE: Dec. 30, 1998
SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction
MODELS:
1994 - 1999 (AN) Dakota
1994 - 1999 (BR/BE)Ram Truck
1998 - 1999 (DN) Durango
1995 - 1998 (ZG) Grand Cherokee (International Market)
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE.
AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED).
SYMPTOM/CONDITION:
Some vehicles may exhibit one or more of the following:
Spark knock complaints when the vehicle is under load.
Various single cylinder misfire (1, 3, 7), especially 5 and/or 8.
Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45
mph).
Perceived torque converter EMCC engagement/disengagement around 45 mph.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with
the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are
functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present,
record them on the repair order and repair as necessary before proceeding further with this bulletin.
If no DTC's are present or if the above symptoms/conditions have been described by the customer,
perform the Repair Procedure.
NOTE:
THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE,

SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED.
PARTS REQUIRED:
3 56028186 Clip, Single Wire
2 06503441 Clip, Wire To Hose (5.2L & 5.9L)

1 04364375 Convolute, 10 ft Roll
TIME ALLOWANCE:
Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs.
08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs.
(AN/DN) 5.2/5.9L 0.3 Hrs.
(BR/BE) 5.2/5.9L 0.4 Hrs.

Cross Fire/Ignition Wire Induction > Page 967
FAILURE CODE: 9X - Routed Improperly
Repair Procedure
This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8
plug wires for the 5.2/5.9L applications to minimize induction effects.
NOTE:
IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A
90° ANGLE.
5.2L and 5.9L Engine Procedures
1. Coil Wire Routing (Figure 1 and 2)
A. Remove the coil wire from the distributor cap coil wire tower terminal.
B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front
one-wire clip located along the lower side of the right valve cover.
C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the
studs of the valve cover retaining bolts (Figure 1).
NOTE:
SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE
CLIPS.
D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should
end up at the distributor end.
E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the
coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover
studs).
F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.),
and 82.5 mm (3.25 in.).
G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips.
Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.)
and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may
be easier to perform while the coil wire is loose from the valve cover (before the clips are attached
to the valve cover studs).
H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil
pressure switch (Figure 2).
NOTE:
THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION
WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR
WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD.
I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire
tower terminal.
J. Position the original piece of coil wire convolute so it protects the wire against chafing with
components at the rear of the engine.
2. No.8 Cylinder Plug Wire Routing (Figure 3)
A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal.
B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve
cover.
C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3).
D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the
right valve cover and with other engine components.
E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n
06503441. The small end of the clip is positioned over the convolute. The large end of the clip is
fastened to a heater hose (A/C line on ZJ models).
NOTE:
MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL
WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND
CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS.
F. Install the No.8 cylinder plug wire to its distributor cap terminal.
3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5)
A. Remove the No.4 cylinder plug wire from the distributor cap terminal.
B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the
two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire
slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty
(Figure 5).
C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires
from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain
the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove
any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips.
NOTE:
EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING
LAYOUT APPLIES.
D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On
ZJ models this may not be possible due to the location of the bulkhead.
NOTE:
MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM
THE NO.8 CYLINDER PLUG WIRE.
E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7).
A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor
cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for
1998 and prior model years.
B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder
plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and
the No.5 tower terminals (Figure 9).
NOTE:
MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE
NO.5 CYLINDER PLUG WIRE.
5. No. 5 Cylinder Plug Wire Routing (Figure 10)
A. Remove the No.5 cylinder plug wire from its distributor cap terminal.
B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left
valve cover.
C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube
elbow.
D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the
valve cover and any engine components. Secure the small end of the hose to wire clip p/n
06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose.
NOTE:
MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7
CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE
CYLINDER HEAD AND/OR EXHAUST COMPONENTS.
3.9L Engine
A. Remove the coil wire from the distributor cap tower terminal.
B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front
one-wire clip on the right valve cover.
C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs
(Figure 11).
studs).
F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and
one (1) at 82.5 mm (3.25 in.).
Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm
(4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform
while the coil wire is loose from the valve cover (before the clips are attached to the valve cover
studs).
NOTE:
WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR
Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire
tower terminal.
Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 >
NO: 18-48-98
DATE: Dec. 30, 1998
MODELS:
1994 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
NOTE:
SYMPTOM/CONDITION:
mph).
DIAGNOSIS:
NOTE:

PARTS REQUIRED:

TIME ALLOWANCE:
08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs.
(AN/DN) 5.2/5.9L 0.3 Hrs.
(BR/BE) 5.2/5.9L 0.4 Hrs.

Ignition System - Cross Fire/Ignition Wire Induction > Page 978
Repair Procedure
NOTE:
90° ANGLE.
NOTE:
CLIPS.
studs).
and 82.5 mm (3.25 in.).
NOTE:
tower terminal.
cover.
NOTE:
(Figure 5).
NOTE:
LAYOUT APPLIES.
NOTE:
NOTE:
valve cover.
elbow.
NOTE:
3.9L Engine
(Figure 11).
studs).
one (1) at 82.5 mm (3.25 in.).
studs).
NOTE:
tower terminal.
Ignition Cable: Specifications
MINIMUM = MAXIMUM 250 Ohms Per Inch = 1000 Ohms Per Inch 3000 Ohms Per Foot = 12,000
Ohms Per Foot
Ignition Cable: Description and Operation
SYSTEM OPERATION
Spark plug cables are sometimes referred to as secondary ignition wires. These cables transfer
electrical current from the ignition coil(8) and/or distributor, to individual spark plugs at each
cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide
suppression of radio frequency emissions from the ignition system.
Ignition Cable: Testing and Inspection
Heat Shields
Check the spark plug cable connections for good contact at the coil(s), distributor cap towers, and
spark plugs. Terminals should be fully seated. The insulators should be in good condition and
should fit tightly on the coil, distributor and spark plugs. Spark plug cables with insulators that are
cracked or torn must be replaced.
Clean high voltage ignition cables with a cloth moistened with a non-flammable solvent. Wipe the
cables dry. Check for brittle or cracked insulation.
Spark plug cable heat shields are pressed into the cylinder head to surround each spark plug cable
boot and spark plug . These shields protect the spark plug boots from damage (due to intense
engine heat generated by the exhaust manifolds) and should not be removed. After the spark plug
cable has been installed, the lip of the cable boot should have a small air gap to the top of the heat
shield.
Testing
When testing secondary cables for damage with an oscilloscope, follow the instructions of the
equipment manufacturer. If an oscilloscope is not available, spark plug cables may be tested as
follows:
CAUTION: Do not leave any one spark plug cable disconnected for longer than necessary during
testing. This may cause possible heat damage to the catalytic converter. Total test time must not
exceed ten minutes.
With the engine running, remove spark plug cable from spark plug (one at a time) and hold next to
a good engine ground. If the cable and spark plug are in good condition, the engine rpm should
drop and the engine will run poorly If engine rpm does not drop, the cable and/or spark plug may
not be operating properly and should be replaced. Also check engine cylinder compression.
With the engine not running, connect one end of a test probe to a good ground. Start the engine
and run the other end of the test probe along the entire length of all spark plug cables. If cables are
cracked or punctured, there will be a noticeable spark jump from the damaged area to the test
probe. The cable running from the ignition coil to the distributor cap can be checked in the same
manner. Cracked, damaged or faulty cables should be replaced with resistance type cable. This
can be identified by the words ELECTRONIC SUPPRESSION printed on the cable jacket.
Use an ohmmeter to test for open circuits, excessive resistance or loose terminals. If equipped,
remove the distributor cap from the distributor. Do not remove cables from cap. Remove cable from
spark plug. Connect ohmmeter to spark plug terminal end of cable and to corresponding electrode
in distributor cap. Resistance should be 250 to 1000 Ohms per inch of cable. If not, remove cable
from distributor cap tower and connect ohmmeter to the terminal ends of cable. If resistance is not
within specifications as found in the SPARK PLUG CABLE RESISTANCE chart, replace the cable.
Test all spark plug cables in this manner.
Spark Plug Cable Resistance MINIMUM = MAXIMUM 250 Ohms Per Inch = 1000 Ohms Per Inch
3000 Ohms Per Foot = 12,000 Ohms Per Foot
To test ignition coil-to-distributor cap cab]e, do not remove the cable from the cap. Connect
ohmmeter to rotor button (center contact) of distributor cap and terminal at ignition coil end of
cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart,
remove the cable from the distributor cap. Connect the ohmmeter to the terminal ends of the cable.
If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, replace
the cable. Inspect the ignition coil tower for cracks, burns or corrosion.
Ignition Cable: Service and Repair

Cable Removal
CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap,
twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off
with a steady, even force.
Engine Firing Order
Install cables into the proper engine cylinder firing order.
When replacing the spark plug and coil cables, route the cables correctly and secure in the proper
retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It
could also cause cross ignition of the plugs or short circuit the cables to ground.
When installing new cables, make sure a positive connection is made. A snap should be felt when
a good connection is made between the plug cable and the distributor cap tower.
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor
Cap > Component Information > Testing and Inspection
Distributor Cap: Testing and Inspection
Cap Inspection-External-Typical
Cap Inspection-Internal-Typical
Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for
cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the
inside (caused by condensation entering the cap through cracks). Replace any cap that displays
charred or eroded terminals. The machined surface of a terminal end (faces toward rotor) will
indicate some evidence of erosion from normal operation. Examine the terminal ends for evidence
of mechanical interference with the rotor tip.
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition
Rotor > Component Information > Testing and Inspection
Ignition Rotor: Testing and Inspection
Rotor Inspection-Typical
Visually inspect the rotor for cracks, evidence of corrosion or the effects of arcing on the metal tip.
Also check for evidence of mechanical interference with the cap. Some charring is normal on the
end of the metal tip. The silicone-dielectric-varnish-compound applied to the rotor tip for radio
interference noise suppression, will appear charred. This is normal. Do not remove the charred
compound. Test the spring for insufficient tension. Replace a rotor that displays any of these
adverse conditions.
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Spark Plug: Specifications
Electrode Gap ......................................................................................................................................

..................................................... 0.89 mm (0.035 in) Torque ............................................................
............................................................................................................................................... 41 Nm
(30 ft lb)
Information > Specifications > Page 998
Spark Plug: Application and ID
Plug Type ............................................................................................................................................

..................................................................... RC12YC
Spark Plug: Description and Operation
SYSTEM OPERATION
All engines use resistor type spark plugs. Remove the spark plugs and examine them for burned
electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in
which they were removed from the engine. A single plug displaying an abnormal condition indicates
that a problem exists in the corresponding cylinder.
Spark plugs that have low milage may be cleaned and reused if not otherwise defective, carbon or
oil fouled.
Spark Plug: Testing and Inspection
Normal Operating
Spark Plug Cable Resistance
The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is
evident with most grades of commercial gasoline. There will not be evidence of electrode burning.
Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000
miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the
electrodes filed, have the gap set and then be installed.
Some fuel refiners in several areas of the United States have introduced a manganese additive
(MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug
to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by
coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits.
Cold Fouling/Carbon Fouling
Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are
basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking
valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be
caused by a clogged air cleaner element or repeated short operating times (short trips).
Wet Fouling Or Gas Fouling
A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings,
leaking valve guide seals or excessive cylinder wear can cause wet fouling. In new or recently
overhauled engines, wet fouling may occur before break-in (normal oil control) is achieved. This
condition can usually be resolved by cleaning and reinstalling the fouled plugs.
Oil Or Ash Encrusted
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
Scavenger Deposit
Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but this is
a normal condition caused by chemical additives in certain fuels. These additives are designed to
change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that
accumulation on the ground electrode and shell area may be heavy, but the deposits are easily
removed. Spark plugs with scavenger deposits can be considered normal in condition and can be
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
Preignition Damage
Preignition damage is usually caused by excessive combustion chamber temperature. The center
electrode dissolves first and the ground electrode dissolves somewhat latter. Insulators appear
relatively deposit free. Determine if the spark plug has the correct heat range rating for the engine.
Determine if ignition timing is over advanced or if other operating conditions are causing engine
overheating. (The heat range rating refers to the operating temperature of a particular type spark
plug. Spark plugs are designed to operate within specific temperature ranges. This depends upon
the thickness and length of the center electrodes porcelain insulator.)
Spark Plug Overheating
Overheating is indicated by a white or gray center electrode insulator that also appears blistered.
The increase in electrode gap will be considerably in excess of 0.001 inch per 1000 miles of
operation. This suggests that a plug with a cooler heat range rating should be used. Over
advanced ignition timing, detonation and cooling system malfunctions can also cause spark plug
overheating.
Spark Plug: Service and Repair
Heat Shields
Spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and
spark plug.
If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides
of shield for removal. Each shield is slotted to allow for compression and removal. To install the
shields, align shield to machined opening in cylinder head and tap into place with a block of wood.
PLUG REMOVAL 1. Remove engine cover. 2. Always remove spark plug or ignition coil cables by
grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady
motion. Never pull directly on the cable. Internal damage to cable will result,
3. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area
around the spark plug. This will help prevent
foreign material from entering the combustion chamber.
4. Remove the spark plug using a quality socket with a rubber or foam insert. 5. Inspect the spark
plug condition.
Plug Cleaning The plugs may be cleaned using commercially available spark plug cleaning
equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before
adjusting gap.
CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will
remain on the spark plug insulator arid will cause plug misfire.
Plug Gap Adjustment Check the spark plug gap with a gap gauge tool. If the gap is not correct,
adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center
electrode.
Spark Plug Gap V-8 Engines: 1.01 mm (.040 in).
PLUG INSTALLATION Special care should be taken when installing spark plugs into the cylinder
head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be
damaged.
Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in
a change in the spark plug gap or a cracked porcelain insulator.
when replacing the spark plug and ignition coil cables, route the cables correctly and secure them
in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce
ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground.
1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark
plugs to 35-41 N.m (26-30 ft. lbs.) torque. 3. Install spark plug cables over spark plugs.
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Compression Check: Specifications
Compression should not be less than 689 kPa (100 psi) and not vary more than 172 kPa (25 psi)
from cylinder to cylinder. -
If cylinder(s) have abnormally low compression pressures, repeat procedure.
- If the same cylinder(s) repeat an abnormally low reading, it could indicate the existence of a
problem in the cylinder.
NOTE: The recommended compression pressures are to be used only as a guide to diagnosing
engine problems. An engine should NOT be disassembled to determine the cause of low
compression unless some malfunction is present.
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Compression Check: Testing and Inspection
CYLINDER COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test can be utilized to diagnose several engine
malfunctions.
Ensure the battery is completely charged and the engine starter motor is in good operating
condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.
1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the
throttle in the wide-open position. 4. Disconnect the ignition coil. 5. Insert a compression pressure
gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the
compression pressure on the 3rd revolution. Continue the test for the remaining cylinders.
Minimum cylinder compression pressure is 689 kPa (100 psi).

Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Valve Clearance: Specifications
These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all
times.
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams
Belt Routing-All Engines

Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1014
Drive Belt: Description and Operation
ACCESSORY DRIVE BELT/TENSION
The accessory drive components are operated by a single, crankshaft driven, serpentine drive belt.
An automatic belt tensioner is used to maintain correct belt tension at all times. Correct accessory
drive belt tension is required to be sure of optimum performance of belt driven engine accessories.
If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power
steering assist, loss of air conditioning capacity, reduced generator output rate and greatly reduced
belt life. It is not necessary to adjust belt tension on any engine. All engines are equipped with an
automatic belt tensioner. The tensioner maintains correct belt tension at all times. Due to use of
this belt tensioner, do not attempt to use a belt tension gauge on any engine.
Drive Belt: Testing and Inspection
VISUAL DIAGNOSIS
Belt Ware Patterns
When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface
of the belt from rib to rib, are considered normal. These are not a reason to replace the belt.
However, cracks running along a rib (not across) are not normal. Any belt with cracks running
along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe
glazing. Refer to the Accessory Drive Belt Diagnosis charts for further belt diagnosis.
NOISE DIAGNOSIS
Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to
resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or
excessive end play.
ACCESSORY DRIVE BELT DIAGNOSIS CHART

Drive Belt: Service and Repair
ACCESSORY DRIVE BELT
An automatic belt tensioner is used to maintain correct belt tension at all times.
CAUTION: Do not attempt to check belt tension with a belt tension gauge on vehicles equipped
with an automatic belt tensioner.
REMOVAL
Belt Tensioner-Typical
1. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 2. Rotate tensioner

assembly clockwise (as viewed from front) until tension has been relieved from belt. 3. Remove
belt from idler pulley first. 4. Remove belt from vehicle.
INSTALLATION
CAUTION: When installing "serpentine" accessory drive belt, belt must be routed correctly. If not,
engine may overheat due to water pump rotating in wrong direction. The correct belt with correct
length must be used.
The following belt routing schematics are published from the latest information available at the time
of publication. If anything differs between these schematics and the Belt Routing Label, use the
schematics on Belt Routing Label. This label is located in the engine compartment. 1. Position
drive belt over all pulleys except idler pulley. This pulley is located between generator and A/C
compressor. 2. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 3. Rotate
socket/wrench clockwise. Place belt over idler pulley. Let tensioner rotate back into place. Remove
wrench. Be sure belt is properly seated
on all pulleys.
Tensioner Indexing Marks
4. Check belt indexing marks. 5. The tensioner is equipped with an indexing arrow on back of
tensioner and an indexing mark on tensioner housing. If a new belt is being installed,
arrow must be within approximately 3 mm (1/8 in.) of indexing mark (Point B). Belt is considered
new if it has been used 15 minutes or less. If this specification cannot be met, check for:
^ The wrong belt being installed (incorrect length/ width)
^ Worn bearings on an engine accessory (A/C compressor, power steering pump, water pump,
idler pulley or generator)
^ A pulley on an engine accessory being loose
^ Misalignment of an engine accessory
^ Belt incorrectly routed. A used belt should be replaced if tensioner indexing arrow has moved
beyond point A.
Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Service and Repair
REMOVAL
body.
INSTALLATION
engine cover.
AIR CLEANER ELEMENT
REMOVAL
INSTALLATION
engine cover.
Dodge Workshop Manuals > Maintenance > Filters > Crankcase Filter > Component Information > Description and
Operation
Crankcase Filter: Description and Operation
Fig 9 Crankcase Breather Filter
CRANKCASE BREATHER/FILTER
The crankcase breather/filter (Fig. 9) is located on the cylinder head (valve) cover. The filter may
be cleaned by washing it thoroughly in kerosene or an equivalent. Filter must be thoroughly
drained. More frequent service may be necessary for vehicles operated extensively on short run,
stop and go, extended engine idle service or extreme dust conditions.
Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service
and Repair
cylinder chamber.
battery.

Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications
Oil Filter: Specifications
Oil Filter Connector 50 ft.lb

Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page
1033
Oil Filter: Description and Operation
FILTER SPECIFICATION
All Dodge Ram engines are equipped with a high quality full-flow, disposable type oil filter. Chrysler
Corporation recommends a Mopar or equivalent oil filter be used.
Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page
1034
Oil Filter: Service and Repair
OIL FILTER REMOVAL
1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench loosen filter.
Oil Filter Removal-Typical
3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss. 4. When
filter separates from adapter nipple, tip gasket end upward to minimize oil spill. Remove filter from
vehicle.
Oil Filter Sealing Surface-Typical

5. With a wiping cloth, clean the gasket sealing surface of oil and grime.
OIL FILTER INSTALLATION
1. Lightly lubricate oil filter gasket with engine oil or chassis grease. 2. Thread filter onto adapter
nipple. When gasket makes contact with sealing surface, hand tighten filter one full turn, do not
over tighten. 3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks.
Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Description and
Operation
Refrigerant Filter: Description and Operation
SYSTEM OPERATION
A single filter-drier unit is used for both the front-only A/C system, and for the combined front and
rear A/C system. The filter-drier is mounted on the right side of the engine compartment in front of
the heater-A/C housing. It is located in the liquid line between the condenser outlet and the
evaporator inlet. Refrigerant enters the filter-drier as a high-pressure, high-temperature liquid.
The filter-drier performs a filtering action to prevent foreign material in the refrigerant from
contaminating the expansion valve. A desiccant bag is mounted inside the filter-drier canister to
absorb any moisture which may have entered and become trapped within the refrigerant system. In
addition, during periods of high demand air conditioner operation, the filter-drier acts as a reservoir
to store surplus liquid refrigerant.
The filter-drier cannot be repaired. If the filter-drier is faulty or damaged, if the refrigerant system
has been contaminated, or if the system has been left open to the atmosphere for an
indeterminable period, it must be replaced.
Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Description and
Refrigerant Filter: Service and Repair
WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION

BEFORE PERFORMING THE FOLLOWING OPERATION.
REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the
refrigerant system.
Filter-Drier Remove/Install
3. Remove the screw that secures the filter-drier to its mounting bracket. 4. Remove the screw that
secures the liquid line block fitting to the filter-drier inlet. Separate the liquid line block fitting from
the filter-drier inlet.
Install plugs in, or tape over all of the opened refrigerant line fittings.
5. Remove the screw that secures the filter-drier outlet to the suction line jumper block fitting.
Separate the filter-drier outlet from the suction line
jumper block fitting. Install plugs in, or tape over all of the opened refrigerant line fittings.
6. Remove the filter-drier from the engine compartment.
INSTALLATION 1. Remove the tape or plugs from the suction line jumper block fitting and the
filter-drier outlet. Position the filter-drier outlet to the suction line
jumper block fitting and secure the connection with a screw. Tighten the mounting screw to 13.5
N.m (120 in. lbs.).
2. Remove the tape or plugs from the liquid line block fitting and the filter-drier inlet. Position the
liquid line block fitting to the filter-drier inlet and
secure the connection with a screw. Tighten the mounting screw to 13.5 N.m (120 in. lbs.).
3. Reinstall the screw that secures the filter-drier to its mounting bracket. Tighten the mounting
screw 8.5N.m (75 in. lbs.). 4. Connect the battery negative cable. 5. Evacuate the refrigerant
system. 6. Charge the refrigerant system.
NOTE: If the filter-drier is replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the
vehicle.
Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Description and
Operation
Coolant Line/Hose: Description and Operation
Radiator Hoses-Typical
Rubber hoses route coolant to and from the radiator, intake manifold and heater core. Radiator
lower hoses are spring-reinforced to prevent collapse from water pump suction at moderate and
high engine speeds. Inspect the hoses at regular intervals. Replace hoses that are cracked, feel
brittle when squeezed or swell excessively when the system is pressurized. The use of molded
replacement hoses is recommended. When performing a hose inspection, inspect the radiator
lower hose for proper position and condition of the spring.
Hose Clamp Tool-Typical
WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM
HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING
THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094). SNAP-ON CLAMP
TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY
GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS.
Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Description and
Clamp Number/Letter Location
CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If
replacement is necessary, use only an original equipment clamp with matching number or letter.
For all vehicles: In areas where specific routing and clamps are not provided, be sure that hoses
are positioned with sufficient clearance. Check clearance from exhaust manifolds and pipe, fan
blades, drive belts and sway bars. Improperly positioned hoses can be damaged, resulting in
coolant loss and engine overheating. Ordinary worm gear type hose clamps (when equipped) can
be removed with a straight screwdriver or a hex socket. To prevent damage to hoses or clamps,
the hose clamps should be tightened to 4 Nm (34 inch lbs.) torque. Do not over tighten hose
clamps.
Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Rear
Heater-A/C Unit Plumbing
Heater Hose: Service and Repair Rear Heater-A/C Unit Plumbing
The rear heater-A/C unit plumbing is used only on models with the optional rear heater-A/C unit.
while the formed metal rear heater-A/C unit suction line, liquid line, and heater lines are available
for separate service replacement, the rear heater-A/C unit must be removed from the vehicle in
order to service them. The molded and straight heater hoses used on the rear heater-A/C unit can
be serviced in the vehicle.
Any kinks or sharp bends in the rear heater-A/C unit plumbing will reduce the capacity of the entire
heating and air conditioning system. Kinks and sharp bends reduce the system flow. High
pressures are produced in the refrigerant system when the air conditioning compressor is
operating. High temperature coolant is present in the heater plumbing when the engine is
operating. Extreme care must be exercised to make sure that each of the plumbing connections is
pressure-tight and leak free.

REMOVAL 1. Remove the rear heater-A/C unit from the vehicle. 2. Disconnect the rear heater-A/C
unit liquid and suction lines from the expansion valve. See Expansion Valve - Rear replacement
procedures. 3. Disconnect the rear heater-A/C unit heater hoses from the heater inlet and outlet
lines.
Rear Heater-A/c Plumbing Remove/Install
4. Disengage the seal from the plumbing plate, which is secured to the forward outboard corner of
the rear heater-A/C unit lower housing. Push the
bottom of the seal out through the top of the plumbing plate from underneath.
5. Remove the plumbing lines and seal as an assembly from the rear heater-A/C unit. 6. If the
suction line is being serviced, remove the tie-wraps that secure each end of the insulator to the
line, then slide the insulator off. 7. Push the line through the hole from the top of the seal, twisting
and turning the line as needed, while pulling it from the bottom of the seal.
INSTALLATION 1. Push the line through the hole from the bottom of the seal, twisting and turning
the line as needed, while pulling it from the top of the seal. 2. If the suction line is being serviced,
slide the insulator onto the line, then secure each end of the insulator to the line with a tie-wrap. 3.
Position the plumbing lines and seal as an assembly to the rear heater-A/C unit. 4. Reinstall the
seal to the plumbing plate. Push the seal into the plumbing plate from the top until it is fully seated.
5. Connect the rear heater-A/C unit heater hoses to the heater inlet and outlet lines. 6. Connect the
rear heater-A/C unit liquid and suction lines to the expansion valve. 7. Reinstall the rear heater-A/C
unit in the vehicle.
Heater-A/C Unit Plumbing > Page 1048
Heater Hose: Service and Repair Underbody Plumbing
The underbody plumbing lines are used only on models with the optional rear heater-A/C unit.
While the underbody suction line, liquid line, and combination heater line are available for separate
service replacement, all lines must be removed from the vehicle as a unit for service.
Any kinks or sharp bends in the underbody plumbing will reduce the capacity of the entire heating
and air conditioning system. Kinks and sharp bends reduce the system flow. High pressures are
produced in the refrigerant system when the air conditioning compressor is operating. High
temperature coolant is present in the heater plumbing when the engine is operating. Extreme care
must be exercised to make sure that each of the plumbing connections is pressure-tight and leak
free.

REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant
system. 4. From the engine compaftment, disconnect the underbody liquid line at the liquid line
extension and the underbody suction line at the suction line
jumper. Install plugs in, or tape over all of the opened refrigerant line fittings.
5. From the engine compaftment, disconnect the heater supply and return hoses from the
underbody combination heater line. 6. Remove the engine cover from the passenger compaftment.
7. Raise and support the vehicle. 8. Disengage the front park brake release cable routing clip from
the underbody suction line.
Rear Heater-A/C Pluming Connections Remove/Install

9. From under the vehicle, disconnect the flare nut on the underbody liquid line from the threaded
10. From under the vehicle, disconnect the flare nut on the underbody suction line from the
threaded fitting on the rear heater-A/C unit suction line.
11. From under the vehicle, disconnect the heater supply and return hoses from the rear
heater-A/C unit heater lines.
Heater-A/C Unit Plumbing > Page 1049
Underbody Plumbing Remove/Install
12. Remove the nut that secures the underbody plumbing clamp to the front floor panel near the
left side of the engine cover opening. 13. Remove the screw that secures the underbody plumbing
clamp to the front floor panel reinforcement. 14. Remove the screws that secure the two underbody
refrigerant line clamps to the side panel to underbody reinforcement. 15. Remove the underbody
plumbing bundle from the vehicle.
INSTALLATION
1. From under the vehicle, position the underbody plumbing bundle to the side panel to underbody
reinforcement and secure it by loosely installing
the two clamp mounting screws.
2. From under the vehicle, connect the heater supply and return hoses to the rear heater-A/C unit
heater lines. 3. From under the vehicle, remove the tape or plugs from the suction line fittings at the
rear of the underbody plumbing bundle and at the rear
heater-A/C unit. Connect the flare nut on the underbody suction line to the threaded fitting on the
rear heater-A/C unit suction line. Tighten the fitting to 47 N.m 420 in. lbs.
4. From under the vehicle, remove the tape or plugs from the liquid line fittings at the rear of the
underbody plumbing bundle and at the rear
heaterA/C unit. Connect the flare nut on the underbody liquid line to the threaded fitting on the rear
heaterA/C unit liquid line. Tighten the fitting to 27 N.m 244 in. lbs.
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and
Operation
Hose/Line HVAC: Description and Operation
SYSTEM OPERATION
Refrigerant Line The refrigerant lines and hoses are used to carry the refrigerant between the
various air conditioning system components. A barrier hose design with a nylon tube inner hose
liner is used for the R-134a air conditioning system on this vehicle. This nylon liner helps to further
contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The
ends of the refrigerant hoses are made from lightweight aluminum, and use brazeless fittings.
Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air
conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good
rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the
diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at
least 80 millimeters (3 inches) from the exhaust manifold.
High pressures are produced in the refrigerant system when the air conditioning compressor is
operating. Extreme care must be exercised to make sure that each of the refrigerant system
connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose
refrigerant lines at least once a year to make sure they are in good condition and properly routed.
The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be
replaced.
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
A/C Discharge Hose/Line Replacement
Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement
WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL IN FORMATION

refrigerant system. 3. Unplug the wire harness connector from the high pressure cut-off switch. 4.
Remove the radiator grille from the vehicle.
Suction And Discharge Line Remove/Install
5. Remove the screw that secures the block fitting on the discharge line to the block fitting on the
inlet of the condenser, and separate the fitting from
the condenser. Install plugs in, or tape over all of the opened refrigerant line fittings.
6. Disconnect the flare nut on the suction line from the threaded fitting on the suction line jumper.
Install plugs in, or tape over all of the opened
refrigerant line fittings.
7. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in,
or tape over all of the opened refrigerant line
fittings.
8. Remove the suction and discharge line assembly from the vehicle.
INSTALLATION 1. Remove the tape or plugs from the refrigerant line fittings on the compressor
and the refrigerant line manifold. Install the manifold to the
compressor. Tighten the mounting screw to 22 N.m (200 in. lbs.).
2. Remove the tape or plugs from the refrigerant line fittings on the suction line and the suction line
jumper. Connect the flare nut on the suction line
to the threaded fitting on the suction line jumper. Tighten the fitting to 47 N.m (420 in. lbs.).
3. Remove the tape or plugs from the discharge line block fitting and the inlet of the condenser.
Connect the liquid line to the condenser inlet and
secure the connection with a screw. Tighten the mounting screw to 22 N.m (200 in. lbs.).
4. Reinstall the radiator grille to the vehicle. 5. Plug in the wire harness connector to the high
pressure cut-off switch. 6. Connect the battery negative cable. 7. Evacuate the refrigerant system.
8. Charge the refrigerant system.
A/C Discharge Hose/Line Replacement > Page 1055
Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement

refrigerant system.
Liquid Line Remove/Install
3. Remove the screw that secures the block fitting of the liquid line to the inlet of the filter-drier, and
separate the fitting from the filter-drier. Install
plugs in, or tape over all of the opened refrigerant line fittings.
4. Remove the radiator grille from the vehicle. 5. Remove the screw that secures the block fitting on
the liquid line to the block fitting on the outlet of the condenser, and separate the fitting from
6. Remove the liquid line from the engine compartment.
INSTALLATION 1. Remove the tape or plugs from the liquid line block fitting and the outlet of the
condenser. Connect the liquid line to the condenser outlet and
2. Reinstall the radiator grille to the vehicle. 3. Remove the tape or plugs from the liquid line block
fitting and the inlet of the filter-drier. Connect the liquid line to the filter-drier inlet and secure
the connection with a screw. Tighten the mounting screw to 13.5 N.m (120 in. lbs.).
4. Connect the battery negative cable. 5. Evacuate the refrigerant system. 6. Charge the refrigerant
system.
Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement
Suction and Discharge Line

fittings.
Suction Line Jumper
conditioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. High pressures are produced in the refrigerant system when the
air conditioning compressor is operating. Extreme care must be exercised to make sure that each
of the refrigerant system connections is pressure-tight and leak free.

REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the low pressure
cut-off switch from the fitting on the suction line jumper. See Low Pressure Cut-Off Switch
Replacement for the
procedures.
3. Recover the refrigerant from the refrigerant system.
Suction Line Jumper Remove/Install
5. If the vehicle is equipped with the optional rear heater-A/C unit, go to Step 7. If not, go to Step 9.
6. Disconnect the flare nut on the underbody plumbing suction line from the threaded fitting on the
suction line jumper. Install plugs in, or tape over
all of the opened refrigerant line fittings.

7. Disconnect the flare nut on the underbody plumbing liquid line from the threaded fitting on the
liquid line extension. Install plugs in, or tape over
secures the block fitting of the suction line jumper to the outlet of the filter-drier, and separate the
fitting from the
fitter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings.
10. Remove the screw that secures the block fitting of the suction line jumper to the expansion
valve, and separate the fitting from the expansion valve.
11. Remove the suction line jumper from the engine compartment.
INSTALLATION 1. Remove the tape or plugs from the block fitting on the suction line jumper and
the expansion valve. Position the suction line jumper block fitting
to the expansion valve and secure the connection with a screw. Tighten the mounting screw to 22
N.m (200 in. lbs.).
2. Remove the tape or plugs from the block fitting on the suction line jumper and the outlet of the
fitter-drier. Position the outlet of the filter-drier to
the suction line jumper block fitting and secure the connection with a screw. Tighten the mounting
screw to 13.5 N.m (120 in. lbs.).
screw to 8.5 N.m (75 in. lbs.). 4. If the vehicle is equipped with the optional rear heater-A/C unit, go
to Step 6. If not, go to Step 8. 5. Remove the tape or plugs from the refrigerant tine fittings on the
underbody plumbing liquid line and the liquid line extension. Connect the flare
nut on the underbody plumbing liquid line to the threaded fitting on the liquid line extension. Tighten
the fitting to 27 N.m (244 in. lbs.).
6. Remove the tape or plugs from the refrigerant line fittings on the underbody plumbing suction
line and the suction line jumper. Connect the flare
nut on the underbody plumbing suction line to the threaded fitting on the suction line jumper.
Tighten the fitting to 47 N.m (420 in. lbs.).
jumper Connect the flare nut on the suction line
8. Install the low pressure cut-off switch to the fitting on the suction line jumper. See Low Pressure
Cut-Off Switch. 9. Connect the battery negative cable.
10. Evacuate the refrigerant system. 11. Charge the refrigerant system.
Hose/Line HVAC: Service and Repair Rear Heater-A/C Unit Plumbing

unit liquid and suction lines from the expansion valve. 3. Disconnect the rear heater-A/C unit heater
hoses from the heater inlet and outlet lines.
Hose/Line HVAC: Service and Repair Underbody Plumbing
free.

REMOVAL
jumper. See Suction Line Jumper in the Replacement. Install plugs in, or tape over all of the
opened refrigerant line fittings.
INSTALLATION
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications
Power Steering Line/Hose: Specifications
Pressure Line ......................................................................................................................................

...................................................... 35 Nm (25 ft. lbs.) Return Line .....................................................
.......................................................................................................................................... 35 Nm (25
ft. lbs.)
Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications
Brake Fluid: Specifications
BRAKE FLUID
Specification ........................................................................................................................................
.................................................................. DOT 3
Standard ..............................................................................................................................................
........................................................... SAE J1703
NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703
standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake
system. Use only Mopar brake fluid or an equivalent from a tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An
open container of brake fluid will absorb moisture from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission
fluid, power steering fluid, etc.
Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1068
Brake Fluid: Testing and Inspection
CAUTION:
The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic
fluid tends to absorb moisture from the atmosphere over periods of time. As hydraulic brake fluid
absorbs moisture, it effects the function of the vehicles hydraulic brake system. For this reason, the
vehicle's hydraulic brake fluid should be drained and replaced using fresh clean hydraulic brake
fluid every two years. When replacing hydraulic brake fluid, use only Mopar brake fluid or an
equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications.
BRAKE FLUID CONTAMINATION
Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the
presence of petroleum in the brake fluid.
To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid
separates into layers, there is mineral oil or other fluid contamination of the brake fluid.
If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the
rubber parts or components containing rubber coming into contact with the brake fluid. This
includes the master cylinder, proportioning valves, caliper seals, wheel cylinder seals, ABS
hydraulic control unit (HCU), and all hydraulic fluid hoses.
Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1069
Brake Fluid: Service and Repair
Always clean the master cylinder filler caps before checking fluid level. If not cleaned, dirt from the
caps could enter the fluid.
Correct fluid level is to the bottom of the ring indicators on the reservoir. If necessary, add fluid to
correct the level. With disc brake equipped vehicles, fluid level in the front brake reservoir will
decrease slightly in proportion to normal lining wear.
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications
Coolant: Capacity Specifications
Coolant Capacity .................................................................................................................................

...................................................... 12.3 L (13.1 Qts.)
NOTES:
- Nominal refill capacities are shown. A variation may be observed from vehicle to vehicle due to
manufacturing tolerances and refill procedures.
- Add 0.9L (1 Qt.) if equipped with an auxiliary rear mounted heater.
- Capacities shown include vehicles with air conditioning and/or heavy-duty cooling systems.
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications > Page 1074
Coolant: Fluid Type Specifications
The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle
operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide
protection against freezing to -37° C (-35° F). The antifreeze concentration must always be a
minimum of 44%, year round, in all climates. If percentage is lower than 44%, engine parts may be
eroded by cavitation, and cooling system components may be severely damaged by corrosion.
Maximum protection against freezing is provided with a 68% antifreeze concentration, which
prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer
temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the
specific heat of antifreeze is lower than that of water.
100 Percent Ethylene-Glycol Should Not Be Used
Use of 100 Percent Ethylene-Glycol will cause formation of additive deposits in the system, as the
corrosive inhibitive additives in ethylene-glycol require the presence of water to dissolve. The
deposits act as insulation, causing temperatures to rise as high as 149° C (300° F). this
temperature is hot enough to melt plastic and soften solder. The increased temperature can result
in engine detonation. In addition, 100 % ethylene-glycol freezes at 22° C (-8° F).
Propylene-Glycol Formulations Should Not Be Used
Propylene-glycol formulations do not meet the required specifications. It's overall effective
temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50
propylene-glycol and water is -32° C (-26° F), 5 degrees higher than ethylene-glycol's freeze point.
The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257° F) at
96.5 kPa (14 PSI), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can
result in boil-over and freeze up. Propylene-Glycol also has a poorer heat transfer characteristics
than ethylene-glycol. This can increase cylinder head temperatures under certain conditions.
Propylene-Glycol/Ethylene-Glycol Mixtures Should Not Be Used
Propylene-glycol/ethylene-glycol mixtures can cause the destabilization of various corrosion

inhibitors, causing damage to the coling system components. Also, once ethylene-glycol and
propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining the
freeze point will not be accurate. Both the refractive index and specific gravity differ between the
ethylene-glycol and propylene-glycol.
CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can
cause problems associated with 100 percent ethylene-glycol.
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation >
Coolant Performance
Coolant: Description and Operation Coolant Performance
ETHYLENE-GLYCOL MIXTURES
open ating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide
protection against freezing to -37 deg. C 05 deg. F). The anti-freeze concentration must always be
a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine
parts may be eroded by cavitation, and cooling system components may be severely damaged by
corrosion. Maximum protection against freezing is provided with a 68 percent antifreeze
concentration, which prevents freezing down to -67.7 deg. C (-90 deg. F). A higher percentage will
freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to
overheat because the specific heat of antifreeze is lower than that of water.
100 Percent Ethylene-Glycol Should Not Be Used in Chrysler Vehicles Use of 100 percent
ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive
additives in ethylene-glycol require the presence of water to dissolve. The deposits act as
insulation, causing temperatures to rise to as high as 149 deg. C (300) deg. F). This temperature is
hot, enough to melt plastic and soften solder. The increased temperature can result in engine
detonation. In addition, 100 percent ethylene-glycol freezes at 22 deg. C (-8 deg. F).
Propylene-glycol Formulations Should Not Be Used in Chrysler Vehicles Propylene-glycol

formulations do not meet Chrysler coolant specifications. It's overall effective temperature range is
smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32
deg. C (-26 deg. F). 5 deg. C higher than ethylene-glycol's freeze point. The boiling point
(protection against summer boil-over) of propylene-glycol is 125 deg. C (257 deg. F ) at 96.5 kPa
(14 psi), compared to 128 deg. C (263 deg. F) for ethylene-glycol. Use of propylene-glycol can
result in boil-over or freeze-up in Chrysler vehicles, which are designed for ethylene-glycol.
Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can
increase cylinder head temperatures under certain conditions.
Propylene-glycol/Ethylene-glycol Mixtures Should Not Be Used in Chrysler Vehicles

Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion
inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol
and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining
freeze point will not be accurate. Both the refractive index and specific gravity differ between
ethylene glycol and propylene glycol.
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation >
Coolant Performance > Page 1077
Coolant: Description and Operation Selection and Additives
The presence of aluminum components in the cooling system requires strict corrosion protection.
Maintain coolant at specified level with a mixture of ethylene-glycol based antifreeze and water.
Chrysler Corporation recommends Mopar Antifreeze or equivalent. If coolant becomes
contaminated or looses color, drain and flush cooling system and fill with correctly mixed solution.
A 0.25 percent emulsifiable oil is added to the radiator at the factory to prevent solder corrosion.
CAUTION: Do not use coolant additives that are claimed to improve engine cooling.
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page
1078
Coolant: Service and Repair
Refer to Cooling System, Service and Repair for applicable service procedures.
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
A/T - ATF+4 Fluid Usage/Applications
Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications
NUMBER: 21-010-06
GROUP: Transmission
DATE: April 14, 2006
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH

16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE
REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602)
MODELS:
1989 - 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
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

A/T - ATF+4 Fluid Usage/Applications > Page 1083
2007 (JS) Avenger/Sebring
2002 - 2007 (KJ) Liberty
1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M
2005 - 2007 (LX/LE) 300/Magnum/Charger
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
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
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.
A/T - ATF+4 Fluid Usage/Applications > Page 1084
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:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications
Fluid - A/T: Capacity Specifications
Transmission Fluid
32RH ...................................................................................................................................................
................................................. 8.0-8.3L (8.4-8.7 Qt) 46RE ................................................................
............................................................................................................................. 10.8-11.0L
(11.4-11.6 Qt)
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Fluid - A/T: Fluid Type Specifications
Transmission Fluid Type Type ............................................................................................................

....................................................... MOPAR ATF +4 Type 9602 or Equivalent
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1088
Fluid - A/T: Service Precautions
DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission
damage may occur.
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service
Bulletins > Differential Cover - Updated Sealer & Fluid
Fluid - Differential: Technical Service Bulletins Differential Cover - Updated Sealer & Fluid
NUMBER: 03-08-00
GROUP: Axle & Propeller Shaft
DATE: Sep. 5, 2000 SUBJECT: RTV Use On Corporate Axle
MODELS:
NOTE:
THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH AN 8.25, 9.25, OR C205F
CORPORATE AXLE.
DISCUSSION: The axle lubricant used in all corporate axles was changed in formulation starting at
the beginning of the 1998 model year. The corporate axles involved include: the 8.25 and 9.25 rear
axles, and the C205F front axle. The new lubricant in use is SAE 75W-90 p/n 05010320AA. The
lubricant change was made as a fuel economy improvement.
The new axle lubricant is more chemically aggressive/reactive when in contact with the previous
used Room Temperature Vulcanizable (RTV) sealant. Because of this condition, the RTV used in
assembly of the pan/cover to the axle housing was revised and improved.
When re-sealing axle covers, using the proper sealing material to minimize any potential sealant
breakdown is important. The only recommended sealing material for all corporate axle covers is
MOPAR RTV Sealant, p/n 05013477M. This RTV is red/orange in color.
NOTE:
IF SAE 75W-90 LUBRICANT IS USED TO REFILL ANY CORPORATE AXLE, THEN THE
RED/ORANGE MOPAR RTV SEALANT, P/N 05013477AA, SHOULD BE USED TO SEAL THE
COVER TO THE AXLE HOUSING.
To optimize sealant performance and enhance adhesion, flanges should be clean and free of
residual lubricant. The mating flanges should first be cleaned of any excess old RTV using a plastic
putty knife. Final cleaning/degreasing shall be done by spraying MOPAR Brake Parts Cleaner, p/n
04549623, on the carrier and cover flanges, followed by a wipe with a clean dry cloth. Care should
be taken to avoid spraying the parts cleaner inside the carrier. Once the RTV has been applied, the
axle cover is to be installed to the housing within 3 to 5 minutes to prevent skinning over of the
RTV.
NOTE:
IF THE AXLE COVER IS NOT INSTALLED WITHIN THE 3 TO 5 MINUTE TIME FRAME, THE
CARRIER COVER FACE MUST BE RECLEANED AND NEW RTV APPLIED, OR ADHESION
QUALITY WILL BE COMPROMISED.
Immediately install the cover attaching bolts and tighten them to the specified torque to prevent a
shimming effect by the RTV.

Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service
Bulletins > Differential Cover - Updated Sealer & Fluid > Page 1093
Fluid - Differential: Technical Service Bulletins Differential - Lubricant & Sealing Requirements
NO: 03-02-98
GROUP: Axle And Propshaft
DATE: Apr. 3, 1996
SUBJECT: 8-1/4 - 9-1/4 Axle Lubricant And Sealing Requirements
MODELS: 1998 (AB) Ram Van 1998 (AN) Dakota 1998 (BR/BE) Ram Truck 1998 (DN) Durango
1998 (XJ) Cherokee
DISCUSSION:
With the introduction of the 1998 model year, the axle lubricant in the 8-1/4 and 9-1/4 axles was
changed in formulation to improve fuel economy. When adding lubricant or if service is performed
that requires new lubricant use 75W90 p/n 5010320AA.
This lubricant is more aggressive toward RTV sealants than previously used axle lubricants. When
resealing the axle cover, using the proper sealing material to minimize any potential fluid foaming
and/or seal breakdown is important. Currently the only recommended sealing material for mall axle
covers or transmission pans is MOPAR RTV Sealant (grey in color) p/n 82300234.

Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications >
Capacity Specifications
Fluid - Differential: Capacity Specifications
Differential Oil Capacity
8 1/4 .....................................................................................................................................................
........................................................ 2.22L (4.7 pints) With TRAC-LOK ..............................................
..................................................................................................................... include 5 oz. friction
modifier 9 1/4 .......................................................................................................................................
...................................................................... 2.32L (4.9 pints) With TRAC-LOK ................................
................................................................................................................................... include 5 oz.
friction modifier 248RBI .......................................................................................................................
............................................................................... 2.96L (6.25 pints) With TRAC-LOK .....................
.............................................................................................................................................. include 6
oz. friction modifier
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications >
Capacity Specifications > Page 1096
Fluid - Differential: Fluid Type Specifications
Differential Fluid Type
Grade ...................................................................................................................................................
................................................................... API GL-5
Viscosity ..............................................................................................................................................
........................................................................... 90W
TRAC-LOK differentials require the specified amount of friction modifier.

Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page
1097
Fluid - Differential: Service Precautions
DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur.
Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications
Engine Oil: Capacity Specifications
Engine Oil
Without Filter Change ..........................................................................................................................

............................................................. 4.2L (4.5 Qt)
Capacity shown is without filter. When replacing filter, additional oil may be needed
Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Engine Oil: Fluid Type Specifications
Engine Oil
API Classification .................................................................................................................................

........................................... SH or SH/CD or Above Above 0°F (-18°C)..............................................
........................................................................................................................................................
10W-30 Below 32°F (0°C)....................................................................................................................
..................................................................................... 5W-30
Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1103
Engine Oil: Service Precautions
WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID
PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED
ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR
HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN
RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR
DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR
AREA.
Engine Oil: Description and Operation
ENGINE OIL SPECIFICATION.
CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Engine Oil Container Standard Notations

Use an engine oil that is API Service Grade Certified. Standard engine oil identification notations
have been adopted to aid in the proper selection of engine oil. The identifying notations are located
on the label of engine oil plastic bottles and the top of engine oil cans.
SAE VISCOSITY
Temperature/Engine Oil Viscosity
An SAE viscosity grade is used to specify the viscosity of engine oil. SAE 1OW-30 specifies a
multiple viscosity engine oil. When choosing an engine oil, consider the range of temperatures the
vehicle will be operated in before the next oil change. Select an engine oil that is best suited to your
area's particular ambient temperature range and variation.
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY
CON-SERVING is located on the label of an engine oil container.
Engine Oil: Testing and Inspection
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result. To
ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level.
The acceptable oil level is in the SAFE RANGE on the engine oil dipstick. 1. Position vehicle on
level surface. 2. With engine OFF, allow approximately ten minutes for oil to settle to bottom of
crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Install dipstick and verify it is
seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add
oil only if level is below the SAFE RANGE area on the dipstick.
ENGINE OIL PRESSURE
1. Remove oil pressure sending unit. 2. Install Oil Pressure Line and Gauge Tool C-3292. Start
engine and record pressure. Refer to Oil Pressure in Engine Specifications for the proper
pressures.
Engine Oil: Service and Repair
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals described in the Maintenance Schedule.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface
and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a
suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to
drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug
and gasket if damaged.
6. Install drain plug in crankcase. 7. Lower vehicle and fill crankcase with specified type and
amount of engine oil described. 8. Install oil fill cap. 9. Start engine and inspect for leaks.
10. Stop engine and inspect oil level.
USED ENGINE OIL DISPOSAL
Care should be exercised when disposing used engine oil after it has been drained from a vehicle
engine.
Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Steering - Power Steering Fluid Usage
Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage
NUMBER: 19-005-03
GROUP: Steering
DATE: Aug. 29, 2003
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH
SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO
ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
SUBJECT: Power Steering Fluid Usage
MODELS:
1993 - 2003 (AB) Ram Van
1994 - 2004 (AN) Dakota
1994 - 2002 (BR/BE) Ram Pickup
2004 (CS) Pacifica
1998-2004 (DN) Durango
2002 - 2004 (DR) Ram Pickup
1996 - 2000 (GS) Chrysler Voyager (International Markets)
2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 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
1993 - 2002 (SR) Viper/Viper Coupe
2001 - 2004 (ST) Sebring Coupe/Stratus Coupe

2003 - 2004 (VA) Sprinter
1999 - 2004 (WG) Grand Cherokee (International Markets)

Bulletins > Steering - Power Steering Fluid Usage > Page 1111
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.
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 Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications >
Power Steering Fluid: Capacity Specifications
Capacity ...............................................................................................................................................
....................................................... 1.28 L (2.7 pints)
Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications >
Power Steering Fluid: Fluid Type Specifications
The recommended lubricant is Mopar Power Steering Fluid.

Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
R134a Single Capacity

...........................................................................................................................................................
0.96 kg (33.86 oz. or 2.12 lbs)
R134a Dual Capacity

.............................................................................................................................................................
1.30 kg (45.85 oz. or 2.87 lbs)
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Refrigerant: Fluid Type Specifications
Hydrofluorocarbon (HFC), ...................................................................................................................

............................................... R-134a liquefied gas
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1122
Refrigerant: Description and Operation
SYSTEM OPERATION
The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a.
Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain
ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless
liquefied gas.
Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like
CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global
warming.
R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a
small amount of R-12 added to an R-134a refrigerant system will cause compressor failure,
refrigerant oil sludge or poor air conditioning system performance. In addition, the PolyAlkylene
Glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible
with the mineral-based refrigerant oils used in an R-12 refrigerant system.
R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles
have all been designed with unique fittings to ensure that an R-134a system is not accidentally
contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine
compartment of the vehicle and on the compressor identifying to service technicians that the air
conditioning system is equipped with R-134a.
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications
Refrigerant Oil: Capacity Specifications
Total System ........................................................................................................................................

........................................ (Front only) 236 ml 8.0 oz.
Total System ........................................................................................................................................

.................................. (Front & Rear) 295 ml 10.0 oz.
Condenser ...........................................................................................................................................
................................................................ 30 ml 1.0 oz.
Evaporator ...........................................................................................................................................
............................................................... 60 ml 2.0 oz. Filter-Drier ......................................................
................................................................................................................................................... 30 ml
1.0 oz.
Compressor
............................................................................................................................................. Drain and
measure the oil from the old compressor
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Refrigerant Oil: Fluid Type Specifications
Synthetic-based, Polyalkylene Glycol ..................................................................................................

......................................................................... SP-10
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page
1128
Refrigerant Oil: Service and Repair
Refrigerant Oil Level
Refrigerant Oil Capacities
When an air conditioning system is assembled at the factory, all components except the
compressor and the combination coil, if the vehicle is so equipped, are refrigerant oil free. After the
refrigerant system has been charged and operated, the refrigerant oil in the compressor and the
combination coil is dispersed throughout the refrigerant system. The combination coil, evaporator,
filter-drier, condenser, and compressor will each retain a significant amount of the needed
refrigerant oil.
It is important to have the correct amount of oil in the refrigerant system. This ensures proper
lubrication of the compressor. Too little oil will result in damage to the compressor. Too much oil
will reduce the cooling capacity of the air conditioning system.
It will not be necessary to check the oil level in the compressor or to add oil, unless there has been
an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting,
a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant
oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at
the leak point by the presence of a wet, shiny surface around the leak.
Refrigerant oil must be added when a filter-drier, evaporator coil, combination coil, or condenser
are replaced. See the Refrigerant Oil Capacities chart. When a compressor is replaced, the
refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant
oil from the new compressor, then fill the new compressor with the same amount of refrigerant oil
that was drained out of the old compressor.
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Bleeding Procedures
Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures
W/ Four Wheel Antilock Brakes
ABS system bleeding requires conventional bleeding methods plus use of the DRB scan tool. The
procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and
bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to
remove any air remaining in the system.
1. Perform base brake bleeding. 2. Connect scan tool to the Data Link Connector. 3. Select
ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the
instructions displayed. When scan tool
displays TEST COMPLETE, disconnect scan tool and proceed.
4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify
proper brake operation before moving vehicle.
W/ Rear Wheel Antilock Brakes
GENERAL INFORMATION
RWAL brake bleeding can be performed manually, or with pressure bleeding equipment.
Use Mopar DOT 3 brake fluid, or an equivalent meeting SAE J1703-F and DOT 3 standards, to fill
and bleed the brake system.
Bleed only one brake component at a time. Recommended bleed sequence is: -
master cylinder
- combination valve
- rear antilock valve
- left rear wheel
- right rear wheel
- right front wheel
- left front wheel
MANUAL BLEEDING
Use a bleed hose at each caliper/cylinder bleed screw. Attach one end of the hose to the bleed
screw and insert the opposite end in glass container partially filled with brake fluid. A glass
container makes it easier to see air bubbles as they exit the bleed hose. Be sure the end of the
bleed hose remains immersed in fluid. This prevents air from being drawn back into the system.
Do not allow the master cylinder to run out of fluid when bleeding the brakes. An empty cylinder will
allow air to be drawn back into the system. Check fluid level frequently during bleeding operations.
Be sure to tighten each brake line fitting, or bleed screw once bleeding is completed. Loose fittings
and bleed screws allows air to enter the system.
PRESSURE BLEEDING
If pressure bleeding equipment will be used, the front brake metering valve will have to be held
open to bleed the front brakes. The valve stem is located in the forward end of the combination
valve. The stem must either be pressed inward, or held outward slightly. a spring clip tool or helper
is needed to hold the valve stem in position.
Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the
tank manufacturers pressure recommendations. Generally, a tank pressure of 15 - 20 psi is
sufficient for bleeding.
Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding.
Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to
leakage, or drawing air back into the system.
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Bleeding Procedures > Page 1133
Brake Bleeding: Service and Repair Base Brake System Bleeding
GENERAL INFORMATION
Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards
only. Use fresh, clean fluid from a sealed container at all times.
Do not pump the brake pedal at any time while bleeding. Air in the system will be compressed into
small bubbles that are distributed throughout the hydraulic system. This will make additional
bleeding operations necessary.
Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will
allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add
fluid as needed.
Bleed only one brake component at a time in the following sequence: -
master cylinder
- combination valve
- right rear wheel
- left rear wheel
- right front wheel

- left front wheel
MANUAL BLEEDING
1. Remove reservoir filler caps and fill reservoir with Mopar, or equivalent quality DOT 3 brake fluid.
2. If calipers, or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws.
Then close each bleed screw as fluid starts to
drip from it. Top off master cylinder reservoir once more before proceeding.
Bleed Hose Setup
3. Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially
filled with brake fluid. Be sure end of bleed hose is
immersed in fluid.
4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close
the bleeder. Repeat bleeding until fluid stream is
clear and free of bubbles. Then move to the next wheel.
PRESSURE BLEEDING
leakage, or drawing air back into the system. Use adapter provided with the equipment or Adapter
6921 or equivalent.
Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
WARNING: The airbag system is a sensitive, complex electro-mechanical unit. Before attempting
to diagnose, remove or install the airbag system components you must first disconnect and isolate
the battery negative (ground) cable. Failure to do so could result in accidental deployment of the
airbag and possible personal injury. The fasteners, screws, and bolts, originally used for the airbag
components, have special coatings and are specifically designed for the airbag system. They must
never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct
fasteners provided in the service package or fasteners listed in the parts books
.
Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions
> Page 1137
Air Bag(s) Arming and Disarming: Service and Repair
Air Bag System Arming and Disarming
The airbag system is a sensitive, complex electromechanical unit. Before attempting to diagnose or
service any airbag system or related steering wheel, steering column, or instrument panel
components you must first disconnect and isolate the battery negative (ground) cable. Then wait
two minutes for the system capacitor to discharge before further system service. This is the only
sure way to disable the airbag system. Failure to do this could result in accidental airbag
deployment and possible personal injury.
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Description and Operation
Circuit Breaker: Description and Operation
SYSTEM OPERATION
An automatic resetting circuit breaker in the junction block is used to protect the power seat system
circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition
caused by an obstructed or stuck seat adjuster.
The circuit breaker cannot be repaired and, if faulty or damaged, it must be replaced.
An automatic resetting circuit breaker in the junction block is used to protect the power window
system circuit. The circuit breaker can protect the system from a short circuit, or from an overload
condition caused by an obstructed or stuck window glass or regulator.
The circuit breaker cannot be repaired and, if faulty, it must be replaced.

Description and Operation > Page 1142
Circuit Breaker: Testing and Inspection
1. Locate the correct circuit breaker in the junction block. Pull out the circuit breaker slightly, but be
certain that the circuit breaker terminals still
contact the terminals in the junction block cavities.
2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter
positive lead, check both terminals of the circuit breaker for battery voltage.
If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither
terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as
required.
Circuit Breaker: Service and Repair
Panel/Instrument Panel End Cap.
Junction Block
3. Unplug the circuit breaker from the junction block. 4. Install the circuit breaker by aligning its
terminals with the cavities in the junction block and pushing the circuit breaker firmly into place. 5.
Connect the battery negative cable. 6. Test the circuit breaker operation. 7. Reinstall the end cap
on the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument
Panel/Instrument Panel End
Cap.
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Locations > Power Distribution Center
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Locations > Power Distribution Center > Page 1148
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations

Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component
Malfunction Indicator Lamp: Description and Operation
Data Link Connector
As a functional test, the MIL (check engine) illuminates at key-on before engine cranking.
Whenever the Powertrain Control Module (PCM) sets a Diagnostic Trouble Code (DTC) that affects
vehicle emissions, it illuminates the MIL. If a problem is detected, the PCM sends a message to the
instrument cluster to illuminate the lamp. The PCM illuminates the MIL only for DTC's that affect
vehicle emissions. There are some monitors that may take two consecutive trips, with a detected
fault, before the MIL is illuminated. The MIL stays on continuously when the PCM has entered a
Limp-In mode or identified a failed emission component. Also, the MIL either flashes or illuminates
continuously when the PCM detects active engine misfire.
Additionally, the PCM may reset (turn off) the MIL when one of the following occur:
^ PCM does not detect the malfunction for 3 consecutive trips (except misfire and Fuel system
Monitors).
^ PCM does not detect a malfunction while performing three successive engine misfire or fuel
system tests. The PCM performs these tests while the engine is operating within ± 375 RPM of and
within 10 % of the load of the operating condition at which the malfunction was first detected.
Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component
Malfunction Indicator Lamp: Testing and Inspection
The diagnosis found here addresses an inoperative malfunction indicator (Check Engine) lamp
condition. If the lamp comes on and stays on with the engine running, refer to Powertrain
Management/Computers and Control Systems/Testing and Inspection. See: Powertrain
Management/Computers and Control Systems/Testing and Inspection

INJURY.
If the malfunction indicator lamp falls to light during the bulb test (about two seconds after the
ignition switch is turned to the On position), replace the malfunction indicator lamp bulb with a
known good unit. If the indicator lamp still fails to operate, diagnosis of the Powertrain Control
Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a
DRB scan tool. For further diagnosis of the malfunction indicator lamp and the instrument cluster
circuitry, refer to Instrument Panel/Testing and Inspection. See: Instrument Panel, Gauges and
Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Description
and Operation
Spare Tire: Description and Operation
The temporary spare tire is designed for emergency use only. The original tire should be repaired
and reinstalled at the first opportunity, or replaced with a new. Do not exceed speeds of 50 MPH
when the temporary spare tire is in use on the vehicle.
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 1170
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:

NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Bulletins > System Information > Service and Repair
cylinder chamber.
battery.

Bulletins > All Other Service Bulletins for Wheels: > 21-04-00 > Jun > 00 > Customer Interest for Wheels: > 19-002-01A >
Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 1184
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Component
Information > Diagrams

Information > Diagrams > Page 1189
SYSTEM OPERATION

INJURY.
Horns/Headlamp
Switch Replacement.

Information > Page 1193

INJURY.
Horns/Headlamp
Switch Replacement.

Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page
1202
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:

NOTE:
1203
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

1204
NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-002-01A > Sep > 01 > Steering/Suspension -
Wander Diagnosis/Repair
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
Wander Diagnosis/Repair > Page 1210
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis
and Correction Revised
Wheel Bearing: All Technical Service Bulletins Steering Wander - Diagnosis and Correction
Revised
NUMBER: 19-07-00
GROUP: Steering

following:
NOTE:
DIAGNOSIS:
box).
NOTE:
NOTE:
ROADS, ETC.).

and Correction Revised > Page 1217
NOTE:

new cotter pin.
and Correction Revised > Page 1218
specifications.
NOTE:
VAN/WAGONS.

Service Bulletins > All Other Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and
Correction Revised
Revised
NUMBER: 19-07-00
GROUP: Steering

following:
NOTE:
DIAGNOSIS:
box).
NOTE:
NOTE:
ROADS, ETC.).

Correction Revised > Page 1224
NOTE:

new cotter pin.
Correction Revised > Page 1225
specifications.
NOTE:
VAN/WAGONS.

Wheel Bearing: Specifications Lubricant Type
Lubricant Type
Wheel Bearing Grease NLGI GC rated automotive grease

Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front
Wheel Bearing: Service and Repair Front
REMOVAL
1. Lock brake pedal in up position. 2. Raise and support the vehicle. 3. Remove the wheel and tire
assembly. 4. Remove disc brake caliper. 5. Remove the dust cap, cotter pin, and remaining hub
components from spindle. 6. Carefully slide the hub/rotor from spindle.
CAUTION: Use care to prevent inner wheel bearing and seal from contacting spindle threads
during removal).
7. Remove the seal and inner wheel bearing from the hub/rotor. Remove the inner bearing races
from hub/rotor with a pin punch.
INSTALLATION
1. Install the new bearing cup(s) with an appropriate installation tool. 2. Apply a coating of Mopar
(R) Wheel Bearing Grease to inner surface area of hub. Install inner wheel bearing and new
bearing seal. 3. Inspect bearing and seal contact surfaces on spindle for burrs and or roughness. 4.
Remove all rough contact surfaces from spindle. Apply a coating of lubricant.
during installation.
5. Carefully slide the hub/rotor onto spindle. Install outer wheel bearing, washer and retaining nut.
6. Tighten the nut to 41 - 54 Nm (30 - 40 ft. lbs.) to preload bearing while rotating the hub/rotor.
Stop hub/rotor and loosen nut to completely release
bearing preload torque. Tighten the nut finger-tight and install the nut lock. Install a new cotter pin.
7. The adjustment (above) should have 0.254 - 0.0762 mm (0.001 - 0.003 inch) end play. 8. Clean
the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with
lubricant. Install the cap. 9. Install disc brake caliper.
10. Install the wheel and tire assembly and lower the vehicle.
Repair > Front > Page 1229
Wheel Bearing: Service and Repair Rear
8 1/4 and 9 1/4 Axles
REMOVAL
1. Remove axle shaft.
Axle Seal Removal
2. Remove axle shaft seal from the end of the axle tube with a small pry bar.
NOTE: The seal and bearing can be removed at the same time with the bearing removal tool.
Axle Shaft Bearing Removal Tool
3. Remove the axle shaft bearing from the axle tube with Bearing Removal Tool Set 6310, using
Adapter Foot 6310-9.
INSTALLATION
NOTE: Do not install the original axle shaft seal. Always install a new seal.
1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube.
Axle Shaft Seal And Bearing Installation
2. Install the axle shaft bearing with Installer C-4198 and Handle C-4171. Ensure that the bearing
part number is against the installer. Verify that the
bearing in installed straight and the tool fully contacts the axle tube when seating the bearing.
3. Install a new axle seal with Installer C-4076-B and Handle C-4735-1. When the tool contacts the
axle tube, the seal is installed to the correct
depth.
4. Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. 5. Install
the axle shaft.
With 9 1/4 Axle
REMOVAL
Axle Seal Removal

3. Remove the axle shaft bearing from the axle tube with Bearing Removal Tool C-4828.
INSTALLATION
2. Install the axle shaft bearing with Installer C-4826-1 and Handle C-4171. Ensure that the bearing
part number is against the installer. Verify that
the bearing in installed straight and the tool fully contacts the axle tube when seating the bearing.
3. Install a new axle seal with Installer C-4826-1, Adapter C-4826-2, and Handle C-4171. When the
tool contacts the axle tube, the seal is installed to
the correct depth.
the axle shaft.
248 RBI Axle
REMOVAL
1. Remove wheel and tire assembly. 2. Remove brake drum. 3. Remove the axle shaft. 4. Remove
the lock wedge and adjustment nut. Use Socket DD-1241-JD to remove the adjustment nut. 5.
Remove the hub assembly. The outer axle bearing will slide out as the hub is being removed. 6.
Remove inner grease seal and discard. Use Installer 5064 and Handle C-4171 to drive grease seal
and inner axle bearing from the hub. 7. Remove the bearing cups from the hub bore. Use a brass
drift, or an appropriate removal tool, to tap out the cups.
INSTALLATION
1. Thoroughly clean both axle bearings and interior of the hub with an appropriate cleaning solvent.
2. Install the bearing cups. Use Installer 8151 and Handle C-4171 to install the bearing cups. 3.
Apply lubricant to surface area of the bearing cup. 4. Install the inner axle bearing in the hub. 5.
Install a new bearing grease seal. Use Installer 8149 and Handle C-4171 to install the grease seal.
6. Inspect the bearing and seal contact surfaces on the axle tube spindle for burrs and/or
roughness. Remove all the rough contact surfaces from the
axle spindle. Apply a coating of multi-purpose NLGI, grade 2, EP-type lubricant to the axle.
CAUTION: Use care to prevent the bearing grease seal from contacting the axle tube spindle
threads during installation. Otherwise, the seal could be damaged.
7. Carefully slide the hub onto the axle. 8. Install the outer axle bearing. 9. Install the hub bearing
adjustment nut. Use Socket DD-1241-JD to install the adjustment nut.
10. Tighten the adjustment nut to 163-190 Nm (120-140 ft. lbs.) while rotating the wheel. 11.
Loosen the adjustment nut 1/8 of-a-turn to provide 0.001-inch to 0.010-inch wheel bearing end
play. 12. Tap the locking wedge into the spindle keyway and adjustment nut. Try to ensure that the
locking wedge is installed into a new position in the
adjustment nut.
13. Install the axle shaft. 14. Install the brake drum. 15. Install the wheel and tire assembly.
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
> Wheel Tightening Sequence
Wheel Fastener: Specifications Wheel Tightening Sequence
Wheel Torque Sequence - Master

> Wheel Tightening Sequence > Page 1236
Wheel Fastener: Specifications Lug Nut Torque
15 Inch 5 Stud Wheel

...........................................................................................................................................................
109 - 150 Nm (80 - 110 ft. lbs.) 16 Inch 8 Stud Wheel
.........................................................................................................................................................
163 - 203 Nm (120 - 150 ft. lbs.)
> Page 1237
Wheel Fastener: Service and Repair
REMOVAL
1. Remove wheel and tire assembly. 2. Remove disc brake rotor. 3. Place rotor on flat surface and
drive studs out of the with a hammer and punch.
INSTALLATION
1. Turn the rotor over and place in a vise. 2. Drive new studs into the rotor with hammer and punch.
3. Install rotor. 4. Install wheel and tire assembly.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information >
Service and Repair
Access Cover: Service and Repair
NOTE: The engine cover is attached with screws at the rear and with latches at the dash
extension.
REMOVAL
1. Remove screws attaching holddown brackets to floor pan. 2. Disengage latches from dash
extension.
3. Remove engine cover from vehicle.
INSTALLATION
1. Position engine cover on floor pan. 2. Ensure seal is seated correctly. 3. Position holddown
brackets on cover and install screws in floor pan finger tight. 4. Engage latches with dash panel
extension. 5. Tighten screws attaching cover to floor pan.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
malfunctions.

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Bearing > Component Information > Specifications
Camshaft Bearing: Specifications
BEARING DIAMETERS:
No.1 .....................................................................................................................................................
.......... 50.800 - 50.825 mm (2.0000 - 2.0010 inch) No.2 .....................................................................
.......................................................................................... 50.394 - 50.419 mm (1.9840 - 1.9850
inch) No.3 ............................................................................................................................................
................... 50.013 - 50.038 mm (1.9690 - 1.9700 inch) No.4 ............................................................
................................................................................................... 49.606 - 49.632 mm (1.9530 -
1.9540 inch) No.5 ................................................................................................................................
............................... 39.688 - 39.713 mm (1.5625 - 1.5635 inch)
DIAMETRICAL CLEARANCE:
Standard
............................................................................................................................................................
0.0254 - 0.0762 mm 10.001 - 0.003 inch) Max. Allowable ..................................................................
........................................................................................................... 0.127 mm (0.005 inch)
BEARING JOURNAL DIAMETER:
No.1 .....................................................................................................................................................
.......... 50.749 - 50.775 mm (1.9980 - 1.9990 inch) No.2 .....................................................................
.......................................................................................... 50.343 - 50.368 mm (1.9820 - 1.9830
inch) No.3 ............................................................................................................................................
................... 49.962 - 49.987 mm (1.9670 - 1.9680 inch) No.4 ............................................................
................................................................................................... 49.555 - 49.581 mm (1.9510 -
1.9520 inch) No.5 ................................................................................................................................
............................... 39.637 - 39.662 mm (1.5605 - 1.5615 inch)
Bearing > Component Information > Specifications > Page 1251
Camshaft Bearing: Service and Repair
REMOVAL
NOTE: This procedure requires that the engine is removed from the vehicle.
1. With engine completely disassembled, drive out rear cam bearing core hole plug.
Camshaft Bearings Removal?installation With Tool C-3132-A
2. Install proper size adapters and horseshoe washers (part of Camshaft Bearing Remover/Installer
Tool C-3132-A) at back of each bearing shell.
Drive out bearing shells.
INSTALLATION
1. Install new camshaft bearings with Camshaft Bearing Remover/Installer Tool C-3132-A by
sliding the new camshaft bearing shell over proper
adapter.
2. Position rear bearing in the tool. Install horseshoe lock and by reversing removal procedure,
carefully drive bearing shell into place. 3. Install remaining bearings in the same manner. Bearings
must be carefully aligned to bring oil holes into full register with oil passages from the
main bearing. If the camshaft bearing shell oil holes are not in exact alignment, remove and install
them correctly. Install a new core hole plug at the rear of camshaft. Be sure this plug does not leak.
Gear/Sprocket > Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Camshaft Sprocket Bolt .......................................................................................................................

.................................................... 68 Nm (50 ft. lbs.)
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Specifications
Camshaft: Specifications
Bearing Diameter
No.1 2.000 - 2.001 in
No.2 1.984 - 1.985 in
No.3 1.969 - 1.970 in
No.4 1.953 - 1.954 in
No.5 1.5625 - 1.5635 in
Bearing Journal Diameter
No.1 1.998 - 1.999 in
No.2 1.982 - 1.983 in
No.3 1.967 - 1.968 in
No.4 1.951 - 1.952 in
No.5 1.5605 - 1.5615 in
Bearing to Journal Clearance
Standard 0.001 - 0.003 in
Service Limit 0.005 in
Camshaft End Play 0.002 - 0.010 in
Lift (@ zero lash) - Intake 0.410 in
Lift (@ zero lash) - Exhaust 0.417 in
Exhaust Valve
Closes (ATDC) 33 deg
Opens (BBDC) 56 deg

Duration 269 deg
Intake Valve
Closes (ATDC) 62 deg
Opens (BBDC) 17 deg
Duration 249 deg
Valve Overlap 41 deg
Camshaft Bolt 50 ft.lb
Camshaft Thrust Plate Bolts 210 in.lb

Engine > Component Information > Service and Repair > Camshaft Replacement
Camshaft: Service and Repair Camshaft Replacement
Camshaft And Sprocket Assembly
NOTE: The camshaft has an integral oil pump and distributor drive gear.
REMOVAL
1. Remove the radiator. Refer to Cooling System for the correct procedures. 2. Remove the A/C
Condenser (if equipped) 3. Remove the engine cover. 4. Remove intake manifold. 5. Remove
cylinder head covers. 6. Remove timing case cover and timing chain. 7. Remove rocker arms. 8.
Remove push rods and tappets. Identify each part so it can be installed in its original location.
Timing Chain Oil Tap Installation
9. Remove distributor and lift out the oil pump and distributor drive shaft.
10. Remove camshaft thrust plate, note location of oil tab. 11. Install a long bolt into front of
camshaft to facilitate removal of the camshaft. Remove camshaft, being careful not to damage cam
bearings with
the cam lobes.
INSTALLATION
1. Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 51 mm
(2 inches) of its final position in cylinder block.
Engine > Component Information > Service and Repair > Camshaft Replacement > Page 1260
Camshaft Holding Tool C-3509 (Installed Position)

2. Install Camshaft Gear Installer Tool C-3509 with tongue back of distributor drive gear. 3. Hold
tool in position with a distributor lockplate bolt. This tool will restrict camshaft from being pushed in
too far and prevent knocking out, the
welch plug in rear of cylinder block. Tool should remain installed until the camshaft and crankshaft
sprockets and timing chain have been installed.
4. Install camshaft thrust plate and chain oil tab. Make sure tang enters lower right hole in thrust
plate. Tighten bolts to 24 Nm (210 inch lbs.) torque.
Top edge of tab should be flat against thrust plate in order to catch oil for chain lubrication.
5. Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.
6. Place timing chain around both sprockets. 7. Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in camshaft sprocket. 8. Lift sprockets and chain (keep
sprockets tight against the chain in position as described).
Alignment Of Timing Marks
9. Slide both sprockets evenly over their respective shafts and use a straightedge to check
alignment of timing marks.
10. Install the camshaft bolt/cup washer. Tighten bolt to 68 Nm (50 ft. lbs.) torque. 11. Measure
camshaft end play. Refer to Specifications for proper clearance. If not within limits install a new
thrust plate. 12. Each tappet reused must be installed in the same position from which it was
removed. When camshaft is replaced, all of the tappets must be
replaced.
Engine > Component Information > Service and Repair > Camshaft Replacement > Page 1261
Camshaft: Service and Repair Shaft Prealignments
NOTE: Before installing the distributor, the oil pump drive shaft must be aligned to number one
cylinder.
1. Rotate crankshaft until No.1 cylinder is at top dead center on the firing stroke. 2. When in this
position, the timing mark of vibration damper should be under "O" on the timing indicator.
Position Of Oil Pump Shaft Slot
3. Install the shaft so that after the gear spirals into place, it will index with the oil pump shaft. The
slot on top of oil pump shaft should be aligned
towards the left front intake manifold attaching bolt hole.
4. Install distributor.
After the distributor has been installed, its rotational position must be set using the SET SYNC
mode of the DRB scan tool.
Do not attempt to adjust ignition timing by rotating the distributor. It has no effect on ignition timing.
Adjusting distributor position will effect fuel synchronization only.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Specifications
Lifter / Lash Adjuster: Specifications
Body Diameter 0.9035 - 0.9040 in
Clearance in Block 0.0011 - 0.0024 in
Dry Lash 0.06 - 0.210 in

Adjuster, Valve > Component Information > Specifications > Page 1265
Lifter / Lash Adjuster: Testing and Inspection
HYDRAULIC TAPPETS
Before disassembling any part of the engine to correct tappet noise, check the oil pressure. If
vehicle has no oil pressure gauge, install a reliable gauge at the pressure sending-unit. The
pressure should be between 207-552 kPa (30-80 psi) at 3,000 RPM. Check the oil level after the
engine reaches normal operating temperature. Allow 5 minutes to stabilize oil level, check dipstick.
The oil level in the pan should never be above the FULL mark or below the ADD OIL mark on
dipstick. Either of these two conditions could be responsible for noisy tappets.
OIL LEVEL HIGH
If oil level is above the FULL mark, it is possible for the connecting rods to dip into the oil. With the
engine running, this condition could create foam in the oil pan. Foam in oil pan would be fed to the
hydraulic tappets by the oil pump causing them to lose length and allow valves to seat noisily.
LOW
Low oil level may allow oil pump to take in air. When air is fed to the tappets, they lose length,
which allows valves to seat noisily. Any leaks on intake side of oil pump through which air can be
drawn will create the same tappet action. Check the lubrication system from the intake strainer to
the pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may
be intermittent or constant, and usually more than one tappet will be noisy. When oil level and
leaks have been corrected, operate the engine at fast idle. Run engine for a sufficient time to allow
all of the air inside the tappets to be bled out.
TAPPET NOISE DIAGNOSIS
1. To determine source of tappet noise, operate engine at idle with cylinder head covers removed.
2. Feel each valve spring or rocker arm to detect noisy tappet. The noisy tappet will cause the
affected spring and/or rocker arm to vibrate or feel
rough in operation.
NOTE: Worn valve guides or cocked springs are sometimes mistaken for noisy tappets.
If such is the case, noise may be dampened by applying side thrust on the valve spring. If noise is
not appreciably reduced, it can be assumed the noise is in the tappet. Inspect the rocker arm push
rod sockets and push rod ends for wear.
3. Valve tappet noise ranges from light noise to a heavy click. A light noise is usually caused by
excessive leak-down around the unit plunger, or by
the plunger partially sticking in the tappet body cylinder. The tappet should be replaced. A heavy
click is caused by a tappet check valve not seating, or by foreign particles wedged between the
plunger and the tappet body. This will cause the plunger to stick in the down position. This heavy
click will be accompanied by excessive clearance between the valve stem and rocker arm as valve
closes. In either case, tappet assembly should be removed for inspection and cleaning.
4. The valve train generates a noise very much like a light tappet noise during normal operation.
Care must be taken to ensure that tappets are making
the noise. If more than one tappet seems to be noisy, it's probably not the tappets.
Adjuster, Valve > Component Information > Service and Repair > Removal and Installation
Lifter / Lash Adjuster: Service and Repair Removal and Installation
REMOVAL
1. Remove the air cleaner. 2. Remove cylinder head cover. 3. Remove rocker assembly and push
rods. Identify push rods to ensure installation in original location. 4. Remove intake manifold. 5.
Remove yoke retainer and aligning yokes. 6. Slide Hydraulic Tappet Remover/Installer Tool
C-4129-A through opening in cylinder head and seat tool firmly in the head of tappet. 7. Pull tappet
out of bore with a twisting motion. If all tappets are to be removed, identify tappets to ensure
installation in original location. 8. If the tappet or bore in cylinder block is scored., scuffed, or shows
signs of sticking, ream the bore to next oversize. Replace with oversize tappet.
CAUTION: The plunger and tappet bodies are not interchangeable. The plunger and valve must
always be fitted to the original body. It is advisable to work on one tappet at a time to avoid mixing
of parts. Mixed parts are not compatible. DO NOT disassemble a tappet on a dirty work bench.
NOTE: To disassemble and assemble tappets refer to Disassembly and Assembly procedures.
INSTALLATION
1. Lubricate tappets. 2. Install tappets and push rods in their original positions. Ensure that the oil
feed hole in the side of the tappet body faces up (away from the
crankshaft).
3. Install aligning yokes with ARROW toward camshaft. 4. Install yoke retainer. Tighten the bolts to
23 Nm (200 inch lbs.) torque. 5. Install the intake manifold. 6. Install push rods in original positions.
7. Install rocker arms. 8. Install cylinder head covers. 9. Start and operate engine. Warm up to
normal. operating temperature.
CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have become quiet.
Adjuster, Valve > Component Information > Service and Repair > Removal and Installation > Page 1268
Lifter / Lash Adjuster: Service and Repair Disassembly and Assembly
CAUTION: The plunger and tappet bodies are not interchangeable. The plunger and valve must
always be fitted to the original body. It is advisable to work on one tappet at a time to avoid mixing
of parts. Mixed parts are not compatible. DO NOT disassemble a tappet on a dirty work bench.
DISASSEMBLE
Hydraulic Tappet Assembly
1. Pry out plunger retainer spring clip. 2. Clean varnish deposits from inside of tappet body above
plunger cap. 3. Invert tappet body and remove plunger cap, plunger, check valve, check valve
spring, check valve retainer and plunger spring. Check valve could
be flat or ball.
ASSEMBLE
1. Clean all tappet parts in a solvent that will remove all varnish and carbon. 2. Replace tappets
that are unfit for further service with new assemblies. 3. If plunger shows signs of scoring or wear,
install a new tappet assembly. If valve is pitted, or valve seat on end of plunger is prevented from
seating, install a new tappet assembly.
4. Assemble tappets.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod >
Component Information > Specifications
Push Rod: Specifications
Push Rod Length 6.915 - 6.935 in

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod >
Component Information > Specifications > Page 1272
Push Rod: Service and Repair
ROCKER ARMS AND PUSH RODS
REMOVAL
1. Disconnect spark plug wires by pulling on the boot straight out in line with plug. 2. Remove
cylinder head cover and gasket.
Rocker Arms
3. Remove the rocker arm bolts and pivots. Place them on a bench in the same order as removed.
4. Remove the push rods and place them on a bench in the same order as removed.
INSTALLATION
1. Rotate the crankshaft until the "V8" mark lines up with the TDC mark on the timing chain case
cover. This mark is located 147° ATDC from the
No. 1 firing position.
2. Install the push rods in the same order as removed. 3. Install rocker arm and pivot assemblies in
the same order as removed. Tighten the rocker arm bolts to 28 Nm (21 ft. lbs.) torque.
CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation.
Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes).
4. Install cylinder head cover. 5. Connect spark plug wires.

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications
Rocker Arm Assembly: Specifications
Rocker Arm Bolts 21 ft.lb

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications > Page 1276
Rocker Arm Assembly: Service and Repair
REMOVAL
Rocker Arms
INSTALLATION

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing
> Component Information > Specifications
Connecting Rod Bearing: Specifications
Bearing Clearance
....................................................................................................................................................
0.013-0.056 mm (0.0005-0.0022 in)
Side Clearance ....................................................................................................................................

........................... 0.152-0.356 mm (0.006-0.014 in)
> Component Information > Service and Repair > Fitting Connecting Rod Bearings
Connecting Rod Bearing: Service and Repair Fitting Connecting Rod Bearings
Fit all rods on a bank until completed. DO NOT alternate from one bank to another, because
connecting rods and pistons are not interchangeable from one bank to another. The bearing caps
are not interchangeable and should be marked at removal to ensure correct assembly. Each
bearing cap has a small V-groove across the parting face. When installing the lower bearing shell,
make certain that the V-groove in the shell is in line with the V-groove in the cap. This provides
lubrication of the cylinder wall in the opposite bank. The bearing shells must be installed so that the
tangs are in the machined grooves in the rods and caps. Limits of taper or out-of-round on any
crankshaft journals should be held to 0.025 mm (0.001 inch). Bearings are available in 0.025 mm
(0.001 inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm (0.010 inch) and 0.305 mm
(0.012 inch) undersize. Install the bearings in pairs. DO NOT use a new bearing half with an old
bearing half. DO NOT file the rods or bearing caps.
> Component Information > Service and Repair > Fitting Connecting Rod Bearings > Page 1283
Connecting Rod Bearing: Service and Repair Connecting Rod Bearing Clearance
CONNECTING ROD BEARING CLEARANCE
Engine connecting rod bearing clearances can be determined by use of Plastigage, or equivalent.
The following is the recommended procedures for the use of Plastigage: 1. Remove oil film from
surface to be checked. Plastigage is soluble in oil. 2. Place a piece of Plastigage across the entire
width of the bearing cap shell. Position the Plastigage approximately 6.35 mm (1/4 inch) off center
and away from the oil holes. In addition, suspect areas can be checked by placing the Plastigage in
the suspect area.
3. The crankshaft must be turned until the connecting rod to be checked starts moving toward the
top of the engine. Only then should the rod cap with
Plastigage in place be assembled. Tighten the 3.9L, and 5.2L rod cap nut to 61 Nm (45 ft. lbs.)
torque. DO NOT rotate the crankshaft or the Plastigage may be smeared, giving inaccurate results.
4. Remove the bearing cap and compare the width of the flattened Plastigage with the scale
provided on the package. Plastigage generally comes in 2
scales (one scale is in inches and the other is a metric scale). Locate the band closest to the same
width. This band shows the amount of clearance. Differences in readings between the ends
indicate the amount of taper present. Record all readings taken (refer to Engine Specifications).
5. Plastigage is available in a variety of clearance ranges. The 0.025-0.076 mm (0.001-0.003 inch)

range is usually the most appropriate for checking
engine bearing clearances.

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine
> Component Information > Specifications > Connecting Rod Cap Bolts/Nuts
Connecting Rod: Specifications Connecting Rod Cap Bolts/Nuts
Cap Bolts .............................................................................................................................................

................................................. 61 Nm (45 ft. lbs.)
> Component Information > Specifications > Connecting Rod Cap Bolts/Nuts > Page 1288
Connecting Rod: Specifications Connecting Rod Specifications
Bearing Clearance
................................................................................................................................................. 0.013 -
0.056 mm (0.0005 - 0.0022 inch) Max. Allowable ...............................................................................
.................................................................................................... 0.08 mm (0.003 inch) Piston Pin
Bore Diameter ..................................................................................................................................
24.966 - 24.978 mm (0.9829 - 0.9834 inch) Side Clearance (Two Rods)
...................................................................................................................................... 0.152 - 0.356
mm (0.006 - 0.014 inch) Total Weight (Less Bearing)
.........................................................................................................................................................
758 grams (25.74 ounces)
Cap Bolts .............................................................................................................................................

..................................................... 61 Nm (45 ft. lbs.)
> Component Information > Service and Repair > Checking Clearances
Connecting Rod: Service and Repair Checking Clearances
CONNECTING ROD BEARING CLEARANCE
Engine connecting rod bearing clearances can be determined by use of Plastigage, or equivalent.
The following is the recommended procedures for the use of Plastigage: 1. Remove oil film from
surface to be checked. Plastigage is soluble in oil. 2. Place a piece of Plastigage across the entire
width of the bearing cap shell. Position the Plastigage approximately 6.35 mm (1/4 inch) off center
and away from the oil holes. In addition, suspect areas can be checked by placing the Plastigage in
the suspect area.
3. The crankshaft must be turned until the connecting rod to be checked starts moving toward the
top of the engine. Only then should the rod cap with
Plastigage in place be assembled. Tighten the 3.9L, and 5.2L rod cap nut to 61 Nm (45 ft. lbs.)
torque. DO NOT rotate the crankshaft or the Plastigage may be smeared, giving inaccurate results.
4. Remove the bearing cap and compare the width of the flattened Plastigage with the scale
provided on the package. Plastigage generally comes in 2
scales (one scale is in inches and the other is a metric scale). Locate the band closest to the same
width. This band shows the amount of clearance. Differences in readings between the ends
indicate the amount of taper present. Record all readings taken (refer to Engine Specifications).
5. Plastigage is available in a variety of clearance ranges. The 0.025-0.076 mm (0.001-0.003 inch)

range is usually the most appropriate for checking
engine bearing clearances.

> Component Information > Service and Repair > Checking Clearances > Page 1291
Connecting Rod: Service and Repair Fitting Connecting Rod Bearings
Fit all rods on a bank until completed. DO NOT alternate from one bank to another, because
connecting rods and pistons are not interchangeable from one bank to another. The bearing caps
are not interchangeable and should be marked at removal to ensure correct assembly. Each
bearing cap has a small V-groove across the parting face. When installing the lower bearing shell,
make certain that the V-groove in the shell is in line with the V-groove in the cap. This provides
lubrication of the cylinder wall in the opposite bank. The bearing shells must be installed so that the
tangs are in the machined grooves in the rods and caps. Limits of taper or out-of-round on any
crankshaft journals should be held to 0.025 mm (0.001 inch). Bearings are available in 0.025 mm
(0.001 inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm (0.010 inch) and 0.305 mm
(0.012 inch) undersize. Install the bearings in pairs. DO NOT use a new bearing half with an old
bearing half. DO NOT file the rods or bearing caps.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing
> Component Information > Specifications > Rebuild Specifications
Crankshaft Main Bearing: Specifications Rebuild Specifications
Main Bearing Journals
Diameter
..............................................................................................................................................................
71.361-71.387 mm (2.8095-2.8105 in.) Out-of-Round (Max) ..............................................................
........................................................................................................ 0.0254 mm (0.001 in.) Taper
(Max) ...................................................................................................................................................
................................ 0.0254 mm (0.001 in.)
Diametrical Clearance
No. 1 ....................................................................................................................................................
.................... 0.013-0.038 mm (0.0005-0.0015 in.) Service Limit (No. 1) ............................................
....................................................................................................................... 0.0381 mm (0.0015 in.)
No. 2,3,4,5 ...........................................................................................................................................
.................... 0.013-0.051 mm (0.0005-0.0002 in.) Service Limit (Nos. 2,3,4,5)
..........................................................................................................................................................
0.064 mm (0.0025 in.)
End Play ..............................................................................................................................................

........................ 0.051-0.178 mm (0.002-0.178 in.) Service Limit ........................................................
............................................................................................................................ 0.254 mm (0.010
in.)
> Component Information > Specifications > Rebuild Specifications > Page 1296
Crankshaft Main Bearing: Specifications Torque Specifications
Cap Bolts .............................................................................................................................................

.................................................. 115 Nm (85 ft. lbs.)
> Component Information > Specifications > Page 1297
Crankshaft Main Bearing: Service and Repair
FITTING CRANKSHAFT MAIN BEARINGS
Main Bearing Identification
Bearing caps are not interchangeable and should be marked at removal to ensure correct
assembly. Upper and lower bearing halves are NOT interchangeable. Lower main bearing halves
of No.2 and 4 are interchangeable. Upper and lower No.3 bearing halves are flanged to carry the
crankshaft thrust loads. They are NOT interchangeable with any other bearing halves in the engine.
Bearing shells are available in standard and the following undersizes: 0.25 mm (0.001 inch), 0.051
mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm (0.010 inch) and 0.305 mm (0.012 inch). Never
install an undersize bearing that will reduce clearance below specifications.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Dimensions
Crankshaft: Specifications Dimensions
CONNECT ROD JOURNAL:
Diameter
............................................................................................................................................................
53.950 - 53.975 mm (2.124 - 2.125 inch) Out-of-Round (Max.) ..........................................................
......................................................................................................... 0.0254 mm (0.001 inch) Taper
(Max.) ..................................................................................................................................................
.............................. 0.0254 mm (0.001 inch)
DIAMETRICAL CLEARANCE:
No. 1 ....................................................................................................................................................
.............. 0.013 - 0.038 mm (0.0005 - 0.0015 inch) Max. Allowable No. 1 ..........................................
..................................................................................................................... 0.0381 mm (0.0015 inch)
Nos. 2,3,4 and 5
................................................................................................................................................ 0.013 -
0.051 mm (0.0005 - 0.0020 inch) Max. Allowable (Nos. 2,3,4 and 5)
.............................................................................................................................................. 0.064
mm (0.0025 inch)
END PLAY:
Standard ..............................................................................................................................................
.................. 0.051 - 0.178 mm (0.002 - 0.007 inch) Max. Allowable ....................................................
......................................................................................................................... 0.254 mm (0.010 inch)
MAIN BEARING JOURNALS:
Diameter
........................................................................................................................................................
71.361 - 71.387 mm (2.8095 - 2.8105 inch) Out-of-Round (Max.) ......................................................
............................................................................................................. 0.0254 mm (0.001 inch)
Taper (Max.) ........................................................................................................................................
........................................ 0.0254 mm (0.001 inch)
Component Information > Specifications > Dimensions > Page 1302
Crankshaft: Specifications
Crankshaft Main Bearing Caps 85 ft.lb

Component Information > Service and Repair > Removal and Installation
Crankshaft: Service and Repair Removal and Installation
Location Of Crankshaft Identification
A crankshaft which has undersize journals will be stamped with 1/4 inch letters on the milled flat on
the No.3 crankshaft counterweight. FOR EXAMPLE: R2 stamped on the No.3 crankshaft
counterweight indicates that the No.2 rod journal is 0.025 mm (0.001 in) undersize. M4 indicates
that the No.4 main journal is 0.025 mm (0.001 in) undersize. R3 M2 indicates that the No.3 rod
journal and the No.2 main journal are 0.025 mm (0.001 in) undersize. When a crankshaft is
replaced, all main and connecting rod bearings should be replaced with new bearings. Therefore,
selective fitting of the bearings is not required when a crankshaft and bearings are replaced.
REMOVAL
1. Remove the oil pan. 2. Remove the oil pump from the rear main bearing cap. 3. Identify bearing
caps before removal. Remove bearing caps and bearings one at a time. 4. Lift the crankshaft out of
the block. 5. Remove and discard the crankshaft rear oil seals. 6. Remove and discard the front
crankshaft oil seal.
CLEANING
Clean Loctite 518 residue and sealant from the cylinder block and rear cap mating surface. Do this
before applying the Loctite drop and the installation of rear cap.
INSTALLATION
1. Lightly oil the new upper seal lips with engine oil. 2. Install the new upper rear bearing oil seal
with the white paint facing towards the rear of the engine. 3. Position the crankshaft into the
cylinder block. 4. Lightly oil the new lower seal lips with engine oil. 5. Install the new lower rear
bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine.
Sealant Application To Bearing Cap
6. Apply 5 mm (0.20 in) drop of Loctite 518, or equivalent, on each side of the rear main bearing
cap. DO NOT over apply sealant or allow the
sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after
sealant application.
Component Information > Service and Repair > Removal and Installation > Page 1305
7. To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than 2 times for proper engagement.
8. Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately
tighten to 115 Nm (85 ft. lbs.) torque. 9. Install oil pump.
10. Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (refer to
Oil Pan Replacement).
11. Install new front crankshaft oil seal. 12. Immediately install the oil pan.
Crankshaft: Service and Repair Cleaning and Inspection
INSPECTION OF JOURNALS
The crankshaft connecting rod and main journals should be checked for excessive wear, taper and
scoring. The maximum taper or out-of-round on any, crankshaft journal is 0.025 mm (0.001 inch).
Journal grinding should not exceed 0.305 mm (0.012 inch) under the standard journal diameter.
DO NOT grind thrust faces of No.3 main bearing. DO NOT nick crank pin or bearing fillets. After
grinding, remove rough edges from crankshaft oil holes and. clean out all oil passages.
CAUTION: After any journal grind, it is important that the final paper or cloth polish be in the same
direction as the engine rotates.
Crankshaft: Service and Repair Service Procedures
Location Of Crankshaft Identification
A crankshaft which has undersize journals will be stamped with 1/4 inch letters on the milled flat on
the No.3 crankshaft counterweight. FOR EXAMPLE: R2 stamped on the No.3 crankshaft
counterweight indicates that the No.2 rod journal is 0.025 mm (0.001 in) undersize. M4 indicates
that the No.4 main journal is 0.025 mm (0.001 in) undersize. R3 M2 indicates that the No.3 rod
journal and the No.2 main journal are 0.025 mm (0.001 in) undersize. When a crankshaft is
replaced, all main and connecting rod bearings should be replaced with new bearings. Therefore,
selective fitting of the bearings is not required when a crankshaft and bearings are replaced.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Engine Block Heater: Description and Operation
BLOCK HEATER
An optional engine block heater is available for all models. The heater is equipped with a power
cord that is located behind the grille. The cord is attached to an engine compartment component
with tie-straps. The heater warms the engine providing easier engine starting and faster warm-up in
low temperatures. The heater is mounted in a core hole of the engine cylinder block (in place of
freeze plug) with the heating element immersed in engine coolant. The power cord is located
behind the radiator grille. Connect the power cord to a grounded, 110-120 volt AC electrical outlet
with a grounded, three wire extension cord.
WARNING: DO NOT OPERATE ENGINE UNLESS BLOCK HEATER CORD HAS BEEN
DISCONNECTED FROM POWER SOURCE AND SECURED IN PLACE. THE POWER CORD
MUST BE SECURED IN ITS RETAINING CLIPS AND ROUTED AWAY FROM EXHAUST
MANIFOLDS AND MOVING PARTS.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Engine Block Heater: Service and Repair
REMOVAL
1. Disconnect negative battery cable at battery.
WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE
RADIATOR DRAIN PLUG WITH SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS
FROM COOLANT CAN OCCUR.
2. Drain coolant from radiator and cylinder block.
Engine Block Heater
3. Remove power cord from block heater. 4. Loosen screw at center of block heater. Remove block
heater assembly.
INSTALLATION
1. Thoroughly clean cylinder block core hole and block heater seat. 2. Insert block heater assembly
with element loop pointing down. 3. With block heater fully seated, tighten center screw to 2 Nm
(17 inch lbs.) torque. 4. Fill cooling system with recommended coolant.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug >
Expansion/Freeze Plug: Specifications
Pipe Plugs All ......................................................................................................................................

................................................... 34 Nm (25 ft. lbs.)
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug >
Expansion/Freeze Plug: Service and Repair
Location Of Cup Plugs In Oil Galleries
Engine core plugs have been pressed into the oil galleries behind the camshaft thrust plate . This
will reduce internal leakage and help maintain higher oil pressure at idle.
REMOVAL
Core Hole Plug Removal
1. Using a blunt tool such as a drift or a screwdriver and a hammer, strike the bottom edge of the
cup plug. 2. With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove
plug.
CLEANING
Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer.
Make certain the new plug is cleaned of all oil or grease.
INSTALLATION
1. Coat edges of plug and core hole with Mopar Gasket Maker, or equivalent.
CAUTION: DO NOT drive cup plug into the casting as restricted coolant flow can result and cause
serious engine problems.
2. Using proper plug drive, drive cup plug into hole. The sharp edge of the plug should be at least
0.50 mm (0.020 inch) inside the lead-in chamfer. 3. It is not necessary to wait for curing of the
sealant. The cooling system can be filled and the vehicle placed in service immediately.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer -
Crankshaft Pulley > Component Information > Specifications > Crankshaft Pulley
Harmonic Balancer - Crankshaft Pulley: Specifications Chrankshaft Pulley
Chrankshaft Pulley
Torque Specifications 24 Nm (210 in.lbs.)

Crankshaft Pulley > Component Information > Specifications > Crankshaft Pulley > Page 1320
Harmonic Balancer - Crankshaft Pulley: Specifications
Vibration Damper Bolt 135 ft.lb

Crankshaft Pulley > Component Information > Specifications > Page 1321
Harmonic Balancer - Crankshaft Pulley: Service and Repair
VIBRATION DAMPER
REMOVAL
1. Disconnect the negative cable from the battery. 2. Remove fan shroud retainer bolts and set
shroud back over engine. 3. Remove the cooling system fan. 4. Remove the serpentine belt. 5.
Remove the vibration damper pulley. 6. Remove vibration damper bolt and washer from end of
crankshaft.
Vibration Damper Assembly
7. Install bar and screw from Puller Tool Set C-3688. Install 2 bolts with washers through the puller
tool and into the vibration damper. 8. Pull vibration damper off of the crankshaft.
INSTALLATION
1. Position the vibration damper onto the crankshaft.
Installing Vibration Damper
2. Place installing tool, part of Puller Tool Set C-3688 in position and press the vibration damper
onto the crankshaft. 3. Install the crankshaft bolt and washer. Tighten the bolt to 183 Nm (135 ft.
lbs.) torque. 4. Install the crankshaft pulley. Tighten the pulley bolts to 23 Nm (200 inch lbs.) torque.
5. Install the serpentine belt. 6. Install the cooling system fan. Tighten the bolts to 23 Nm (17 ft.
lbs.) torque. 7. Position the fan shroud and install the bolts. Tighten the retainer bolts to 11 Nm (95
inch lbs.) torque. 8. Connect the negative cable to the battery.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Piston: Specifications
Clearance at Top of Skirt 0.0005 - 0.0015 in
Land Clearance (Diam.) 0.020 - 0.026 in
Ring Groove Depth (#1&2) 0.187 - 0.193 in
Ring Groove Depth (#3) 0.157 - 0.164 in
Piston Length 3.19 inch
Weight 20.53 - 20.67 oz (US)

Piston: Description and Operation
PISTONS
The pistons are elliptically turned so that the diameter at the pin boss is less than its diameter
across the thrust face. This allows for expansion under normal operating conditions. Under
operating temperatures, expansion forces the pin bosses away from each other, causing the piston
to assume a more nearly round shape. All pistons are machined to the same weight, regardless of
size, to maintain piston balance. The piston pin rotates in the piston only and is retained by the
press interference fit of the piston pin in the connecting rod.
Piston: Service and Repair Removal and Installation
REMOVAL
1. Remove the engine from the vehicle. 2. Remove the cylinder head. 3. Remove the oil pan. 4.
Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from
cylinder block. Be sure to keep tops of pistons
covered during this operation.
5. Be sure the connecting rod and connecting rod cap are identified with the cylinder number.
Remove connecting rod cap. Install connecting rod bolt
guide set on connecting rod bolts.

6. Pistons and connecting rods must be removed from top of cylinder block. When removing the
assemblies from the engine, rotate crankshaft so that
the connecting rod is centered in cylinder bore and at BDC. Be careful not to nick crankshaft
journals.
7. After removal, install bearing cap on the mating rod.
INSPECTION
Piston Measurements
Check the crankshaft connecting rod journal for excessive wear, taper and scoring. Check the
cylinder block bore for out-of-round, taper, scoring and scuffing. Check the pistons for taper and
elliptical shape before they are fitted into the cylinder bore.
NOTE: To fit pistons and rings refer to Fitting Pistons and/or Fitting Piston Rings.
INSTALLATION
1. Be sure that compression ring gaps are staggered so that neither is in-line with oil ring rail gap.
Proper Ring Installation
2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the
rail gaps located properly. 3. Immerse the piston head and rings in clean engine oil. Slide Piston
Ring Compressor Tool C-385 over the piston and tighten with the special
wrench (part of Tool C-385). Be sure position of rings does not change during this operation.
4. Install connecting rod bolt protectors on rod bolts, the long protector should be installed on the
numbered side of the connecting rod. 5. Rotate crankshaft so that the connecting rod journal is on
the center of the cylinder bore. Be sure connecting rod and cylinder bore number are the
same. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal.
6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide
connecting rod into position on crankshaft journal. 7. The notch or groove on top of piston must be
pointing toward front of engine. The larger chamfer of the connecting rod bore must be installed
toward crankshaft journal fillet.
8. Install rod caps. Be sure connecting rod, connecting rod cap and cylinder bore number are the
same. Install nuts on cleaned and oiled rod bolts and
tighten nuts to 61 Nm (45 ft. lbs.) torque.
9. Install the oil pan.
10. Install the cylinder head. 11. Install the engine into the vehicle.
Piston: Service and Repair Fitting Pistons
Piston Measurements
Piston and cylinder wall must be clean and dry Specified clearance between the piston and the
cylinder wall is 0.013-0.038 mm (0.0005-0.0015 inch) at 21°C (70°F). Piston diameter should be
measured at the top of skirt, 90° to piston pin axis location A. Cylinder bores should be measured
halfway down the cylinder bore and transverse to the engine crankshaft center line. Pistons and
cylinder bores should be measured at normal room temperature, 21°C (70°F).
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine >
Piston Pin: Specifications
Clearance in Piston 0.00023 - 0.00074 in
Diameter 0.9845 - 0.9848 in
End Play NONE
Length 2.67 - 3.69 in

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Piston Ring: Specifications
Ring Gap
Compression Ring (Top) 0.012 - 0.022 in
Compression Ring (2nd) 0..022 - 0.031 in
Oil Ring (Steel Rails) 0.015 - 0.055 in
Ring Side Clearance
Compression Rings 0.0016 - 0.0033 in
Oil Ring (Steel Rails) 0.002 - 0.008 in

Ring Width
Compression Rings 0.060 - 0.061 in
Oil Ring (Steel Rails) - Max. 0.018 - 0.019 in

Piston Ring: Service and Repair
1. Measurement of end gaps:
a. Measure piston ring gap 2 inches from bottom of cylinder bore. An inverted piston can be used
to push the rings down to ensure positioning
rings squarely in the cylinder bore before measuring.
b. Insert feeler gauge in the gap. The top compression ring gap should be between 0.254-0.508
mm (0.010-0.020 inch). The second compression
ring gap should be between 0.508-0.762 mm (0.020-0.030 inch). The oil ring gap should be
0.254-1.270 mm (0.010-0.050 inch).
c. Rings with insufficient end gap may be properly filed to the correct dimension. Rings with excess
gaps should not be used.
2. Install rings and confirm ring side clearance:
a. Install oil rings being careful not to nick or scratch the piston. Install the oil control rings
according to instructions in the package. It is not
necessary to use a tool to install the upper and lower rails. Insert oil rail spacer first, then side rails.
Top Compression Ring Identification (Typical)
Compression Ring Chamfer Location (Typical)
b. Install the second compression rings using Installation Tool C-4184. The compression rings must
be installed with the identification mark face
up (toward top of piston) and chamfer facing down. An identification mark on the ring is a drill point,
a stamped letter "O", an oval depression or the word TOP.
Second Compression Ring Identification (Typical)

Proper Ring Installation
c. Using a ring installer, install the top compression ring with the chamfer facing up. An
identification mark on the ring is a drill point, a stamped
letter "O", an oval depression or the word TOP facing up.
d. Measure side clearance between piston ring and ring land. Clearance should be 0.074-0.097
mm (0.0029-0.0038 inch) for the compression
rings. The steel rail oil ring should be free in groove, but should not exceed 0.246 mm (0.0097 inch)
side clearance.
e. Pistons with insufficient or excessive side clearance should be replaced.

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance >
System Information > Specifications
times.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair
cylinder chamber.
battery.

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Rocker Arm Assembly: Specifications
Rocker Arm Bolts 21 ft.lb

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Rocker Arm Assembly: Service and Repair
REMOVAL
Rocker Arms
INSTALLATION

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Valve Cover: Service and Repair Removal and Installation
CYLINDER HEAD COVER
Cylinder Head Cover Gasket
NOTE: A steel backed silicon gasket is used with the cylinder head cover. This gasket can be used
again.
REMOVAL
1. Disconnect the negative cable from the battery. 2. Disconnect closed ventilation system and
evaporation control system from cylinder head cover. 3. Remove cylinder head cover and gasket.
The gasket may be used again.
CLEANING
Clean cylinder head cover gasket surface. Clean head rail, if necessary.
INSTALLATION
1. The cylinder head cover gasket can. be used again. Install the gasket onto the head rail.. 2.
Position the cylinder head cover onto the gasket. Tighten the bolts to 11 Nm (95 inch lbs.) torque.
3. Install closed crankcase ventilation system and evaporation control system. 4. Connect the
negative cable to the battery.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Valve Cover: Service and Repair Cleaning and Inspection
CYLINDER HEAD COVER
A steel-backed silicone gasket is used with the cylinder head cover. This gasket is reuseable.
Cylinder Head Cover Gasket
A steel backed silicon gasket is used with the cylinder head cover. This gasket can be used again.
CLEANING
Clean cylinder head cover gasket surface. Clean head rail, if necessary.
INSPECTION
Inspect cover for distortion and straighten, if necessary. Check the gasket for use in head cover
installation. If damaged, use a new gasket.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide >
Valve Guide: Specifications
Guide Bore 0.313 - 0.314 in

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Valve Seat: Specifications
Angle 44.25 - 44.75 deg
Runout (Max) 0.003 in
Width (Finish) - Intake 0.040 - 0.060 in
Width (Finish) - Exhaust 0.060 - 0.080 in

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Valve Seat: Service and Repair
For information regarding valve seat regrinding, please refer to Valve, Intake/Exhaust; Service and
Repair
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Valve Spring: Specifications
Free Lenght 1.967 in
Spring Tension (valve closed) 85 lbf at 1.64 in
Spring Tension (valve open) 200 lbf at 1.212 in
Installed Height 1.64 in
Number of Coils 6.8
Wire Diameter 0.177 in

Component Information > Service and Repair > Cylinder Head Off
Valve Spring: Service and Repair Cylinder Head Off
Refer to Valves, Intake/Exhaust, Service and Repair for procedure.

Component Information > Service and Repair > Cylinder Head Off > Page 1366
Valve Spring: Service and Repair Cylinder Head On
1. Remove the air cleaner. 2. Remove cylinder head covers and spark plugs. 3. Remove coil wire
from distributor and secure to good ground to prevent engine from starting. 4. Using suitable socket
and flex handle at crankshaft retaining bolt, turn engine so the No.1 piston is at TDC on the
compression stroke. 5. Remove rocker arms. 6. With air hose attached to an adapter installed in
No.1 spark plug hole, apply 620-689 kPa (90-100 psi) air pressure. 7. Using Valve Spring
Compressor Tool MD-998772A with adaptor 6716A, compress valve spring and remove retainer
valve locks and valve
spring.
8. Install seals on the exhaust valve stem and position down against valve guides. 9. The intake
valve stem seals should be pushed firmly and squarely over the valve guide using the valve stem
as a guide. DO NOT force seal against
top of guide. When installing the valve retainer locks, compress the spring only enough to install
the locks.
10. Follow the same procedure on the remaining 7 cylinders using the firing sequence
1-8-4-3-6-5-7-2. Make sure piston in cylinder is at TDC on the
valve spring that is being removed.
11. Remove adapter from the No.1 spark plug hole. 12. Install rocker arms. 13. Install covers and
coil wire to distributor. 14. Install air cleaner. 15. Road test vehicle.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Valve: Specifications
Face Angle 43.25 - 43.75 deg
Head Diameter - Intake 1.88 in
Head Diameter - Exhaust 1.617 in
Length (Overall) - Intake 4.969 - 4.994 in
Lenght (Overall) - Exhaust 4.978 - 5.012 in
Stem Diameter - Intake 0.372 - 0.373 in
Stem Diameter - Exhaust 0.371 - 0.372 in

Stem to Guide Clearance - Intake 0.001 - 0.003 in
Stem to Guide Clearance - Exhaust 0.002 - 0.004 in
Service Limit ( Rocking Methood) 0.017 in

Valve: Description and Operation
VALVES AND VALVE SPRINGS
The valves are arranged in-line and inclined 18°. The rocker pivot support and the valve guides are
cast integral with the heads.
Valve: Service and Repair Removal and Installation
VALVES AND VALVE SPRINGS-HEAD REMOVED
REMOVAL 1. Remove the cylinder head. 2. Compress valve springs using Valve Spring
Compressor Tool MD- 998772A and adaptor 6716A. 3. Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs. 4. Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the valve guides. Identify valves to ensure
installation in original location.
VALVE CLEANING Clean valves thoroughly. Discard burned, warped and cracked valves. Remove
carbon and varnish deposits from inside of valve guides with a reliable guide cleaner.
INSTALLATION 1. Coat valve stems with lubrication oil and insert them in cylinder head. 2. If
valves or seats are reground, check valve stem height. If valve is too long, replace cylinder head. 3.
Install new seals on all valve guides. Install valve springs and valve retainers. 4. Compress valve
springs with Valve Spring Compressor Tool MD-998772A and adaptor 6716A, install locks and
release tool. If valves and/or
seats are ground, measure the installed height of springs. Make sure the measurement is taken
from bottom of spring seat in cylinder head to the bottom surface of spring retainer. If spacers are
installed, measure from the top of spacer. If height is greater than 42.86 mm (1-11/16 inches),
install a 1.587 mm (1/16 inch) spacer in head counterbore. This should bring spring height back to
normal 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).
Valve: Service and Repair Valve Service
VALVE CLEANING
Clean valves thoroughly Discard burned, warped and cracked valves. Remove carbon and varnish
deposits from inside of valve guides with a reliable guide cleaner.
VALVE INSPECTION
Measure valve stems for wear. If wear exceeds 0.051 mm (0.002 inch), replace the valve.
REFACING VALVES AND VALVE SEATS
Valve Face And Seat Angles
The intake and exhaust valves have a 43-1/4° to 43-3/4° face angle and a 44-1/4° to 44-3/4° seat
angle.
VALVES
Intake And Exhaust Valves
Inspect the remaining margin after the valves are refaced. Valves with less than 1.190 mm (0.047
inch) margin should be discarded.
VALVE GUIDES
Measure valve stem guide clearance as follows:

Positioning Valve With Tool C-3973
1. Install Valve Guide Sleeve Tool C-3973 over valve stem and install valve. The special sleeve
places the valve at the correct height for checking
with a dial indicator.
Measuring Valve Guide Wear
2. Attach Dial Indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being
measured.
Reamer Sizes
3. Move valve to and from the indicator. The total dial indicator reading should not exceed 0.432
mm (0.017 inch). Ream the guides for valves with
over-size stems if dial indicator reading is excessive or if the stems are scuffed or scored. Service
valves with oversize stems are available. Slowly turn reamer by hand and clean guide thoroughly
before installing new valve. Ream the valve guides from standard to 0.381 mm (0.015 inch). Use a
2 step procedure so the valve guides are reamed true in relation to the valve seat: ^
Step 1-Ream to 0.0763 mm (0.003 inch).
^ Step 2-Ream to 0.381 mm (0.015 inch).
VALVE SEATS
Refacing Valve Seats
CAUTION: DO NOT un-shroud valves during valve seat refacing.
1. When refacing valve seats, it is important that, the correct size valve guide pilot be used for
reseating stones. A true and complete surface must be
obtained.
2. Measure the concentricity of valve seat using a. dial indicator. Total runout should not exceed
0.051 mm (0.002 inch) total indicator reading. 3. Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian
blue
then set valve in place. Rotate the valve with light, pressure. If the blue is transferred to the center
of valve face, contact is satisfactory. If the blue is transferred to the top edge of valve face, lower
valve seat, with a 15° stone. If the blue is transferred to bottom edge of valve face raise valve seat
with a 60° stone.
4. When seat is properly positioned the width of intake seats should be 1.016-1.524 mm
(0.040-0.060 inch). The width of the exhaust seats should be
1.524-2.032 mm (0.060-0.080 inch).
VALVE SPRING INSPECTION
Testing Valve Spring For Compression Length
Whenever valves have been removed for inspection, reconditioning or replacement, valve springs
should be tested. As an example the compression length of the spring to be tested is 1-5/16 inch.
Turn table of Universal Valve Spring Tester Tool until surface is in line with the 1-5/16 inch mark on
the threaded stud. Be sure the zero mark is to the front. Place spring over stud on the table and lift
compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on
torque wrench at this instant. Multiply this reading by 2. This will give the spring load at test length.
Fractional measurements are indicated on the table for finer adjustments. Refer to specifications to
obtain specified height and allowable tensions. Discard the springs that do not meet specifications.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Diagrams

Drive Belt > Component Information > Diagrams > Page 1380
Drive Belt: Description and Operation
ACCESSORY DRIVE BELT/TENSION
An automatic belt tensioner is used to maintain correct belt tension at all times. Correct accessory
drive belt tension is required to be sure of optimum performance of belt driven engine accessories.
If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power
steering assist, loss of air conditioning capacity, reduced generator output rate and greatly reduced
belt life. It is not necessary to adjust belt tension on any engine. All engines are equipped with an
automatic belt tensioner. The tensioner maintains correct belt tension at all times. Due to use of
this belt tensioner, do not attempt to use a belt tension gauge on any engine.
Drive Belt: Testing and Inspection
VISUAL DIAGNOSIS
Belt Ware Patterns
When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface
of the belt from rib to rib, are considered normal. These are not a reason to replace the belt.
However, cracks running along a rib (not across) are not normal. Any belt with cracks running
along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe
glazing. Refer to the Accessory Drive Belt Diagnosis charts for further belt diagnosis.
NOISE DIAGNOSIS
Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to
resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or
excessive end play.
ACCESSORY DRIVE BELT DIAGNOSIS CHART

Drive Belt: Service and Repair
ACCESSORY DRIVE BELT
An automatic belt tensioner is used to maintain correct belt tension at all times.
REMOVAL
1. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 2. Rotate tensioner

assembly clockwise (as viewed from front) until tension has been relieved from belt. 3. Remove
belt from idler pulley first. 4. Remove belt from vehicle.
INSTALLATION
CAUTION: When installing "serpentine" accessory drive belt, belt must be routed correctly. If not,
engine may overheat due to water pump rotating in wrong direction. The correct belt with correct
length must be used.
schematics on Belt Routing Label. This label is located in the engine compartment. 1. Position
drive belt over all pulleys except idler pulley. This pulley is located between generator and A/C
compressor. 2. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 3. Rotate
socket/wrench clockwise. Place belt over idler pulley. Let tensioner rotate back into place. Remove
wrench. Be sure belt is properly seated
on all pulleys.
4. Check belt indexing marks. 5. The tensioner is equipped with an indexing arrow on back of
tensioner and an indexing mark on tensioner housing. If a new belt is being installed,
arrow must be within approximately 3 mm (1/8 in.) of indexing mark (Point B). Belt is considered
new if it has been used 15 minutes or less. If this specification cannot be met, check for:
^ The wrong belt being installed (incorrect length/ width)
^ Worn bearings on an engine accessory (A/C compressor, power steering pump, water pump,
idler pulley or generator)
^ A pulley on an engine accessory being loose
^ Misalignment of an engine accessory
^ Belt incorrectly routed. A used belt should be replaced if tensioner indexing arrow has moved
beyond point A.
Drive Belt Tensioner > Component Information > Specifications
Drive Belt Tensioner: Specifications
Belt Tensioner Pulley 45 ft.lb
Belt Tensioner to Bracket 50 ft.lb

Drive Belt Tensioner > Component Information > Specifications > Page 1388
Drive Belt Tensioner: Description and Operation
AUTOMATIC BELT TENSIONER
Drive belts on all engines are equipped with a spring loaded automatic belt tensioner. This belt
tensioner will be used with all belt configurations, such as with or without power steering or air
conditioning.
Drive Belt Tensioner > Component Information > Specifications > Page 1389
Drive Belt Tensioner: Service and Repair
REMOVAL
1. Remove accessory drive belt. 2. Disconnect wiring and secondary cable from ignition coil. 3.
Remove ignition coil from coil mounting bracket (two bolts). Do not remove coil mounting bracket
from cylinder head. 4. Remove tensioner assembly from mounting bracket (one nut).
WARNING: BECAUSE OF HIGH SPRING PRESSURE, DO NOT ATTEMPT TO DISASSEMBLE

AUTOMATIC TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY (EXCEPT FOR PULLEY).
5. Remove pulley bolt. Remove pulley from tensioner.
INSTALLATION
1. Install pulley and pulley bolt to tensioner. Tighten bolt to 61 Nm (45 ft. lbs.). 2. Install tensioner
assembly to mounting bracket. An indexing tab is located on back of tensioner. Align this tab to slot
in mounting bracket. Tighten
nut to 67 Nm (50 ft. lbs.) torque.
3. Connect all wiring to ignition coil. 4. Install coil to coil bracket. If nuts and bolts are used to
secure coil to coil bracket, tighten to 11 Nm (100 inch lbs.) torque. If coil mounting
bracket has been tapped for coil mounting bolts, tighten bolts to 5 Nm (50 inch lbs.) torque.
CAUTION: To prevent damage to coil case, coil mounting bolts must be torqued.
5. Install drive belt.
6. Check belt indexing marks.

Engine Mount > Component Information > Specifications
Engine Mount: Specifications
Insulator Bracket to Block (Front) 30 ft.lb
Insulator to Bracket/Crossmember (Front) 75 ft.lb

Engine Mount > Component Information > Specifications > Page 1393
Engine Mount: Service and Repair
REMOVAL
1. Raise hood and position fan to assure clearance for radiator top tank and hose. 2. Disconnect
the negative cable from the battery.
CAUTION: DO NOT lift the engine by the intake manifold.
3. Install engine lifting fixture. 4. Raise vehicle on hoist.
Front Mounts-Right Side
Front Mounts-Left Side
5. Remove nuts from brackets and insulators. 6. Raise engine with support fixture only far enough
to remove insulators.
INSTALLATION
1. If removed, install the engine mounting bracket to the cylinder block. Tighten the bolts to 88 Nm
(65 ft. lbs.) torque. 2. With engine raised SLIGHTLY, install insulators. 3. Lower engine with support
fixture while guiding insulator studs into attaching holes in crossmember and brackets. 4. Tighten
the attaching nuts to 102 Nm (75 ft. lbs.) torque.
Engine Mount > Component Information > Specifications > Page 1394
5. Lower the vehicle. 6. Remove engine support fixture.
Idler Pulley > Component Information > Specifications
Idler Pulley: Specifications
Idler Pully 45 ft.lb

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Engine Oil Pressure: Specifications
OIL PRESSURE
@ Curb Idle (Min.*) ..............................................................................................................................

................................................... 41.4 kPa (6 psi) @ 3000 rpm ..........................................................
................................................................................................................... 207 - 552 kPa (30 - 80
psi) Bypass Valve Setting ....................................................................................................................
............................................... 62 - 103 kPa (9 - 15 psi) Switch Actuating pressure
.........................................................................................................................................................
34.5 - 48.3 kPa (5 - 7 psi)
CAUTION: If oil pressure is zero at curb idle, DO NOT RUN ENGINE.

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick
Tube > Component Information > Description and Operation
Engine Oil Dip Stick - Dip Stick Tube: Description and Operation
OIL LEVEL INDICATOR (DIPSTICK)
Engine Oil Dipstick Location
The engine oil level indicator is located at the right front of the engine, left of the generator.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug >
Engine Oil Drain Plug: Specifications
Oil Drain Plug 25 ft.lb

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil
Without Filter Change ..........................................................................................................................

............................................................. 4.2L (4.5 Qt)
Capacity shown is without filter. When replacing filter, additional oil may be needed
Information > Specifications > Capacity Specifications > Page 1412
Engine Oil: Fluid Type Specifications
Engine Oil
API Classification .................................................................................................................................

........................................... SH or SH/CD or Above Above 0°F (-18°C)..............................................
........................................................................................................................................................
10W-30 Below 32°F (0°C)....................................................................................................................
..................................................................................... 5W-30
Engine Oil: Service Precautions
WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID
PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED
ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR
HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN
RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR
DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR
AREA.
Engine Oil: Description and Operation
ENGINE OIL SPECIFICATION.
CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Engine Oil Container Standard Notations

Use an engine oil that is API Service Grade Certified. Standard engine oil identification notations
have been adopted to aid in the proper selection of engine oil. The identifying notations are located
on the label of engine oil plastic bottles and the top of engine oil cans.
SAE VISCOSITY
Temperature/Engine Oil Viscosity
An SAE viscosity grade is used to specify the viscosity of engine oil. SAE 1OW-30 specifies a
multiple viscosity engine oil. When choosing an engine oil, consider the range of temperatures the
vehicle will be operated in before the next oil change. Select an engine oil that is best suited to your
area's particular ambient temperature range and variation.
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY
CON-SERVING is located on the label of an engine oil container.
Engine Oil: Testing and Inspection
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result. To
ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level.
The acceptable oil level is in the SAFE RANGE on the engine oil dipstick. 1. Position vehicle on
level surface. 2. With engine OFF, allow approximately ten minutes for oil to settle to bottom of
crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Install dipstick and verify it is
seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add
oil only if level is below the SAFE RANGE area on the dipstick.
ENGINE OIL PRESSURE
1. Remove oil pressure sending unit. 2. Install Oil Pressure Line and Gauge Tool C-3292. Start
engine and record pressure. Refer to Oil Pressure in Engine Specifications for the proper
pressures.
Engine Oil: Service and Repair
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals described in the Maintenance Schedule.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface
and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a
suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to
drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug
and gasket if damaged.
6. Install drain plug in crankcase. 7. Lower vehicle and fill crankcase with specified type and
amount of engine oil described. 8. Install oil fill cap. 9. Start engine and inspect for leaks.
10. Stop engine and inspect oil level.
USED ENGINE OIL DISPOSAL
Care should be exercised when disposing used engine oil after it has been drained from a vehicle
engine.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component
Oil Filter: Specifications
Oil Filter Connector 50 ft.lb

Oil Filter: Description and Operation
FILTER SPECIFICATION
All Dodge Ram engines are equipped with a high quality full-flow, disposable type oil filter. Chrysler
Corporation recommends a Mopar or equivalent oil filter be used.
Oil Filter: Service and Repair
OIL FILTER REMOVAL
1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench loosen filter.
Oil Filter Removal-Typical
3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss. 4. When
filter separates from adapter nipple, tip gasket end upward to minimize oil spill. Remove filter from
vehicle.
Oil Filter Sealing Surface-Typical

5. With a wiping cloth, clean the gasket sealing surface of oil and grime.
OIL FILTER INSTALLATION
1. Lightly lubricate oil filter gasket with engine oil or chassis grease. 2. Thread filter onto adapter
nipple. When gasket makes contact with sealing surface, hand tighten filter one full turn, do not
over tighten. 3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Oil Pan: Specifications
Oil Pan Bolts 215 in.lb
Oil Pan Drain Plugs 25 ft.lb

Oil Pan: Service and Repair
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine oil dipstick. 3. Remove air cleaner inlet
duct. 4. Unbolt the engine controller from the cowl and secure out of the way. DO NOT
DISCONNECT. 5. Remove upper cooling fan shroud fasteners. 6. Remove engine cover. 7. Raise
vehicle on hoist. 8. Drain engine oil. 9. Remove transmission oil cooler lines from the oil pan
mounting clip.
10. Remove engine to transmission. support braces. 11. Remove starter motor. 12. Remove
transmission inspection cover.
Engine Mount Insulator-Right Side
Engine Mount Insulator-Left Side
13. Remove left and right engine mount insulator nuts. 14. Remove the oil pan fasteners.
15. Remove the oil pan from the vehicle. Note: The crankshaft may have to be rotated for the oil
pan to clear the #1&2 journal counterweight on
removal.
CLEANING
1. Clean the cylinder block and oil pan mating surfaces. 2. Trim or remove excess sealant film in
the rear main cap oil pan gasket groove. DO NOT remove the sealant inside the rear main cap
slots. 3. If present, trim excess sealant from inside the engine. Clean oil pan in solvent and wipe
dry with a clean cloth. Clean oil screen and pipe
thoroughly in clean solvent. Inspect condition of the screen.
INSPECTION
1. Inspect the oil pan drain plug and hole for, stripped or damaged threads. Repair as necessary. 2.
Inspect oil pan mounting flange for bends or distortion. Straighten flange, if necessary.
INSTALLATION
Fabrication Of Alignment Dowels
1. Fabricate four alignment dowels from 5/16 x 1 1/2 inch bolts. Cut the head off the bolts and cut a
slot into the top of the dowel. This will allow
easier installation and removal with a screwdriver.
Position Of Dowels In Cylinder Block
2. Install the dowels in the cylinder block. 3. Apply a small amount of Mopar Silicone Rubber
Adhesive Sealant, or equivalent in the comer of the cap and the cylinder block. 4. Slide the one
piece gasket over the dowels and onto the block. 5. Position the oil pan over the dowels and onto
the gasket. 6. Install the oil pan bolts. Tighten the bolts to 24 Nm (215 inch lbs.). 7. Remove the
dowels. Install and tighten the remaining pan bolts to 24 Nm (215 inch lbs.). 8. Install and tighten
the oil pan drain plug to 34 Nm (25 ft. lbs.). 9. Lower the engine while aligning the engine mount
insulators with the brackets.
10. Install the mount insulator nuts and tighten to 102 Nm (75 ft. lbs.). 11. Install the transmission
inspection cover. 12. Install the starter motor.
13. Install the engine to transmission support brackets. 14. Install the transmission oil cooler lines
into the mounting clips. 15. Lower the vehicle. 16. Install the upper cooling fan shroud. 17. Fasten
the controller to the cowl. 18. Install the air cleaner inlet duct. 19. Install the engine oil dipstick. 20.
Fill the crankcase with engine oil. 21. Connect the battery negative cable. 22. Start engine and
check for leaks.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge >
Oil Pressure Gauge: Description and Operation
SYSTEM OPERATION
The oil pressure gauge gives an indication of the engine oil pressure. The instrument cluster
circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper
gauge pointer position based upon engine oil pressure messages received from the Powertrain
Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus.
The PCM uses an input from the engine oil pressure sensor and internal programming to decide
what engine oil pressure messages are required. The PCM then sends the proper messages to the
instrument cluster on the CCD data bus. If the PCM messages indicate that oil pressure is too low,
the instrument cluster circuitry moves the gauge needle to the 0 PSI graduation on the gauge face,
turns on the Check Gauges lamp, and sends a chime tone request to the Central Timer Module
(CTM). If the PCM messages indicate that oil pressure is too high, the instrument cluster circuitry
moves the gauge needle to the 110 PSI graduation on the gauge face.
The engine oil pressure sensor is installed in a threaded hole that penetrates an oil passage of the
engine. The engine oil pressure sensor contains a flexible diaphragm and a variable resistor coil.
The diaphragm moves in response to changes in the engine oil pressure, which changes the
internal electrical resistance of the sensor.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge >
Oil Pressure Gauge: Testing and Inspection
If the problem being diagnosed is related to oil pressure gauge accuracy, be certain to confirm that
the problem is with the gauge and not with the engine oiling system performance. The actual
engine oil pressure should be checked with a test gauge and compared to the instrument cluster oil
pressure gauge readings before you proceed with gauge diagnosis.

INJURY.
NOTE: Increased oil pressure gauge needle activity may be noted with this instrument cluster than
with previous designs. This increased needle activity is due to changes that were made to the
instrument cluster software that are intended to make the gauge more responsive, and not due to
any problem with the engine oiling or oil pressure gauge systems. No attempt at service of these
systems should be made, unless the oil pressure gauge readings remain in the high end or the low
end of the normal range.
Diagnosis of the oil pressure sensor and circuit, the Chrysler Collision Detection (CCD) data bus,
and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For
further diagnosis of the oil pressure gauge and the instrument cluster circuitry, see Instrument
Cluster in the Diagnosis and Testing.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor >
Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions
NUMBER: 26-01-99C
DATE: January, 1999

Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 1440
vi

538

589
589A
589B
589C
589D
589E
589F
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Cover > Component
Oil Pump Cover: Specifications
Oil Pump Cover Bolts 95 in.lb

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications
OIL PRESSURE
@ Curb Idle (Min.*) ..............................................................................................................................

................................................... 41.4 kPa (6 psi) @ 3000 rpm ..........................................................
................................................................................................................... 207 - 552 kPa (30 - 80
psi) Bypass Valve Setting ....................................................................................................................
............................................... 62 - 103 kPa (9 - 15 psi) Switch Actuating pressure
.........................................................................................................................................................
34.5 - 48.3 kPa (5 - 7 psi)
CAUTION: If oil pressure is zero at curb idle, DO NOT RUN ENGINE.

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Technical Service Bulletins > Customer Interest for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil
Consumption
Intake Manifold: Customer Interest Engine - Spark Knock/Oil Consumption
NUMBER: 09-05-00
GROUP: Engine
DATE: Feb.25, 2000
MODELS: 1994 - 1999
(AB) Ram Van
1994 - 1999 (AN) Dakota
1994 - 1999 (BRIBE) Ram Truck
1998 - 1999 (DN) Durango
1996 - 1998 (ZG) Grand Cherokee
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-06-99, DATED SEP.10,

1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION
AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
SUBJECT: Spark Knock And Engine Oil Consumption Due To Intake Manifold Pan Gasket Oil
Leak
OVER VIEW: This bulletin involves the replacement of the engine intake manifold plenum pan
gasket.
NOTE:
THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH A 3.9L, 5.2L. OR 5.9L GASOLINE
ENGINE.
SYMPTOM/CONDITION: An engine intake manifold plenum pan gasket oil leak may occur on
some V-6 and V-8 style engines. The oil leak is internal to the engine so no external oil leakage will
be present. Two symptoms of this oil leak condition may be present. The vehicle operator may
experience an engine spark knock during acceleration and/or an increase in the amount of engine
oil consumed by the engine.
DIAGNOSIS: Make sure Technical Service Bulletin (TSB) 18-48-98 has been performed.
NOTE:
IT IS IMPORTANT THAT THE COIL AND SPARK PLUG WIRES ARE ROUTED EXACTLY AS
SPECIFIED IN TSB 18-48-98 TO ACHIEVE THE MOST BENEFIT.
Inspect the Positive Crankcase Ventilation (PCV) valve. Shake the PCV valve to verify that the
pintle inside of the PCV valve is free. Replace the PVC if the pintle is not free.
If the intake manifold plenum pan gasket is leaking, an additional vacuum source will be created
inside of the engine at the location of the pan gasket leakage. Engine combustion blow-by gases,
oil vapor, and air from the crankcase filter/breather may be drawn past the leaking pan gasket and
into the intake manifold. In most cases when this condition occurs, an engine at idle will create the
highest vacuum and lowest amount of engine blow-by.
1. Allow the engine to reach normal operating temperature.
2. Stop the engine.

3. Disconnect the breather hose from the air cleaner.
Consumption > Page 1464
4. Attach a vacuum/pressure gauge to the end of the breather hose (Figure 1).
5. Disconnect the PCV valve hose from the intake manifold.
6. Seal off the intake manifold PCV valve hose port opening.
7. Seal off the open end of the PCV valve hose (Figure 2).
NOTE:
DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP

PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO THE NORMAL PROCESS
OF EXHAUST BLOW-BY GASES LEAKING PAST THE ENGINE PISTON RINGS AND
ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7
kpa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING
DIAGNOSTIC PROCEDURE.
8. Start the warmed engine and observe the vacuum gauge.

9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3 psi (20.7 kPa)
of pressure to develop in the engine crankcase.
10. If the attached vacuum / pressure gauge does not indicate that a vacuum is present in the
engine crankcase, then the intake manifold plenum pan gasket is good and no further internal
engine vacuum leak diagnosis is required.
11. If an internal vacuum leak is present then perform the Repair Procedure.
PARTS REQUIRED: For the 5.2L / 5.9L:
1 04897383AC Package, Intake Manifold Flange Gasket and Bolts
1 05017208AA Gasket, Intake Manifold Plenum Pan
15 06034583 Bolt, Intake Manifold Plenum Pan
1 53030541 Gasket, Throttle Body
2(AR) 04318001 Conditioner, Combustion Chamber
For the 3.9L:

2(AR)04318001 Conditioner, Combustion Chamber
REPAIR PROCEDURE:
1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation
instructions.
NOTE:
CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE
INTAKE MANIFOLD PLENUM CHAMBER.
NOTE:
THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE
FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE
MANIFOLD FLANGE BOLTS.
3.9L Bolt Tightening Sequence and Torque Procedure:
3.9 Plenum Pan Bolt Torque Procedure
3.9 Intake Manifold Flange Bolt Torque Procedure

5.2L / 5.9L Plenum Bolt Tightening Sequence and Torque Procedure:
5.2L / 5.9L Plenum Pan Bolt Torque Procedure
5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure
2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to
TSB 09-48-98 for additional assistance.
3. Start the engine and allow it to warm to normal engine operating temperature.
4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n
04318001) per the instructions.
NOTE:
ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2
TO 2.5 HOURS.
NOTE:
A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE

REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE
PLENUM PAN GASKET.
5. Verify proper engine oil level.
Time Allowance
FAILURE CODE: P8- New Part

Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark
Knock/Oil Consumption
Intake Manifold: All Technical Service Bulletins Engine - Spark Knock/Oil Consumption
NUMBER: 09-05-00
GROUP: Engine
DATE: Feb.25, 2000
MODELS: 1994 - 1999
(AB) Ram Van
1994 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango

Leak
gasket.
NOTE:
ENGINE.
NOTE:
2. Stop the engine.

Knock/Oil Consumption > Page 1474
NOTE:


For the 3.9L:

REPAIR PROCEDURE:
instructions.
NOTE:
NOTE:

NOTE:
TO 2.5 HOURS.
NOTE:

PLENUM PAN GASKET.
Time Allowance

Intake Manifold: Specifications
PLENUM PAN BOLTS
Tighten the bolts, in sequence, as follows: ^
Step 1-Tighten bolts to 2.7 Nm (24 inch lbs.) torque.
^ Step 2-Tighten bolts to 5.4 Nm (48 inch lbs.) torque.
^ Step 4-Check that all bolts are tighten to 9.5 Nm (84 inch lbs.) torque.
MANIFOLD BOLTS
Install the intake manifold bolts and tighten as follows: ^
Step 1-Tighten bolts 1 through 4, in sequence, to 8 Nm (72 inch lbs.) torque. Tighten in alternating
steps 1.4 Nm (12 inch lbs.) torque at a time.
^ Step 2-Tighten bolts 5 through 12, in sequence, to 8 Nm (72 inch lbs.) torque.
^ Step 3-Check that all bolts are tighten to 8 Nm (72 inch lbs.) torque.
^ Step 4-Tighten all bolts, in sequence, to 16 Nm (12 ft. lbs.) torque.
^ Step 5-Check that all bolts are tighten to 16 Nm (12 ft. lbs.) torque.
Intake Manifold: Description and Operation
INTAKE MANIFOLD
The aluminum intake manifold is a single plane design with equal length runners. The manifold is
sealed by flange side gaskets with front and rear cross-over gaskets.
Intake Manifold: Testing and Inspection
INTAKE MANIFOLD DIAGNOSIS
An intake manifold leak is characterized by lower than normal manifold vacuum. Also, one or more
cylinder may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT PUT
YOUR HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR LOOSE
CLOTHING.
1. Start the engine allowing it to warm up. 2. Inspect for disconnected vacuum hoses or hardened
or cracked vacuum lines. 3. With a spray bottle, spray a small stream of water on the suspect area.
4. If there is a change in RPM'S, the suspected leak has been found. 5. Repair as required.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection
Intake Manifold: Service and Repair Cleaning and Inspection
CLEANING
Clean manifold in solvent and blow dry with compressed air. Clean cylinder block front and rear
gasket surfaces using a suitable solvent. The plenum pan rail must be clean and dry (free of all
foreign material).
INSPECTION
Inspect manifold for cracks. Inspect mating surfaces of manifold for flatness with a straightedge.
and Repair > Cleaning and Inspection > Page 1484
Intake Manifold: Service and Repair Intake Manifold Replacement
REMOVAL
1. Disconnect the battery negative cable. 2. Drain the cooling system. 3. Remove the engine cover.
4. Remove the air cleaner. 5. Remove the generator. 6. Disconnect the accelerator linkage and if
so equipped, the speed control and transmission kickdown cables. 7. Remove the distributor. Refer
to Powertrain Management for the correct procedure. 8. Disconnect and remove the oil pressure
sending unit. 9. Disconnect the coolant temperature sending unit(s).
10. Disconnect the injector harness and secure out of the way. 11. Disconnect the IAC, MAP, and
TPS connectors from the throttle body. 12. Disconnect the heater hoses and bypass hose. 13.
Disconnect the vacuum supply hoses from the intake manifold. 14. Preform the Fuel System
Pressure Release procedure (refer to Powertrain Management). 15. Disconnect the fuel supply
line. 16. Remove intake manifold bolts. 17. Lift the intake manifold and throttle body out of the
engine compartment as an assembly. 18. Remove and discard the flange side gaskets and the
front and rear cross-over gaskets.
Throttle Body Assembly-MPI
19. Remove the throttle body bolts and lift the throttle body off the intake manifold. Discard the
gasket. 20. Remove the plenum pan as follows:
a. Turn the intake manifold upside down. Support the manifold. b. Remove the bolts and lift the pan
off the manifold. Discard the gasket.
INSTALLATION
1. Install the plenum pan, if removed, as follows:
a. Turn the intake manifold upside down. Support the manifold. b. Place a new plenum pan gasket
onto the seal rail of the intake manifold. Position the pan over the gasket. Align all the gasket and
pan holes
with the intake manifold.
c. Hand start all bolts. d. Tighten the bolts, in sequence, as follows:
V6 & V8 ENGINES
Plenum Pan Bolt Tightening Sequence
^ Step 4-Check that all bolts are tighten to 9.5 Nm (84 inch lbs.) torque.
^ Using a new gasket, install the throttle body, onto the intake manifold. Tighten the bolts to 23 Nm
(200 inch lbs.) torque.
Cross-Over Gaskets And Locator Dowels
3. Place the 4 plastic locator dowels into the holes in the block. 4. Apply Mopar Silicone Rubber
Adhesive Sealant, or equivalent, to the four corner joints. An excessive amount of sealant is not
required to ensure a
leak proof seal. However, an excessive amount of sealant; may reduce the effectiveness of the
flange gasket. The sealant should be slightly higher than the crossover gaskets, approx. 5 mm (0.2
in).
5. Install the front and rear cross-over gaskets into the dowels.
Intake Manifold Flange Gasket Alignment
6. Install the flange gaskets. Ensure that the vertical port alignment tab is resting on the deck face
of the block. Also the horizontal alignment tabs
must be in position with the mating cylinder head gasket tabs. The words MANIFOLD SIDE should
be visible on the center of each flange gasket.
7. Carefully lower intake manifold into position on the cylinder block and cylinder heads. Use the
alignment dowels in the cross-over gaskets to
position the intake manifold. After intake manifold is in place, inspect to make sure seals are in
place.
8. Install the intake manifold bolts and tighten as follows:
V-6 ENGINE
Intake Manifold Bolt Torque Sequence - (V-6)
^ Step 1-Tighten bolts 1 and 2 to 8 Nm (72 inch lbs.) torque. Tighten in alternating steps 1.4 Nm
(12 inch lbs.) torque at a time.
V-8 ENGINE
Intake Manifold Bolt Torque Sequence - (V-8)
^ Step 1-Tighten bolts I through 4, in sequence, to 8 Nm (72 inch lbs.) torque. Tighten in alternating
steps 1.4 Nm (12 inch lbs.) torque at a time.
9. Connect the vacuum supply hoses to the intake manifold.
10. Connect the fuel injector harness to the injectors. 11. Connect the coolant temperature sending
unit(s). 12. Connect the heater hoses and bypass hose. 13. Install the distributor assembly. Refer
to Powertrain Management for the correct procedure. 14. Install and connect the oil pressure
sending unit. 15. Connect the accelerator linkage and if so equipped, the speed control and
transmission kickdown cables. 16. Install the fuel supply line. 17. Connect the MAP, TPS, and IAC
connectors. 18. Install the generator and drive belt. Tighten generator mounting bolts to 41 Nm (30
ft. lbs.) torque. 19. Install the air cleaner. 20. Fill cooling system. 21. Connect the battery negative
cable. 22. Start engine and check for leaks. 23. Install the engine cover.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge
SYSTEM OPERATION
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge

INJURY.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Description and Operation
Crankshaft Main Bearing Seal: Description and Operation
CRANKSHAFT REAR OIL SEALS
The service seal is a two piece, Viton seal. The upper seal half can be installed with crankshaft
removed from engine or with crankshaft installed. When a new upper seal is installed, install a new
lower seal. The lower seal half can be installed only with the rear main bearing cap removed.
Bearing Seal > Component Information > Description and Operation > Page 1497
Crankshaft Main Bearing Seal: Service and Repair
The service seal is a 2 piece, Viton seal. The upper seal half can be installed with crankshaft
removed from engine or with crankshaft installed. When a new upper seal is installed, install a new
lower seal.
The lower seal half can only be installed with the rear main bearing cap removed.
UPPER SEAL REPLACEMENT-CRANKSHAFT REMOVED
1. Remove the crankshaft. 2. Clean the cylinder block rear cap and block mating surfaces. Make
sure the seal groove is free of debris. 3. Lightly oil the new upper seal lip with engine, oil. 4. Install
the new upper rear bearing oil seal with the white paint facing towards the rear of the engine. 5.
Position the crankshaft into the cylinder block. 6. Lightly oil the new lower seal lip with engine oil. 7.
Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards
the rear of the engine.
Sealant Application To Bearing Cap
8. Apply a 5 mm (0.20 in) drop of Loctite 518, or equivalent, on each side of the rear main bearing
cap. DO NOT over apply sealant or allow the
10. Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately
tighten to 115 Nm (85 ft. lbs.) torque. 11. Install oil pump. 12. Apply Mopar Silicone Rubber
Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan
sealing. Apply
enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off
the oil pan seal groove.
13. Install new front crankshaft oil seal. 14. Immediately install the oil pan.
UPPER SEAL REPLACEMENT-CRANKSHAFT INSTALLED
1. Remove the oil pan. 2. Remove the oil pump from the rear main bearing cap. 3. Remove the rear
main bearing cap. Remove and discard the old lower oil seal. 4. Carefully remove and discard the
old upper oil seal. 5. Lightly oil the new upper seal lips with engine oil. To allow ease of installation
of the seal, loosen at least the 2 main bearing caps forward of the
rear bearing cap. Clean the cylinder block rear cap mating surface. Make sure the seal groove is
free of debris.
6. Rotate the new upper seal into the cylinder block being careful not to shave or cut the outer
surface of the seal. To assure proper installation, use
the installation tool provided with the kit. Install the new seal with the white paint facing towards the
rear of the engine.
7. Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards
the rear of the engine. 8. Apply 5 mm (0.20 in) drop of Loctite 518, or equivalent, on each side of
the rear main bearing cap. DO NOT over apply sealant or allow the
sealant application. Be sure the white paint faces toward the rear of the engine.
10. Install the rear main bearing cap with cleaned and oiled cap bolts. Alternately tighten ALL cap
bolts to 115 Nm (85 ft. lbs.) torque. 11. Install oil pump.
Bearing Seal > Component Information > Description and Operation > Page 1498
Apply Sealant To Bearing Cap To Block Joint
12. Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing. Apply
the oil pan gasket groove.
13. Immediately install the oil pan.
LOWER SEAL REPLACEMENT
1. Remove the oil pan. 2. Remove the oil pump from the rear main bearing cap. 3. Remove the rear
main bearing cap and discard the old lower seal. 4. Clean the cylinder block rear cap mating
surface including the oil pan gasket groove. 5. Carefully install a new upper seal (refer to Upper
Seal Replacement-Crankshaft Installed procedure above). 6. Lightly oil the new lower seal lips with
engine oil. 7. Install a new lower seal in bearing cap with white paint facing the rear of engine. 8.
Apply 5 mm (0.20 in) drop of Loctite 518, or equivalent, on each side of the rear main bearing cap.
DO NOT over apply sealant or allow the
10. Install the rear main bearing cap with cleaned and oiled cap bolts. Alternately tighten the cap
bolts to 115 Nm (85 ft. lbs.) torque. 11. Install oil pump. 12. Apply Mopar Silicone Rubber Adhesive
Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing.
Apply
the oil pan seal groove.
13. Immediately install the oil pan.

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket
> Component Information > Testing and Inspection
Cylinder Head Gasket: Testing and Inspection
FAILURE DIAGNOSIS
A leaking engine cylinder head gasket usually results in loss of power, loss of coolant, and engine
misfiring.
An engine cylinder head gasket leak can be located between adjacent cylinders or between a
cylinder and the adjacent water jacket. -
An engine cylinder head gasket leaking between adjacent cylinders is indicated by a loss of power
and/or engine misfire.
- An engine cylinder head gasket leaking between a cylinder and an adjacent water jacket is
indicated by coolant foaming or overheating and loss of coolant.
Cylinder To Cylinder Leakage Test To determine if an engine cylinder head gasket is leaking
between adjacent cylinders, follow the procedures outlined in Cylinder Compression Pressure Test.
An engine cylinder head gasket leaking between adjacent cylinders will result in approximately a
50-70% reduction in compression pressure.
Cylinder To Water Jacket Leakage Test
WARNING: Use extreme caution when the engine is operating. Do not stand in a direct line with
the fan. Do not put your hands near the pulleys, belts, oft the fan. Do not wear loose clothing.
Remove the radiator cap.
Start the engine and allow it to warm up until the engine thermostat opens.
If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant.
If bubbles are not visible, install a radiator pressure tester and pressurize the coolant system.
If a cylinder is leaking combustion pressure into the water jacket, the tester pointer will pulsate with
every combustion stroke of the cylinder.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal
Front Crankshaft Seal: Service and Repair
The oil seal can be replaced without removing the timing chain cover provided the cover is not
misaligned.
1. Disconnect the negative cable from the battery. 2. Remove vibration damper. 3. If front seal is
suspected of leaking, check front oil seal alignment to crankshaft. The seal installation/alignment
tool 6635, should fit with
minimum interference. If tool does not fit, the cover must be removed and installed properly.
4. Place a suitable tool behind the lips of the oil seal to pry the oil seal outward. Be careful not to
damage the crankshaft seal bore of cover.
Placing Oil On Installation Tool 6635
5. Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635. Seat the oil
seal in the groove of the tool.
Position Tool And Seal Onto Crankshaft
6. Position the seal and tool onto the crankshaft.

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal
> Component Information > Service and Repair > Page 1505
Installing Oil Seal
7. Using the vibration damper bolt, tighten the bolt to draw the seal into position on the crankshaft.
8. Remove the vibration damper bolt and seal installation tool. 9. Inspect the seal flange on the
vibration damper.
10. Install the vibration damper. 11. Connect the negative cable to the battery.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket
> Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb >
00 > Engine - Spark Knock/Oil Consumption
Intake Manifold Gasket: Customer Interest Engine - Spark Knock/Oil Consumption
NUMBER: 09-05-00
GROUP: Engine
DATE: Feb.25, 2000
MODELS: 1994 - 1999
(AB) Ram Van
1994 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango

Leak
gasket.
NOTE:
ENGINE.
NOTE:
2. Stop the engine.

00 > Engine - Spark Knock/Oil Consumption > Page 1514
NOTE:


For the 3.9L:

REPAIR PROCEDURE:
instructions.
NOTE:
NOTE:

NOTE:
TO 2.5 HOURS.
NOTE:

PLENUM PAN GASKET.
Time Allowance

> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: >
09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption
Intake Manifold Gasket: All Technical Service Bulletins Engine - Spark Knock/Oil Consumption
NUMBER: 09-05-00
GROUP: Engine
DATE: Feb.25, 2000
MODELS: 1994 - 1999
(AB) Ram Van
1994 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango

Leak
gasket.
NOTE:
ENGINE.
NOTE:
2. Stop the engine.

09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1524
NOTE:


For the 3.9L:

REPAIR PROCEDURE:
instructions.
NOTE:
NOTE:

NOTE:
TO 2.5 HOURS.
NOTE:

PLENUM PAN GASKET.
Time Allowance

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Cylinder Head Off
Valve Guide Seal: Service and Repair Cylinder Head Off
Refer to Valves, Intake/Exhaust, Service and Repair for procedure.

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Cylinder Head Off > Page 1533
Valve Guide Seal: Service and Repair Cylinder Head On
Refer to Valve Spring, Service and Repair for procedure.

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Locations

Sender > Component Information > Locations > Page 1538
Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions
NUMBER: 26-01-99C
DATE: January, 1999

Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page
1543
vi
1544
538

1545
589
1546
589A
1547
589B
1548
589C
1549
589D
1550
589E
1551
589F
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Camshaft Gear/Sprocket: Specifications
Camshaft Sprocket Bolt .......................................................................................................................

.................................................... 68 Nm (50 ft. lbs.)
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Measuring Timing Chain Stretch
Timing Chain: Service and Repair Measuring Timing Chain Stretch

NOTE: To access timing chain Refer to Timing Cover.
1. Place a scale next to the timing chain so that any movement of the chain may be measured. 2.
Place a torque wrench and socket over camshaft sprocket attaching bolt. Apply torque in the
direction of crankshaft rotation to take up slack; 41
Nm (30 ft. lbs.) torque with cylinder head installed or 20 Nm (15 ft. lbs.) torque with cylinder head
removed. With a torque applied to the camshaft sprocket bolt, crankshaft should not be permitted
to move. It may be necessary to block the crankshaft to prevent rotation.
Measuring Timing Chain Wear And Stretch
3. Hold a scale with dimensional reading even with the edge of a chain link. With cylinder heads
installed, apply 14 Nm (30 ft. lbs.) torque in the
reverse direction. With the cylinder heads removed, apply 20 Nm (15 ft. lbs.) torque in the reverse
direction. Note the amount of chain movement.
4. Install a new timing chain, if its movement exceeds 3.175 mm (1/8 inch). 5. If chain is not
satisfactory, remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and
camshaft sprockets. 6. Place both camshaft sprocket and crankshaft sprocket on the bench with
timing marks on exact imaginary center line through both camshaft and
crankshaft bores.
sprockets tight against the chain in position as described).
10. Slide both sprockets evenly over their respective shafts and use a straightedge to check
alignment of timing marks. 11. Install the camshaft bolt. Tighten the bolt to 47 Nm (35 ft. lbs.)
torque. 12. Check camshaft end play. The end play should be 0.051-0.152 mm (0.002-0.006 inch)
with a new thrust plate and up to 0.254 mm (0.010 inch)
with a used thrust plate. If not within these limits install a new thrust plate.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Measuring Timing Chain Stretch > Page 1560
Timing Chain: Service and Repair Timing Chain Replacement
REMOVAL
1. Disconnect battery negative cable. 2. Remove Timing Cover.
3. Re-install the vibration damper bolt finger tight. Using a suitable socket and breaker bar, rotate
the crankshaft to align timing marks. 4. Remove camshaft sprocket attaching bolt and remove
timing chain with crankshaft and camshaft sprockets.
INSTALLATION
1. Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.
sprockets tight against the chain in position as described). 5. Slide both sprockets evenly over their
respective shafts and use a straightedge to check alignment of timing marks. 6. Install the camshaft
bolt. Tighten the bolt to 68 Nm (50 ft. lbs.) torque. 7. Check camshaft end play. The end play
should be 0.051-0.152 mm (0.002-0.006 inch) with a new thrust plate and up to 0.254 mm (0.010
inch)
with a used thrust plate. If not within these limits install a new thrust plate.
8. Install the timing chain cover.

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Timing Cover: Specifications
Chain Case Cover Bolts 30 ft.lb

Timing Cover: Service and Repair
REMOVAL
1. Disconnect the negative cable from the battery. 2. Drain cooling system. 3. Remove the
serpentine belt. 4. Remove water pump. Refer to Cooling System 5. Remove power steering pump.
Refer to Steering and Suspension. 6. Remove vibration damper. 7. Remove fuel lines (refer to
Powertrain Management). 8. Loosen oil pan bolts and remove the front bolt at each side. 9.
Remove the cover bolts.
10. Remove chain case cover and gasket using extreme caution to avoid damaging oil pan gasket.
Removal Of Front Crankshaft Oil Seal
11. Place a suitable tool behind the lips of the oil seal to pry the oil seal outward. Be careful not to
damage the crankshaft seal surface of cover.
CLEANING
Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs. The
water pump mounting surface must be cleaned.
INSTALLATION
1. Using a new cover gasket, carefully install chain case cover to avoid damaging oil pan gasket.
Use a small amount of Mopar Silicone Rubber
Adhesive Sealant, or equivalent, at the joint between timing chain cover gasket and the oil pan
gasket. Finger tighten the timing chain cover bolts at this time.
CAUTION: If chain cover is replaced for any reason, make sure the oil hole (passenger side of
cover) is plugged.
Placing Oil Seal On Installation Tool 6635
2. Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635. Seat the oil
seal in the groove of the tool.
Position Tool And Seal Onto Crankshaft
3. Position the seal and tool onto the crankshaft. 4. Tighten the 4 lower chain case cover bolts to
13N.m (10 ft.lbs.) to prevent the cover from tipping during seal installation.
Installing Oil Seal
5. Using the vibration damper bolt, tighten the bolt to draw the seal into position on the crankshaft.
6. Loosen the 4 bolts tightened in step 4 to allow realignment of front cover assembly. 7. Tighten
chain case cover bolts to 41 Nm (30 ft. lbs.) torque. Tighten oil pan bolts to 24 Nm (215 inch lbs.)
torque. 8. Remove the vibration damper bolt and seal installation tool. 9. Install vibration damper.
10. Install water pump and housing assembly using new gaskets (refer to Cooling System). Tighten
bolts to 41 Nm (30 ft. lbs.) torque. 11. Install power steering pump. Refer to Steering and
Suspension. 12. Install the serpentine belt. 13. Install the cooling system fan. Tighten the bolts to
23 Nm (17 ft. lbs.) torque. 14. Position the fan shroud and install the bolts. Tighten the bolts to 11
Nm (95 inch lbs.) torque. 15. Fill cooling system. 16. Connect the negative cable to the battery.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage
NO: 14-03-98
MODELS: 1996 - 1998 (AB)
Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
DISCUSSION:

Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications
Fuel Pressure

........................................ 339 ± 34 kPa (49.2 ± 5 psi)

minutes
Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 1573
seconds.

Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test
Test.
operational.
(Fig. 9) or (Fig. 10).

Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 1576
Adapter Tool.
on Adapter Tool.
specification.
information.
location.
ARE CONNECTED.
type-2 and type-3.
Starter Relay
Type-2 Relay
Type-3 Relay
pump module is OK.
seconds.

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel
Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions
NUMBER: 26-02-99A

Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page
1586
45
1587
46
1588
47
1589
152
1590
156
1591
316
1592
620
1593
622
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications

......................................................... 500 to 900 rpm
Speed > System Information > Specifications > Page 1597

Speed > System Information > Specifications > Page 1598
column.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Component Information > Service and Repair
REMOVAL
body.
INSTALLATION
engine cover.
AIR CLEANER ELEMENT
REMOVAL
INSTALLATION
engine cover.
Filter > Fuel Pressure Release > System Information > Service and Repair
cylinder chamber.
battery.

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Number One Cylinder > Component Information > Locations
Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: >
18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction
NO: 18-48-98
DATE: Dec. 30, 1998
MODELS:
1994 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
NOTE:
SYMPTOM/CONDITION:
mph).
DIAGNOSIS:
NOTE:

PARTS REQUIRED:

TIME ALLOWANCE:
08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs.
(AN/DN) 5.2/5.9L 0.3 Hrs.
(BR/BE) 5.2/5.9L 0.4 Hrs.

18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1621
Repair Procedure
NOTE:
90° ANGLE.
NOTE:
CLIPS.
studs).
and 82.5 mm (3.25 in.).
NOTE:
tower terminal.
cover.
NOTE:
(Figure 5).
NOTE:
LAYOUT APPLIES.
NOTE:
NOTE:
valve cover.
elbow.
NOTE:
3.9L Engine
(Figure 11).
studs).
one (1) at 82.5 mm (3.25 in.).
studs).
NOTE:
tower terminal.
Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98
> Ignition System - Cross Fire/Ignition Wire Induction
NO: 18-48-98
DATE: Dec. 30, 1998
MODELS:
1994 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
NOTE:
SYMPTOM/CONDITION:
mph).
DIAGNOSIS:
NOTE:

PARTS REQUIRED:

TIME ALLOWANCE:
08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs.
(AN/DN) 5.2/5.9L 0.3 Hrs.
(BR/BE) 5.2/5.9L 0.4 Hrs.

> Ignition System - Cross Fire/Ignition Wire Induction > Page 1632
Repair Procedure
NOTE:
90° ANGLE.
NOTE:
CLIPS.
studs).
and 82.5 mm (3.25 in.).
NOTE:
tower terminal.
cover.
NOTE:
(Figure 5).
NOTE:
LAYOUT APPLIES.
NOTE:
NOTE:
valve cover.
elbow.
NOTE:
3.9L Engine
(Figure 11).
studs).
one (1) at 82.5 mm (3.25 in.).
studs).
NOTE:
tower terminal.
Cable > Component Information > Technical Service Bulletins > Page 1638
Ohms Per Foot
SYSTEM OPERATION
Heat Shields
shield.
Testing
follows:
exceed ten minutes.

Cable Removal
Engine Firing Order
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection
Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection
adverse conditions.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications
Electrode Gap ......................................................................................................................................

..................................................... 0.89 mm (0.035 in) Torque ............................................................
............................................................................................................................................... 41 Nm
(30 ft lb)
Plug > Component Information > Specifications > Page 1652
Plug Type ............................................................................................................................................

..................................................................... RC12YC
SYSTEM OPERATION
oil fouled.
Normal Operating

Scavenger Deposits
Scavenger Deposit
Preignition Damage
Preignition Damage
overheating.
Heat Shields
spark plug.
plug condition.
adjusting gap.
electrode.
damaged.
Compression Check > System Information > Specifications
Compression Check > System Information > Specifications > Page 1661
malfunctions.

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications
times.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications
Water Pump: Specifications
Water Pump Mounting Bolts 30 ft.lb
Water Pump Pulley 16 ft.lb
Water Pump-to-Chain Case Cover Bolt 31 ft.lb

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Water Pump: Description and Operation
A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold,
radiator core, cooling system hoses and heater core. The pump is driven from the engine
crankshaft by a drive belt.
The water pump impeller is pressed onto the rear of a shaft that rotates in a bearing pressed into
the water pump body. The body has a small hole for ventilation. The water pump seals are
lubricated by antifreeze in the coolant mixture. Additional lubrication is not necessary.
A quick test to determine if pump is working is to check if heater warms properly. A defective water
pump will not be able to circulate heated coolant through the long heater hose to the heater core.
The water pump on all models can be removed without discharging the air conditioning system (if
equipped).
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and
Repair > Water Pump Replacement
Water Pump: Service and Repair Water Pump Replacement
REMOVAL
The water pump on all engines is bolted directly to the engine timing chain case/cover. A gasket is
used as a seal between the water pump and timing chain case/cover. If water pump is replaced
because of bearing/shaft damage or leaking shaft seal, the mechanical cooling fan assembly
should also be inspected. Inspect for fatigue cracks, loose blades or loose rivets that could have
resulted from excessive vibration. Replace fan if any of these conditions are found. Also check
condition of the thermal viscous fan drive. 1. Disconnect negative battery cable from battery. 2.
Drain cooling system. 2. Do not waste reusable coolant. If solution is clean, drain coolant into a
clean container for reuse. 3. Remove the plastic air cleaner intake tube. 4. Remove two-piece fan
shroud. Remove lower half first.
5. Remove upper radiator hose at radiator.

Repair > Water Pump Replacement > Page 1671
Fan Blade And Viscous Fan Drive-Typical
6. The thermal viscous fan drive is attached (threaded) to the water pump hub shaft. Remove the
fan/fan drive assembly from water pump by turning
the mounting nut counterclockwise (as viewed from front). Threads on the fan drive are RIGHT
HAND. A Snap-On 36 MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set
number 2017DSP) can be used. Place a bar or screwdriver between the water pump pulley bolts to
prevent the pulley from rotating.
7. If water pump is being replaced, do not unbolt fan blade assembly from the thermal viscous fan
drive. 8. Remove fan blade/fan drive assembly from vehicle. 9. After removing fan blade/fan drive
assembly, do not place the thermal viscous fan drive in the horizontal position. If stored
horizontally, the
silicone fluid in the viscous drive could drain into its bearing assembly and contaminate the bearing
lubricant.
10. Do not remove the water pump pulley bolts at this time.
Automatic Belt Tensioner-Typical
11. Remove accessory drive belt as follows: The drive belt is equipped with a spring loaded
automatic belt tensioner. Relax the tension from the belt
by rotating the tensioner clockwise (as viewed from front). When all belt tension has been relaxed,
remove accessory drive belt.
12. Remove the four water pump pulley-to-water pump hub bolts and remove pulley from engine.
13. Remove the lower radiator hose at water pump.
Coolant Return Tube-Typical
14. Loosen heater hose coolant return tube mounting bolt and remove tube from water pump.
Discard the old tube O-ring. 15. Remove the seven water pump mounting bolts. 16. Loosen the
clamp at the water pump end of bypass hose. Slip the bypass hose from the water pump while
removing pump from engine. Do not
remove the clamp from the bypass hose.
17. Discard old gasket.
CAUTION: Do not pry the water pump at timing chain case/cover. The machined surfaces may be
damaged resulting in leaks.
INSTALLATION
Water Pump Bolts-Typical
1. Clean gasket mating surfaces. 2. Using a new gasket, install water pump to engine as follows:
Guide water pump fitting into bypass hose as pump is being installed. Install water
pump mounting bolts. Tighten bolts in a criss-cross pattern to 40 Nm (30 ft. lbs.) torque.
3. Position bypass hose clamp to bypass hose. 4. Spin water pump to be sure that pump impeller
does not rub against timing chain case/cover. 5. Install a new O-ring to the heater hose coolant
return tube. Coat the new O-ring with antifreeze before installation. 6. Install coolant return tube
and its mounting bolt to engine. Be sure the slot in tube bracket is bottomed to mounting bolt. This
will properly
position return tube.
7. Connect radiator lower hose to water pump. 8. Connect heater hose and hose clamp to coolant
return tube. 9. Install water pump pulley. Tighten bolts to 27 Nm (20 ft. lbs.) torque. Place a bar or
screwdriver between water pump pulley bolts to prevent
pulley from rotating.
10. Relax tension from automatic belt tensioner. Install drive belt.
CAUTION: When installing the serpentine accessory drive belt, belt must be routed correctly. If not,
engine may overheat due to water pump rotating in wrong direction. Refer to the Belt Routing Label
for correct belt routing. The correct belt with correct length must be used.
The provided belt routing schematics are published from the latest information available at the time
schematics on Belt Routing Label. This label is located in the engine compartment.
11. Install the fan blade/viscous fan drive assembly to water pump shaft. 12. Install fan shroud. 13.
Install plastic air cleaner intake tube. 14. Install upper radiator hose and hose clamp to radiator. 15.
Fill cooling system. 16. Connect negative battery cable. 17. Start and warm the engine. Check for
leaks.
Water Pump: Service and Repair Cleaning and Inspection
Replace water pump assembly if it has any of the following conditions: ^
The body is cracked or damaged
^ Water leaks from the shaft seal. This is evident by traces of coolant below the vent hole
^ Loose or rough turning bearing. Also inspect thermal viscous fan drive
^ Impeller rubs either the pump body or timing chain case/cover

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications
Coolant: Capacity Specifications
Coolant Capacity .................................................................................................................................

...................................................... 12.3 L (13.1 Qts.)
NOTES:
- Nominal refill capacities are shown. A variation may be observed from vehicle to vehicle due to
manufacturing tolerances and refill procedures.
- Add 0.9L (1 Qt.) if equipped with an auxiliary rear mounted heater.
- Capacities shown include vehicles with air conditioning and/or heavy-duty cooling systems.
Specifications > Capacity Specifications > Page 1680
Coolant: Fluid Type Specifications
operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide
protection against freezing to -37° C (-35° F). The antifreeze concentration must always be a
minimum of 44%, year round, in all climates. If percentage is lower than 44%, engine parts may be
eroded by cavitation, and cooling system components may be severely damaged by corrosion.
Maximum protection against freezing is provided with a 68% antifreeze concentration, which
prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer
temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the
specific heat of antifreeze is lower than that of water.
100 Percent Ethylene-Glycol Should Not Be Used
Use of 100 Percent Ethylene-Glycol will cause formation of additive deposits in the system, as the
corrosive inhibitive additives in ethylene-glycol require the presence of water to dissolve. The
deposits act as insulation, causing temperatures to rise as high as 149° C (300° F). this
temperature is hot enough to melt plastic and soften solder. The increased temperature can result
in engine detonation. In addition, 100 % ethylene-glycol freezes at 22° C (-8° F).
Propylene-Glycol Formulations Should Not Be Used
Propylene-glycol formulations do not meet the required specifications. It's overall effective
temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50
propylene-glycol and water is -32° C (-26° F), 5 degrees higher than ethylene-glycol's freeze point.
The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257° F) at
96.5 kPa (14 PSI), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can
result in boil-over and freeze up. Propylene-Glycol also has a poorer heat transfer characteristics
than ethylene-glycol. This can increase cylinder head temperatures under certain conditions.
Propylene-Glycol/Ethylene-Glycol Mixtures Should Not Be Used
Propylene-glycol/ethylene-glycol mixtures can cause the destabilization of various corrosion

inhibitors, causing damage to the coling system components. Also, once ethylene-glycol and
propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining the
freeze point will not be accurate. Both the refractive index and specific gravity differ between the
ethylene-glycol and propylene-glycol.
Description and Operation > Coolant Performance
Coolant: Description and Operation Coolant Performance
ETHYLENE-GLYCOL MIXTURES
open ating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide
protection against freezing to -37 deg. C 05 deg. F). The anti-freeze concentration must always be
a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine
parts may be eroded by cavitation, and cooling system components may be severely damaged by
corrosion. Maximum protection against freezing is provided with a 68 percent antifreeze
concentration, which prevents freezing down to -67.7 deg. C (-90 deg. F). A higher percentage will
freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to
overheat because the specific heat of antifreeze is lower than that of water.
100 Percent Ethylene-Glycol Should Not Be Used in Chrysler Vehicles Use of 100 percent
ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive
additives in ethylene-glycol require the presence of water to dissolve. The deposits act as
insulation, causing temperatures to rise to as high as 149 deg. C (300) deg. F). This temperature is
hot, enough to melt plastic and soften solder. The increased temperature can result in engine
detonation. In addition, 100 percent ethylene-glycol freezes at 22 deg. C (-8 deg. F).
Propylene-glycol Formulations Should Not Be Used in Chrysler Vehicles Propylene-glycol

formulations do not meet Chrysler coolant specifications. It's overall effective temperature range is
smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32
deg. C (-26 deg. F). 5 deg. C higher than ethylene-glycol's freeze point. The boiling point
(protection against summer boil-over) of propylene-glycol is 125 deg. C (257 deg. F ) at 96.5 kPa
(14 psi), compared to 128 deg. C (263 deg. F) for ethylene-glycol. Use of propylene-glycol can
result in boil-over or freeze-up in Chrysler vehicles, which are designed for ethylene-glycol.
Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can
increase cylinder head temperatures under certain conditions.
Propylene-glycol/Ethylene-glycol Mixtures Should Not Be Used in Chrysler Vehicles

Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion
inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol
and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining
freeze point will not be accurate. Both the refractive index and specific gravity differ between
ethylene glycol and propylene glycol.
Description and Operation > Coolant Performance > Page 1683
Coolant: Description and Operation Selection and Additives
The presence of aluminum components in the cooling system requires strict corrosion protection.
Maintain coolant at specified level with a mixture of ethylene-glycol based antifreeze and water.
Chrysler Corporation recommends Mopar Antifreeze or equivalent. If coolant becomes
contaminated or looses color, drain and flush cooling system and fill with correctly mixed solution.
A 0.25 percent emulsifiable oil is added to the radiator at the factory to prevent solder corrosion.
CAUTION: Do not use coolant additives that are claimed to improve engine cooling.
Coolant: Service and Repair
Refer to Cooling System, Service and Repair for applicable service procedures.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Coolant Line/Hose: Description and Operation
Radiator Hoses-Typical
Rubber hoses route coolant to and from the radiator, intake manifold and heater core. Radiator
lower hoses are spring-reinforced to prevent collapse from water pump suction at moderate and
high engine speeds. Inspect the hoses at regular intervals. Replace hoses that are cracked, feel
brittle when squeezed or swell excessively when the system is pressurized. The use of molded
replacement hoses is recommended. When performing a hose inspection, inspect the radiator
lower hose for proper position and condition of the spring.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
For all vehicles: In areas where specific routing and clamps are not provided, be sure that hoses
are positioned with sufficient clearance. Check clearance from exhaust manifolds and pipe, fan
blades, drive belts and sway bars. Improperly positioned hoses can be damaged, resulting in
coolant loss and engine overheating. Ordinary worm gear type hose clamps (when equipped) can
be removed with a straight screwdriver or a hex socket. To prevent damage to hoses or clamps,
the hose clamps should be tightened to 4 Nm (34 inch lbs.) torque. Do not over tighten hose
clamps.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information
> Service and Repair
Coolant Reservoir: Service and Repair
REMOVAL
1. Disconnect the battery negative cable. 2. Remove the windshield washer reservoir. 3. Remove
overflow hose at reserve/overflow tank.
Coolant Recovery Bottle-Removal/Installation
4. Remove the two bolts at top of tank and remove tank. A slot is located on the radiator support
panel (sheet metal) to support the lower part of tank.
Slip tank from this slot.
INSTALLATION
1. Slip the tank into the slot on radiator support. 2. Install bolts and tighten to 6 Nm (50 inch lbs.)
torque. 3. Install overflow hose to tank. 4. Install the windshield washer reservoir. 5. Connect the
battery negative cable.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Technical Service Bulletins > Engine Cooling Fan - Roaring Noise Explanation
Fan Blade: Technical Service Bulletins Engine Cooling Fan - Roaring Noise Explanation
NO: 07-05-98
GROUP: Cooling
DATE: Sep. 4, 1998
SUBJECT:
Engine Cooling Fan Noise
MODELS:
1998 - 1999 (AB) Ram Van/Wagon 1997 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango
DISCUSSION:
Some vehicles may exhibit an engine cooling fan "roar" noise. This noise is created by a large
cooling fan that is required to provide optimum cooling for low vehicle speed operation in hot
weather conditions and for heavy trailer towing. Since the large cooling fan is unnecessary in most
operating conditions, these vehicles are also equipped with viscous fan drives that allow the fan to
operate at variable speeds based upon temperature loads. The viscous fan drive will engage the
fan for maximum cooling when temperatures are high and allow the fan to operate at slower
speeds when temperatures are low. In addition, at engine start-up, the viscous fan drive engages
the fan for maximum cooling until the fluid in the viscous clutch can dissipate out of the clutch drive
grooves allowing the fan to operate at a slower speed.
Because of the viscous fan drive, the noise may occur during high temperature conditions and for
the first 1-2 minutes of operation. Due to the roar of the fan, customers may also complain of a
perceived loss of power, automatic transmission slippage, or that the transmission is slaying into a
low gear too long (delayed upshift).
Customers concerned about this noise should be advised that this condition is normal and no
repair attempts should be made.

Fan Blade: Service and Repair Removal and Installation
For additional information, also refer to the Fan Clutch.
REMOVAL
Fan belt removal is not necessary to remove cooling system fan. 1. Disconnect the negative battery
cable at battery. 2. Remove the plastic air cleaner intake tube. 3. Remove two-piece fan shroud.
Remove lower half first.
Fan Blade/Viscous Fan Drive Assembly
4. The thermal viscous fan drive/fan blade assembly is attached (threaded) to the water pump hub
shaft. Remove the fan blade/fan drive assembly
from water pump by turning the mounting nut counterclockwise (as viewed from front). Threads on
the viscous fan drive are RIGHT HAND. A Snap-On 36 MM Fan Wrench (number SP346 from
Snap-On Cummins Diesel Tool Set number 2017DSP) can be used. Place a bar or screwdriver
between the water pump pulley bolts to prevent the pulley from rotating. Do not unbolt fan blade
assembly from the viscous fan drive at this time.
5. After removing fan blade/fan drive assembly do not place the thermal viscous fan drive in the
horizontal position. If stored horizontally, the
silicone fluid in the viscous fan drive could drain into its bearing assembly and contaminate the
bearing lubricant.
CAUTION: Do not remove the water pump pulley-to-water pump bolts. This pulley is under spring
tension.
6. Remove the four bolts securing the fan blade assembly to the viscous fan drive.
INSTALLATION
1. Install fan blade assembly to viscous fan drive. Tighten bolts to 23 Nm (17 ft. lbs.) torque. 2.
Install the fan blade/viscous fan drive assembly to water pump shaft. 3. Install fan shroud. 4. Install
air cleaner intake tube. 5. Connect negative battery cable.
Fan Blade: Service and Repair Cleaning and Inspection
The fan cannot be repaired. If the fan is damaged, it must be replaced. Inspect the fan as follows:
1. Remove fan blade and viscous fan drive assembly from engine. Refer to the preceding Removal
procedure. 2. Remove fan blade assembly from viscous fan drive unit (four bolts). 3. Lay fan on a
flat surface with leading edge facing down. With tip of blade touching flat surface, replace fan if
clearance between opposite blade
and surface is greater than 2.0 mm (0.090 inch). Rocking motion of opposite blades should not
exceed 2.0 mm (0.090 inch). Test all blades in this manner.
WARNING: DO NOT ATTEMPT TO BEND OR STRAIGHTEN FAN BLADES IF NOT WITHIN

SPECIFICATIONS.
4. Inspect fan assembly for cracks, bends, loose rivets or broken welds. Replace fan if any damage
is found.
CAUTION: If the fan blade assembly is replaced because of mechanical damage, the water pump
and thermal viscous fan drive should also be inspected. These components could have been
damaged due to excessive vibration.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Technical Service Bulletins > Viscous Fan Drive - Service Procedures
Fan Clutch: Technical Service Bulletins Viscous Fan Drive - Service Procedures
NO: 07-09-98
GROUP: Cooling
DATE: Dec. 18, 1998
SUBJECT: Viscous Fan Drive Service
MODELS:
1998 - 1999 (AB) Ram Van
1998 - 1999 (AN) Dakota
1998 (ZJ) Grand Cherokee
1998 (ZG) Grand Cherokee (International Market)

NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L GASOLINE
ENGINE BUILT AFTER JANUARY 5, 1998 (MDH 0105XX).
DISCUSSION:
Vehicles built after January 5, 1998 have the water pump pulley pressed onto the water pump hub
shaft. As in previous models, the viscous fan drive is threaded onto the water pump hub shaft.
Because the pulley is pressed onto the hub shaft, viscous fan drive removal/installation procedures
are unique.
The fan/viscous fan drive assembly can be removed or installed from the water pump by turning
the mounting nut. To remove the fan/viscous fan drive assembly, turn the nut counterclockwise as
viewed from the front. To install the fan/viscous fan drive assembly, turn the nut clockwise as
viewed from the front. Threads on the viscous fan drive are RIGHT-HANDED. Snap-On 36 mm Fan
Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP) can be used
to remove/install the fan drive assembly on gasoline engines. To hold the water pump pulley from
rotating, place Miller Special Tool 6958 Spanner Wrench onto the water pump pulley with adapter
pins 8346 inserted into the holes on the pulley (Figure 1).
NOTE:
REPLACEMENT WATER PUMP P/N 53021018 HAS BEEN SUPERSEDED TO P/N 53021018AB
WHICH WILL HAVE THE PULLEY PRESSED ONTO THE WATER PUMP HUB SHAFT. WATER
PUMP P/N 53021018 WAS USED TO SERVICE 1993 - 1998 3.9L/5.2L/5.9L (GASOLINE
ENGINES) WATER PUMPS.
Component Information > Technical Service Bulletins > Viscous Fan Drive - Service Procedures > Page 1704
Fan Clutch: Technical Service Bulletins Engine Cooling Fan - Roaring Noise Explanation
NO: 07-05-98
GROUP: Cooling
DATE: Sep. 4, 1998
SUBJECT:
Engine Cooling Fan Noise
MODELS:
1998 - 1999 (AB) Ram Van/Wagon 1997 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango
DISCUSSION:
Some vehicles may exhibit an engine cooling fan "roar" noise. This noise is created by a large
cooling fan that is required to provide optimum cooling for low vehicle speed operation in hot
weather conditions and for heavy trailer towing. Since the large cooling fan is unnecessary in most
operating conditions, these vehicles are also equipped with viscous fan drives that allow the fan to
operate at variable speeds based upon temperature loads. The viscous fan drive will engage the
fan for maximum cooling when temperatures are high and allow the fan to operate at slower
speeds when temperatures are low. In addition, at engine start-up, the viscous fan drive engages
the fan for maximum cooling until the fluid in the viscous clutch can dissipate out of the clutch drive
grooves allowing the fan to operate at a slower speed.
Because of the viscous fan drive, the noise may occur during high temperature conditions and for
the first 1-2 minutes of operation. Due to the roar of the fan, customers may also complain of a
perceived loss of power, automatic transmission slippage, or that the transmission is slaying into a
low gear too long (delayed upshift).
Customers concerned about this noise should be advised that this condition is normal and no
repair attempts should be made.

Fan Clutch: Specifications
Cooling Fan to Viscous Drive 200 in.lb

Fan Clutch: Description and Operation
VISCOUS FAN DRIVE
Fan Blade/Viscous Fan Drive Assembly
Viscous Fan Drive-Typical
The thermal viscous fan drive is a silicone-fluid- filled coupling used to connect the fan blades to
the water pump shaft. The coupling allows the fan to be driven in a normal manner. This is done at
low engine speeds while limiting the top speed of the fan to a predetermined maximum level at
higher engine speeds. A thermostatic bi-metallic spring coil is located on the front face of the
viscous fan drive unit (a typical viscous unit is shown in. This spring coil reacts to the temperature
of the radiator discharge air. It engages the viscous fan drive for higher fan speed if the air
temperature from the radiator rises above a certain point. Until additional engine cooling is
necessary, the fan will remain at a reduced rpm regardless of engine speed. Only when sufficient
heat is present, will the viscous fan drive engage. This is when the air flowing through the radiator
core causes a reaction to the bimetallic coil. It then increases fan speed to provide the necessary
additional engine cooling. Once the engine has cooled, the radiator discharge temperature will
drop. The bimetallic coil again reacts and the fan speed is reduced to the previous disengaged
speed.
CAUTION: Engines equipped with serpentine drive belts have reverse rotating fans and viscous
fan drives. They are marked with the word REVERSE to designate their usage. Installation of the
wrong fan or viscous fan drive can result in engine overheating.
CAUTION: If the viscous fan drive is replaced because of mechanical damage, the cooling fan
blades should also be inspected. Inspect for fatigue cracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan blade assembly if any of these conditions are
found. Also inspect water pump bearing and shaft assembly for any related damage due to a
viscous fan drive malfunction.
NOISE
NOTE: It is normal for fan noise to be louder (roaring) when:

^ The underhood temperature is above the engagement point for the viscous drive coupling. This
may occur when ambient (outside air temperature) is very high.
^ Engine loads and temperatures are high such as when towing a trailer.
^ Cool silicone fluid within the fan drive unit is being redistributed back to its normal disengaged
(warm) position. This can occur during the first 15 seconds to one minute after engine start-up on a
cold engine.
LEAKS Viscous fan drive operation is not affected by small oil stains near the drive bearing. If
leakage appears excessive, replace the fan drive unit.
Fan Clutch: Testing and Inspection
VISCOUS FAN DRIVE
TESTING
If the fan assembly free-wheels without drag (the fan blades will revolve more than five turns when
spun by hand), replace the fan drive. This spin test must be performed when the engine is cool. For
the following test, the cooling system must be in good condition. It also will ensure against
excessively high coolant temperature.
WARNING: BE SURE THAT THERE IS ADEQUATE FAN BLADE CLEARANCE BEFORE

DRILLING.
1. Drill a 3.18-mm (1/8-in) diameter hole in the top center of the fan shroud. 2. Obtain a dial
thermometer with an 8 inch stem (or equivalent). It should have a range of -18° to 105°C (0° to
220°F). Insert thermometer through
the hole in the shroud. Be sure that there is adequate clearance from the fan blades.
3. Connect a tachometer and an engine ignition timing light (timing light is to be used as a strobe
light). 4. Block the air flow through the radiator. Secure a sheet of plastic in front of the radiator (or
air conditioner condenser). Use tape at the top to secure
the plastic and be sure that the air flow is blocked.
5. Be sure that the air conditioner (if equipped) is turned off.
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN
A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR
FAN. DO NOT WEAR LOOSE CLOTHING.
6. Start the engine and operate at 2400 rpm. Within ten minutes the air temperature (indicated on
the dial thermometer) should be up to 88° C (190°
F). Fan drive engagement should have started to occur at between 74° to 82° C (165° to 180° F).
Engagement is distinguishable by a definite increase in fan flow noise (roaring). The timing light
also will indicate an increase in the speed of the fan.
7. When the air temperature reaches 88° C (190° F), remove the plastic sheet. Fan drive
disengagement should have started to occur at between 57°
to 79° C (135° to 175° F). A definite decrease of fan flow noise (roaring) should be noticed. If not,
replace the defective viscous fan drive unit.
Fan Clutch: Service and Repair
VISCOUS FAN DRIVE
Refer to Fan Blade for removal and installation procedures of the viscous drive unit. Viscous Fan
Drive Fluid Pump Out Requirement: After installing a new viscous fan drive, bring the engine speed
up to approximately 2000 rpm and hold for approximately two minutes. This will ensure proper fluid
distribution within the drive.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service
Bulletins > Engine Controls - ECT Sensor Test revisions
NUMBER: 26-11-97F

81-699-97019

Bulletins > Engine Controls - ECT Sensor Test revisions > Page 1715
165
Torque 11 Nm


following:
conditioning:


REMOVAL

SENSOR.
type tab.
INSTALLATION
battery.
Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Specifications
Fan Shroud: Specifications
Fan Shroud to Radiator 50 in.lb

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Heater Control Valve
Cable > Component Information > Service and Repair
Heater Control Valve Cable: Service and Repair
The rear water valve control cable is used only on models with the optional rear heater-A/C unit.
The rear water valve control cable can be removed without removing the rear heater-A/C unit from
the vehicle.
REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Disconnect the control cable
from the rear water valve. 3. Remove the rear mode control motor from the rear heater-A/C unit.
Rear Water Valve Control Cable Remove/Install
4. Remove the screw that secures the rear water valve control cable flag retainer to the rear
heater-A/C unit upper housing. 5. Remove the water valve control cable adaptor from the rear
heat-A/C mode door pivot shaft. 6. Remove the rear water valve control cable and adaptor from the
rear heater-A/C unit upper housing. 7. Separate the rear water valve control cable end from the
hole on the end of the adaptor lever.
INSTALLATION 1. Install the rear water valve control cable end into the hole on the end of the
adaptor lever. 2. Position the rear water valve control cable and adaptor to the rear heater-A/C unit
upper housing. 3. Install the rear water valve control cable adaptor into the rear heat-A/C mode
door pivot shaft. Be certain to index the alignment splines on the
adaptor to the spline in the pivot shaft.
4. Install the screw that secures the rear water valve control cable flag retainer to the rear
heater-A/C unit upper housing. Tighten the mounting screw
to 2.2 N.m (20 in. lbs.).
5. Reinstall the rear mode control motor onto the rear heater-A/C unit. 6. Connect the control cable
to the rear water valve. 7. Connect the battery negative cable.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Heater Core: Description and Operation
SYSTEM OPERATION
Front
The heater core is located in the heater-A/C housing, on the right side of the engine compartment.
It is a heat exchanger made of rows of tubes and fins. Engine coolant is circulated through heater
hoses to the heater core whenever the front water valve is open. As the coolant flows through the
heater core, heat removed from the engine is transferred to the heater core fins and tubes.
Air directed through the heater core picks up the heat from the heater core fins. The blend air door
allows control of the heater output air temperature by controlling how much of the air flowing
through the heater-A/C housing is directed through or around the heater core. The blower motor
speed controls the volume of air flowing through the heater-A/C system.
The heater core cannot be repaired and, if faulty or damaged, it must be replaced.
Rear
Models equipped with the optional rear heater-A/C unit have a combination coil located within the
rear unit housing. The combination coil functions as both the rear heater core and the rear
evaporator coil. See Combination Coil in the Description and Operation for more information.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Heater Core: Service and Repair
Front
REMOVAL 1. Remove the heater-A/C housing from the engine compartment. Refer to: "Housing
Assembly HVAC : Service and Repair" See: Heating and
Air Conditioning/Housing Assembly HVAC/Service and Repair
2. Remove the top cover from the heater-A/C housing.
Heater Core Remove/Install
3. Remove the screw that secures the heater core tube support bracket to the mounting boss on
the top of the heater-A/C housing. 4. Lift the heater core out of the heater-A/C housing
INSTALLATION 1. Insert the heater core into the bottom of the heater-A/C housing. 2. Install the
screw that secures the heater core tube support bracket to the mounting boss on the top of the
heater-A/C housing. Tighten the mounting
3. Reinstall the top cover to the heater-A/C housing. 4. Reinstall the heater-A/C housing in the
engine compartment.
Rear
The heater core for the optional rear heater-A/C unit is integral with the air conditioning evaporator
coil. This unit is referred to as the combination coil.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Rear Heater-A/C Unit Plumbing

lines.
Service and Repair > Rear Heater-A/C Unit Plumbing > Page 1740
free.

REMOVAL

Service and Repair > Rear Heater-A/C Unit Plumbing > Page 1741
INSTALLATION
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Hose Clamp, Cooling System > Component
Hose Clamp: Specifications
Hose Clamp (Worm Gear) 34 in.lb

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Description and Operation
Temperature Gauge: Description and Operation
SYSTEM OPERATION
The coolant temperature gauge gives an indication of the engine coolant temperature. The
instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry
calculates the proper gauge pointer position based upon engine coolant temperature messages
received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD)
data bus.
The PCM uses an input from the engine coolant temperature sensor and internal programming to
decide what engine coolant temperature messages are required. The PCM then sends the proper
messages to the instrument cluster on the CCD data bus.
If the PCM messages indicate that coolant temperature is too high, the instrument cluster circuitry
moves the gauge needle to the high end of the scale on the gauge face, turns on the Check
Gauges lamp, and sends a chime tone request to the Central Timer Module (CTM).
The engine coolant temperature sensor is installed in a threaded hole that penetrates a coolant
passage of the engine. It is a thermistor-type sensor that changes its internal resistance with
changes in engine coolant temperature.
Temperature Gauge > Component Information > Description and Operation > Page 1749
Temperature Gauge: Testing and Inspection
If the problem being diagnosed is related to coolant temperature gauge accuracy, be certain to
confirm that the problem is with the gauge and not with cooling system performance. The actual
engine coolant temperature should be checked with a test gauge or thermometer and compared to
the instrument cluster coolant temperature gauge readings before you proceed with gauge
diagnosis.

INJURY.
Diagnosis of the coolant temperature sensor and circuit, the Chrysler Collision Detection (CCD)
data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool.
For further diagnosis of the coolant temperature gauge and the instrument cluster circuitry, see
Instrument Cluster in the Diagnosis and Testing.
Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation
Temperature Warning Lamp/Indicator: Description and Operation
SYSTEM OPERATION
Transmission Oil Temperature Warning Lamp The transmission oil temperature warning lamp gives
an indication when the Powertrain Control Module (PCM) has detected that the automatic
transmission oil is overheated. The lamp is controlled by the instrument cluster circuitry based upon
messages received from the PCM on the Chrysler Collision Detection (CCD) data bus. The PCM
sends lamp-on messages for about two seconds when the ignition switch is turned to the On
position as a bulb test.
Following the bulb test, the PCM uses an input from the automatic transmission oil temperature
sensor located within the transmission, along with its internal programming, to decide whether a
condition exists that requires the transmission oil temperature warning lamp to be turned on. The
PCM then sends the proper messages to the instrument cluster on the CCD data bus to turn the
lamp on or off. When the instrument cluster receives a message to turn the transmission oil
temperature warning lamp on, it also sends a chime tone request to the Central Timer Module
(CTM).
Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation > Page 1753
Temperature Warning Lamp/Indicator: Testing and Inspection
Transmission Oil Temperature Warning Lamp
The diagnosis found here addresses an inoperative transmission oil temperature warning lamp
condition. If the transmission oil temperature warning lamp comes on and stays on with the engine
running.

INJURY.
If the transmission oil temperature warning lamp fails to light during the bulb test (about two
seconds after the ignition switch is turned to the On position), diagnosis of the Powertrain Control
DRB scan tool. For further diagnosis of the transmission oil temperature warning lamp and the
instrument cluster circuitry, see Instrument Cluster in the Diagnosis and Testing.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug >
Radiator Drain Plug: Service and Repair
The radiator draincock is replaceable. Unscrew the draincock in a clockwise direction and remove
from radiator. Install replacement draincock.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information >
Radiator Cap: Description and Operation
Radiator Pressure Cap And Filler Neck-Typical
Radiators are equipped with a pressure cap, which releases pressure at some point within a range
of 97-138 kPa (14-20 psi). The pressure relief point (in pounds) is engraved on top of cap. The
cooling system will operate at pressures slightly above atmospheric pressure. This results in a
higher coolant boiling point allowing increased radiator cooling capacity. The cap contains a
spring-loaded pressure relief valve that opens when system pressure reaches release range of
97-138 kPa (14-20 psi). A vent valve in the center of cap allows a small coolant flow through cap
when coolant is below boiling temperature. The valve is completely closed when boiling point is
reached. As the coolant cools, it contracts and creates a vacuum in the cooling system. This
causes the vacuum valve to open and coolant in the reserve/overflow tank to be drawn through its
connecting hose into radiator. If the vacuum valve is stuck shut, the radiator hoses will collapse on
cool down. Clean the vent valve. A rubber gasket seals radiator filler neck to prevent leakage. This
is done to keep system under pressure. It also maintains vacuum during coolant cool-down
allowing coolant to return from reserve/ overflow tank.
Testing and Inspection > Radiator Cap - Pressure Testing
Radiator Cap: Testing and Inspection Radiator Cap - Pressure Testing
PRESSURE TESTING
Pressure Testing Radiator Cap
Remove cap from radiator. Be sure that sealing surfaces are clean. Moisten rubber gasket with
water and install cap on pressure tester 7700 or an equivalent. Operate tester pump to bring
pressure to 104 kPa (15 psi) on gauge. If pressure cap fails to hold pressure of at least 97 kPa (14
psi) replace cap. The pressure cap may test properly while positioned on tool 7700 (or equivalent).
It may not hold pressure or vacuum when installed on radiator. If so, inspect radiator filler neck and
cap's top gasket for damage. Also inspect for dirt or distortion that may prevent cap from sealing
properly.
CAUTION: Radiator pressure testing tools are very sensitive to small air leaks, which will not cause
cooling system problems. A pressure cap that does not have a history of coolant loss should not be
replaced just because it leaks slowly when tested with this tool. Add water to tool. Turn tool upside
down and recheck pressure cap to confirm that cap needs replacement.
INSPECTION
Hold cap at eye level, right side up. The vent valve at bottom of cap should open. If rubber gasket
has swollen and prevents vent valve from opening, replace cap. Hold cap at eye level, upside
down. If any light can be seen between vent valve and rubber gasket, replace cap. Do not use a
replacement cap that has a spring to hold vent shut. A replacement cap must be the type designed
for a coolant reserve/overflow system with a completely sealed diaphragm spring and a rubber
gasket. This gasket is used to seal to radiator filler neck top surface. Use of proper cap will allow
coolant return to radiator.
Testing and Inspection > Radiator Cap - Pressure Testing > Page 1763
Radiator Cap: Testing and Inspection Radiator Cap to Filler Neck Seal - Pressure Relief Check
RADIATOR CAP-TO-FILLER NECK SEAL PRESSURE RELIEF CHECK
The pressure cap upper gasket (seal) pressure relief can be tested by removing overflow hose
from radiator filler neck nipple. Attach hose of pressure tester tool 7700 (or equivalent) to nipple. It
will be necessary to disconnect hose from its adapter for filler neck. Pump air into radiator. The
pressure cap upper gasket should relieve at 69-138 kPa (10-20psi) and hold pressure at a
minimum of 55 kPa (8 psi).
WARNING: THE WARNING WORDS (DO NOT OPEN HOT) ON RADIATOR PRESSURE CAP,
ARE A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM.
TO PREVENT SCALDING OR INJURY, RADIATOR CAP SHOULD NOT BE REMOVED WHILE
SYSTEM IS HOT AND/OR UNDER PRESSURE.
Do not remove radiator cap at any time except for the following purposes: ^
Check and adjust antifreeze freeze point
^ Refill system with new antifreeze
^ Conducting service procedures
^ Checking for vacuum leaks

WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT AT LEAST 15 MINUTES BEFORE
REMOVING RADIATOR CAP. WITH A RAG, SQUEEZE RADIATOR UPPER HOSE TO CHECK
IF SYSTEM IS UNDER PRESSURE. PLACE A RAG OVER CAP AND WITHOUT PUSHING CAP
DOWN, ROTATE IT COUNTERCLOCKWISE TO FIRST STOP. ALLOW FLUID TO ESCAPE
THROUGH THE COOLANT RESERVE/OVERFLOW HOSE INTO RESERVE/OVERFLOW TANK.
SQUEEZE RADIATOR UPPER HOSE TO DETERMINE WHEN PRESSURE HAS BEEN
RELEASED. WHEN COOLANT AND STEAM STOP BEING PUSHED INTO TANK AND SYSTEM
PRESSURE DROPS, REMOVE RADIATOR CAP COMPLETELY.
RADIATOR CAP
PRESSURE TESTING
Pressure Testing Radiator Cap
Remove cap from radiator. Be sure that sealing surfaces are clean. Moisten rubber gasket with
water and install cap on pressure tester 7700 or an equivalent. Operate tester pump to bring
pressure to 104 kPa (15 psi) on gauge. If pressure cap fails to hold pressure of at least 97 kPa (14
psi) replace cap. The pressure cap may test properly while positioned on tool 7700 (or equivalent).
It may not hold pressure or vacuum when installed on radiator. If so, inspect radiator filler neck and
cap's top gasket for damage. Also inspect for dirt or distortion that may prevent cap from sealing
properly.
CAUTION: Radiator pressure testing tools are very sensitive to small air leaks, which will not cause
cooling system problems. A pressure cap that does not have a history of coolant loss should not be
replaced just because it leaks slowly when tested with this tool. Add water to tool. Turn tool upside
down and recheck pressure cap to confirm that cap needs replacement.
INSPECTION
Testing and Inspection > Radiator Cap - Pressure Testing > Page 1764
Hold cap at eye level, right side up. The vent valve at bottom of cap should open. If rubber gasket
has swollen and prevents vent valve from opening, replace cap. Hold cap at eye level, upside
down. If any light can be seen between vent valve and rubber gasket, replace cap. Do not use a
replacement cap that has a spring to hold vent shut. A replacement cap must be the type designed
for a coolant reserve/overflow system with a completely sealed diaphragm spring and a rubber
gasket. This gasket is used to seal to radiator filler neck top surface. Use of proper cap will allow
coolant return to radiator.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
NUMBER: 26-11-97F

81-699-97019

165
Torque 11 Nm


following:
conditioning:


REMOVAL

SENSOR.
type tab.
INSTALLATION
battery.
Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
SYSTEM OPERATION
data bus.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
diagnosis.

INJURY.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator,
Engine Cooling > Component Information > Description and Operation
SYSTEM OPERATION
(CTM).
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator,
Engine Cooling > Component Information > Description and Operation > Page 1788
running.

INJURY.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Thermostat: Specifications
THERMOSTAT TEMPERATURE OPERATING RANGE:
INFORMATION NOT SUPPLIED BY THE MANUFACTURER.

Thermostat: Description and Operation
Thermostats installed in the 3.9L/5.2L/5.9L engines are of the wax- pellet-driven,

reverse-poppet-choke-type. The wax pellet is located in a sealed container at spring end of
thermostat. When heated, the pellet expands, overcoming closing spring tension and water pump
pressure to force valve to open. Coolant leakage into pellet container will cause thermostat to fail in
open position. Do not attempt to free a sticking thermostat with a prying device. The thermostat
controls the operating temperature of the engine by controlling the amount of coolant flow to
radiator. On all engines, the thermostat is closed below 88°C (192°F). When coolant reaches this
temperature, thermostat begins to open allowing coolant flow to radiator. This provides quick
engine warm-up and overall temperature control. The thermostat is designed to provide a minimum
engine operating temperature range of from 88 to 93°C (192 to 199°F). The thermostat should be
fully open for maximum coolant flow during operation in hot ambient temperatures of approximately
104°C (220°F). Above 104°C (220°F), coolant temperature is controlled by radiator, fan and
ambient temperature. An arrow, plus the word UP is stamped on front flange next to air bleed. The
words TO RAD are stamped on one arm of thermostat. They indicate proper installed position. The
same thermostat is used for winter and summer seasons.
CAUTION: Do not operate an engine without a thermostat, except for servicing or testing.
An engine should not be operated without a thermostat, except for servicing or testing. Operating
without a thermostat causes longer engine warm-up time, unreliable warm-up performance,
increased exhaust emissions and crankcase condensation that can result in sludge formation.
Thermostat: Service and Repair
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR DRAINCOCK OR CAP WITH THE SYSTEM HOT
AND PRESSURIZED. SERIOUS BURNS FROM THE COOLANT CAN OCCUR.
Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for
reuse. If the thermostat is being replaced, be sure that the replacement is the specified thermostat
for the vehicle model and engine type. Factory installed thermostat housings on all engines are
installed on a gasket with an anti-stick coating. This will aid in gasket removal and clean-up. 1.
Disconnect negative battery cable at battery. 2. Drain cooling system until coolant level is below
thermostat. 3. If equipped with air conditioning:
a. Remove engine cover from vehicle interior.
Generator Support Bracket
b. Remove the support bracket (generator mounting bracket-to-intake manifold) located near the
rear of generator.
Automatic Belt Tensioner-Belt Removal/Installation
c. The generator must be partially removed. Drive belts on all engines are equipped with a spring
loaded automatic belt tensioner. Remove the
generator drive belt as follows:
d. Attach a socket/wrench to the pulley mounting bolt of the automatic tensioner.

e. Rotate the tensioner assembly clockwise (as viewed from front) until tension has been relieved
from belt. f.
Remove belt from generator pulley.
g. Remove the two generator mounting bolts. Do not remove any wiring at generator. h. Remove
generator. Position generator to gain access for thermostat gasket removal.
PCM Location
i. Remove the three powertrain control module (PCM) mounting bolts and remove PCM. Do not
disconnect 60-way connector from PCM. Lay PCM aside.
4. Remove upper radiator hose clamp. Remove upper radiator hose at thermostat housing. 5.
Position the wiring harness (behind the thermostat housing) to gain access to thermostat housing.
Thermostat-Typical
6. Remove thermostat housing mounting bolts, thermostat housing, gasket and thermostat. Discard
old gasket.
INSTALLATION
1. Clean mating areas of intake manifold and thermostat housing. 2. Install thermostat (spring side
down) into recessed machined groove on intake manifold. 3. Install gasket on intake manifold and
over thermostat.
Thermostat Position
4. Position the thermostat housing to the intake manifold. Note the word FRONT stamped on the
housing. For adequate clearance, this must be
placed towards the front of vehicle. The housing should be slightly angled forward after installation
to intake manifold.
5. Install two housing-to-intake manifold bolts.
Tighten bolts to 23 Nm (200 inch lbs.) torque.
CAUTION: Housing must be tightened evenly and thermostat must be centered into recessed
groove in intake manifold. If not, it may result in a cracked housing, damaged intake manifold
threads or coolant leak.
6. Install upper radiator hose to thermostat housing. 7. Air conditioned vehicles:
a. Install generator.
Tighten bolts to 41 Nm (30 ft. lbs.).
b. Install support bracket (generator mounting bracket-to-intake manifold).
Tighten bolts to 54 Nm (40 ft. lbs.) torque.
Accessory Drive Belt Routing-All Engines
CAUTION: When installing the serpentine accessory drive belt, the belt must be routed correctly. If
not, the engine may overheat due to the water pump rotating in the wrong direction. Refer to
Engine, Drive Belts, Mounts, Brackets and Accessories, d
Drive Belt for correct engine belt routing. The correct belt with the correct length must be used.
c. Position the drive belt over all pulleys except the idler pulley (located between the generator and
A/C compressor). d. Attach a socket/wrench to the pulley mounting bolt of the automatic tensioner.
e. Rotate the socket/wrench clockwise. Place the belt over the idler pulley. Let tensioner rotate
back into place. Remove wrench. Be sure belt is
properly seated on all pulleys.
f. Install PCM.
schematics on Belt Routing Label. This label is located in the engine compartment. 8. Fill cooling
system. 9. Connect battery negative cable.
10. Start and warm engine. Check for leaks. 11. Install engine cover (if A/C equipped).
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling >
Thermostat Housing: Specifications
Thermostat Housing 225 in.lb

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications
Water Pump: Specifications
Water Pump Mounting Bolts 30 ft.lb
Water Pump Pulley 16 ft.lb
Water Pump-to-Chain Case Cover Bolt 31 ft.lb

Water Pump: Description and Operation
A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold,
radiator core, cooling system hoses and heater core. The pump is driven from the engine
crankshaft by a drive belt.
The water pump impeller is pressed onto the rear of a shaft that rotates in a bearing pressed into
the water pump body. The body has a small hole for ventilation. The water pump seals are
lubricated by antifreeze in the coolant mixture. Additional lubrication is not necessary.
A quick test to determine if pump is working is to check if heater warms properly. A defective water
pump will not be able to circulate heated coolant through the long heater hose to the heater core.
The water pump on all models can be removed without discharging the air conditioning system (if
equipped).
Service and Repair > Water Pump Replacement
Water Pump: Service and Repair Water Pump Replacement
REMOVAL
The water pump on all engines is bolted directly to the engine timing chain case/cover. A gasket is
used as a seal between the water pump and timing chain case/cover. If water pump is replaced
because of bearing/shaft damage or leaking shaft seal, the mechanical cooling fan assembly
should also be inspected. Inspect for fatigue cracks, loose blades or loose rivets that could have
resulted from excessive vibration. Replace fan if any of these conditions are found. Also check
condition of the thermal viscous fan drive. 1. Disconnect negative battery cable from battery. 2.
Drain cooling system. 2. Do not waste reusable coolant. If solution is clean, drain coolant into a
clean container for reuse. 3. Remove the plastic air cleaner intake tube. 4. Remove two-piece fan
shroud. Remove lower half first.
5. Remove upper radiator hose at radiator.

Service and Repair > Water Pump Replacement > Page 1807
Fan Blade And Viscous Fan Drive-Typical
6. The thermal viscous fan drive is attached (threaded) to the water pump hub shaft. Remove the
fan/fan drive assembly from water pump by turning
the mounting nut counterclockwise (as viewed from front). Threads on the fan drive are RIGHT
HAND. A Snap-On 36 MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set
number 2017DSP) can be used. Place a bar or screwdriver between the water pump pulley bolts to
prevent the pulley from rotating.
7. If water pump is being replaced, do not unbolt fan blade assembly from the thermal viscous fan
drive. 8. Remove fan blade/fan drive assembly from vehicle. 9. After removing fan blade/fan drive
assembly, do not place the thermal viscous fan drive in the horizontal position. If stored
horizontally, the
silicone fluid in the viscous drive could drain into its bearing assembly and contaminate the bearing
lubricant.
10. Do not remove the water pump pulley bolts at this time.
Automatic Belt Tensioner-Typical
11. Remove accessory drive belt as follows: The drive belt is equipped with a spring loaded
automatic belt tensioner. Relax the tension from the belt
by rotating the tensioner clockwise (as viewed from front). When all belt tension has been relaxed,
remove accessory drive belt.
12. Remove the four water pump pulley-to-water pump hub bolts and remove pulley from engine.
13. Remove the lower radiator hose at water pump.
Coolant Return Tube-Typical
14. Loosen heater hose coolant return tube mounting bolt and remove tube from water pump.
Discard the old tube O-ring. 15. Remove the seven water pump mounting bolts. 16. Loosen the
clamp at the water pump end of bypass hose. Slip the bypass hose from the water pump while
removing pump from engine. Do not
remove the clamp from the bypass hose.
17. Discard old gasket.
CAUTION: Do not pry the water pump at timing chain case/cover. The machined surfaces may be
damaged resulting in leaks.
INSTALLATION
Water Pump Bolts-Typical
1. Clean gasket mating surfaces. 2. Using a new gasket, install water pump to engine as follows:
Guide water pump fitting into bypass hose as pump is being installed. Install water
pump mounting bolts. Tighten bolts in a criss-cross pattern to 40 Nm (30 ft. lbs.) torque.
3. Position bypass hose clamp to bypass hose. 4. Spin water pump to be sure that pump impeller
does not rub against timing chain case/cover. 5. Install a new O-ring to the heater hose coolant
return tube. Coat the new O-ring with antifreeze before installation. 6. Install coolant return tube
and its mounting bolt to engine. Be sure the slot in tube bracket is bottomed to mounting bolt. This
will properly
position return tube.
7. Connect radiator lower hose to water pump. 8. Connect heater hose and hose clamp to coolant
return tube. 9. Install water pump pulley. Tighten bolts to 27 Nm (20 ft. lbs.) torque. Place a bar or
screwdriver between water pump pulley bolts to prevent
pulley from rotating.
10. Relax tension from automatic belt tensioner. Install drive belt.
CAUTION: When installing the serpentine accessory drive belt, belt must be routed correctly. If not,
engine may overheat due to water pump rotating in wrong direction. Refer to the Belt Routing Label
for correct belt routing. The correct belt with correct length must be used.
The provided belt routing schematics are published from the latest information available at the time
schematics on Belt Routing Label. This label is located in the engine compartment.
11. Install the fan blade/viscous fan drive assembly to water pump shaft. 12. Install fan shroud. 13.
Install plastic air cleaner intake tube. 14. Install upper radiator hose and hose clamp to radiator. 15.
Fill cooling system. 16. Connect negative battery cable. 17. Start and warm the engine. Check for
leaks.
Water Pump: Service and Repair Cleaning and Inspection
Replace water pump assembly if it has any of the following conditions: ^
The body is cracked or damaged
^ Water leaks from the shaft seal. This is evident by traces of coolant below the vent hole
^ Loose or rough turning bearing. Also inspect thermal viscous fan drive
^ Impeller rubs either the pump body or timing chain case/cover

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Service Precautions > Customer Safety Information
Catalytic Converter: Customer Safety Information
CATALYTIC CONVERTER
The catalytic converter routinely reaches operating temperatures of 650° C (1200° F) and will stay
hot for some time after the engine has been shut off. Do NOT park the vehicle over any object or
material that could ignite (i.e. dry leaves, cardboard, puddles of oil, or other combustibles).
CARBON MONOXIDE
Exhaust gas contains toxic carbon monoxide. Do not run the engine in confined areas or breathe
concentrated exhaust gases. Breathing exhaust gases may cause loss of consciousness or death.
EXHAUST SYSTEM LEAKS
Repair any leaks in the exhaust system as soon as possible. Hot gases escaping from the leak can
ignite flammable materials and may set the vehicle on fire.
Also exhaust may circulate through the passenger compartment causing throat, sinus, and eye
irritation, light headedness, headaches, and increased irritability, especially while driving with
windows closed.
FUEL ODORS/EXCESSIVE EMISSIONS
Be alert for fuel odors and excessive tailpipe emissions (black smoke etc...). These indicate a
problem that should be corrected as soon as possible (excessive emissions can ruin oxygen
sensors, catalytic converters, and other expensive emission components).
Information > Service Precautions > Customer Safety Information > Page 1816
Catalytic Converter: Technician Safety Information
WHEN SERVICING ANY VEHICLE OBSERVE THE FOLLOWING CAUTIONS:
1. Always wear appropriate eye protection.
2. Block the drive wheels as a safety routine before beginning any service with the vehicle on the
ground.
3. Never work under a vehicle supported only by a jack. Use jackstands on a flat and level hard
surface for safe support.
4. Use caution when working near the catalytic converter to prevent the possibility of burns. The
temperatures within the converter can exceed
1200°F.
5. Exercise care when working with spring or tension loaded fasteners such as E-clips, or snap
rings, careless removal can cause personal injury.
Catalytic Converter: Vehicle Damage Warnings
CATALYTIC CONVERTERS
On vehicles equipped with catalytic converters, the following conditions must be observed:
- Use only "UNLEADED FUEL".
- Avoid running out of fuel.
- In case of poor engine operation (misfiring), avoid driving the vehicle and correct the problem as
soon as possible.
- Do not disconnect any spark plug wires with the engine running.
- Avoid push starting the vehicle.
- If running on a dynamometer, make sure the catalytic converter is well ventilated.
- Use caution when working near the catalytic converter to prevent the possibility of burns.
OXYGEN SENSORS AND SILICONE
Do not use silicone based products on an oxygen sensor equipped vehicle to avoid damaging the
sensor.
COMPRESSION TESTING
When performing a compression test, remove the fuel pump relay fuse, and disconnect power to
the ignition (This will stop fuel flow to the injectors and prevent engine from starting).
Information > Service Precautions > Page 1818
Catalytic Converter: Description and Operation
CONSTRUCTION
The stainless steel catalytic converter body is designed to last the life of the vehicle.
HEAT
Excessive heat can result in bulging or other distortion, but excessive heat will not be the fault of
the converter. If unburned fuel enters the converter, overheating may occur. If a converter is
heat-damaged, correct the cause of the damage at the same time the converter is replaced. Also,
inspect all other components of the exhaust system for heat damage.
CAUTION: Unleaded gasoline must be used to avoid contaminating the catalyst core.
Information > Service and Repair > Removal and Installation
Catalytic Converter: Service and Repair Removal and Installation
CATALYTIC CONVERTER WITH PIPES
REMOVAL
1. Raise and support vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5
minutes for penetration.
3. Remove clamps and nuts. 4. Remove the catalytic converter.
INSTALLATION
1. Assemble converter and clamps loosely in place. 2. Install the exhaust pipe onto exhaust
manifolds, tighten 34 Nm (25 ft. lbs.). 3. Tighten all clamp nuts to 43 Nm (32 ft. lbs.) torque. 4.
Lower the vehicle. 5. Start the engine and inspect for exhaust leaks and exhaust system contact
with the body panels. A minimum of 25.4 mm (1.0 in.) is required
between exhaust system components and body/frame parts. Adjust the alignment, if needed.
CLEANING
Clean ends of pipes and muffler to assure a good seal at mating surfaces.
Information > Service and Repair > Removal and Installation > Page 1821
Catalytic Converter: Service and Repair Cleaning and Inspection
CATALYTIC CONVERTER
INSPECTION
Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be
a result of overheating. If the converter has a heat shield attached make sure it is not bent or loose.
WARNING: UNLEADED FUEL MUST BE USED TO PREVENT BLOCKAGE OR

CONTAMINATION TO THE CATALYST CORE.
If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber
mallet may indicate a damaged core.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information
> Specifications
Exhaust Manifold: Specifications
To Head Bolts/Nuts .............................................................................................................................

..................................................... 34 Nm (25 ft. lbs.) To Exhaust Pipe ...............................................
......................................................................................................................................... 26 Nm (19
ft. lbs.)
Exhaust Manifold: Description and Operation
The exhaust manifolds are constructed of cast iron and are LOG type with balanced flow. Engine
exhaust manifolds are constructed with porting for air injection into the LOG.
> Service and Repair > Removal and Installation
Exhaust Manifold: Service and Repair Removal and Installation
REMOVAL
1. Disconnect the negative cable from the battery. 2. Raise and support the vehicle. 3. Remove the
bolts and nuts attaching the exhaust pipe to the engine exhaust manifold. 4. Lower the vehicle. 5.
Remove the engine cover.
Engine Heat Shield-Left Side
6. Remove the exhaust heat shields. 7. Remove bolts, nuts and washers attaching manifold to
cylinder head. 8. Remove manifold from the cylinder head.
INSTALLATION
CAUTION: If the studs came out with the nuts when removing the engine exhaust manifold, install
new studs. Apply sealer on the coarse thread ends.. Water leaks may develop at the studs if this
precaution is not taken.
Engine Exhaust Manifold Installation - V-6

> Service and Repair > Removal and Installation > Page 1828
Engine Exhaust Manifold Installation - V-8
1. Position the engine exhaust manifolds on the two studs located on the cylinder head. Install
conical washers and nuts on these studs. 2. Install two bolts and conical washers at the inner ends
of the engine exhaust manifold outboard. arms. Install two bolts WITHOUT washers on the
center arm of engine exhaust manifold. Starting at the center arm and working outward, tighten the
bolts and nuts to 34 Nm (25 ft. lbs.) torque.
3. Install the exhaust heat shields. Tighten the screws to 6 Nm (55 inch lbs.) torque. 4. Install the
engine cover. 5. Raise and support the vehicle. 6. Assemble exhaust pipe to manifold and secure
with bolts, nuts and retainers. Tighten the bolts and nuts to 26 Nm (19 ft. lbs.) torque. 7. Lower the
vehicle. 8. Connect the negative cable to the battery.
> Service and Repair > Removal and Installation > Page 1829
Exhaust Manifold: Service and Repair Cleaning and Inspection
CLEANING
Clean mating surfaces on cylinder head and manifold. Wash with solvent and blow dry with
compressed air.
INSPECTION
Inspect manifold for cracks. Inspect mating surfaces of manifold for flatness with a straight edge.
Gasket surfaces must be flat within 0.2 mm per 300 mm (0.008 inch per foot).
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Specifications
Exhaust Pipe: Specifications
Exhaust Pipe - to - Exhaust Manifold 25 ft.lb
Ehaust Clamps (All) Nuts 32 ft.lb

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Exhaust Pipe: Service and Repair
TAILPIPE
WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, WEAR
PROTECTIVE EYE COVERING AND DO NOT ALLOW THE FLAME NEAR THE FUEL LINES.
CAUTION: When servicing or replacing exhaust system components, be sure to disconnect all
oxygen sensor connectors. Allowing the exhaust system to hang by the harness will damage the
wiring and/or sensor.
REMOVAL
1. Disconnect battery negative cable. 2. Raise and support the vehicle.
3. Remove the tailpipe hanger rods from the front and rear mount insulators. 4. Remove the tailpipe
to muffler exhaust clamp. 5. Heat the muffler to tailpipe connection with an oxygen/acetylene torch.
6. Remove the tailpipe.
INSTALLATION
1. Clean ends of pipes and muffler to assure mating of all parts. 2. Position the tailpipe into the
muffler. Install the nuts onto the clamp bolt finger tight. 3. Insert the tailpipe hanger rods into the
insulators. 4. Verify exhaust system alignment and tighten the muffler rear clamp nuts to 43 Nm (32
ft. lbs.) torque. 5. Lower the vehicle. 6. Start the engine and inspect for exhaust leaks and exhaust
system contact with the body panels. Adjust the alignment, if needed.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component
Exhaust Pipe/Muffler Hanger: Specifications
Tailpipe Hanger (Front) Bolts 30 in.lb
Tailpipe Hanger (Rear) Bolt 170 in.lb

Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Heat Shield: Specifications
Heat Shields (All) Bolts/Nuts 100 in.lb

Heat Shield: Description and Operation
Exhaust heat shields are needed to protect both the vehicle and the environment from the high
temperatures developed by the catalytic converter. The
combustion reaction facilitated by the catalyst releases additional heat in the exhaust system.
Under severe operating conditions, the temperature increases in the area of the reactor. Such
conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. DO
NOT remove spark plug wires from plugs or by any other means short out cylinders. Failure of the
catalytic converter can occur due to a temperature increase caused by unburned fuel passing
through the converter. Do not allow the engine to operate at fast idle for extended periods (over 5
minutes). This condition may result in excessive temperatures in the exhaust system and on the
floor pan.
Heat Shield: Service and Repair
REMOVAL
1. Raise and support the vehicle.
2. Remove the nuts or bolts holding the exhaust heat shield to the floor pan, crossmember or
bracket. 3. Slide the shield out around the exhaust system.
INSTALLATION
1. Position the exhaust heat shield to the floor pan, crossmember or bracket and install the nuts or
bolts. 2. Tighten the nuts or bolts to 11 Nm (100 inch lbs.). 3. Lower the vehicle.
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair
Muffler: Service and Repair
WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, WEAR
PROTECTIVE EYE COVERING AND DO NOT ALLOW THE FLAME NEAR THE FUEL LINES.
CAUTION: When servicing or replacing exhaust system components, be sure to disconnect all
oxygen sensor connectors. Allowing the exhaust system to hang by the harness will damage the
wiring and/or sensor.
REMOVAL
1. Disconnect battery negative cable. 2. Raise and support the vehicle.
3. Remove tailpipe front and rear hanger rods from their insulators. 4. Remove muffler to converter
and muffler to tailpipe exhaust clamps. 5. Heat muffler to tailpipe connection with an
oxygen/acetylene torch. Twist tailpipe off of muffler. 6. Heat muffler to converter connection with an
oxygen/acetylene torch. Twist muffler off of converter pipe. 7. Remove muffler from vehicle.
INSTALLATION
1. Install the muffler into the catalytic converter flange pipe. Install the clamp and tighten the nuts
by hand. 2. Install the tailpipe into the rear of the muffler. Install the clamp and tighten the nuts by
hand. 3. Connect the tailpipe hanger rods to the insulators. 4. Verify exhaust system alignment and
tighten both muffler clamp nuts to 43 Nm (32 ft. lbs.) torque. 5. Lower the vehicle. 6. Connect the
battery negative cable. 7. Start the engine and inspect for exhaust leaks and exhaust system
contact with the body panels. Adjust the alignment, if needed.
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component
Locations
Module Locations
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component

Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Introduction
8w-01-002
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

position
problem
Testing For Voltage
Testing For Voltage


Probing Tool

CTM Connector
CTM Connector
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Central Timer Module Description
would perform.
- Chime
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Central Timer Module Description > Page 1878
harnesses.
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Component Tests and General Diagnostics
- symptom analysis
- problem isolation

Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM
June 1999
Models
transmission)
NOTE:
Subject
Repair
Parts Information
payments.
Number Allowance

NOTE:
Parts Return
Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 1889
Not Applicable
48326-2757
Service Office.
Service Procedure
Using the MDS1
power them up.
MENU screen.
MENU.
NOTE:
Using the MDS2

SCREEN.
SCREEN.
NOTE:
begin the session.
NOTE:
Fig. 1
Fig. 2
Owner Letter
The problem is...
and processed.
What you must do...
If you need help...
vehicle repaired.
Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-08-99F > Aug
> 99 > Engine Controls/Charging System - Manual Updates
Manual Updates
NUMBER: 26-08-99F
DATE: August, 1999

> 99 > Engine Controls/Charging System - Manual Updates > Page 1897
71
> 99 > Engine Controls/Charging System - Manual Updates > Page 1898
744
Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 831 > Jun > 99 >
June 1999
Models
transmission)
NOTE:
Subject
Repair
Parts Information
payments.
Number Allowance

NOTE:
Parts Return
Recall - Reprogram PCM > Page 1903
Not Applicable
48326-2757
Service Office.
Service Procedure
Using the MDS1
power them up.
MENU screen.
MENU.
NOTE:
Using the MDS2

SCREEN.
SCREEN.
NOTE:
begin the session.
NOTE:
Fig. 1
Fig. 2
Owner Letter
The problem is...
and processed.
What you must do...
If you need help...
vehicle repaired.
Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun
> 98 > Powertrain Control Module - Service Precaution
Precaution
NO: 18-21-98
DATE: Jun. 5, 1998
SUBJECT:
MODELS:
1996 - 1998 (AB) Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
DISCUSSION:

Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 26-12-97H >
Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions
Manual Revisions
NUMBER: 26-12-97H
81-699-97027

Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 1914
29
56
58
412
Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 21-08-99 > Apr > 99
> A/T - Buzz/Whining in Reverse When Cold
Manual Updates
NUMBER: 26-08-99F
DATE: August, 1999

> A/T - Buzz/Whining in Reverse When Cold > Page 1923
71
> A/T - Buzz/Whining in Reverse When Cold > Page 1924
744
wiper motor.
Information > Diagrams > Diagram Information and Instructions
Introduction
8w-01-002
Information > Diagrams > Diagram Information and Instructions > Page 1929
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

position
problem
Testing For Voltage
Testing For Voltage


Probing Tool
SYSTEM OPERATION
Information > Service and Repair > Module Replacement
REMOVAL
INSTALLATION
Information > Service and Repair > Module Replacement > Page 1951
Important Note:
and Airbag modules.
PCM).
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Locations

> Component Information > Locations > Page 1955
8w-10-2

SYSTEM OPERATION

TESTING

volt power source.

REMOVAL
INSTALLATION
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations

Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1964
8w-10-2


Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >

8w-10-2

SYSTEM OPERATION

TESTING

volt power source.

REMOVAL
INSTALLATION
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations
1981

1982
.
1983
SYSTEM OPERATION
Inspection > Testing
on battery tray.
REMOVAL
INSTALLATION
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations

Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page
1990

1991
SYSTEM OPERATION
1992
this
test.
necessary.
1993
REMOVAL
INSTALLATION
engine cover.
NUMBER: 26-11-97F

81-699-97019

165
Torque 11 Nm


following:
conditioning:


REMOVAL

SENSOR.
type tab.
INSTALLATION
battery.
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
Mounting Bolts 8 Nm
Page 2008
Page 2009

Page 2010
SYSTEM OPERATION
Sensor Operation
outer edge.
Page 2011
Page 2012
REMOVAL
INSTALLATION
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications
IAT Sensor
Torque 28 Nm
Page 2016

Page 2017

Page 2018
Page 2019
REMOVAL
INSTALLATION
connector.
> Page 2023

> Page 2024

> Page 2025
test meter probes.

> Page 2026
necessary.
> Page 2027
REMOVAL
INSTALLATION
> Engine Controls/Fuel System - Manual Revisions
NUMBER: 26-01-99C
DATE: January, 1999

vi
538

589
589A
589B
589C
589D
589E
589F
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications
Torque 30 Nm
Bank Locations

Bank Locations > Page 2046


REMOVAL
into sensor.
INSTALLATION
Revisions
NUMBER: 26-02-99A

45
46
47
152
156
316
620
622

millivolts.
WOT.
REMOVAL
INSTALLATION
rotated.
Locations

Introduction
8w-01-002
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

position
problem
Testing For Voltage
Testing For Voltage


Probing Tool
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2094
Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. See: Brakes
and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor The sensor
is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB)
computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine
vehicle speed and distance covered. The PCM will then determine strategies for fuel system and
speed control system operation.
Four Wheel Antilock Brakes
REMOVAL
INSTALLATION
Four Wheel Antilock Brakes > Page 2097
REMOVAL
sensor stud.
INSTALLATION
Revisions
NUMBER: 26-02-99A

45
46
47
152
156
316
620
622

millivolts.
WOT.
REMOVAL
INSTALLATION
rotated.
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations


SYSTEM OPERATION
this
test.
necessary.
REMOVAL
INSTALLATION
engine cover.
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications
Mounting Bolts 8 Nm

SYSTEM OPERATION
Sensor Operation
outer edge.
REMOVAL
INSTALLATION
Operation
SYSTEM OPERATION
REMOVAL
Lower Shroud Screws
Shroud Pivot Point

Upper Shroud Screws
removal.
removal.
INSTALLATION
position.

Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage
NO: 14-03-98
MODELS: 1996 - 1998 (AB)
Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
DISCUSSION:

System Information > Specifications > Pressure, Vacuum and Temperature Specifications
Fuel Pressure

........................................ 339 ± 34 kPa (49.2 ± 5 psi)

minutes
System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 2148
seconds.

System Information > System Diagnosis > Fuel Pressure Leak Down Test
Test.
operational.
(Fig. 9) or (Fig. 10).

System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2151
Adapter Tool.
on Adapter Tool.
specification.
information.
location.
ARE CONNECTED.
type-2 and type-3.
Starter Relay
Type-2 Relay
Type-3 Relay
pump module is OK.
seconds.

Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture >
System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions
NUMBER: 26-02-99A

System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2161
45
46
47

152
156

316

620
622
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System

......................................................... 500 to 900 rpm

column.
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
REMOVAL
body.
INSTALLATION
engine cover.
AIR CLEANER ELEMENT
REMOVAL
INSTALLATION
engine cover.
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair
cylinder chamber.
battery.

Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing >
Number One Cylinder > Component Information > Locations
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 >
NO: 18-48-98
DATE: Dec. 30, 1998
MODELS:
1994 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
NOTE:
SYMPTOM/CONDITION:
mph).
DIAGNOSIS:
NOTE:

PARTS REQUIRED:

TIME ALLOWANCE:
08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs.
(AN/DN) 5.2/5.9L 0.3 Hrs.
(BR/BE) 5.2/5.9L 0.4 Hrs.

Repair Procedure
NOTE:
90° ANGLE.
NOTE:
CLIPS.
studs).
and 82.5 mm (3.25 in.).
NOTE:
tower terminal.
cover.
NOTE:
(Figure 5).
NOTE:
LAYOUT APPLIES.
NOTE:
NOTE:
valve cover.
elbow.
NOTE:
3.9L Engine
(Figure 11).
studs).
one (1) at 82.5 mm (3.25 in.).
studs).
NOTE:
tower terminal.
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec
> 98 > Ignition System - Cross Fire/Ignition Wire Induction
NO: 18-48-98
DATE: Dec. 30, 1998
MODELS:
1994 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
NOTE:
SYMPTOM/CONDITION:
mph).
DIAGNOSIS:
NOTE:

PARTS REQUIRED:

TIME ALLOWANCE:
08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs.
(AN/DN) 5.2/5.9L 0.3 Hrs.
(BR/BE) 5.2/5.9L 0.4 Hrs.

> 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2207
Repair Procedure
NOTE:
90° ANGLE.
NOTE:
CLIPS.
studs).
and 82.5 mm (3.25 in.).
NOTE:
tower terminal.
cover.
NOTE:
(Figure 5).
NOTE:
LAYOUT APPLIES.
NOTE:
NOTE:
valve cover.
elbow.
NOTE:
3.9L Engine
(Figure 11).
studs).
one (1) at 82.5 mm (3.25 in.).
studs).
NOTE:
tower terminal.
Ohms Per Foot
SYSTEM OPERATION
Heat Shields
shield.
Testing
follows:
exceed ten minutes.

Cable Removal
Engine Firing Order
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Distributor Cap > Component Information > Testing and Inspection
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Ignition Rotor > Component Information > Testing and Inspection
adverse conditions.
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Electrode Gap ......................................................................................................................................

..................................................... 0.89 mm (0.035 in) Torque ............................................................
............................................................................................................................................... 41 Nm
(30 ft lb)
Plug Type ............................................................................................................................................

..................................................................... RC12YC
SYSTEM OPERATION
oil fouled.
Normal Operating

Scavenger Deposits
Scavenger Deposit
Preignition Damage
Preignition Damage
overheating.
Heat Shields
spark plug.
plug condition.
adjusting gap.
electrode.
damaged.
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 2236
malfunctions.

Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
times.
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor
IAT Sensor
Torque 28 Nm


REMOVAL
INSTALLATION
connector.
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor >

.
SYSTEM OPERATION
Component Information > Testing and Inspection > Testing
Component Information > Testing and Inspection > Page 2256
on battery tray.
REMOVAL
INSTALLATION
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Component Locations
Module Locations
Component Information > Locations > Component Locations > Page 2261

Component Information > Diagrams > Diagram Information and Instructions
Introduction
8w-01-002
Component Information > Diagrams > Diagram Information and Instructions > Page 2264
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

position
problem

Testing For Voltage
Testing For Voltage


Probing Tool

CTM Connector
CTM Connector

Component Information > Description and Operation > Central Timer Module Description
would perform.
- Chime
Component Information > Description and Operation > Central Timer Module Description > Page 2287
harnesses.
Component Information > Testing and Inspection > Component Tests and General Diagnostics
- symptom analysis
- problem isolation

Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >


SYSTEM OPERATION
this
test.
necessary.
REMOVAL
INSTALLATION
engine cover.
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - ECT Sensor
Test revisions
NUMBER: 26-11-97F

81-699-97019

Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - ECT Sensor
Test revisions > Page 2301
165
Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 2302
Torque 11 Nm


following:
conditioning:


REMOVAL

SENSOR.
type tab.
INSTALLATION
battery.
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Mounting Bolts 8 Nm

SYSTEM OPERATION
Sensor Operation
outer edge.
REMOVAL
INSTALLATION
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Data Link Connector: Locations
Data Link Connector
Data Link Connector

Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Data Link Connector

Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall -
Reprogram PCM
June 1999
Models
transmission)
NOTE:
Subject
Repair
Parts Information
payments.
Number Allowance

NOTE:
Parts Return
Not Applicable
48326-2757
Service Office.
Service Procedure
Using the MDS1
power them up.
MENU screen.
MENU.
NOTE:
Using the MDS2

SCREEN.
SCREEN.
NOTE:
begin the session.
NOTE:
Fig. 1
Fig. 2
Owner Letter
The problem is...
and processed.
What you must do...
If you need help...
vehicle repaired.
[Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates
Manual Updates
NUMBER: 26-08-99F
DATE: August, 1999

Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates > Page 2336
71
Powertrain Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates > Page 2337
744
Powertrain Control Module: > 831 > Jun > 99 > Recall - Reprogram PCM
June 1999
Models
transmission)
NOTE:
Subject
Repair
Parts Information
payments.
Number Allowance

NOTE:
Parts Return
Powertrain Control Module: > 831 > Jun > 99 > Recall - Reprogram PCM > Page 2342
Not Applicable
48326-2757
Service Office.
Service Procedure
Using the MDS1
power them up.
MENU screen.
MENU.
NOTE:
Using the MDS2

SCREEN.
SCREEN.
NOTE:
begin the session.
NOTE:
Fig. 1
Fig. 2
Owner Letter
The problem is...
and processed.
What you must do...
If you need help...
vehicle repaired.
Powertrain Control Module: > 18-21-98 > Jun > 98 > Powertrain Control Module - Service Precaution
Precaution
NO: 18-21-98
DATE: Jun. 5, 1998
SUBJECT:
MODELS:
1996 - 1998 (AB) Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
DISCUSSION:

Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions
Manual Revisions
NUMBER: 26-12-97H
81-699-97027

Powertrain Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page
2353
29
2354
56
2355
58
2356
412
[Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain
Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates
Manual Updates
NUMBER: 26-08-99F
DATE: August, 1999

Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates > Page 2362
71
Control Module: > 26-08-99F > Aug > 99 > Engine Controls/Charging System - Manual Updates > Page 2363
744
Control Module: > 18-21-98 > Jun > 98 > Powertrain Control Module - Service Precaution
Precaution
NO: 18-21-98
DATE: Jun. 5, 1998
SUBJECT:
MODELS:
1996 - 1998 (AB) Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
DISCUSSION:

Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions
Manual Revisions
NUMBER: 26-12-97H
81-699-97027

Control Module: > 26-12-97H > Dec > 97 > Engine Controls/Fuel System - Service Manual Revisions > Page 2372
29
56
58
412
[Engine Control Module] > Component Information > Technical Service Bulletins > Page 2376
[Engine Control Module] > Component Information > Technical Service Bulletins > Page 2377
wiper motor.
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions
Introduction
8w-01-002
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2380
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

position
problem

Testing For Voltage
Testing For Voltage


Probing Tool
[Engine Control Module] > Component Information > Diagrams > Page 2399
SYSTEM OPERATION
[Engine Control Module] > Component Information > Service and Repair > Module Replacement
REMOVAL
INSTALLATION
[Engine Control Module] > Component Information > Service and Repair > Module Replacement > Page 2402
Important Note:
and Airbag modules.
PCM).
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator -
Electronic > Component Information > Specifications
Idle Speed/Throttle Actuator - Electronic: Specifications IAC Motor
IAC Motor
Mounting Bolts 7 Nm
Electronic > Component Information > Specifications > Page 2406
Idle Speed/Throttle Actuator - Electronic: Locations
Map Sensor,idle Air Control Motor,TP Sensor

Idle Air Control Motor Connector

Idle Speed/Throttle Actuator - Electronic: Testing and Inspection
To perform a complete test of the idle air control motor and circuits see Computers and Control
Systems /System Diagnosis/Procedures/Diagnostic Charts.
Idle Speed/Throttle Actuator - Electronic: Service and Repair
REMOVAL
1. Remove air cleaner assembly. 2. Disconnect electrical connector from Idle Air Control (IAC)
motor.
Fig. 84 Mounting Bolts (Screws) - IAC
3. Remove two mounting bolts (screws). 4. Remove IAC motor from throttle body
INSTALLATION
1. Install IAC motor to throttle body 2. Install and tighten two mounting bolts (screws) to 7 N.m (60
in. lbs.) torque. 3. Install electrical connector. 4. Install air cleaner assembly.
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations

Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2413
8w-10-2

SYSTEM OPERATION

TESTING

volt power source.

REMOVAL
INSTALLATION
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >
Data Link Connector
Monitors).
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >
Management/Computers and Control Systems/Testing and Inspection. See: Testing and Inspection

INJURY.
circuitry, refer to Instrument Panel/Testing and Inspection. See: Instrument Panel, Gauges and
Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Specifications
Sensor > Component Information > Specifications > Page 2425


test meter probes.

necessary.
REMOVAL
INSTALLATION
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor >
Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions
NUMBER: 26-01-99C
DATE: January, 1999

vi

538

589
589A
589B
589C
589D
589E
589F
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Torque 30 Nm
Information > Locations > Oxygen Sensor Bank Locations

Information > Locations > Oxygen Sensor Bank Locations > Page 2448


REMOVAL
into sensor.
INSTALLATION
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules -
Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations
Module Locations
Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations >
Page 2458

Instructions
Introduction
8w-01-002
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

position
problem
Testing For Voltage
Testing For Voltage


Probing Tool

CTM Connector
CTM Connector
Timer Module Description
would perform.
- Chime
Timer Module Description > Page 2484
harnesses.
Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component
Tests and General Diagnostics
- symptom analysis
- problem isolation

Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM
June 1999
Models
transmission)
NOTE:
Subject
Repair
Parts Information
payments.
Number Allowance

NOTE:
Parts Return
Not Applicable
48326-2757
Service Office.
Service Procedure
Using the MDS1
power them up.
MENU screen.
MENU.
NOTE:
Using the MDS2

SCREEN.
SCREEN.
NOTE:
begin the session.
NOTE:
Fig. 1
Fig. 2
Owner Letter
The problem is...
and processed.
What you must do...
If you need help...
vehicle repaired.
Engine Controls/Charging System - Manual Updates
Manual Updates
NUMBER: 26-08-99F
DATE: August, 1999

71
744
Reprogram PCM
June 1999
Models
transmission)
NOTE:
Subject
Repair
Parts Information
payments.
Number Allowance

NOTE:
Parts Return
Not Applicable
48326-2757
Service Office.
Service Procedure
Using the MDS1
power them up.
MENU screen.
MENU.
NOTE:
Using the MDS2

SCREEN.
SCREEN.
NOTE:
begin the session.
NOTE:
Fig. 1
Fig. 2
Owner Letter
The problem is...
and processed.
What you must do...
If you need help...
vehicle repaired.
Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun > 98 >
Powertrain Control Module - Service Precaution
Precaution
NO: 18-21-98
DATE: Jun. 5, 1998
SUBJECT:
MODELS:
1996 - 1998 (AB) Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
DISCUSSION:

Engine Controls/Fuel System - Service Manual Revisions
Manual Revisions
NUMBER: 26-12-97H
81-699-97027

29
56
58
412
Controls/Charging System - Manual Updates
Manual Updates
NUMBER: 26-08-99F
DATE: August, 1999

71
744
Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun > 98 > Powertrain
Control Module - Service Precaution
Precaution
NO: 18-21-98
DATE: Jun. 5, 1998
SUBJECT:
MODELS:
1996 - 1998 (AB) Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
DISCUSSION:

Controls/Fuel System - Service Manual Revisions
Manual Revisions
NUMBER: 26-12-97H
81-699-97027

29
56
58
412
wiper motor.
Introduction
8w-01-002
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

position
problem
Testing For Voltage
Testing For Voltage


Probing Tool
Diagrams > Page 2566
SYSTEM OPERATION
Service and Repair > Module Replacement
REMOVAL
INSTALLATION
Service and Repair > Module Replacement > Page 2569
Important Note:
and Airbag modules.
PCM).

8w-10-2

SYSTEM OPERATION

TESTING

volt power source.

REMOVAL
INSTALLATION
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches -
Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations
Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2582

.
SYSTEM OPERATION
Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection >
Testing
Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page
2587
on battery tray.
REMOVAL
INSTALLATION
Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations

Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2591

SYSTEM OPERATION
this
test.
necessary.
REMOVAL
INSTALLATION
engine cover.
Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Technical Service Bulletins > Engine Controls - ECT Sensor Test revisions
NUMBER: 26-11-97F

81-699-97019

Technical Service Bulletins > Engine Controls - ECT Sensor Test revisions > Page 2599
165
Torque 11 Nm


following:
conditioning:


REMOVAL

SENSOR.
type tab.
INSTALLATION
battery.
Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
Mounting Bolts 8 Nm
Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2609

SYSTEM OPERATION
Sensor Operation
outer edge.
REMOVAL
INSTALLATION
Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications
IAT Sensor
Torque 28 Nm
Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2617


REMOVAL
INSTALLATION
connector.
Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page
2624

2625

2626
test meter probes.

2627
necessary.
2628
REMOVAL
INSTALLATION
Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine
Controls/Fuel System - Manual Revisions
NUMBER: 26-01-99C
DATE: January, 1999

Controls/Fuel System - Manual Revisions > Page 2633
vi
538

589
589A
589B
589C
589D
589E
589F
Computers and Control Systems > Oxygen Sensor > Component Information > Specifications
Torque 30 Nm
Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations

Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations
> Page 2647
Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2648


REMOVAL
into sensor.
INSTALLATION
Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel
System/Engine Controls - Manual Revisions
Revisions
NUMBER: 26-02-99A

System/Engine Controls - Manual Revisions > Page 2656
45
46
47
152
156
316
620
622
Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page
2664
2665
2666

2667
millivolts.
WOT.
2668
REMOVAL
INSTALLATION
rotated.
Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations
Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
2672

Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Introduction
8w-01-002
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

position
problem
Testing For Voltage
Testing For Voltage


Probing Tool
Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2695
Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > With Four
Wheel Antilock Brakes
REMOVAL
INSTALLATION
Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > With Four
Wheel Antilock Brakes > Page 2698
REMOVAL
sensor stud.
INSTALLATION
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions
Revisions
NUMBER: 26-02-99A

Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 2703
45
46
47

152
156

316

620
622

millivolts.
WOT.
REMOVAL
INSTALLATION
rotated.
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 2719

Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Introduction
8w-01-002
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

position
problem

Testing For Voltage
Testing For Voltage


Probing Tool
Component Information > Service and Repair > With Four Wheel Antilock Brakes
REMOVAL
INSTALLATION
Component Information > Service and Repair > With Four Wheel Antilock Brakes > Page 2745
REMOVAL
sensor stud.
INSTALLATION
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Service Precautions > Customer Safety Information
Catalytic Converter: Customer Safety Information
CATALYTIC CONVERTER
The catalytic converter routinely reaches operating temperatures of 650° C (1200° F) and will stay
hot for some time after the engine has been shut off. Do NOT park the vehicle over any object or
material that could ignite (i.e. dry leaves, cardboard, puddles of oil, or other combustibles).
CARBON MONOXIDE
Exhaust gas contains toxic carbon monoxide. Do not run the engine in confined areas or breathe
concentrated exhaust gases. Breathing exhaust gases may cause loss of consciousness or death.
EXHAUST SYSTEM LEAKS
Repair any leaks in the exhaust system as soon as possible. Hot gases escaping from the leak can
ignite flammable materials and may set the vehicle on fire.
Also exhaust may circulate through the passenger compartment causing throat, sinus, and eye
irritation, light headedness, headaches, and increased irritability, especially while driving with
windows closed.
FUEL ODORS/EXCESSIVE EMISSIONS
Be alert for fuel odors and excessive tailpipe emissions (black smoke etc...). These indicate a
problem that should be corrected as soon as possible (excessive emissions can ruin oxygen
sensors, catalytic converters, and other expensive emission components).
Catalytic Converter: Technician Safety Information
WHEN SERVICING ANY VEHICLE OBSERVE THE FOLLOWING CAUTIONS:
1. Always wear appropriate eye protection.
2. Block the drive wheels as a safety routine before beginning any service with the vehicle on the
ground.
3. Never work under a vehicle supported only by a jack. Use jackstands on a flat and level hard
surface for safe support.
4. Use caution when working near the catalytic converter to prevent the possibility of burns. The
temperatures within the converter can exceed
1200°F.
5. Exercise care when working with spring or tension loaded fasteners such as E-clips, or snap
rings, careless removal can cause personal injury.
Catalytic Converter: Vehicle Damage Warnings
CATALYTIC CONVERTERS
On vehicles equipped with catalytic converters, the following conditions must be observed:
- Use only "UNLEADED FUEL".
- Avoid running out of fuel.
- In case of poor engine operation (misfiring), avoid driving the vehicle and correct the problem as
soon as possible.
- Do not disconnect any spark plug wires with the engine running.
- Avoid push starting the vehicle.
- If running on a dynamometer, make sure the catalytic converter is well ventilated.
- Use caution when working near the catalytic converter to prevent the possibility of burns.
OXYGEN SENSORS AND SILICONE
Do not use silicone based products on an oxygen sensor equipped vehicle to avoid damaging the
sensor.
COMPRESSION TESTING
When performing a compression test, remove the fuel pump relay fuse, and disconnect power to
the ignition (This will stop fuel flow to the injectors and prevent engine from starting).
Catalytic Converter: Description and Operation
CONSTRUCTION
The stainless steel catalytic converter body is designed to last the life of the vehicle.
HEAT
Excessive heat can result in bulging or other distortion, but excessive heat will not be the fault of
the converter. If unburned fuel enters the converter, overheating may occur. If a converter is
heat-damaged, correct the cause of the damage at the same time the converter is replaced. Also,
inspect all other components of the exhaust system for heat damage.
CAUTION: Unleaded gasoline must be used to avoid contaminating the catalyst core.
Catalytic Converter: Service and Repair Removal and Installation
CATALYTIC CONVERTER WITH PIPES
REMOVAL
1. Raise and support vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5
minutes for penetration.
3. Remove clamps and nuts. 4. Remove the catalytic converter.
INSTALLATION
1. Assemble converter and clamps loosely in place. 2. Install the exhaust pipe onto exhaust
manifolds, tighten 34 Nm (25 ft. lbs.). 3. Tighten all clamp nuts to 43 Nm (32 ft. lbs.) torque. 4.
Lower the vehicle. 5. Start the engine and inspect for exhaust leaks and exhaust system contact
with the body panels. A minimum of 25.4 mm (1.0 in.) is required
between exhaust system components and body/frame parts. Adjust the alignment, if needed.
CLEANING
Clean ends of pipes and muffler to assure a good seal at mating surfaces.
Catalytic Converter: Service and Repair Cleaning and Inspection
CATALYTIC CONVERTER
INSPECTION
Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be
a result of overheating. If the converter has a heat shield attached make sure it is not bent or loose.
WARNING: UNLEADED FUEL MUST BE USED TO PREVENT BLOCKAGE OR

CONTAMINATION TO THE CATALYST CORE.
If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber
mallet may indicate a damaged core.
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations
Purge Solenoid,mounting Bracket, Left Front Wheel-house,LDP.LDP Filter

Canister Purge Solenoid > Component Information > Locations > Page 2761
Evaporative Solenoid Connector

Canister Purge Solenoid: Description and Operation
EVAP Purge Solenoid And LDP
DESCRIPTION
All engines use a duty cycle EVAP canister purge solenoid. The solenoid regulates the rate of
vapor flow from the EVAP canister to the throttle body. The Powertrain Control Module (PCM)
operates the solenoid.
OPERATION
During the cold start warm-up period and the hot start time delay, the PCM does not energize the
solenoid. When de-energized, no vapors are purged. The PCM deenergizes the solenoid during
open loop operation.
The engine enters closed loop operation after it reaches a specified temperature and the time delay
ends. During closed loop operation, the PCM energizes and de-energizes the solenoid 5 or 10
times per second, depending upon operating conditions. The PCM varies the vapor flow rate by
changing solenoid pulse width. Pulse width is the amount of time the solenoid energizes. The PCM
adjusts solenoid pulse width based on engine operating condition.
CIRCUIT OPERATION
The Powertrain Control Module (PCM) operates the EVAP/Purge solenoid by providing a ground
path on circuit K52. Circuit K52 connects to PCM cavity C20. Circuit F18 supplies battery voltage to
the EVAP/Purge solenoid.
Canister Purge Solenoid: Service and Repair
EVAP Purge Solenoid And LDP
REMOVAL
The duty cycle purge solenoid is attached to a bracket mounted to the left-inner wheelhouse
(fender).
NOTE: The purge solenoid shown in is for vehicles equipped with a Leak Detection Pump (LDP). If
not equipped with an LDP, the location/mounting is slightly different.
1. Disconnect electrical wiring connector at solenoid. 2. Disconnect vacuum harness at solenoid. 3.

Remove solenoid from support bracket.
INSTALLATION
1. Install solenoid assembly to support bracket. 2. Connect vacuum harness. 3. Connect wiring
connector.
Evaporative Emission Control Canister > Component Information > Locations
Canister Mounting Nuts, Driver Door Well, EVAP Canister, Bracket Bolts
Evaporative Emission Control Canister > Component Information > Locations > Page 2767
Evaporative Emission Control Canister: Description and Operation
EVAP Canister
DESCRIPTION
Two, maintenance free, EVAP canisters are used. The canisters are mounted to a common bracket
located under the left side of vehicle behind the drivers door well. The EVAP canisters are filled
with granules of an activated carbon mixture.
OPERATION
Fuel vapors entering the EVAP canisters are absorbed by the charcoal granules. Fuel tank
pressure vents into tile EVAP canisters. Fuel vapors are temporarily held in the canisters until they
can be drawn into the intake manifold. The duty cycle EVAP canister purge solenoid allows the
EVAP canisters to be purged at predetermined times and at certain engine operating conditions.
Evaporative Emission Control Canister > Component Information > Locations > Page 2768
Evaporative Emission Control Canister: Service and Repair
EVAP Canister
Two EVAP canisters are used. The canisters are mounted to a common bracket located under the
left side of vehicle behind the drivers door well.
REMOVAL
1. Remove 2 bolts retaining canister bracket assembly to body. 2. Carefully lower the assembly
and remove fuel tubes/lines at each EVAP canister. Note location of tubes/lines before removal for
easier
installation.
3. Remove canister mounting nuts.
INSTALLATION
1. Position each canister to bracket and install nuts Tighten to 8 Nm (71 in. lbs.) torque. 2. Install
fuel tubes/lines to canister. 3. Position assembly to body. Note locating ears at upper part of
mounting bracket. Position these ears into notches on body. 4. Install 2 bracket bolts and tighten to
10 Nm (95 in. lbs.) torque.
Evaporative System Service Port > Component Information > Locations
EVAP System Test Port, Power Brake Booster, Steering Column

Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > EVAP System - Leak
Detection Pump Misdiagnosis
Leak Detection Pump: Technical Service Bulletins EVAP System - Leak Detection Pump
Misdiagnosis
NUMBER: 18-01-00
DATE: Feb. 4, 2000
SUBJECT: Misdiagnosed Leak Detection Pump Systems With DTC P1494, P0442, P0455, OR
P0456
MODELS: 1997 - 2000 (AB) Ram Van 1997 - 2000 (AN) Dakota 1997 - 2000 (BR/BE) Ram truck
1998 - 2000 (DN) Durango 1997 - 2000 (FJ) Avenger/Sebring/Talon 1997 - 2000 (JA)
Cirrus/Stratus/Breeze 1997 - 2000 (JX) Sebring Convertible 1997 - 2000 (LH)
Concorde/Intrepid/LHS/3OOMNision 1997 - 2000 (NS) Town & Country/CaravanNoyager 1997 -
2000 (PL) Neon 1997 - 2000 (PR) Prowler 1997 - 2000 (SR) ViperNiper GIS 1997 - 2000 (TJ)
Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1997 - 1998 (ZJ)
GrandCherokee
DISCUSSION: During evaporative system diagnosis, Leak Detection Pumps have mistakenly been
replaced. A thorough inspection for pinched, kinked, or disconnected supply vacuum lines (as
currently listed in the Powertrain Diagnostic Procedures) is a critical step in diagnosing DTC P1494
(LDP SW OR MECHANICAL FAULT). Additionally, the other evaporative leak faults (DTC P0442 -
SMALL LEAK, P0455 - LARGE LEAK, and P0456 - VERY SMALL LEAK) should have the supply
vacuum lines examined for pinches or kinks prior to any LDP component replacement.
The supply vacuum lines should be checked from the engine compartment all the way to the fuel
tank, including the LDP and purge system.
NOTE:
VERIFY ALL RELATED SUPPLY VACUUM LINE ROUTINGS FOR PINCHES, KINKS, OR
DISCONNECTION'S BEFORE REPLACING LDP SYSTEM COMPONENTS.

Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2776
Purge Solenoid, Mounting Bracket, Left Front Wheel-House, LDP Filter

LDP Connector
Leak Detection Pump: Description and Operation
Leak Detection Pump (LDP) Operation And Diagnosis
This bulletin describes the theory of operation for the leak detection system. In addition, information
is provided for each of the Diagnostic Trouble Codes (DTC's) as follows:
P0442-EVAP LEAK MONITOR 0.040" LEAK DETECTED
P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED
P0456-EVAP LEAK MONITOR 0.020" LEAK DETECTED
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND

P1494-LEAK DETECTION PUMP SW OR MECHANICAL FAULT
P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT
INTRODUCTION
The evaporative emission system is designed to prevent the escape of fuel vapors from the fuel
system. Leaks in the system, even small ones, can allow fuel vapors to escape into the
atmosphere. Government regulations require on-board testing to make sure that the evaporative
(EVAP) system is functioning properly. The leak detection system tests for EVAP system leaks and
blockage. It also performs self-diagnostics.
During self-diagnostics, the Powertrain Control Module (PCM) first checks the Leak Detection
Pump (LDP) for electrical and mechanical faults. If the first checks pass, the PCM then uses the
LDP to seal the vent valve and pump air into the system to pressurize
it. If a leak is present, the PCM will continue pumping the LDP to replace the air that leaks out. The
PCM determines the size of the leak based on how fast/long it must pump the LDP as it tries to
maintain pressure in the system.
EVAP LEAK DETECTION SYSTEM COMPONENTS
Service Port: Used with special tools like the Miller Evaporative Emissions Leak Detector (EELD) to
test for leaks in the system.
EVAP Purge Solenoid: The PCM uses the EVAP purge solenoid to control purging of excess fuel
vapors stored in the EVAP canister. It remains closed during leak testing to prevent loss of
pressure.
EVAP Canister The EVAP canister stores fuel vapors from the fuel tank for purging. EVAP Purge
Orifice: Limits purge volume.
EVAP System Air Filter: Provides air to the LDP for pressurizing the system. It filters out dirt while
allowing a vent to atmosphere for the EVAP system.
Leak Detection Pump (LDP) Components

The main purpose of the LDP is to pressurize the fuel system for leak checking. It closes the EVAP
system vent to atmospheric pressure so the system can be pressurized for leak testing. The
diaphragm is powered by engine vacuum. It pumps air into the EVAP system to develop a pressure
of about 7.5' H20(1/4) psi. A reed switch in the LDP allows the PCM to monitor the position of the
LDP diaphragm. The PCM uses the reed switch input to monitor how fast the LDP is pumping air
into the EVAP system. This allows detection of leaks and blockage.
The LDP assembly consists of several parts. The solenoid is controlled by the PCM, and it
connects the upper pump cavity to either engine vacuum or atmospheric pressure. A vent valve
closes the EVAP system to atmosphere, sealing the system during leak testing. The pump section
of the LDP consists of a diaphragm that moves up and down to bring air in through the air filter and
inlet check valve, and pump it out through an outlet check valve into the EVAP system.
The diaphragm is pulled up by engine vacuum, and pushed down by spring pressure, as the LDP
solenoid turns on and off. The LDP also has a magnetic reed switch to signal diaphragm position to
the PCM. When the diaphragm is down, the switch is closed, which sends a 12 V (system voltage)
signal to the PCM. When the diaphragm is up, the switch is open, and there is no voltage sent to
the PCM. This allows the PCM to monitor LDP pumping action as it turns the LDP solenoid on and
off.
LDP AT REST (NOT POWERED)
When the LDP is at rest (no electrical/vacuum) the diaphragm is allowed to drop down if the
internal (EVAP system) pressure is not greater than the return spring. The LDP solenoid blocks the
engine vacuum port and opens the atmospheric pressure port connected through the EVAP system
air filter. The vent valve is held open by the diaphragm. This allows the canister to see atmospheric
pressure.
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 based on reed switch input, the PCM de-energizes the
LDP solenoid, causing it to block the vacuum port, and open the atmospheric port. This connects
the upper pump cavity to atmosphere through the EVAP air filter. The spring is now able to push
the diaphragm down. The downward movement of the diaphragm closes the inlet check valve and
opens the outlet check valve pumping air into the evaporative system. The LDP reed switch turns
from open to closed, allowing the PGM to monitor LDP pumping (diaphragm up/down) activity.
During the pumping mode, the diaphragm will not move down far enough to open the vent valve
The pumping cycle is repeated as the solenoid is turned on and off. When the evaporative system
begins to pressurize, the pressure on the bottom of the diaphragm will begin to oppose the spring
pressure, slowing the pumping action. The PCM watches the time from when the solenoid is
de-energized, until the diaphragm drops down far enough for the reed switch to change from
opened to closed. If the reed switch changes too quickly, a leak may be indicated. The longer it
takes the reed switch to change state, the tighter the evaporative system is sealed. If the system
pressurizes too quickly, a restriction somewhere in the EVAP system may be indicated.
PUMPING ACTION During portions of this test, the PCM uses the reed switch to monitor
diaphragm movement. The solenoid is only turned on by the PCM after the reed switch changes
from open to closed, indicating that the diaphragm has moved down. At other times during the test,
the PCM will rapidly cycle the LDP solenoid on and off to quickly pressurize the system. During
rapid cycling, the diaphragm will not move enough to change the reed switch state. In the state of
rapid cycling, the PCM will use a fixed time interval to cycle the solenoid.
Leak Detection Pump: Testing and Inspection
ENABLING CONDITIONS TO RUN EVAP LEAK DETECTION TEST
NOTE: The following values are approximate and vehicle specific. Use the values seen in pre
test/monitor test screen on the DRB III. See TSB 25-02-98 for more detail
1. Cold start: with ambient temperature (obtained from modeling the inlet air temperature sensor on
passenger vehicles and the battery temperature sensor on Jeep & truck vehicles) between 4C° (40°
F) and 32° C (90° F) for 0.040 leak. Between 4C° (40° F) and 29° C (85° F) for 0.020 leak. 2.
Engine coolant temperature within:-12° to -8°C (10° to 18°F) of battery/ambient. 3. Battery voltage
between 10 and 15 volts.
NOTE: If battery voltage drops below 10 volts for more than 5 seconds during engine cranking, the
EVAP leak detection test will not run.
4. Low fuel warning light off (fuel level must be between 15% and 85% for 0.040 leak and 30% and
85% for 0.020 leak). 5. MAP sensor reading 22 in Hg or above (This is the manifold absolute
pressure, not vacuum). 6. No engine stall during test.
If the system does not pass the EVAP Leak Detection Test, the following DTCs may be set:
- P0442 - EVAP LEAK MONITOR 0.040" LEAK DETECTED
- P0455 - EVAP LEAK MONITOR LARGE LEAK DETECTED
- P0456 - EVAP LEAK MONITOR 0.020" LEAK DETECTED
- P1486 - EVAP LEAK MON PINCHED HOSE FOUND
- P1494 - LEAK DETECTION PUMP SW OR MECH FAULT
- P1495 - LEAK DETECTION PUMP SOLENOID CIRCUIT
A DTC will not be set if a one-trip fault is set or if MIL is illuminated for any of the following:
- Purge Solenoid Electrical Fault
- All Engine Controller Self Test Faults
- All Cam And/or Crank Sensor Fault
- All Map Sensor Faults
- Ambient/battery Temperature Sensor Electrical Faults
- All Coolant Sensor Faults
- All TPS Faults
- LDP Pressure Switch Fault
- EGR Solenoid Fault
- All Injector Faults
- Baro Our Of Range
- Vehicle Speed Faults
- LDP Solenoid Circuit

Figure 6
EVAP leak detection test sequence
When the ignition key is turned to "ON" the LDP diaphragm should be in the down position and the
LDP reed switch should be closed. If the EVAP system has residual pressure, the LDP diaphragm
may be up. This could result in the LDP reed switch being open when the key is turned to "ON" and
a P1494 fault could be set because the PCM is expecting the reed switch to be closed.
After the key is turned "ON", the PCM immediately tests the LDP solenoid circuit for electrical
faults. If a fault is detected, DTC P1495 will set, the MIL will illuminate, and the remaining EVAP
Leak Detection Test is canceled.
NOTE: If battery temperature is not within range, or if the engine coolant temperature is not within a
specified range of the battery temperature, the PCM will not run tests for DTC P1494, P1486,
P0442, P0455 and P0441. These temperature calibrations may be different between models.
FIGURE 6 SECTION 2
If DTC P1495 is not set, the PCM will check for DTC P1494. If the LDP reed switch was closed
when the key was turned to "ON", the PCM energizes the LDP solenoid for up to 8 seconds and
monitors the LDP switch. As the LDP diaphragm is pulled up by engine vacuum, the LDP reed
switch should change from closed to open. If it does not, the PCM sets a temporary fault (P1494) in
memory, and waits until the next time the Enabling Conditions are met to run the test again. If this
is again detected, P1494 is stored and the MIL is illuminated. If the problem is not detected during
the next enabling cycle, the temporary fault will be cleared.
However, if the PCM detects the reed switch open when the key is turned to "ON", the PCM must
determine if this condition is due to residual pressure in the EVAP system, or an actual fault. The
PCM stores information in memory on EVAP system purging from previous engine run or drive
cycles.
If little or no purging took place, residual pressure could be holding the LDP diaphragm up, causing
the LDP switch to be open. Since this is not a malfunction, the PCM cancels the EVAP Leak
Detection Test without setting the temporary fault.
If there was sufficient purging during the previous cycle to eliminate EVAP system pressure, the
PCM judges that this is a malfunction and sets a temporary fault in memory. The next time that the
Enabling Conditions are met, the test will run again. If the fault is again detected, the MIL will
illuminate and DTC 1494 will be stored. If the fault is not detected, the temporary fault will be
cleared.
FIGURE 6 SECTION 3
If no fault has been detected so far, the PCM begins testing for possible blockage in the EVAP
system between the LDP and the fuel tank. This is done by monitoring the time required for the
LDP to pump air into the EVAP system during two to three pump cycles. If no blockage is present,
the LDP diaphragm is able to quickly pump air out of the LDP each time the PCM turns oft the LDP
solenoid. If a blockage is present, the PCM detects that the LDP takes longer to complete each
pump cycle. If the pump cycles take longer than expected (approximately 6 to 10 seconds) the
PCM will suspect a blockage. On the next drive when Enabling Conditions are met, the test will run
again. If blockage is again detected, P1486 is stored, and the MIL is illuminated.
FIGURE 6 SECTION 4
After the LDP blockage tests are completed, the PCM then tests for EVAP system leakage. First,
the PCM commands the LDP to rapidly pump for 20 to 50 seconds (depending on fuel level) to
build pressure in the EVAP system. This evaluates the system J18-24-0 to see if it can be
sufficiently pressurized. This evaluation (rapid pump cycling) may occur several times prior to leak
checking. The LDP reed switch does not close and open during rapid pumping because the
diaphragm does not travel through its full range during this part of the test.
FIGURE 6 SECTION 5
Next, the PCM performs one or more test cycles by monitoring the time required for the LDP reed
switch to close (diaphragm to drop) after the LDP solenoid is turned off.
If the switch does not close, or closes after a long delay, it means that the system does not have
any significant leakage and the EVAP Leak Detection Test is complete.
However, if the LDP reed switch closes quickly, there may be a leak or the fuel level may be low
enough that the LDP must pump more to finish pressurizing the EVAP system. In this case, the
PCM will rapidly pump the LDP again to build pressure in the EVAP system, and follow that by
monitoring the time needed for several LDP test cycles. This process of rapid pumping followed by
several LDP test cycles may repeat several times before the PCM judges that a leak is present.
When leaks are present, the LDP test cycle time will be inversely proportional to the size of the
leak. The larger the leak, the shorter the test cycle time. The smaller the leak, the longer the test
cycle time. DTC's may be set when a leak as small as 0.5 mm (0.020") diameter is present.
If the system detects a leak, a temporary fault will be stored in PCM memory. The time it takes to
detect a .020, .040, or Large leak is based on calibrations that vary from model to model. The
important point to remember is if a leak is again detected on the next EVAP Leak Detection Test,
the MIL will illuminate and a DTC will be stored based on the size of leak detected. If no leak is
detected during the next test, the temporary fault will be cleared.
DIAGNOSTIC TIPS
During diagnosis, you can compare the LDP solenoid activity with the monitor sequence in Figure
6. If the PCM detects a problem that could set a DTC, the testing is halted and LDP solenoid
activity will stop. As each section of the test begins, it indicates that the previous section passed
successfully. By watching to see which tests complete, you can see if any conditions are present
that the PCM considers abnormal.
For example, if the LDP solenoid is energized for the test cycles to test for blockage (P1486), it
means that the LDP has already passed its test for P1494. Then, if the PCM detects a possible
blockage, it will set a temporary fault without turning on the MIL and continue the leak portion of the
test. However, the PCM will assume that the system is already pressurized and skip the rapid
pump cycles.
Always diagnose leaks, if possible, before disconnecting connections. Disconnecting connections

may mask a leak condition.
Keep in mind that if the purge solenoid seat is leaking, it could go undetected since the leak would
end up in the intake manifold. Disconnect the purge solenoid at the manifold when leak checking.
In addition, a pinched hose fault (P1486) could set if the purge solenoid does not purge the fuel
system properly (blocked seat). The purge solenoid must vent the fuel system prior to the LDP
system test. If the purge solenoid cannot properly vent the system the LDP cannot properly
complete the test for P1486 and this fault can set due to pressure being in the EVAP system during
the test sequence.
Multiple actuation's of the DRB Ill® Leak Detection Pump (LDP) Monitor Test can hide a 0.020 leak
because of excess vapor generation. Additionally, any source for additional vapor generation can
hide a small leak in the EVAP system. Excess vapor generation can delay the fall of the LDP
diaphragm thus hiding the small leak. An example of this condition could be bringing a cold vehicle
into a warm shop for testing or high ambient temperatures.
Fully plugged and partially plugged underhood vacuum lines have been known to set MIL
conditions. P1494 and P0456 can be set for this reason. Always, thoroughly, check plumbing for
pinches or blockage before condemning components.
TEST EQUIPMENT
The Evaporative Emission Leak Detector (EELD) Miller Special Tool 8404 is capable of visually
detecting leaks in the evaporative system and will take
the place of the ultrasonic leak detector 6917A. The EELD utilizes shop air and a smoke generator
to visually detect leaks down to 0.020 or smaller. The food grade oil used to make the smoke
includes an UV trace dye that will leave telltale signs of the leak under a black light. This is helpful
when components have to be removed to determine the exact leak location. For detailed test
instructions, follow the operators manual packaged with the EELD.
IMPORTANT
Be sure that the PCM has the latest software update. Reprogram as indicated by any applicable
Technical Service Bulletin. After LDP repairs are completed, verify the repair by running the DRB
Ill® Leak Detection Pump (LDP) Monitor Test as described in Technical Service Bulletin 18-12-99.
Leak Detection Pump: Service and Repair
Leak Detection Pump Mounting
The LDP, LDP filter and EVAP purge solenoid are attached to a common bracket. The assembly is
located in the engine compartment on the left-inner wheelhouse (fender). The LDP and LDP filter
are replaced (serviced) as one unit.
REMOVAL
1. Disconnect negative battery cable at battery 2. Disconnect electrical connector at duty cycle
purge solenoid. 3. Remove duty cycle purge solenoid from bracket. 4. Disconnect electrical
connector at LDP. 5. Carefully remove vapor/vacuum lines at LDP. 6. Remove two bracket
mounting bolts. 7. Remove LDP, LDP filter and bracket assembly from vehicle. 8. Remove 3 LDP
mounting screws and remove LDP from bracket. 9. Remove LDP filter mounting bolt.
INSTALLATION
1. Install LDP filter to bracket. Tighten mounting bolt to 7 Nm (65 in. lbs.) torque. 2. Install LDP to
bracket. Tighten screws to 1 Nm (11 in. lbs.) torque. 3. Install LDP and bracket assembly to body
and install mounting bolts. Tighten bolts to 7 Nm (65 in. lbs.) torque. 4. Carefully install
vapor/vacuum lines to LDP. The vapor/vacuum lines and hoses must be firmly connected. Check
the vapor/vacuum lines at the
LDP, LDP filter and EVAP canister purge solenoid for damage or leaks. If a leak is present, a
Diagnostic Trouble Code (DTC) may be set.
5. Connect electrical connector to LDP. 6. Install duty cycle purge solenoid to bracket. 7. Connect
negative battery cable to battery.
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Crankcase Filter > Component Information > Description and Operation
Crankcase Filter: Description and Operation
Fig 9 Crankcase Breather Filter
CRANKCASE BREATHER/FILTER
The crankcase breather/filter (Fig. 9) is located on the cylinder head (valve) cover. The filter may
be cleaned by washing it thoroughly in kerosene or an equivalent. Filter must be thoroughly
drained. More frequent service may be necessary for vehicles operated extensively on short run,
stop and go, extended engine idle service or extreme dust conditions.
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage
NO: 14-03-98
MODELS: 1996 - 1998 (AB)
Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
DISCUSSION:

Information > Specifications > Pressure, Vacuum and Temperature Specifications
Fuel Pressure

........................................ 339 ± 34 kPa (49.2 ± 5 psi)

minutes
Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 2799
seconds.

Information > System Diagnosis > Fuel Pressure Leak Down Test
Test.
operational.
(Fig. 9) or (Fig. 10).

Adapter Tool.
on Adapter Tool.
specification.
information.
location.
ARE CONNECTED.
type-2 and type-3.
Starter Relay
Type-2 Relay
Type-3 Relay
pump module is OK.
seconds.

Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
cylinder chamber.
battery.

Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information
> Specifications

......................................................... 500 to 900 rpm

column.
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System
Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions
NUMBER: 26-02-99A

45
46
47

152
156

316

620
622
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Accelerator Pedal: Service and Repair
Fig 42 Accelerator Pedal Removal/Installation
CAUTION: Be careful not to damage or kink the cable core wire (within the cable sheathing) while
servicing accelerator pedal or cables.
REMOVAL
1. From inside the vehicle, hold up accelerator pedal.
- Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm (Fig. 42).
- The plastic cable retainer snaps into pedal arm.
2. Remove 2 accelerator pedal/bracket nuts (Fig. 42) and remove pedal/bracket assembly from
vehicle.
Fig 43 Index Tab And Slot
INSTALLATION
1. Position pedal/bracket assembly over the two dash panel mounting studs and install retaining
nuts. 2. Tighten nuts to 8 N.m (75 in. lbs.) torque. 3. From inside the vehicle, hold up the
accelerator pedal.
- Install the throttle cable core wire and plastic cable retainer into the upper end of the pedal arm.
- The plastic retainer is snapped into the pedal arm.
- When installing the plastic retainer to the accelerator pedal arm, note the index tab on the pedal
arm (Fig. 43).
- Align the index slot (Fig. 43) on the plastic cable retainer to this index tab.
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing >
REMOVAL
body.
INSTALLATION
engine cover.
AIR CLEANER ELEMENT
REMOVAL
INSTALLATION
engine cover.
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > Engine - High Driveability Index Fuels
Fuel: Technical Service Bulletins Engine - High Driveability Index Fuels
NO: 14-08-97
GROUP: Fuel
DATE: Nov. 21, 1997
SUBJECT: Poor Driveability With High DI (Driveability Index) Fuel
MODELS:
1996 - 1998 (AN) Dakota
1998 (DN) Durango
1996 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (PL) Neon
1997 (PR) Prowler
1996 - 1998 (SR) Viper Roadster/Coupe
SYMPTOM/CONDITION:
Long cold start times, warm-up sags, hesitations, and driveway die outs. These symptoms are
most noticeable and severe at moderate ambient temperatures between 4 - 27 degrees C (40 - 80
degrees F).
DISCUSSION:
Gasoline with a high Driveability Index (DI) can cause the above described symptoms. DI is a
measure of the gasolines total volatility, or tendency to vaporize completely. A high DI number is
less volatile than a low DI number. Most premium gasoline sold in the U.S. has a higher (worse) DI
index than regular or mid-grade gasoline. Use of premium gasoline is NOT recommended for
vehicles designed to run on 87 (R+M)/2 regular or 89 (R+M)/2 midgrade gasoline. High DI
gasolines also cause higher emissions for the same reasons they cause driveability problems.
For vehicles that require an octane rating of 91 (R+M)/2, premium is recommended, or possibly
required. Using premium fuel with a higher than recommended octane rating is not recommended.
Owners who experience fuel related cold start and warm up driveability problems should try a
gasoline with the recommended octane rating or different brands of gasoline until they find one that
provides good performance.
The octane quality of gasoline is only a measure of its resistance to spark knock. The use of higher
than recommended octane gasoline under normal operating conditions does NOT improve
startability, idle quality, fuel economy, driveability, acceleration, engine durability, or emissions. In
fact, most higher octane gasolines available in the U.S. have higher DI values than regular
gasoline. Customers are most likely to experience poor driveability with premium gasoline than with
regular.
Some vehicles, such as Viper, Prowler, 5.9L Grand Cherokee, 2.0L Turbo Talon, and 2.0L DOHC
Neon have been specifically designed to take advantage of higher octane. These vehicles may
have higher compression ratios, and/or more aggressive spark calibrations which provide optimum
performance with the specified higher octane. However, other vehicles which are not specifically
designed and calibrated to take advantage of higher octane will not benefit from higher octane.
Some vehicles may experience light spark knock in situations such as trailer towing or climbing
steep sustained grades. Light knock or "ping" under these conditions is not harmful. However, if the
customer is concerned about light knock under these circumstances, the use of 89 (R+M)/2 or
even 91 (R+M)/2 premium gasoline may be temporarily warranted. If a vehicle is experiencing
heavy spark knock on gasoline with its designed octane rating, this may be an indication of
excessive combustion chamber deposits, or some other problem. Combustion chamber deposits
can be removed with Mopar Combustion Chamber Conditioner p/n 04318001. Standard diagnostic
procedures may help in identifying other potential causes of excessive knock.
Some gasoline marketers may advertise that their premium gasoline contains extra detergent
additives. Under provisions of the Clean Air Act, ALL gasoline sold in the U.S. must contain
effective deposit control additives. Nevertheless, if fuel injector or intake valve deposits are
suspected of
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > Engine - High Driveability Index Fuels > Page 2838
contributing to poor performance, occasional use of Mopar Fuel Injector Clean Up p/n 04549613 is
a much less expensive way to maintain engine cleanliness than regular use of premium gasoline.
The charts (Figures 1 & 2) show the negative effects of high DI fuel as related to customer
satisfaction.
If fuel quality is suspected in causing a customers driveability concern, your zone technical office
may be able to provide direction on procedures for fuel sample analysis.

Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Fuel Filler Cap: Description and Operation
DESCRIPTION
The loss of any fuel or vapor out of filler neck is prevented by the use of a pressure-vacuum fuel
tank filler tube cap.
OPERATION
Relief valves inside the cap will release fuel tank pressure at predetermined pressures. Fuel tank
vacuum will also be released at predetermined values. This cap must be replaced by a similar unit
if replacement is necessary. This is in order for the system to remain effective.
CAUTION: Remove fuel tank filler tube cap before servicing any fuel system component. This is
done to help relieve tank pressure. If equipped with a California emissions package and a Leak
Detection Pump (LDP), the secondary seal below the fill cap must be pressed (opened) to relieve
fuel tank pressure.
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair
cylinder chamber.
battery.

Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Electrical Specifications
Fuel Injector: Electrical Specifications
Injector Resistance
...................................................................................................................................................... 12
ohms ± 1.2 ohms at 20 ° C (68 ° F)
Information > Specifications > Electrical Specifications > Page 2850
Fuel Injector: Pressure, Vacuum and Temperature Specifications
Injector Fuel Pressure
Normal operating fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). If pressure falls
below 30 psi for five minutes. It must be determine if a fuel injector, fuel pump module check valve
or fuel tube/line is leaking.
Fuel Pressure Leak Down Test
Test.
operational.
Information > Specifications > Electrical Specifications > Page 2851
(Fig. 9) or (Fig. 10).
4. Start engine and bring to normal operating temperature. 5. Observe test gauge. Normal
operating pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). 6. Shut engine off. 7.
Pressure should not fall below 30 psi for five minutes. 8. If pressure falls below 30 psi, it must be
determined if a fuel injector, the check valve within the fuel pump module, or a fuel tube/line is
leaking. 9. Again, start engine and bring to normal operating temperature.
Adapter Tool.
on Adapter Tool.
Injector
Injector #1 Connector
Fuel Injector: Description and Operation
Fuel Injector - Typical
DESCRIPTION
The fuel injectors are electrical solenoids. The injector contains a pintle that closes off an orifice at
the nozzle end. When electric current is supplied to the injector, the armature and needle move a
short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high
pressure, a fine spray is developed in the shape of a pencil stream. The spraying action atomizes
the fuel, adding it to the air entering the combustion chamber.
OPERATION
An individual fuel injector is used for each individual cylinder. The top (fuel entry) end of the injector
is attached into an opening on the fuel rail. The nozzle outlet) ends of the injectors are positioned
into openings in the intake manifold just above the intake valve ports of the cylinder head. The
engine wiring harness connector for each fuel injector is equipped with an attached numerical tag
(INJ 1, INJ 2 etc.). This is used to identify each fuel injector.
The injectors are energized individually in a sequential order by the powertrain control module
(PCM). The PCM will adjust injector pulse width by switching the ground path to each individual
injector on and off. Injector pulse width is the period of time that the injector is energized. The PCM
will adjust injector pulse width based on various inputs it receives.
During start up, battery voltage is supplied to the injectors through the ASD relay. When the engine
is operating, voltage is supplied by the charging system. The PCM determines injector pulse width
based on various inputs.
Fuel Injector: Testing and Inspection
Fig. 10 Fuel Injector Internal Components - Typical
To test the injector only, disconnect the fuel injector wire harness connector from the injector. Place
an ohmmeter across the injector terminals. Resistance reading should be approximately 12 ohms
+/- 1.2 ohms at 20°C (68°F).
CAUTION: Do not leave electrical current applied to the injector for longer than five seconds.
Damage to injector coil or internal injector seals (Fig. 10) could result.
Fuel Injector: Service and Repair

WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE
ENGINE TURNED OFF). BEFORE SERVICING THE FUEL INJECTOR(S), THE FUEL SYSTEM
PRESSURE MUST BE RELEASED.
NOTE: To remove one or more fuel injectors, the fuel rail assembly must be removed from engine.
REMOVAL
1. Remove engine cover. 2. Remove air cleaner assembly. 3. Remove fuel injector rail assembly.
Fig. 33 Fuel Injector Mounting-Typical
Fig. 34 Injector Retaining Clips-Typical Injector
4. Remove the clip(s) retaining the injector(s) to fuel rail. 5. Remove injector(s) from fuel rail.
INSTALLATION
1. Apply a small amount of engine oil to each fuel injector 0-ring. This will help in fuel rail
installation. 2. Install injector(s) and injector clip(s) to fuel rail. 3. Install fuel rail assembly. 4. Install
air cleaner. 5. Start engine and check for leaks. 6. Install engine cover.
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Fuel Line Coupler: Description and Operation
Different types of quick-connect fittings are used to attach various fuel system components. These
are: a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety
latch clips.
CAUTION: The interior components (0-rings, spacers) of quick-connect fitting are not serviced
separately, but new pull tabs are available for some types. Do not attempt to repair damaged
fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly.
Information > Service and Repair > Plastic Retainer Type
Fuel Line Coupler: Service and Repair Plastic Retainer Type
Fig. 15 Plastic Retainer Ring Type Fitting
This type of fitting can be identified by the use of a full-round plastic retainer ring usually black in
color.
CAUTION: The interior components (0-rings, spacers, retainers) of this type of quick-connect fitting
are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is
necessary, replace the complete fuel tube assembly.
WARNING: The fuel system is under a constant pressure (even with the engine off). Before
servicing any fuel system hoses, fittings or lines, the fuel system pressure must be released. Refer
to the fuel system pressure release procedure.
DISCONNECTION/CONNECTION
1. Disconnect negative battery cable from the battery 2. Perform the fuel pressure release
procedure. Refer to the Fuel Pressure Release Procedure. 3. Clean the fitting of any foreign
material before disassembly 4. To release the fuel system component from the quick-connect
fitting, firmly push the fitting towards the component being serviced while firmly
pushing the plastic retainer ring into the fitting. With the plastic ring depressed, pull the fitting from
the component. The plastic retainer ring must be pressed squarely into the fitting body. If this
retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench
on the shoulder of the plastic retainer ring to aid in disconnection.
5. After disconnection, the plastic retainer ring will remain with the quick-connect fitting connector
body. 6. Inspect fitting connector body, plastic retainer ring and fuel system component for
damage. Replace as necessary. 7. Prior to connecting the quick-connect fitting to component being
serviced, check condition of fitting and component. Clean the parts with a
lint-free cloth. Lubricate them with clean engine oil.
8. Insert the quick-connect fitting into the component being serviced until a click is felt. 9. Verify a
locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.).
10. Connect negative battery cable to battery 11. Start engine and check for leaks.
Information > Service and Repair > Plastic Retainer Type > Page 2862
Fuel Line Coupler: Service and Repair Single TAB Type Fittings
Fig. 11 Single-Tab Type Fitting
This type of fitting is equipped with a single pull tab. The tab is removable. After the tab is removed,
the quick-connect fitting can be separated from the fuel system component.
CAUTION: The interior components (0-rings, spacers) of this type of quick-connect fitting are not
serviced separately, but new pull tabs are available. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly.
servicing any fuel system hoses, fittings or lines, the fuel system pressure must be released.
1. Disconnect negative battery cable from battery. 2. Perform the fuel pressure release procedure.
3. Clean the fitting of any foreign material before disassembly.
Fig. 12 Disconnecting Single-Tab Type Fitting
4. Press the release tab on the side of fitting to release pull tab.
CAUTION: If this release tab is not pressed prior to releasing the pull tab, the pull tab will be
damaged.
5. While pressing the release tab on the side of the fitting, use a screwdriver to pry up the pull tab.
Fig. 13 Removing Pull Tab
6. Raise the pull tab until it separates from the quick-connect fitting. Discard the old pull tab. 7.
Disconnect the quick-connect fitting from the fuel system component being serviced. 8. Inspect the
quick-connect fitting body and fuel system component for damage. Replace as necessary. 9. Prior
to connecting the quick-connect fitting to component being serviced, check condition of fitting and
component. Clean the parts with a
10. Insert the quick-connect fitting into the fuel tube or fuel system component until the built-on stop
on the fuel tube or component rests against back
of fitting.
11. Obtain a new pull tab. Push the new tab down until it locks into place in the quick-connect
fitting. 12. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 13.
Connect negative cable to battery. 14. Start engine and check for leaks.
Fuel Line Coupler: Service and Repair Two TAB Type Fittings
Fig. 14 Typical Two-Tab Type Quick-Connect Fitting
Fuel Line Quick Connect Fitting
Fuel Line Quick Connect Fitting
This type of fitting is equipped with tabs located on both sides of the fitting. These tabs are supplied
for disconnecting the quick-connect fitting from component being serviced.
CAUTION: The interior components (0-rings, spacers) of this type of quick-connect fitting are not
serviced separately, but new plastic retainers are available. Do not attempt to repair damaged
fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly.
servicing any fuel system hoses, fittings or lines, the fuel system pressure must be released. Refer
to the fuel pressure release procedure.
1. Disconnect negative battery cable from the battery 2. Perform the fuel pressure release
procedure. Refer to the Fuel Pressure Release Procedure. 3. Clean the fitting of any foreign
material before disassembly 4. To disconnect the quick-connect fitting, squeeze the plastic retainer
tabs against the sides of the quick-connect fitting with your fingers. Tool use is
not required for removal and may damage plastic retainer. Pull the fitting from the fuel system
component being serviced. The plastic retainer will remain on the component being serviced after
fitting is disconnected. The 0-rings and spacer will remain in the quick- connect fitting connector
body.
5. Inspect the quick-connect fitting body and component for damage. Replace as necessary.
CAUTION: When the quick-connect fitting was disconnected, the plastic retainer will remain on the
component being serviced. If this retainer must be removed, very carefully release the retainer from
the component with two small screwdrivers. After removal, inspect the retainer for cracks or any
damage.
6. Prior to connecting the quick-connect fitting to component being serviced, check condition of
fitting and component. Clean the parts with a
7. Insert the quick-connect fitting to the component being serviced and into the plastic retainer.
when a connection is made, a click will be heard. 8. Verify a locked condition by firmly pulling on
fuel tube and fitting (15-30 lbs.). 9. Connect negative cable to battery
10. Start engine and check for leaks.

Fuel Line Coupler: Service and Repair Latch Type Fitting (Fuel Rail-to-Fuel Line)
Quick Connect Fitting At Fuel Rail
A latch clip is used to secure the fuel line quick-connect fitting to the fuel rail. Special tools are not
necessary to separate fuel line from fuel rail with this type of fitting.
CAUTION: The interior components (0-rings, spacers, retainers) of this type of quick-connect fitting
are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is
necessary, replace the complete fuel tube assembly.
WARNING: THE FUEL SYSTEM MAY BE UNDER A CONSTANT PRESSURE EVEN WITH
ENGINE OFF. BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, FUEL
SYSTEM PRESSURE MUST BE RELEASED.
1. Perform fuel pressure release procedure. 2. Disconnect negative battery cable from battery. 3.
Clean fitting of any foreign material before disassembly. 4. Place rag or shop towel below fitting. 5.
Pinch sides of latch and rotate up for removal. 6. Pull fuel line from fuel rail. 7. After disconnection,
locking fingers will remain within quick-connect fitting at end of fuel line. 8. Prior to connecting fuel
line to fuel rail, check condition of both fittings. Clean parts with a lint-free cloth. Lubricate with
clean engine oil. 9. Insert fuel line onto fuel rail.
10. Rotate latch clip (snaps into position). If latch clip will not fit, this indicates fuel line is not
properly installed to fuel rail. Recheck fuel line
connection.
11. Verify a locked condition by firmly pulling on fuel line and fitting (15-30 lbs.). 12. Connect
negative battery cable to battery 13. Start engine and check for leaks.
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Fuel Pressure Regulator: Locations
Fig 1 Top View Of Fuel Pump Module
Fig 3 Side View -- Filter/Pressure Regulator
Fig 2 Fuel Pump Module Components -- Typical
A combination fuel filter and fuel pressure regulator is pressed into a rubber grommet located on
the top of the fuel pump module. A separate frame mounted fuel filter is not used.
Fuel Pressure Regulator: Description and Operation
DESCRIPTION
A combination fuel filter and fuel pressure regulator is used on all engines. It is located on the top
of the fuel pump module. A separate frame mounted fuel filter is not used with any engine.
Both fuel filters (at bottom of fuel pump module and within fuel pressure regulator) are designed for
extended service. They do not require normal scheduled maintenance. Filters should only be
replaced if a diagnostic procedure indicates to do so.
OPERATION
Fuel Pressure Regulator Operation: The pressure regulator is a mechanical device that is not
controlled by engine vacuum or the powertrain control module (PCM).
The regulator is calibrated to maintain fuel system operating pressure of approximately 339 kPa ±
34 kPa (49.2 psi ± 5 psi) at the fuel injectors. It contains a diaphragm, calibrated springs and a fuel
return valve. The internal fuel filter is also part of the assembly
Fuel is supplied to the filter/regulator by the electric fuel pump through an opening tube at the
bottom of filter/regulator. The regulator acts as a check valve to maintain some fuel pressure when
the engine is not operating. This will help to start the engine. A second check valve is located at the
outlet end of the electric fuel pump. If fuel pressure at the pressure regulator exceeds
approximately 49.2 psi, an internal diaphragm opens and excess fuel pressure is routed back into
the tank through the bottom of pressure regulator.
Fuel Pressure Regulator: Service and Repair
Fig 1 Top View Of Fuel Pump Module
NOTE: The fuel filter/fuel pressure regulator is located on top of fuel pump module.
NOTE: Two different types of filter/regulators are used.

- If a rubber grommet is located between the bottom of filter/regulator and top of fuel pump module,
it can be serviced separately. Refer to the following procedure.
- If this grommet is not used, it cannot be serviced separately The Fuel Pump Module assembly
must be replaced. Refer to Fuel Pump Module Removal/Installation for procedures.
WARNING: The fuel system is under a constant pressure, even with engine off. Before servicing
the fuel filter/fuel pressure regulator, the fuel system pressure must be released.
TIP: Fuel pump module removal is not necessary.
REMOVAL
1. Drain fuel tank and remove tank.
- Refer to Fuel Tank Removal/Installation.
Fig 22 Filter/Regulator Location
2. The fuel filter/regulator is pressed into a rubber grommet.
- Remove by twisting and pulling straight up (Fig. 23).
CAUTION: Do not pull the filter/regulator more than three inches from the fuel pump module.
Damage to the coiled fuel tube (line) may result.
Fig 24 Plastic Tube And Snap Ring -- Typical
3. Remove the snap ring retaining the convoluted tube (cover) to the filter/regulator (Fig. 24). Slide
the plastic tube down the fuel tube to clear the
fuel tube clamp.

Fig 25 Fuel Tube And Clamp -- Typical

4. Gently cut the old fuel tube (line) clamp (Fig. 25) taking care not to damage the plastic fuel tube.
Remove and discard the old fuel tube clamp. 5. Remove the plastic fuel tube from the
filter/regulator gently pulling downward. Remove filter/regulator from fuel pump module.
Fig 26 Tightening Fuel Tube Clamp -- Typical
INSTALLATION
1. Install a new clamp over the plastic fuel tube. 2. Install filter/regulator to fuel tube.
- Rotate the filter/regulator in the fuel tube (line) (Fig. 26) until it is pointed to the drivers side of
vehicle (Fig. 22).
3. Tighten line clamp to fuel line using special Hose Clamp Pliers number C-4124 or equivalent
(Fig. 26).
- Do not use conventional side cutters to tighten this type of clamp.
4. Slide the convoluted plastic tube (cover) up to the bottom of filter/regulator and install snap ring
(Fig. 24). 5. Press the filter/regulator (by hand) into the rubber grommet.
- The assembly should be pointed to the drivers side of vehicle (Fig. 22 ).
6. Install fuel tank.
- Refer to Fuel Tank Removal/Installation.
7. Check for fuel leaks.

Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage
NO: 14-03-98
MODELS: 1996 - 1998 (AB)
Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
DISCUSSION:

System Information > Specifications > Pressure, Vacuum and Temperature Specifications
Fuel Pressure

........................................ 339 ± 34 kPa (49.2 ± 5 psi)

minutes
System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 2881
seconds.

System Information > System Diagnosis > Fuel Pressure Leak Down Test
Test.
operational.
(Fig. 9) or (Fig. 10).

Adapter Tool.
on Adapter Tool.
specification.
information.
location.
ARE CONNECTED.
type-2 and type-3.
Starter Relay
Type-2 Relay
Type-3 Relay
pump module is OK.
seconds.

Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >

8w-10-2


Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Fuel Rail: Specifications
Mounting Bolts 23 Nm
Fuel Rail: Description and Operation
Fig. 6 Fuel Rail - Typical
The fuel rail supplies the necessary fuel to each individual fuel injector and is mounted to the lower
half of the two-piece intake manifold. The metal, one-piece fuel rail is not repairable.
The fuel pressure regulator is no longer mounted to the fuel rail on any engine. It is now located on
the fuel tank mounted fuel pump module. The fuel rail is not repairable.
CAUTION: The left and right sections of the fuel rail are connected with a flexible connecting hose.
Do not attempt to separate the rail halves at this connecting hose. Due to the design of this
connecting hose, it does not use any clamps. Never attempt to install a clamping device of any kind
to the hose. When removing the fuel rail assembly for any reason, be careful not to bend or kink
the connecting hose.
Fuel Rail: Service and Repair
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE
ENGINE TURNED OFF). BEFORE SERVICING THE FUEL RAIL ASSEMBLY, THE FUEL
SYSTEM PRESSURE MUST BE RELEASED.
CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate the
rail halves at the connecting hose. Due to the design of this connecting hose, it does not use any
clamps. Never attempt to install a clamping device of any kind to the hose. When removing the fuel
rail assembly for any reason, be careful not to bend or kink the connecting hose.
Fuel Rail Assembly
REMOVAL
1. Remove engine cover. 2. Remove negative battery cable at battery. 3. Remove air cleaner. 4.
Perform the fuel pressure release procedure. 5. Remove throttle body from intake manifold.
Fig. 31 A/C Compressor Support Bracket-Typical
6. If equipped with air conditioning, remove the A-shaped A/C compressor-to-intake manifold
support bracket (three bolts).
Fig. 5 Fuel Injectors-5.2L Engines-Typical
7. Disconnect electrical connectors at all fuel injectors. The factory fuel injection wiring harness is
numerically tagged (INJ 1, INJ 2, etc.) for injector
position identification.
8. Disconnect fuel tube (line) at side of fuel rail. 9. Remove the remaining fuel rail mounting bolts.
10. Clean dirt/debris from each fuel injector at intake manifold. 11. Gently rock and pull the left fuel
rail until the fuel injectors just start to clear the intake manifold. Gently rock and pull the right fuel
rail until the
fuel injectors just start to clear the intake manifold. Repeat this procedure (left/right) until all fuel
injectors have cleared the intake manifold.
12. Remove fuel rail (with injectors attached) from engine.
Fig. 33 Fuel Injector Mounting-Typical

Fig. 34 Injector Retaining Clips-Typical Injector
14. Remove the clip(s) retaining the injector(s) to fuel rail.
INSTALLATION
1. Apply a small amount of engine oil to each fuel injector 0-ring. This will help in fuel rail
installation. 2. Install injector(s) and injector clip(s) to fuel rail. 3. Position the fuel rail/fuel injector
assembly to the injector openings on the intake manifold. 4. Guide each injector into the intake
manifold. Be careful not to tear the injector o-ring. 5. Push the right fuel rail down until fuel injectors
have bottomed on injector shoulder. Push the left fuel rail down until fuel injectors have bottomed
on injector shoulder.
6. Install fuel rail mounting bolts. 7. Connect electrical connector to intake manifold air temperature
sensor. 8. Connect wiring to all fuel injectors. The injector wiring harness is numerically tagged. 9.
Install the A/C support bracket (if equipped).
10. Install throttle body to intake manifold. 11. Install fuel tube (line) at side of fuel rail. 12. Install air
cleaner. 13. Connect battery cable to battery. 14. Start engine and check for leaks. 15. Install
engine cover.
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions
Revisions
NUMBER: 26-12-97H
81-699-97027

2909
29
2910
56
2911
58
2912
412
DESCRIPTION
OPERATION
for procedures.

REMOVAL
plastic fuel
line within module.
INSTALLATION
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Fuel Tank Unit: Specifications Fuel Pump Module
Fuel Pump Module
Locknut 40 ft.lb
Fuel Tank Unit: Description and Operation
Fuel Pump Module
The fuel pump module on all gas powered engines is installed in the top of the fuel tank. The fuel
pump module contains:
- A combination fuel filter/fuel pressure regulator
- Electric fuel pump
- Fuel pump reservoir
- A separate in-tank fuel filter
- Fuel gauge sending unit
- Fuel supply line connection at filter/regulator
- A plastic threaded locknut to retain pump module to fuel tank
- A gasket between tank flange and module
The fuel gauge sending unit (fuel level sensor), and pick-up filter (at bottom of module) may be
serviced separately. If the electrical fuel pump requires service, the entire fuel pump module must
be replaced. The fuel filter/fuel pressure regulator may be serviced separately.
Fuel Tank Unit: Service and Repair
Fuel Pump Module
Fig 28 Locknut Removal/Installation -- Typical
WARNING: The fuel system is under constant pressure, even when the engine is OFF. Always
release fuel pressure before servicing any fuel system component.
CAUTION: Whenever the fuel pump module is serviced, the locknut and gasket must be replaced.
REMOVAL
1. Drain and remove fuel tank. 2. Thoroughly wash and clean area around pump module to prevent
contaminants from entering tank. 3. The fuel pump module locknut is threaded onto fuel tank.
- Install Special Tool 6856 to fuel pump module locknut and remove locknut (Fig. 28).
- The fuel pump module will spring up when locknut is removed.
4. Remove module from fuel tank.
CAUTION: Whenever the fuel pump module is serviced, the locknut and gasket must be replaced.
INSTALLATION
1. Using a new gasket position fuel pump module into opening in fuel tank. 2. Rotate module
assembly and align Index Arrow until pointed to rear of vehicle. 3. Position new locknut over top of
fuel pump module.
4. Install Special Tool 6856 to locknut. 5. Tighten locknut to 24-44 N.m (18-32 ft. lbs.) torque. 6.
Install fuel tank.
Fig 29 Fuel Pump Inlet Filter
FUEL PUMP INLET FILTER
The fuel pump inlet filter (strainer) is located on the bottom of fuel pump module (Fig. 29). The fuel
pump module is located on top of fuel tank.
REMOVAL
1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer
to Fuel Pump Module Removal/Installation. 3. Remove filter by carefully prying 2 lock tabs at
bottom of module with 2 screwdrivers. Filter is snapped to module. 4. Clean bottom of pump
module.
INSTALLATION
1. Snap new filter to bottom of module. 2. Install fuel pump module. Refer to Fuel Pump Module
Removal/Installation. 3. Install fuel tank. Refer to Fuel Tank Removal/Installation.
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator -
Electronic > Component Information > Specifications
Idle Speed/Throttle Actuator - Electronic: Specifications IAC Motor
IAC Motor
Mounting Bolts 7 Nm
Idle Speed/Throttle Actuator - Electronic: Locations
Map Sensor,idle Air Control Motor,TP Sensor

Idle Air Control Motor Connector

Idle Speed/Throttle Actuator - Electronic: Testing and Inspection
To perform a complete test of the idle air control motor and circuits see Computers and Control
Systems /System Diagnosis/Procedures/Diagnostic Charts.
Idle Speed/Throttle Actuator - Electronic: Service and Repair
REMOVAL
1. Remove air cleaner assembly. 2. Disconnect electrical connector from Idle Air Control (IAC)
motor.
Fig. 84 Mounting Bolts (Screws) - IAC
3. Remove two mounting bolts (screws). 4. Remove IAC motor from throttle body
INSTALLATION
1. Install IAC motor to throttle body 2. Install and tighten two mounting bolts (screws) to 7 N.m (60
in. lbs.) torque. 3. Install electrical connector. 4. Install air cleaner assembly.
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations

8w-10-2

SYSTEM OPERATION

TESTING

volt power source.

REMOVAL
INSTALLATION
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations

Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2941
8w-10-2


Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component

8w-10-2

SYSTEM OPERATION

TESTING

volt power source.

REMOVAL
INSTALLATION
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank >
Rollover Valve: Description and Operation
Fuel Pump Module
DESCRIPTION
The fuel tank is equipped with 2 interconnected rollover valves. The valves are located on the top
of the fuel tank. These valves will prevent fuel flow through the fuel tank vent (EVAP) hoses in the
event of an accidental vehicle rollover.
OPERATION
The EVAP canister draws fuel vapors from the fuel tank through these valves. The valves are not
serviced separately if replacement is necessary, the fuel tank must be replaced.
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank >
Rollover Valve: Service and Repair
The rollover valves(s) are/is molded into the fuel tank and are not serviced separately If
replacement is necessary the fuel tank must be replaced.
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel
System/Engine Controls - Manual Revisions
Revisions
NUMBER: 26-02-99A

45
46
47
152
156
316
620
622
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2970

millivolts.
WOT.
REMOVAL
INSTALLATION
rotated.
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Throttle Body: Specifications
Mounting Bolts 23 Nm
Throttle Body: Description and Operation
DESCRIPTION
The throttle position sensor (TPS), idle air control (IAC) motor and manifold absolute pressure
sensor (MAP) are attached to the throttle body The accelerator pedal cable, speed control cable
and transmission control cable (when equipped) are connected to the throttle arm.
A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle
plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are
controlled by the Powertrain Control Module (PCM).
OPERATION
Fig. 30 Throttle Body
Fig. 31 Air Control Passage
Filtered air from the air cleaner enters the intake manifold through the throttle body. Fuel does not
enter the intake manifold through the throttle body. Fuel is sprayed into the manifold by the fuel
injectors. The throttle body is mounted on the intake manifold. It contains an air control passage
controlled by an idle air control (IAC) motor. The air control passage is used to supply air for idle
conditions. A throttle valve (plate) is used to supply air for above idle conditions.
Throttle Body: Testing and Inspection

column.
Throttle Body: Service and Repair
A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle
plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are
controlled by the Powertrain Control Module (PCM).
REMOVAL
1. Remove the air cleaner.
Fig. 40 Sensor And IAC Location - Typical
2. Disconnect throttle body electrical connectors at Manifold Absolute Pressure (MAP) sensor, Idle
Air Control (IAC) motor and Throttle Position
Sensor (TPS).
3. Remove vacuum line at throttle body. 4. Remove all control cables from throttle body (lever) arm.
Refer to Accelerator Cable/Service and Repair.
Fig. 30 Throttle Body
5. Remove four throttle body mounting bolts. 6. Remove throttle body from intake manifold. 7.
Discard old throttle body-to-intake manifold gasket.
INSTALLATION
1. Clean the mating surfaces of the throttle body and the intake manifold. 2. Install new throttle
body-to-intake manifold gasket.
3. Install throttle body to intake manifold. 4. Install four mounting bolts. Tighten bolts to 23 N.m (200
in. lbs.) torque. 5. Install control cables. 6. Install vacuum line to throttle body 7. Install electrical
connectors. 8. Install air cleaner.
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Throttle Cable/Linkage: Service and Repair
Fig 42 Accelerator Pedal Removal/Installation
CAUTION: Be careful not to damage or kink the cable core wire (within the cable sheathing) while
servicing accelerator pedal or cables.
REMOVAL
1. From inside the vehicle, hold up accelerator pedal.
- Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm (Fig. 42).
- Plastic cable retainer snaps into pedal arm.
2. Remove the cable core wire at the pedal arm. 3. From inside the vehicle, pinch both sides of the
cable housing retainer at the dash panel (Fig. 42).
- Remove cable housing from dash panel and pull into the engine compartment.
4. Remove engine cover. 5. Remove the air cleaner housing. 6. Operate the throttle body lever (by
hand) to the full open throttle position. Slip the cable end rearward from pin on throttle lever (Fig.
44).
Fig 45 Cable Release Tab -- Typical
7. Remove cable housing at throttle body mounting bracket by pressing forward on release tab with
a small screwdriver (Fig. 45).
- To prevent cable housing breakage, press on the tab only enough to release the cable from the
bracket.
- Lift the cable housing straight up from bracket while pressing on release tab.
- Remove cable housing.

Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Service and Repair > Page 2986
8. Remove cable from vehicle.
Fig 44 Throttle Cable At Throttle Body -- Typical
INSTALLATION
1. Snap the cable end onto lever pin (Fig. 44). On models with V-8 engines, be sure cable is routed
under plastic cam (Fig. 44). 2. Connect cable to throttle body mounting bracket (push down and
lock). 3. Install the remaining cable housing end into the dash panel opening (snaps into position).
Fig 43 Index Tab And Slot
4. Install the ball end of the cable wire through the hole in the pedal arm.
- Install the plastic cable retainer.
- The plastic retainer is snapped into the pedal arm.
- When installing the retainer to the accelerator pedal arm, note the index tab on the pedal arm
(Fig. 43).
- Align the index slot (Fig. 43) on the plastic retainer to this index tab.
5. Operate and test the throttle before starting engine. 6. Install air cleaner housing. 7. Install
engine cover.
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions
Revisions
NUMBER: 26-02-99A

45
46
47

152
156

316

620
622

millivolts.
WOT.
REMOVAL
INSTALLATION
rotated.
Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder >
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component


SYSTEM OPERATION
this
test.
necessary.
REMOVAL
INSTALLATION
engine cover.
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Mounting Bolts 8 Nm

SYSTEM OPERATION
Sensor Operation
outer edge.
REMOVAL
INSTALLATION
Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Cap >
Component Information > Testing and Inspection
Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component
Information > Testing and Inspection
adverse conditions.
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross
Fire/Ignition Wire Induction
NO: 18-48-98
DATE: Dec. 30, 1998
MODELS:
1994 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
NOTE:
SYMPTOM/CONDITION:
mph).
DIAGNOSIS:
NOTE:

PARTS REQUIRED:

TIME ALLOWANCE:
08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs.
(AN/DN) 5.2/5.9L 0.3 Hrs.
(BR/BE) 5.2/5.9L 0.4 Hrs.

Fire/Ignition Wire Induction > Page 3042
Repair Procedure
NOTE:
90° ANGLE.
NOTE:
CLIPS.
studs).
and 82.5 mm (3.25 in.).
NOTE:
tower terminal.
cover.
NOTE:
(Figure 5).
NOTE:
LAYOUT APPLIES.
NOTE:
NOTE:
valve cover.
elbow.
NOTE:
3.9L Engine
(Figure 11).
studs).
one (1) at 82.5 mm (3.25 in.).
studs).
NOTE:
tower terminal.
Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System -
Cross Fire/Ignition Wire Induction
NO: 18-48-98
DATE: Dec. 30, 1998
MODELS:
1994 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
NOTE:
SYMPTOM/CONDITION:
mph).
DIAGNOSIS:
NOTE:

PARTS REQUIRED:

TIME ALLOWANCE:
08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs.
(AN/DN) 5.2/5.9L 0.3 Hrs.
(BR/BE) 5.2/5.9L 0.4 Hrs.

Repair Procedure
NOTE:
90° ANGLE.
NOTE:
CLIPS.
studs).
and 82.5 mm (3.25 in.).
NOTE:
tower terminal.
cover.
NOTE:
(Figure 5).
NOTE:
LAYOUT APPLIES.
NOTE:
NOTE:
valve cover.
elbow.
NOTE:
3.9L Engine
(Figure 11).
studs).
one (1) at 82.5 mm (3.25 in.).
studs).
NOTE:
tower terminal.
Ohms Per Foot
SYSTEM OPERATION
Heat Shields
shield.
Testing
follows:
exceed ten minutes.

Cable Removal
Engine Firing Order
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Locations
Accessory Drive Belt Tensioner,coil Mounting Bolt,ignition Coil,coil Connector

Ignition Coil: Description and Operation
SYSTEM OPERATION
Battery voltage is supplied to the ignition coil positive terminal from the Automatic Shutdown (ASD)
relay.
The Powertrain Control Module (PCM) opens and closes the ignition coil ground circuit for ignition
coil operation.
Base ignition timing is not adjustable on any engine. By controlling the coil ground circuit, the PCM
is able to set the base timing and adjust the ignition timing advance. This is done to meet changing
engine operating conditions.
The ignition coil is not oil filled. The windings are embedded in an epoxy compound. This provides
heat and vibration resistance that allows the ignition coil to be mounted on the engine.
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing
and Inspection > Ignition Coil Test
Ignition Coil: Testing and Inspection Ignition Coil Test
To perform a complete test of the ignition coil and its circuitry, refer to the DRB scan tool. Also refer
to the appropriate Powertrain Diagnostics Procedures. To test the coil only, refer to the following:
Ignition Coil - Typical
The ignition coil is designed to operate without an external ballast resistor.
Ignition Coil Resistance
Coil Manufacturer = Diamond Primary resistance 21 - 27°C (70 - 80°F) = 0.97 - 1.18 Ohms
Secondary resistance 21 - 27°C (70 - 80°F) = 11,300 - 15,300 Ohms
Coil Manufacturer = Toydenso Primary resistance 21 - 27°C (70 - 80°F) = 0.95 - 1.20 Ohms
Secondary resistance 21 - 27°C (70 - 80°F) = 11,300 - 13,300 Ohms
Inspect the ignition coil for arcing. Test the coil according to coil tester manufacturer's instructions.
Test the coil primary and secondary resistance. Replace any coil that does not meet specifications.
Refer to the IGNITION COIL RESISTANCE chart.
If the ignition coil is being replaced, the secondary spark plug cable must also be checked. Replace
cable if it has been burned or damaged.
Arcing at the tower will carbonize the cable boot, which if it is connected to a new ignition coil, will
cause the coil to fail.
If the secondary coil cable shows any signs of damage, it should be replaced with a new cable and
new terminal. Carbon tracking on the old cable can cause arcing and the failure of a new ignition
coil.
and Inspection > Ignition Coil Test > Page 3070
Ignition Coil: Testing and Inspection Testing For Spark at Coil
Cable Removal
twist the rubber boot slightly (112 turn) to break it loose. Grasp the boot (not the cable) and pull it
off with a steady, even force.
Checking For Spark - Typical
1. Disconnect the ignition coil secondary cable from center tower of tile distributor cap. Hold the
cable terminal approximately 12 mm (1/2 in.) from
a good engine ground.
WARNING: BE VERY CAREFUL WHEN THE ENGINE IS CRANKING. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR LOOSE FITTING
CLOTHING.
2. Rotate (crank) the engine with the starter motor and observe the cable terminal for a steady arc.
If steady arcing does not occur, inspect tile
secondary coil cable. Refer to Spark Plug Cables. Also inspect the distributor cap and rotor for
cracks or burn marks. Repair as necessary. If steady arcing occurs, connect ignition coil cable to
the distributor cap.
3. Remove a cable from one spark plug. 4. Using insulated pliers, hold the cable terminal
approximately 12 mm (1/2 in.) from the engine cylinder head or block while rotating the engine
with the starter motor. Observe the spark plug cable terminal for an arc. If steady arcing occurs, it
can be expected that the ignition secondary system is operating correctly (If the ignition coil cable
is removed for this test, instead of a spark plug cable, the spark intensity will be much higher). If
steady arcing occurs at the spark plug cables, but the engine will not start, connect the DRB scan
tool. Refer to the appropriate Powertrain Diagnostic Procedures service.
and Inspection > Page 3071
Ignition Coil: Service and Repair
The ignition coil is an epoxy filled type. If the coil is replaced, it must be replaced with the same
type.
REMOVAL
Ignition Coil
The coil is mounted to a bracket that is bolted to the front of the right engine cylinder head. This
bracket is also used to mount the automatic belt tensioner. 1. Disconnect the wiring and secondary
cable from the ignition coil.
WARNING: DO NOT REMOVE THE COIL MOUNTING BRACKET-TO-CYLINDER HEAD

MOUNTING BOLTS. THE COIL MOUNTING BRACKET IS UNDER ACCESSORY DRIVE BELT
TENSION. IF THIS BRACKET IS TO BE REMOVED FOR ANY REASON, ALL BELT TENSION
MUST FIRST BE RELIEVED.
2. Remove ignition coil from coil mounting bracket (two bolts).
INSTALLATION 1. Install the ignition coil to coil bracket. If nuts and bolts are used to secure coil to
coil bracket, tighten to 11 N.m (100 in. lbs.) torque. If the coil
mounting bracket has been tapped for coil mounting bolts, tighten bolts to 5 N.m (50 in. lbs.)
torque.
2. Connect all wiring to ignition coil.

Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations

Camshaft Position Sensor > Component Information > Locations > Page 3076

SYSTEM OPERATION
this
test.
necessary.
REMOVAL
INSTALLATION
engine cover.
Crankshaft Position Sensor > Component Information > Specifications
Mounting Bolts 8 Nm
Crankshaft Position Sensor > Component Information > Specifications > Page 3083

SYSTEM OPERATION
Sensor Operation
outer edge.
REMOVAL
INSTALLATION
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation
SYSTEM OPERATION
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 3092
REMOVAL
Lower Shroud Screws
Shroud Pivot Point

Upper Shroud Screws
removal.
removal.
INSTALLATION
position.

Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications
Electrode Gap ......................................................................................................................................

..................................................... 0.89 mm (0.035 in) Torque ............................................................
............................................................................................................................................... 41 Nm
(30 ft lb)
Plug Type ............................................................................................................................................

..................................................................... RC12YC
SYSTEM OPERATION
oil fouled.
Normal Operating

Scavenger Deposits
Scavenger Deposit
Preignition Damage
Preignition Damage
overheating.
Heat Shields
spark plug.
plug condition.
adjusting gap.
electrode.
damaged.
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids -
Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information >
Locations > Component Locations
O/D Solenoid,TCC Solenoid,governor Pressure Sensor,governor Pressure Solenoid

Locations > Component Locations > Page 3113
Solenoid Case Connector,park/neutral Position Switch Connector

Transmission Solenoid Connector

Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 >
A/T - Buzz/Whining in Reverse When Cold
Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold
NUMBER: 21-08-99
GROUP: Transmission
SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse
Is Selected.
OVERVIEW: This bulletin involves replacing the transmission regulator valve.
MODELS: 1996 - 1999
(AB) Ram Van
1996 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
1999 (WJ) Grand Cherokee
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC

TRANSMISSION.
SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission
when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning"
like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100
F.). The condition is caused by a resonance of the transmission regulator valve system.
Other items may cause regulator valve resonance, including air ingestion into the valve body or out
of specification parts. These two items may be the result a possible cracked pump housing, a torn
pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of
specification valve and/or valve body. You should remember these additional items / components
when you perform your diagnosis.
Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve
body or an entire automatic transmission was replaced with components manufactured after
August 1, 1995.
DIAGNOSIS:
Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual,
verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble
Codes (DTC's) are present, record them on the repair order and repair as necessary before
proceeding further with this bulletin.
For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to
determine if it applies to this vehicle before attempting to complete the analysis or repairs
described in this bulletin.
In most instances, the sump temperature of vehicles exhibiting transmission regulator valve
resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to
remain parked in a cool place overnight. Then perform the following steps:
1. Set the vehicle parking brake.
2. Start the engine (make certain windows are closed, to eliminate outside noise).
3. With brakes applied, place the transmission selector lever in reverse.
4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to
normal operating temperature (180 - 210 degrees F).
5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure.
PARTS REQUIRED:
1 04130169 Valve, Steel Transmission Regulator

A/T - Buzz/Whining in Reverse When Cold > Page 3123
1 02464324 Gasket, Transmission Pan
AR 05010124AA Fluid, ATF Plus 3, Type 7176E
EQUIPMENT REQUIRED:
1 C-3763 Gauge Tool, Throttle Pressure Adjustment
REPAIR PROCEDURE:
1. Following the procedures in the applicable service manual, remove the valve body from the
transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND
TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION).
2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n
04130169 (Figure 1). Install the adjusting screw bracket
3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by
following the procedures in the service manual (Refer to Group 21 of the appropriate Service
Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section -
ADJUSTMENTS - VALVE BODY).
4. Following the procedures in the appropriate Service Manual, re-install the valve body with the
new regulator valve into the transmission.
5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill
level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary,
following the applicable service manual procedure (Refer to Group 21 of the appropriate Service
ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT).
TIME ALLOWANCE:

Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 >
Apr > 99 > A/T - Buzz/Whining in Reverse When Cold
Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When
Cold
NUMBER: 21-08-99
GROUP: Transmission
Is Selected.
MODELS: 1996 - 1999
(AB) Ram Van
1996 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
NOTE:

TRANSMISSION.
August 1, 1995.
DIAGNOSIS:
PARTS REQUIRED:

Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3129
EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
TIME ALLOWANCE:

Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations
O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid
Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component

Torque Convertor Clutch Solenoid Connector

Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators -
Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information >
Overdrive Indicator Lamp: Description and Operation
SYSTEM OPERATION
The overdrive-off indicator lamp gives the driver an indication that the automatic transmission
overdrive has been locked out. The lamp is controlled by the Powertrain Control Module (PCM) on
a hard wired circuit to instrument cluster.
The PCM receives an input from the momentary overdrive lockout switch, which is located on the
end of the automatic transmission gearshift selector lever. The PCM uses the overdrive lockout
switch input, along with numerous other sensor inputs and its internal programming to decide
whether the over-drive-off indicator lamp should be on or off. The PCM then turns the lamp on or
off by controlling the ground path for the lamp control circuit.
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators -
Overdrive Indicator Lamp: Testing and Inspection
The diagnosis found here addresses an inoperative overdrive-off indicator lamp condition. If the
overdrive-off indicator lamp comes on and stays on with the engine running, refer to the proper
Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) and the transmission
control system circuits.

INJURY.
component as required and replace the faulty fuse. 2. Turn the ignition switch to the On position.
Check for battery voltage at the fuse in the junction block. If OK, go to Step 4. If not OK, repair the
open circuit to the ignition switch as required.
3. Disconnect and isolate the battery negative cable. Unplug the gray PCM wire harness connector.
Install a jumper wire between the overdrive lamp
driver circuit cavity of the gray PCM wire harness connector and a good ground. Connect the
battery negative cable. Turn the ignition switch to the On position. The overdrive-off indicator lamp
should light. Remove the jumper wire and the lamp should turn off. If OK, refer to the proper
control system circuits. If not OK, go to Step 5.
Remove the instrument cluster. Check for continuity
between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a
good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the short circuit
as required.
5. Check for continuity between the overdrive lamp driver circuit cavities of the gray PCM wire
harness connector and the instrument cluster wire
harness connector (connector A). There should be continuity. If OK, replace the faulty bulb. If not
OK, repair the open circuit as required.
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules -
Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set
NUMBER: 21-04-00
GROUP: Transmission
DATE: June 3O, 2000
High
99Cal14).
MODELS:
**1996** - 1999 (AB) Ram Van
**1996** - 1999 (AN) Dakota
**1996** - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
**1997** - 1999 (TJ) Wrangler
**1996** 1999 (XJ) Cherokee
NOTE:

December 18, 1998.
NOTE:
NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:

Service Bulletins > Customer Interest: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3155
1 CH7000/7001 J1962 Cable
1 MDS2
NOTE:
OR HIGHER.
REPAIR PROCEDURE:
SCREEN.
SCREEN.
NOTE:
BEGIN SESSION.
NOTE:
SOFTWARE.
NOTE:

NOTE:
Service Bulletins > Customer Interest: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3156
TIME ALLOWANCE:

Service Bulletins > All Technical Service Bulletins: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set
NUMBER: 21-04-00
GROUP: Transmission
DATE: June 3O, 2000
High
99Cal14).
MODELS:
**1996** - 1999 (AB) Ram Van
**1996** - 1999 (AN) Dakota
**1996** - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
**1997** - 1999 (TJ) Wrangler
**1996** 1999 (XJ) Cherokee
NOTE:

December 18, 1998.
NOTE:
NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:

Service Bulletins > All Technical Service Bulletins: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3162
1 CH7000/7001 J1962 Cable
1 MDS2
NOTE:
OR HIGHER.
REPAIR PROCEDURE:
SCREEN.
SCREEN.
NOTE:
BEGIN SESSION.
NOTE:
SOFTWARE.
NOTE:

NOTE:
Service Bulletins > All Technical Service Bulletins: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3163
TIME ALLOWANCE:

Service Bulletins > All Other Service Bulletins for Control Module: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse
When Cold
Cold
NUMBER: 21-08-99
GROUP: Transmission
Is Selected.
MODELS: 1996 - 1999
(AB) Ram Van
1996 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
NOTE:

TRANSMISSION.
August 1, 1995.
DIAGNOSIS:
PARTS REQUIRED:

When Cold > Page 3169
EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
TIME ALLOWANCE:

EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
TIME ALLOWANCE:

Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component

8w-10-2

Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches -
Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm
NO: 18-19-98
GROUP: Driveability
DATE: Apr. 10, 1998
MODELS: 1996 - 1998
(AB) Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
NOTE:

PARTS REQUIRED:
REPAIR PROCEDURE:

Technical Service Bulletins > Customer Interest: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm >
Page 3192
21-96-06-90 1.1 Hrs.

Technical Service Bulletins > All Technical Service Bulletins: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at
5,300 Rpm
5,300 Rpm
NO: 18-19-98
GROUP: Driveability
DATE: Apr. 10, 1998
MODELS: 1996 - 1998
(AB) Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
NOTE:

PARTS REQUIRED:
REPAIR PROCEDURE:

Technical Service Bulletins > All Technical Service Bulletins: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at
5,300 Rpm > Page 3198
21-96-06-90 1.1 Hrs.

Technical Service Bulletins > All Other Service Bulletins for Fluid Pressure Sensor/Switch: > 21-04-00 > Jun > 00 > TCM -
MIL ON/DTC P1763 Set
NUMBER: 21-04-00
GROUP: Transmission
DATE: June 3O, 2000
High
99Cal14).
MODELS:
**1996** - 1999 (AB) Ram Van
**1996** - 1999 (AN) Dakota
**1996** - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
**1997** - 1999 (TJ) Wrangler
**1996** 1999 (XJ) Cherokee
NOTE:

December 18, 1998.
NOTE:
NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:

MIL ON/DTC P1763 Set > Page 3204
1 CH7000/7001 J1962 Cable
1 MDS2
NOTE:
OR HIGHER.
REPAIR PROCEDURE:
SCREEN.
SCREEN.
NOTE:
BEGIN SESSION.
NOTE:

SOFTWARE.
NOTE:

NOTE:
TIME ALLOWANCE:

1 CH7000/7001 J1962 Cable
1 MDS2
NOTE:
OR HIGHER.
REPAIR PROCEDURE:
SCREEN.
SCREEN.
NOTE:
BEGIN SESSION.
NOTE:

SOFTWARE.
NOTE:

NOTE:
TIME ALLOWANCE:

Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component

Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
powertrain control module. See: Brakes and Traction Control/Antilock Brakes / Traction Control
Systems/Wheel Speed Sensor
Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component

Governor
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Recalls: > 831 > Jun > 99 > Recall - Reprogram PCM
June 1999
Models
transmission)
NOTE:
Subject
Repair
Parts Information
payments.
Number Allowance
NOTE:
Parts Return
Not Applicable
48326-2757
Service Office.
Service Procedure
Using the MDS1
power them up.
MENU screen.
MENU.
NOTE:
Using the MDS2

SCREEN.
SCREEN.
NOTE:
begin the session.
NOTE:
Fig. 1
Fig. 2
Owner Letter
The problem is...
and processed.
What you must do...
If you need help...
vehicle repaired.
Information > Technical Service Bulletins > Customer Interest: > 18-05-00G > Dec > 00 > Engine - Spark Knock/PCM
Reprogramming
PROM - Programmable Read Only Memory: Customer Interest Engine - Spark Knock/PCM
Reprogramming
NUMBER: 18-05-00 Rev. G
DATE: Dec. 01, 2000
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-05-00 REV F, DATED

SEPT. 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN UPDATE TO THE EMISSIONS
PACKAGES.
SUBJECT: 1998
M.Y. Engine Spark Knock
OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control
Module (PCM) with new software (calibration level 98Cal12 and 98Cal12C)
MODELS: 1998
(AB) Ram Van
1998 (AN) Dakota
1998 (BR/BE) Ram Truck
1998 (DN) Durango
1998 (XJ) Cherokee
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.5L (EPE), 3.9L (EHC), 4.0L
(ERH), 5.2L (ELF), OR 5.9L LIGHT DUTY (EML) GASOLINE ENGINE. SEE THE TWO TABLES -
FOR SPECIFIC APPLICATIONS AND EXCLUSIONS.
Reprogramming > Page 3239
NOTE:
THE FOLLOWING EMISSION PACKAGES ARE NOT APPROVED AND ARE EXCLUDED FROM
THIS BULLETIN. THE PCM CALIBRATION OF ANY EXCLUDED VEHICLE IS NOT TO BE
REPROGRAMMED FOR A SPARK KNOCK COMPLAINT. BEFORE ATTEMPTING A
REPROGRAMMING SESSION INSPECT THE TYPE OF VEHICLE AND ENGINE FOR
POSSIBLE EXCLUSION.
SYMPTOM/CONDITION: Some vehicle engines may exhibit a light-to-moderate spark knock

condition during acceleration (under load).
DIAGNOSIS PROCEDURES:
1. Verify that the following NOTE(s) have been reviewed and completed as necessary.
2. Verify that the engine coolant contains a quality antifreeze. The coolant mixture should consist of
44% to 68% antifreeze.
3. If the only condition seen is the light-to-moderate engine spark knock, then perform the Repair
Procedure.
NOTE:
VERIFY THAT TSB 18-48-98, FOR ENGINE IGNITION WIRE ROUTING, HAS BEEN
COMPLETED
NOTE:
THIS REPAIR PROCEDURE WILL NOT COMPENSATE FOR HEAVY SPARK KNOCK
CONDITIONS. IF HEAVY KNOCK IS EXPERIENCED, FURTHER DIAGNOSIS AND TESTING OF
THE ENGINE WILL BE REQUIRED. REFER TO TSB 09-05-00 FOR ADDITIONAL ASSISTANCE.
NOTE:
WHEN PULLING A HEAVY LOAD OR DRIVING A FULLY LOADED VEHICLE USE A PREMIUM
UNLEADED FUEL TO HELP MINIMIZE SPARK KNOCK.
NOTE:
WHENEVER A POWERTRAIN CONTROL MODULE IS REPLACED DUE TO FAILURE, THE

SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST
REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS
AS NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:
NOTE:
THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR, WHEN
OR HIGHER (SEE THE TABLE).
REPAIR PROCEDURE:
1. Log onto the MDS2 (Mopar Diagnostic System).
NOTE:
AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH
COMMUNICATION. THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2)
WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO
REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK"BUTTON
WHEN ASKED TO BEGIN SESSION.
3. Push the FLASH tab on the MDS2.
NOTE:
A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) THAT INDICATES NO UPDATES ARE
AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING
AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST
SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE ANOTHER VEHICLE
CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION.
SOFTWARE.
NOTE:

MODULES (EATX, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME
DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF
NOTE:
7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig.
1). Attach the label to the PCM and cover the label with the clear plastic overlay.
8. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach
the label near the VECI label (Fig. 2).
TIME ALLOWANCE:
FAILURE CODE: Could be one or more

Information > Technical Service Bulletins > Customer Interest: > 18-05-00F > Sep > 00 > Engine - Spark Knock on
Acceleration
PROM - Programmable Read Only Memory: Customer Interest Engine - Spark Knock on
Acceleration
NUMBER: 18-05-00 Rev F
DATE: September 15, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN
18-05-00 REV E, DATED SEPTEMBER 01, 2000 WHICH SHOULD BE REMOVED FROM YOUR
FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN
EMISSIONS PACKAGE UPDATE TO THE TABLE.
SUBJECT: 1998 Model Year Engine Spark Knock
MODELS: 1998
(AB) Ram Van
1998 (AN) Dakota
1998 (DN) Durango
1998 (XJ) Cherokee
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A GASOLINE ENGINE. SEE THE
TABLE FOR SPECIFIC APPLICATION.

DIAGNOSIS:
1. Verify that the following NOTE(S) have been reviewed and completed as necessary.
2. Verify that the engine coolant contains the correct mixture of a quality antifreeze to water. The
coolant mixture should consist of 44% to 68% antifreeze.
3. If the only condition seen is the light-to-moderate engine spark knock, perform the Repair
Procedure.
NOTE:
VERIFY THAT TSB 18-48-98 HAS BEEN COMPLETED.
NOTE:
THIS FEATURE WILL NOT COMPENSATE FOR HEAVY SPARK KNOCK CONDITIONS. IF
HEAVY KNOCK IS EXPERIENCED, FURTHER DIAGNOSIS AND TESTING WILL BE
REQUIRED. REFER TO TSB 09-05-00 FOR ADDITIONAL ASSISTANCE.
NOTE:
UNLEADED FUEL TO HELP
Acceleration > Page 3246
MINIMIZE SPARK KNOCK.
NOTE:

AS NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:
NOTE:
REPAIR PROCEDURE:
NOTE:
REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON
NOTE
A MESSAGE WILL APPEAR (AFTER STEP 3 OR 4) THAT INDICATES NO UPDATES ARE
SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE
SOFTWARE.
NOTE:

MODULES (TCM, BCM, MIC, SKIM, ECT.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME
COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED.CHECK ALL
NOTE:

Acceleration > Page 3247
7. Type the necessary information on the "Authorized Software Update Label" P/N 04669020
(figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay.
the label near the VECI label (Figure 2).
TIME ALLOWANCE:

Information > Technical Service Bulletins > Customer Interest: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set
MIL ON, Erroneous DTC P0107 Set
NUMBER: 18-08-00
DATE: June 23, 2000
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-03-99, DATED FEB. 19,
SUBJECT: Erroneous MIL Illumination Due To DTC P0107 - Map Sensor Voltage Too Low
Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18 and 98Cal12).
**MODELS:** **1996** - 1998 (AB)
Ram Van
**1996** - 1998 (AN) Dakota
**1996** - 1998 (BR/BE) Ram Truck
1998 (DN) Durango
**1997** - 1998 (TJ) Wrangler
**1996** - 1998 (XJ) Cherokee
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINE.
SYMPTOM/CONDITION: Erroneous MIL illumination with DTC P0107 - MAP SENSOR VOLTAGE
TOO LOW. This may occur during downhill decelerations at altitude or when performing off-road
maneuvers when the engine is operating over 1500 rpm. The MIL illuminates due to the monitor
running during incorrect parameters.
NOTE:
WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE,

THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE
LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED
CONTROLLERS AS NECESSARY.
PARTS REQUIRED:

EQUIPMENT REQUIRED:
1 CH6OOO Scan Tool (DRB III(R))
1 CH700017001 J1962 Cable
1 MDS2
NOTE:
OR HIGHER.
TIME ALLOWANCE:
> Page 3252
Repair Procedure
SCREEN.
4 Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the ORB III(R) MAIN MENU
SCREEN.
NOTE:
BEGIN SESSION.
NOTE:

SOFTWARE.
8. The MDS2 and ORB III(R) will prompt for any operator action needed during the remainder of
NOTE:

NOTE:
(Figure 1) Attach the label to the JTEC PCM and cover the label with the clear plastic overlay.
> Page 3253
Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB
Readiness Monitor Information
I/M Testing - OBDII CARB Readiness Monitor Information
NO: 25-02-98
GROUP: Emissions
DATE: Oct. 23, 1998
SUBJECT:
I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information
MODELS:
1996 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
1995 - 1999 (PL) Neon
1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE

ENGINES.
DISCUSSION:
Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a
prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their
self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or
more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their
tests.
It is important to understand that the MIL will not be illuminated because OBD Readiness reads
"NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions
system occurs. It is possible to have MIL illumination for a detected failure while at the same time
having a "NO" for an OBO Readiness monitor.
NOTE:
MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER

DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS
BULLETIN.
OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM
replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items
occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for
OBD Readiness.
Some customers may be directed back to their dealers for assistance when an I/M test station has
not allowed an I/M test due to Readiness status. The following procedures will help technicians
efficiently run the Readiness tests so an owner can have their I/M test completed.
EQUIPMENT REQUIRED:
1 CH7000/7001 J1962Cable
1 CH7OlO J1962 MMC Cable

Readiness Monitor Information > Page 3258
TIME ALLOWANCE:
FAILURE CODE: XX - Service Adjustment
Repair Procedure
This bulletin involves operating the vehicle under specific parameters to run or complete the OBD
monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions
application. In addition, the parameters to run each monitor will vary.
Preliminary Checks
1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate
as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit.
2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year
diagnostics, engine, DTC's and related functions, read DTC's.
3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the
engine running.
NOTE:
EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS
FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE
ATTEMPTING TO RUN THE MONITORS.
OBD "CARB" Readiness Check
1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status.
2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO"
tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned
to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read
"YES".
NOTE:
THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES
APPLICABLE FOR THE VEHICLE BEING WORKED ON.
The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to
run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The
pre-test/monitor test screen lists all the preliminary parameters that must be met along with the
running parameters for that specific monitor to run. An example of one screen is shown in Figure 1.
NOTE:
1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN.
PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE
MONITORS RUN WILL BE SIMILAR.
The following explains how to interpret each section of the screen:
PRE-TEST REQUIREMENTS
The pre-test requirements include all the operating parameters that must be met before the actual
test can run. The vehicle must be operated until each item within the pre-test section are fulfilled.
LOW VALUE/HIGH VALUE/BAR GRAPH
The low value/high value provides the minimum and maximum operating conditions for each item
(ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when
the lowest value required for each item is met. This provides a visual indication that the parameters
are being met. The vehicle should be driven until most of each pre-test bar graph is filled.
MONITOR REQUIREMENTS
Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in
the monitor requirements section for the monitors to begin running. As the monitor begins to run,
the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle
operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician
must determine if the pre-test requirements or the monitor requirements have fallen outside the
window for the test and the vehicle must be driven accordingly for the test to restart. When the
monitor completes its test, the DRB III(R) will beep 3 consecutive times.
NOTE:
THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE
PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR
SCREEN FOR THIS MONITOR.
MONITOR RUN PROCESS
The following will provide the most efficient order along with tips to help run through the monitor
tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear
Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum
available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The
only monitors that will require attention are those that read "NO" under the OBD "CARB"
Readiness Status screen.
Front Wheel Drive
1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight
soak either indoors or out depending on conditions). The ambient (outside) temperature must be
between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of
ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen
on the DRB III(R) to determine the remaining requirements.
2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the
pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the
requirements.
3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test
screen for this test to complete.
4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the
pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period.
5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the
DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the
monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left
in drive for the test to run. If all parameters are met and the test still will not run, place your foot on
the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells
to update.
6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded.
This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No
Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater
monitor status. It should have switched to "YES". All other monitors should be completed before
running this test.
Rear Wheel Drive
1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either
indoors or outdoors depending on conditions). The ambient (outside) temperature must be between
18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of
on the DRB III(R) to determine the remaining
requirements.
soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must
be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F)
of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test
screen on the DRB III(R) to determine the remaining requirements.
pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet
the requirements.
pre-test screen. Automatic transmission vehicles must be left in drive during the stop period.
monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be
left in drive for the test to run. If all parameters are met and the test will still not run, place your foot
on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF
cells to update.
Information > Technical Service Bulletins > Customer Interest: > 18-36-97 > Dec > 97 > PCM - Incorrect Fault Mature Time
for DTC#B7
PROM - Programmable Read Only Memory: Customer Interest PCM - Incorrect Fault Mature Time
for DTC#B7
NO: 18-36-97
DATE: Dec. 31, 1997
SUBJECT: Incorrect Fault Mature Time - DTC $B7 Leak Detection Pump Solenoid Circuit
MODELS: 1998 (AB)
Ram Van/Wagon
1998 (AN) Dakota
1998 (BR/BE) Ram Truck 1998 (DN)
Durango
1998 (SR) Viper Roadster/Coupe
1998 (TJ) Wrangler
1998 (XJ) Cherokee
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO NOV. 20, 1997 (MDH 1120XX) WITH
GASOLINE ENGINES AND SALES CODE NAE (CALIFORNIA EMISSIONS).
DISCUSSION: Hex code $B7 - LEAK DETECTION PUMP SOLENOID CIRCUIT is a one trip DTC.
Its purpose is to detect electrical shorts or opens in the LDP solenoid circuit. The time it takes for
this DTC to mature has been determined to take too long.
DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III)
with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are
functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the
repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are
present, perform the Repair Procedure.
NOTE:

THE SOFTWARE OF THE REPLACEMENT PCM SHOULD BE VERIFIED FOR THE LATEST
REVISION LEVEL.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 0H7000/7001 J1962 Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM
MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1147 OR
HIGHER MUST BE INSTALLED.
REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the
Powertrain Control Module (PCM) with new software (calibration changes) for the condition listed.
NOTE:
FOR XJ VEHICLES EQUIPPED WITH AN AISIN WARNER TRANSMISSION, DTC $BE (CCD
MESSAGE FROM JTEC FAILURE) CAN BE SET WITHIN THE EATX MODULE DUE TO THE
PCM FLASH AND THE DTC GENERATED WITHIN THE EATX MAY SET DTC $89 (EATX
CONTROLLER DTC PRESENT) WITHIN THE PCM. CHECK FOR AND ERASE THESE FAULTS
PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER.
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
Information > Technical Service Bulletins > Customer Interest: > 18-36-97 > Dec > 97 > PCM - Incorrect Fault Mature Time
for DTC#B7 > Page 3265
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the PCM on the vehicle and compare it to the
part number displayed. If the PCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
NOTE:
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
attach the label near the VECI Label (Figure 2).
08-19-48-97 0.5 Hrs.

Information > Technical Service Bulletins > Customer Interest: > 21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in
Cold Temperatures
A/T - Overdrive Unavailable in Cold Temperatures
NO: 21-06-97 Rev. A
GROUP: Transmission
DATE: Dec. 19, 1997
SUBJECT: Overdrive Unavailable in Extreme Cold Temperatures, Bypass Kit Installation, Inhibitor
Programming
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-06-97, DATED MAR. 21,
1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE MARKED
WITH **ASTERISKS** AND INCLUDE MODEL CHANGES AND PART NUMBER ADDITIONS
FOR V-10 APPLICATIONS.
MODELS: 1996 - **1998**
(AB) Ram Van/Wagon
1996 (AN) Dakota
1996 - **1998** (BRIBE) Ram Truck
1996 - **1998** (ZJ) Grand Cherokee
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINES AND A 42RE,
44RE, 46RE, OR 47RE TRANSMISSION.
SYMPTOM/CONDITION: At ambient temperatures of -20 C (-5 F) or below, the Powertrain Control

Module (PCM) will electronically inhibit the transmission from shifting into overdrive. This will
protect the transmission from damage if the transmission fluid begins to freeze. In extreme cold
climatic regions, this feature can cause customer dissatisfaction due to elimination of overdrive and
less than optimal fuel economy.
DIAGNOSIS: The cold weather by-pass kit along with disabling the inhibitor feature should only be
incorporated for vehicles used in areas of extended cold ambient temperatures.
NOTE:
THIS KIT WILL DECREASE THE MAXIMUM COOLING CAPACITY OF THE TRANSMISSION'S
COOLING SYSTEM. AS A RESULT, IT IS NOT RECOMMENDED THAT THIS BULLETIN BE
PERFORMED UNLESS THE ABOVE STATED CONDITION EXISTS. ALSO, IF THE VEHICLE IS
USED FOR MODERATE TO HEAVY TOWING IT IS NOT RECOMMENDED.
Cold Temperatures > Page 3270
PARTS/EQUIPMENT REQUIRED:
**1 04798668 Kit, By-Pass V-10 Applications**
1 04874284 Kit, Universal By-Pass (See Figure 1 for kit contents)
AR(1) 04318044 Thread Sealant
1 CH7000/7001 J1962 Cable
NOTE:
THE MDS AND DRB III ARE ALSO REQUIRED TO PERFORM PART OF THIS REPAIR AND
THE SYSTEM MUST BE OPERATING
WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE
INSTALLED.
Repair Procedure
This bulletin involves installing a cold weather by-pass kit to the transmission cooler circuit,
selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software
(calibration changes for 1996 models only), and using the DRB III to selectively turn off the
overdrive inhibitor feature for all applications.
NOTE:
IT IS ESSENTIAL THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR

TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE
BYPASS KIT IS NOT INSTALLED.
NOTE:
EVEN WITH BYPASS KIT INSTALLATION AND THE INHIBITOR FEATURE TURNED OFF, 4TH
GEAR WILL BE INHIBITED UNTIL THE OIL SUMP TEMPERATURE REACHES 0 C (30 F). THIS
MAY TAKE SEVERAL MINUTES.
Bypass Kit Installation
1. Record all radio pre-sets and disconnect the negative battery cable.
2. Raise the vehicle for access to the transmission housing. The bypass assembly will be
connected to the existing transmission lines and mounted to the transmission housing by means of
a bypass adapter.
3. During this installation procedure, some transmission fluid will be lost when the transmission
cooler lines are cut (allowing bypass assembly installation). Take proper precautions and check
transmission fluid fill level upon completing the installation.
4. It the cold weather bypass kit has provision for an in-line temperature sensor, the threaded
"therm-o-well" (in the pressure "P" line of the kit) must be plugged with either the temperature
sensor from the existing transmission line or the standard pipe plug provided. Consequently, if the
vehicle being serviced is equipped with a temperature sensor (i.e., heavy duty BR truck), remove
the temperature sensor from the existing line by un-threading and install it in the "pressure" line
provided with the kit. Use Mopar Thread Sealant, p/n 04318044, to ensure a leak free seal.
5. Disconnect the pressure and return lines from the transmission housing fittings.
6. Remove and discard the fittings from the transmission housing.
7. Apply Mopar Thread Sealant, p/n 04318044, to the threaded bypass adapter (# 2 Figure 1).
8. Install the threaded bypass adapter securely into the front pressure port of the transmission
housing and torque to 17.6 Nm (13 ft. lbs.).
9. Make sure the snap ring and O-ring are properly installed in their respective grooves on the nose
of the bypass assembly block. Lubricate the O-ring with ATF.
10. Position the bypass assembly block such that the return port fitting "R" is pointed directly up
and the two other fittings are pointed forward.
11. Firmly press the male nose of the bypass assembly into the female body of the threaded
bypass adapter until it snaps into place. After snapping into place, the bypass assembly is
permanently attached to the adapter.
NOTE:
THE BYPASS ASSEMBLY CAN ROTATE INSIDE THE ADAPTER, AND REMOVAL OF THE
BLOCK FROM THE TRANSMISSION HOUSING (IF REQUIRED) CAN BE ACCOMPLISHED BY
UN-THREADING THE ADAPTER.
CAUTION:
IF FLUSHING THE BYPASS ASSEMBLY IS REQUIRED, IT MUST BE REMOVED FROM THE

TRANSMISSION HOUSING AND FORWARD FLUSHED ONLY. FAILING TO REMOVE THE
VALVE AND REVERSE FLUSHING WILL RESULT IN TRANSMISSION FAILURE BY PLUGGING
THE BYPASS VALVES INTERNAL ORIFICE AND DRAIN BACK VALVE.
12. Apply Mopar Thread Sealant, p/n 04318044, to the threaded end (transmission housing end) of
the compression fitting.
13. Install the threaded compression fitting securely into the rear return port of the transmission
14. Using a small tubing cutter, cut the existing pressure line at approximately 120 mm (5 in.) from
the transmission housing end. Repeat the procedure for the existing return line.
CAUTION:
AFTER CUTTING THE PRESSURE LINE, MARK IT WITH A PIECE OF TAPE FOR
IDENTIFICATION.
15. Identify the proper return line ("R" line) by using the marked labels attached to the tubes.
16. Connect the "R" line to the bypass assembly block and the rearward return port of the
transmission housing. Tighten the compression fitting finger tight, and then wrench tighten it an
additional 1/2 turn. Tighten the inverted flare nut to 6.78 Nm (60 in. lbs.).
17. Select the appropriate "RR" and "P" tubes for the application. Mixing or matching may be
required to provide the best routing for your
application.
18. Loosely connect the pressure line "P" to the pressure port fitting "P" on the bypass assembly
block.
19. Loosely connect the radiator return line, "RR" to the "RR" port fitting, on the bypass assembly
block.
NOTE:
DURING THE INSTALLATION OF THE "P" AND "RR" LINES, THE ORDER MAY BE REVERSED
TO AID IN THE ASSEMBLY PROCESS.
NOTE:
ON 5.2L ZJ MODELS, THE THROTTLE VALVE CABLE AND BRACKET MAY REQUIRE
REMOVAL FOR BYPASS TUBE CLEARANCE. ONCE THE TUBES ARE INSTALLED LOOSELY,
INSTALL THE BRACKET AND THROTTLE VALVE CABLE. MAKE ANY ADJUSTMENTS FOR
CLEARANCE AND TIGHTEN THE BYPASS TUBES AND BRACKET ASSEMBLY.
20. Make sure that the existing return line is properly re-attached to the hanger bracket and lay the
new return line, "RR", beside it.
21. Install the hose bracket (# 12 in Figure 1) required for the overhead line application. The
bracket will replace the existing bracket at the starter mount location. It may require slight
modification to provide the best clearance from the exhaust system.
22. Attach clamp (# 11 in Figure 1) and the rubber hose to the "RR" tube to determine the
approximate rubber hose routing. For connection to the existing return line, the line may be cut
again to provide optimum line routing.
CAUTION:
WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING

COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL
POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE
EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF
CLEARANCE FROM THE EXHAUST SYSTEM.
23. Cut the rubber hose so that it has sufficient length to be attached to the existing return line.
24. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose
fitting (# 10 in Figure 1) to the existing return line.
25. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1).
26. Evaluate the line routing to ensure moving components and exhaust will not interfere with the
new lines. Make modifications as necessary to provide the best routing.
27. Disconnect the "RR" tube from the Bypass Block for access to the "P" port on the block
assembly.
28. Attach a clamp and the rubber hose to the "P" tube and determine the approximate rubber hose
routing. For connection to the existing pressure line, the line may be cut again to provide optimum
line routing.
CAUTION:

29. Cut the rubber hose so that it has sufficient length to be attached to the existing pressure line.
fitting (# 10 in Figure 1) to the existing pressure line.
new lines. Use tie straps and rubber bumpers on the hose to protect the hose from metal surfaces
that may cause chaffing.
33. Torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the
inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line.
34. Connect the "RR" ling and torque both clamps, the compression fitting (finger tight, then wrench
tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line.
35. Re-check to ensure that all connections have been securely tightened and there is sufficient
clearance around the exhaust system.
36. If applicable, connect the wire harness to the temperature sensor.

37. Lower the vehicle.
38. Re-connect the negative battery cable and reset the radio stations recorded in step one.
39. Check and adjust the transmission fluid level as outlined in the appropriate Service Manual.
40. Raise the vehicle and check for leaks (idle in Neutral).
Flash Programming (1996 Models)
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS UPDATE. THE SYSTEM MUST BE
OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST
BE INSTALLED.
them up.
press NEXT MENU.
NOTE:
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020.
Attach the label to the PCM and cover the label with the clear plastic overlay.
attach the label near the VECI Label.
Programming Cold Overdrive Feature (All Applications)
Using the DRB III, use the following procedures to program the overdrive cutoff feature.
1. Connect the DRB III (Scan Tool) to the vehicle and power it up.
2. Use the arrow keys and select # 1 DRB III STANDALONE on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select # 1 1994 - 1998 DIAGNOSTICS on the DRB III STAND-ALONE
MAIN MENU.
4. Use the arrow keys and select # 1 ENGINE on the DRB III SELECT SYSTEM MENU.
5. The module ID screen will appear, press enter to move to next menu.
6. From the SELECT FUNCTION MENU, press the right arrow key for the next page and select # 1
MISCELLANEOUS.
7. From the SELECT MISCELLANEOUS FUNCTION MENU, press the right arrow key for the next
page and select # 1 COLD OVERDRIVE FEATURE.
8. Follow the steps presented on the DRB III which will prompt you through the feature selection.
9. When the password is asked for use: 84362172.
10. Follow the remaining prompts for overdrive feature verification.
NOTE:
IT IS IMPERATIVE THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR

Policy/Time Allowance/Failure Code
TIME ALLOWANCE:
Labor Operation No: 21-25-17-99-1996 AB/AN/BR/ZJ Models 1.7 Hrs.
21-25-17-99-1997/**1998** AB/BR/BE/ZJ Models 1.5 Hrs.

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
Engine Controls - Flash Programming Failure Recovery
NUMBER: 18-037-05
DATE: October 20, 2005
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH
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:
1995 - 2003 (AB) Ramvan/Wagon
1995 - 2004 (AN) Dakota
1994 - 2002 (BRIBE) Ram Pickup
1998 - 2003 (DN) Durango
2002 - 2005 (DR/DH/D1) Ram Pickup
1996 - 2000 (CS) Chrysler Voyager (International Markets)
2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
2002 - 2005 (KJ) Liberty/Cherokee (International Markets)
1995 - 2005 (PL) Neon
2002 (PG) PT Cruiser (International Markets)
1997 - 2002 (PR) Prowler


18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3281
1995 - 2002 (SR) Viper
2003 - 2006 (ZB) Viper
2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster
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,
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.
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.
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)

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.
Disclaimer:
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:
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).
^ 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.
^ 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.
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)

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.
^ 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.

^ 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.
^ 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.
^ 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.
NGC
Types:
^ 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.
^ 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.
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.
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.
^ Follow DRBIII® prompts carefully

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.
^ 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.
ELECTRONIC VEHICLE INFORMATION CENTER (EVIC)
Types:
^ EVIC
NOTE:
02-03 LH & WJ, and 03-04 KJ
FRONT CONTROL MODULE (FCM)
Types:
^ FCM
NOTE:
Front control modules are found on CS, DR, RG, and RS vehicles.

INTEGRATED POWER MODULE (IPM)
Types:
^ 1PM
NOTE:
Integrated power modules are found on CS, DR, RG, and RS vehicles.
POWER LIFT GATE (PLG)
Types:
^ PLC
NOTE:
Power liftgate modules are found on CS and RS.
^ 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:
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:
CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC)

Types:
^ MICs, eMICs
NOTE:
MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB
^ 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.
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.
^ Follow DRBIII® prompts carefully.
ADJUSTABLE PEDAL MODULE (APM)
Types:
^ APM
NOTE:
Found on CS, RS, and WJ vehicles.
RAIN SENSOR MODULE (RSM)
Types:
^ RSM
NOTE:RSM modules are found on CS, RS, and WJ vehicles.

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.
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.

18-05-00G > Dec > 00 > Engine - Spark Knock/PCM Reprogramming
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Spark
Knock/PCM Reprogramming
DATE: Dec. 01, 2000

PACKAGES.
SUBJECT: 1998
MODELS: 1998
(AB) Ram Van
1998 (AN) Dakota
1998 (DN) Durango
1998 (XJ) Cherokee
NOTE:
18-05-00G > Dec > 00 > Engine - Spark Knock/PCM Reprogramming > Page 3304
NOTE:
POSSIBLE EXCLUSION.

Procedure.
NOTE:
COMPLETED
NOTE:
NOTE:
NOTE:

AS NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:
NOTE:
REPAIR PROCEDURE:
NOTE:
NOTE:
SOFTWARE.
NOTE:

NOTE:
TIME ALLOWANCE:

18-05-00F > Sep > 00 > Engine - Spark Knock on Acceleration
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Spark Knock
on Acceleration
MODELS: 1998
(AB) Ram Van
1998 (AN) Dakota
1998 (DN) Durango
1998 (XJ) Cherokee
NOTE:

DIAGNOSIS:
Procedure.
NOTE:
NOTE:
NOTE:
18-05-00F > Sep > 00 > Engine - Spark Knock on Acceleration > Page 3311
NOTE:

AS NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:
NOTE:
REPAIR PROCEDURE:
NOTE:
NOTE
SOFTWARE.
NOTE:

NOTE:

TIME ALLOWANCE:

18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set
NUMBER: 18-08-00
DATE: June 23, 2000
**MODELS:** **1996** - 1998 (AB)
Ram Van
**1996** - 1998 (AN) Dakota
**1996** - 1998 (BR/BE) Ram Truck
1998 (DN) Durango
**1997** - 1998 (TJ) Wrangler
**1996** - 1998 (XJ) Cherokee
NOTE:
NOTE:

PARTS REQUIRED:

EQUIPMENT REQUIRED:
1 CH700017001 J1962 Cable
1 MDS2
NOTE:
OR HIGHER.
TIME ALLOWANCE:
18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set > Page 3317
Repair Procedure
SCREEN.
SCREEN.
NOTE:
BEGIN SESSION.
NOTE:

SOFTWARE.
NOTE:

NOTE:
831 > Jun > 99 > Recall - Reprogram PCM
June 1999
Models
transmission)
NOTE:
Subject
Repair
Parts Information
payments.
Number Allowance

NOTE:
Parts Return
831 > Jun > 99 > Recall - Reprogram PCM > Page 3323
Not Applicable
48326-2757
Service Office.
Service Procedure
Using the MDS1
power them up.
MENU screen.
MENU.
NOTE:
Using the MDS2

SCREEN.
SCREEN.
NOTE:
begin the session.
NOTE:
Fig. 1
Fig. 2
Owner Letter
The problem is...
and processed.
What you must do...
If you need help...
vehicle repaired.
25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information
NO: 25-02-98
GROUP: Emissions
DATE: Oct. 23, 1998
SUBJECT:
MODELS:
1996 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
1995 - 1999 (PL) Neon
1997 - 1999 (PR) Prowler
NOTE:

ENGINES.
DISCUSSION:
tests.
NOTE:

BULLETIN.
OBD Readiness.
EQUIPMENT REQUIRED:
1 CH7000/7001 J1962Cable

25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3330
TIME ALLOWANCE:
Repair Procedure
Preliminary Checks
engine running.
NOTE:
"YES".
NOTE:
NOTE:
NOTE:
MONITOR RUN PROCESS
Front Wheel Drive
requirements.
to update.
running this test.
Rear Wheel Drive
requirements.
the requirements.
cells to update.
18-36-97 > Dec > 97 > PCM - Incorrect Fault Mature Time for DTC#B7
PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Incorrect Fault
Mature Time for DTC#B7
NO: 18-36-97
DATE: Dec. 31, 1997
MODELS: 1998 (AB)
Ram Van/Wagon
1998 (AN) Dakota
Durango
1998 (TJ) Wrangler
1998 (XJ) Cherokee
NOTE:
NOTE:

REVISION LEVEL.
1 0H7000/7001 J1962 Cable
NOTE:
NOTE:
them up.
18-36-97 > Dec > 97 > PCM - Incorrect Fault Mature Time for DTC#B7 > Page 3337
press NEXT MENU.
NOTE:
08-19-48-97 0.5 Hrs.

21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures
NO: 21-06-97 Rev. A
GROUP: Transmission
DATE: Dec. 19, 1997
Programming
MODELS: 1996 - **1998**
(AB) Ram Van/Wagon
1996 (AN) Dakota
1996 - **1998** (BRIBE) Ram Truck
NOTE:

NOTE:
21-06-97A > Dec > 97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3342
1 CH7000/7001 J1962 Cable
NOTE:
INSTALLED.
Repair Procedure
NOTE:

NOTE:
a bypass adapter.
NOTE:
CAUTION:

CAUTION:
IDENTIFICATION.
application.
block.
block.
NOTE:
NOTE:
CAUTION:

assembly.
line routing.
CAUTION:


NOTE:
BE INSTALLED.
them up.
press NEXT MENU.
NOTE:
MAIN MENU.
MISCELLANEOUS.
NOTE:

TIME ALLOWANCE:

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
Engine Controls - Flash Programming Failure Recovery
NUMBER: 18-037-05
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH
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:
1995 - 2003 (AB) Ramvan/Wagon
1995 - 2004 (AN) Dakota
1994 - 2002 (BRIBE) Ram Pickup
1998 - 2003 (DN) Durango
2002 - 2005 (DR/DH/D1) Ram Pickup
1996 - 2000 (CS) Chrysler Voyager (International Markets)
2002 - 2005 (KJ) Liberty/Cherokee (International Markets)
1995 - 2005 (PL) Neon
1997 - 2002 (PR) Prowler


1995 - 2002 (SR) Viper
2003 - 2006 (ZB) Viper
DISCUSSION:
NOTE:
modules.

RECALL.
session.
installed.

DRBIII(R) CABLES
NOTE:
reprogramming.
sessions.

APPLICATION.
installation.
interruptions.

become functional.
NOTE:
PREPARING TO FLASH
Disclaimer:
NOTE:
vehicles).
NOTE:
jump box".
followed.
more information.
Error Messages
ERROR MESSAGES
recommendations.
Checksum Errors
Controller Type.
user.
reloaded.
NOTE:
recovery method.
NOTE:
document.

SBEC
Types:
NOTE:
JTEC
Types:
^ JTEC, JTEC+
NOTE:
NOTE:
NGC Types:
NOTE:
NOTE:
this NOTE.

flash.
CUMMINS
Types:
NOTE:
SIEMENS
Types:
^ SIM-70
NOTE:
Specifics:
BOSCH
Types:
NOTE:
EATX
Types:
NOTE:
service bulletin.
NGC
Types:
^ NGC1, NGC2, NGC3
NOTE:
SIEMENS
Types:
^ EG552
NOTE:
JTEC
Types:
^ JTEC,JTEC+
NOTE:
communications.
updated modules.

18-24-95.
Types:
^ TCCM
NOTE:

Types:
^ BCM
NOTE:
NOTE:
Types:
^ CTM
NOTE:
Types:
^ EVIC
NOTE:
02-03 LH & WJ, and 03-04 KJ
Types:
^ FCM
NOTE:

Types:
^ 1PM
NOTE:
Types:
^ PLC
NOTE:
Types:
^ PSDM
NOTE:
Specifics:
Types:
^ DSDM
NOTE:
NOTE:
Types:
^ DDM
NOTE:
Types:
^ PDM
NOTE:

Types:
^ MICs, eMICs
NOTE:
Types:
^ ARKEM
NOTE:
Types:
^ HVAC, ATC, MTC
NOTE:
Types:
^ APM
NOTE:
Types:
^ RSM

Types:
^ ITM
NOTE:
Types:
^ SRS, ORC
NOTE:

18-05-00G > Dec > 00 > Engine - Spark Knock/PCM Reprogramming
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Spark
Knock/PCM Reprogramming
DATE: Dec. 01, 2000

PACKAGES.
SUBJECT: 1998
MODELS: 1998
(AB) Ram Van
1998 (AN) Dakota
1998 (DN) Durango
1998 (XJ) Cherokee
NOTE:
NOTE:
POSSIBLE EXCLUSION.

Procedure.
NOTE:
COMPLETED
NOTE:
NOTE:
NOTE:

AS NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:
NOTE:
REPAIR PROCEDURE:
NOTE:
NOTE:
SOFTWARE.
NOTE:

NOTE:
TIME ALLOWANCE:

18-05-00F > Sep > 00 > Engine - Spark Knock on Acceleration
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Spark Knock
on Acceleration
MODELS: 1998
(AB) Ram Van
1998 (AN) Dakota
1998 (DN) Durango
1998 (XJ) Cherokee
NOTE:

DIAGNOSIS:
Procedure.
NOTE:
NOTE:
NOTE:
NOTE:

AS NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:
NOTE:
REPAIR PROCEDURE:
NOTE:
NOTE
SOFTWARE.
NOTE:

NOTE:

TIME ALLOWANCE:

18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set
NUMBER: 18-08-00
DATE: June 23, 2000
**MODELS:** **1996** - 1998 (AB)
Ram Van
**1996** - 1998 (AN) Dakota
**1996** - 1998 (BR/BE) Ram Truck
1998 (DN) Durango
**1997** - 1998 (TJ) Wrangler
**1996** - 1998 (XJ) Cherokee
NOTE:
NOTE:

PARTS REQUIRED:

EQUIPMENT REQUIRED:
1 CH700017001 J1962 Cable
1 MDS2
NOTE:
OR HIGHER.
TIME ALLOWANCE:
Repair Procedure
SCREEN.
SCREEN.
NOTE:
BEGIN SESSION.
NOTE:

SOFTWARE.
NOTE:

NOTE:
25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information
NO: 25-02-98
GROUP: Emissions
DATE: Oct. 23, 1998
SUBJECT:
MODELS:
1996 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
1995 - 1999 (PL) Neon
1997 - 1999 (PR) Prowler
NOTE:

ENGINES.
DISCUSSION:
tests.
NOTE:

BULLETIN.
OBD Readiness.
EQUIPMENT REQUIRED:
1 CH7000/7001 J1962Cable

TIME ALLOWANCE:
Repair Procedure
Preliminary Checks
engine running.
NOTE:
"YES".
NOTE:
NOTE:
NOTE:
MONITOR RUN PROCESS
Front Wheel Drive
requirements.
to update.
running this test.
Rear Wheel Drive
requirements.
the requirements.
cells to update.
18-36-97 > Dec > 97 > PCM - Incorrect Fault Mature Time for DTC#B7
PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Incorrect Fault
Mature Time for DTC#B7
NO: 18-36-97
DATE: Dec. 31, 1997
MODELS: 1998 (AB)
Ram Van/Wagon
1998 (AN) Dakota
Durango
1998 (TJ) Wrangler
1998 (XJ) Cherokee
NOTE:
NOTE:

REVISION LEVEL.
1 0H7000/7001 J1962 Cable
NOTE:
NOTE:
them up.
18-36-97 > Dec > 97 > PCM - Incorrect Fault Mature Time for DTC#B7 > Page 3402
press NEXT MENU.
NOTE:
08-19-48-97 0.5 Hrs.

NO: 21-06-97 Rev. A
GROUP: Transmission
DATE: Dec. 19, 1997
Programming
MODELS: 1996 - **1998**
(AB) Ram Van/Wagon
1996 (AN) Dakota
1996 - **1998** (BRIBE) Ram Truck
NOTE:

NOTE:
1 CH7000/7001 J1962 Cable
NOTE:
INSTALLED.
Repair Procedure
NOTE:

NOTE:
a bypass adapter.
NOTE:
CAUTION:

CAUTION:
IDENTIFICATION.
application.
block.
block.
NOTE:
NOTE:
CAUTION:

assembly.
line routing.
CAUTION:


NOTE:
BE INSTALLED.
them up.
press NEXT MENU.
NOTE:
MAIN MENU.
MISCELLANEOUS.
NOTE:

TIME ALLOWANCE:

1995 - 2002 (SR) Viper
2003 - 2006 (ZB) Viper
DISCUSSION:
NOTE:
modules.

RECALL.
session.
installed.

DRBIII(R) CABLES
NOTE:
reprogramming.
sessions.

APPLICATION.
installation.
interruptions.

become functional.
NOTE:
PREPARING TO FLASH
Disclaimer:
NOTE:
vehicles).
NOTE:
jump box".
followed.
more information.
Error Messages
ERROR MESSAGES
recommendations.
Checksum Errors
Controller Type.
user.
reloaded.
NOTE:
recovery method.
NOTE:
document.

SBEC
Types:
NOTE:
JTEC
Types:
^ JTEC, JTEC+
NOTE:
NOTE:
NGC Types:
NOTE:
NOTE:
this NOTE.

flash.
CUMMINS
Types:
NOTE:
SIEMENS
Types:
^ SIM-70
NOTE:
Specifics:
BOSCH
Types:
NOTE:
EATX
Types:
NOTE:
service bulletin.
NGC
Types:
^ NGC1, NGC2, NGC3
NOTE:
SIEMENS
Types:
^ EG552
NOTE:
JTEC
Types:
^ JTEC,JTEC+
NOTE:
communications.
updated modules.

18-24-95.
Types:
^ TCCM
NOTE:

Types:
^ BCM
NOTE:
NOTE:
Types:
^ CTM
NOTE:
Types:
^ EVIC
NOTE:
02-03 LH & WJ, and 03-04 KJ
Types:
^ FCM
NOTE:

Types:
^ 1PM
NOTE:
Types:
^ PLC
NOTE:
Types:
^ PSDM
NOTE:
Specifics:
Types:
^ DSDM
NOTE:
NOTE:
Types:
^ DDM
NOTE:
Types:
^ PDM
NOTE:

Types:
^ MICs, eMICs
NOTE:
Types:
^ ARKEM
NOTE:
Types:
^ HVAC, ATC, MTC
NOTE:
Types:
^ APM
NOTE:
Types:
^ RSM

Types:
^ ITM
NOTE:
Types:
^ SRS, ORC
NOTE:

831 > Jun > 99 > Recall - Reprogram PCM
June 1999
Models
transmission)
NOTE:
Subject
Repair
Parts Information
payments.
Number Allowance

NOTE:
Parts Return
Not Applicable
48326-2757
Service Office.
Service Procedure
Using the MDS1
power them up.
MENU screen.
MENU.
NOTE:
Using the MDS2

SCREEN.
SCREEN.
NOTE:
begin the session.
NOTE:
Fig. 1
Fig. 2
Owner Letter
The problem is...
and processed.
What you must do...
If you need help...
vehicle repaired.
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Locations > Component Locations

Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Locations > Component Locations >
Page 3451

Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Locations > Page 3452

Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins
> Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold
NUMBER: 21-08-99
GROUP: Transmission
Is Selected.
MODELS: 1996 - 1999
(AB) Ram Van
1996 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
NOTE:

TRANSMISSION.
August 1, 1995.
DIAGNOSIS:
PARTS REQUIRED:

> Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold
> Page 3461
EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
TIME ALLOWANCE:

> All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse
When Cold
Cold
NUMBER: 21-08-99
GROUP: Transmission
Is Selected.
MODELS: 1996 - 1999
(AB) Ram Van
1996 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
NOTE:

TRANSMISSION.
August 1, 1995.
DIAGNOSIS:
PARTS REQUIRED:

> All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse
EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
TIME ALLOWANCE:

Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations >
Component Locations
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations >
Component Locations > Page 3475

Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3476

Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids -
A/T > Overdrive Solenoid, A/T > Component Information > Locations > Component Locations

A/T > Overdrive Solenoid, A/T > Component Information > Locations > Component Locations > Page 3483

A/T > Overdrive Solenoid, A/T > Component Information > Locations > Page 3484

A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold
NUMBER: 21-08-99
GROUP: Transmission
Is Selected.
MODELS: 1996 - 1999
(AB) Ram Van
1996 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
NOTE:

TRANSMISSION.
August 1, 1995.
DIAGNOSIS:
PARTS REQUIRED:

A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3493
EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
TIME ALLOWANCE:

A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold
Cold
NUMBER: 21-08-99
GROUP: Transmission
Is Selected.
MODELS: 1996 - 1999
(AB) Ram Van
1996 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
NOTE:

TRANSMISSION.
August 1, 1995.
DIAGNOSIS:
PARTS REQUIRED:

A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page
3499
EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
TIME ALLOWANCE:

A/T > Shift Solenoid, A/T > Component Information > Locations
A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations
A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 3507

A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3508

Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component
Information > Specifications > 32RE 3-Speed
Band: Specifications 32RE 3-Speed
SERVICE SPECIFICATIONS
Band Adjustment From 72 inch lbs.:
Front Band ...........................................................................................................................................

........................................ Back Off 2.25 Turns Rear Band .................................................................
........................................................................................................................ Back Off 4 Turns
TORQUE SPECIFICATIONS
Plug, front band reaction .....................................................................................................................

................................................. 17 Nm (13 ft. lbs.) Locknut, front band adj ........................................
................................................................................................................................ 34 Nm (25 ft. lbs.)
Information > Specifications > 32RE 3-Speed > Page 3513
Band: Specifications 46RE (A518) 4-Speed
Band Adjustment From 72 inch lbs.:
Front Band ...........................................................................................................................................

...................................... Back Off 2-7/8 Turns Rear Band ..................................................................
....................................................................................................................... Back Off 2 Turns
Plug, front band reaction .....................................................................................................................

................................................. 17 Nm (13 ft. lbs.) Locknut, front band adj ........................................
................................................................................................................................ 34 Nm (25 ft. lbs.)
Band: Adjustments
FRONT BAND ADJUSTMENT
The front (kickdown) band adjusting screw is located on the left side of the transmission case
above the manual valve and throttle valve levers. 1. Raise vehicle.
Front Band Adjustment Screw Location
2. Loosen band adjusting screw locknut. Then back locknut off 3-5 turns. Be sure adjusting screw
turns freely in case. Apply lubricant to screw
threads if necessary.
3. Tighten band adjusting screw to 8 Nm (72 inch lbs.) torque with Inch Pound Torque Wrench
C-3380-A, a 3-in. extension and 5/16 socket.
Band Adjustment Adapter Tool
CAUTION: If Adapter C-3705 is needed to reach the adjusting screw, tighten the screw to only 5
Nm (47-50 inch lbs.) torque.
46RE Transmission -
Back off front band adjusting screw 2-7/8 turns.
- Hold adjuster screw in position and tighten locknut to 41 Nm (30 ft. lbs.) torque.
47RE Transmission -
Back off front band adjusting screw 1-7/8 turns.
- Hold adjuster screw in position and tighten locknut to 43 Nm (30 ft. lbs.) torque.
4. Lower vehicle.
REAR BAND ADJUSTMENT
The transmission oil pan must be removed for access to the rear band adjusting screw. 1. Raise
vehicle. 2. Remove transmission oil pan and drain fluid. 3. Loosen band adjusting screw locknut
5-6 turns. Be sure adjusting screw turns freely in lever.
Rear Band Adjustment Screw Location
4. Tighten adjusting screw to 8 Nm (72 inch lbs.) torque.
46RE Transmission -
Back off adjusting screw 2 turns.
- Hold adjusting screw in place and tighten locknut to 34 Nm (25 ft. lbs.) torque.
47RE Transmission -
Back off adjusting screw 3 turns.
- Hold adjusting screw in place and tighten locknut to 34 Nm (25 ft. lbs.) torque.
5. Position new gasket on oil pan and install pan on transmission. Tighten pan bolts to 17 Nm (13
ft. lbs.) torque. 6. Lower vehicle and refill transmission with MOPAR ATF+4, Type 9602 fluid.
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Specifications > Direct Clutch
Clutch: Specifications Direct Clutch
Direct Clutch Disc Usage .....................................................................................................................

........................................................................ 8 Disc
Information > Specifications > Direct Clutch > Page 3520
Clutch: Specifications Front Clutch
Front Clutch Spring Usage ..................................................................................................................

.................................................................... 9 Springs
Clutch: Specifications Overdrive Clutch
Overdrive Clutch Disc Usage ..............................................................................................................

....................................................................... 4 Discs
Clutch: Specifications 32RE 3-Speed
Clutch Pack Clearance:
Front 4-Disc
..............................................................................................................................................................
1.70 - 3.40 mm (0.067 - 0.134 inch) Rear 4-Disc ................................................................................
............................................................................... 0.81 - 1.40 mm (0.032 - 0.055 inch)
Front Clutch Spring Usage ..................................................................................................................

..................................................................... 1 Spring
Clutch: Specifications 46RE (A518) 4-Speed
Clutch Pack Clearance:
Front 3-Disc
..............................................................................................................................................................
1.78 - 3.28 mm (0.070 - 0.129 inch) Rear 4-Disc ................................................................................
............................................................................... 0.64 - 1.14 mm (0.025 - 0.045 inch)
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM
- MIL ON/DTC P1763 Set
NUMBER: 21-04-00
GROUP: Transmission
DATE: June 3O, 2000
High
99Cal14).
MODELS:
**1996** - 1999 (AB) Ram Van
**1996** - 1999 (AN) Dakota
**1996** - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
**1997** - 1999 (TJ) Wrangler
**1996** 1999 (XJ) Cherokee
NOTE:

December 18, 1998.
NOTE:
NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:

- MIL ON/DTC P1763 Set > Page 3532
1 CH7000/7001 J1962 Cable
1 MDS2
NOTE:
OR HIGHER.
REPAIR PROCEDURE:
SCREEN.
SCREEN.
NOTE:
BEGIN SESSION.
NOTE:
SOFTWARE.
NOTE:

NOTE:
- MIL ON/DTC P1763 Set > Page 3533
TIME ALLOWANCE:

Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun
> 00 > TCM - MIL ON/DTC P1763 Set
NUMBER: 21-04-00
GROUP: Transmission
DATE: June 3O, 2000
High
99Cal14).
MODELS:
**1996** - 1999 (AB) Ram Van
**1996** - 1999 (AN) Dakota
**1996** - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
**1997** - 1999 (TJ) Wrangler
**1996** 1999 (XJ) Cherokee
NOTE:

December 18, 1998.
NOTE:
NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:

> 00 > TCM - MIL ON/DTC P1763 Set > Page 3539
1 CH7000/7001 J1962 Cable
1 MDS2
NOTE:
OR HIGHER.
REPAIR PROCEDURE:
SCREEN.
SCREEN.
NOTE:
BEGIN SESSION.
NOTE:
SOFTWARE.
NOTE:

NOTE:
> 00 > TCM - MIL ON/DTC P1763 Set > Page 3540
TIME ALLOWANCE:

Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Extension Housing: Service and Repair
REMOVAL
1. Shift transmission into manual low (1) position. 2. Hoist and support vehicle on safety stands. 3.
Mark propeller shaft and axle yoke for alignment reference. Then disconnect and remove shaft. 4.
Remove vehicle speed sensor. 5. Remove bolts attaching extension housing to rear support. 6.
Using a suitable lifting device, raise transmission off rear mount. 7. Remove rear crossmember. 8.
Remove bolts holding extension housing to transmission case. 9. Verify that transmission is in 1
position. Park lock rod is easier to disengage in this position.
10. Remove access plate and gasket from underside of extension housing.
Rear Bearing Retaining Ring
11. Using a snap ring plier, spread retaining ring holding rear bearing in extension housing. 12.
While spreading retaining ring, pull extension away from transmission case. 13. Separate extension
housing from vehicle.
INSTALLATION
Before installing the extension housing, verify that all gasket sealing surfaces are clean. 1. Position
new gasket on housing. Use petroleum jelly to hold gasket in place. 2. Install locating ring in
extension housing, if removed. 3. Slide housing onto output shaft. 4. Insert park rod past sprag and
slide housing onto shaft unlit the retaining ring contacts the rear bearing. 5. Spread rear bearing
retaining ring. 6. Push extension housing forward until fully seated against transmission case.
Release locating ring and verify that it is fully seated in rear bearing. 7. Install bolts to hold
extension housing to transmission case. Tighten bolts to 43 Nm (32 ft. lbs.) torque. 8. Install gasket
and access plate on underside of extension housing. 9. Install rear crossmember.
10. Remove support lift from under transmission. 11. Install bolts to hold extension housing to rear
mount. Tighten bolts to 68 Nm (50 ft. lbs.) torque. 12. Install speed sensor. 13. Align and install
propeller shaft. 14. Lower vehicle. 15. Top off transmission fluid level if necessary and road test to
verify repair.
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage/Applications
Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications
NUMBER: 21-010-06
GROUP: Transmission
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 - 1993 (AD) Ram Truck
1989 - 1994 (AG) Daytona
1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible
1989 - 2004 (AN) Dakota
1990 - 1991 (AQ) Maserati
1998 - 2003 (DN) Durango
2002 - 2007 (DR/DH/D1) Ram Truck
2007 (DC) Ram 3500 Cab Chassis
1996 - 2000 (CS) Chrysler Voyager (International Market)
2004 - 2007 (HB) Durango

2007 (JK) Wrangler
2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan

Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage/Applications > Page 3549
2007 (JS) Avenger/Sebring
2002 - 2007 (KJ) Liberty
1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M
2005 - 2007 (LX/LE) 300/Magnum/Charger
1995 - 2005 (PL) Neon
2002 - 2003 (PG) PT Cruiser (International Markets)
1997 - 2002 (PR) Prowler
2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines
2005 - 2007 (WK/WH) Grand Cherokee
2006 - 2007 (XK/XH) Commander
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.
Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage/Applications > Page 3550
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:
Disclaimer:
Fluid - A/T: Capacity Specifications
Transmission Fluid
32RH ...................................................................................................................................................
................................................. 8.0-8.3L (8.4-8.7 Qt) 46RE ................................................................
............................................................................................................................. 10.8-11.0L
(11.4-11.6 Qt)
Fluid - A/T: Fluid Type Specifications
Transmission Fluid Type Type ............................................................................................................

....................................................... MOPAR ATF +4 Type 9602 or Equivalent
Fluid - A/T: Service Precautions
DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission
damage may occur.
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T >
Fluid Pan: Specifications
32/36RH, 46RE Bolt, Fluid Pan ...........................................................................................................

............................................................................... 17 Nm (13 ft. lbs.)
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure
Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure
Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm
NO: 18-19-98
GROUP: Driveability
DATE: Apr. 10, 1998
MODELS: 1996 - 1998
(AB) Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
NOTE:

PARTS REQUIRED:
REPAIR PROCEDURE:

Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure
Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 3566
21-96-06-90 1.1 Hrs.

Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid
Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm
5,300 Rpm
NO: 18-19-98
GROUP: Driveability
DATE: Apr. 10, 1998
MODELS: 1996 - 1998
(AB) Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
NOTE:

PARTS REQUIRED:
REPAIR PROCEDURE:

Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid
Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 3572
21-96-06-90 1.1 Hrs.

Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Specifications > 32RE 3-Speed
Fluid Pump: Specifications 32RE 3-Speed
Oil Pump Gear Tip Clearance

........................................................................................................................... 0.089 - 0.190 mm
(0.0035 - 0.0075 inch)
Bolt, oil pump .......................................................................................................................................

................................................ 20 Nm (15 ft. lbs.)
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Specifications > 32RE 3-Speed > Page 3577
Fluid Pump: Specifications 46RE (A518) 4-Speed
Oil Pump Gear Tip Clearance

............................................................................................................................... 0.089 - 0.190 mm
(0.004 - 0.008 inch)
Bolt, Oil Pump ......................................................................................................................................

................................................ 20 Nm (15 ft. lbs.)
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Governor: > 18-19-98 > Apr > 98 > A/T -
Engine Bucking/Surging at 5,300 Rpm
Governor: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm
NO: 18-19-98
GROUP: Driveability
DATE: Apr. 10, 1998
MODELS: 1996 - 1998
(AB) Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
NOTE:

PARTS REQUIRED:
REPAIR PROCEDURE:

Component Information > Technical Service Bulletins > Customer Interest for Governor: > 18-19-98 > Apr > 98 > A/T -
Engine Bucking/Surging at 5,300 Rpm > Page 3586
21-96-06-90 1.1 Hrs.

Component Information > Technical Service Bulletins > All Technical Service Bulletins for Governor: > 18-19-98 > Apr > 98
> A/T - Engine Bucking/Surging at 5,300 Rpm
Governor: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm
NO: 18-19-98
GROUP: Driveability
DATE: Apr. 10, 1998
MODELS: 1996 - 1998
(AB) Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
NOTE:

PARTS REQUIRED:
REPAIR PROCEDURE:

Component Information > Technical Service Bulletins > All Technical Service Bulletins for Governor: > 18-19-98 > Apr > 98
> A/T - Engine Bucking/Surging at 5,300 Rpm > Page 3592
21-96-06-90 1.1 Hrs.

Governor: Locations

Governor
The governor pressure sender and the transmission fluid temperature thermistor are separate
sensors in the same component. This component is attached to the governor body in the solenoid
assembly of the valve body.
Governor Pressure Sensor Connector

Governor: Service and Repair
REMOVAL
1. Hoist and support vehicle on safety stands. 2. Remove transmission fluid pan and filter.
3. Disengage wire connectors from pressure sensor and solenoid. 4. Remove screws holding
pressure solenoid retainer to governor body.
5. Separate solenoid retainer from governor.
6. Pull solenoid from governor body. 7. Remove bolts holding governor body to valve body.
8. Separate governor body from valve body. 9. Remove governor body gasket.
10. Remove retainer holding pressure sensor to governor body.
11. Pull pressure sensor from governor body.

NOTE: Before installing the pressure sensor and solenoid in the governor body, replace O-ring
seals, clean the gasket surfaces and replace gasket.
INSTALLATION
1. Lubricate O-ring on pressure sensor with transmission fluid. 2. Align pressure sensor to bore in
governor body. 3. Push pressure sensor into governor body. 4. Install retainer to hold pressure
sensor to governor body. 5. Place gasket in position on back of governor body. 6. Place governor
body in position on valve body. 7. Install bolts to hold governor body to valve body. 8. Lubricate
O-ring, on pressure solenoid, with transmission fluid. 9. Align pressure solenoid to bore in governor
body.
10. Push solenoid into governor body. 11. Place solenoid retainer in position on governor. 12.
Install screws to hold pressure solenoid retainer to governor body. 13. Engage wire connectors into
pressure sensor and solenoid. 14. Install transmission fluid pan and (new) filter. 15. Lower vehicle
and road test to verify repair.
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Input Shaft, A/T >
Input Shaft: Specifications 32RE 3-Speed
Input Shaft End Play

................................................................................................................................................... 0.127
- 1.22 mm (0.005 - 0.048 inch)
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Input Shaft, A/T >
Input Shaft: Specifications 46RE (A518) 4-Speed
Input Shaft End Play

..................................................................................................................................................... 0.86
- 2.13 mm (0.034 - 0.084 inch)
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators -
A/T > Overdrive Indicator Lamp > Component Information > Description and Operation
SYSTEM OPERATION
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators -
A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Page 3606

INJURY.
as required.
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T >
Overdrive Solenoid, A/T > Component Information > Locations > Component Locations

Overdrive Solenoid, A/T > Component Information > Locations > Component Locations > Page 3612

Overdrive Solenoid, A/T > Component Information > Locations > Page 3613

Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp
SYSTEM OPERATION
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp

INJURY.
as required.
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Planetary Gears: Specifications 32RE 3-Speed
Planetary End Play

......................................................................................................................................................
0.127 - 1.22 mm (0.005 - 0.048 inch)
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Planetary Gears: Specifications 46RE (A518) 4-Speed
Planetary End Play

......................................................................................................................................................
0.150 - 1.22 mm (0.006 - 0.048 inch)
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating
Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold
NUMBER: 21-08-99
GROUP: Transmission
Is Selected.
MODELS: 1996 - 1999
(AB) Ram Van
1996 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
NOTE:

TRANSMISSION.
August 1, 1995.
DIAGNOSIS:
PARTS REQUIRED:

Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating
Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3631
EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
TIME ALLOWANCE:

Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold
Cold
NUMBER: 21-08-99
GROUP: Transmission
Is Selected.
MODELS: 1996 - 1999
(AB) Ram Van
1996 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
NOTE:

TRANSMISSION.
August 1, 1995.
DIAGNOSIS:
PARTS REQUIRED:

Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3637
EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
TIME ALLOWANCE:

Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: >
21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set
NUMBER: 21-04-00
GROUP: Transmission
DATE: June 3O, 2000
High
99Cal14).
MODELS:
**1996** - 1999 (AB) Ram Van
**1996** - 1999 (AN) Dakota
**1996** - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
**1997** - 1999 (TJ) Wrangler
**1996** 1999 (XJ) Cherokee
NOTE:

December 18, 1998.
NOTE:
NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:

21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3647
1 CH7000/7001 J1962 Cable
1 MDS2
NOTE:
OR HIGHER.
REPAIR PROCEDURE:
SCREEN.
SCREEN.
NOTE:
BEGIN SESSION.
NOTE:
SOFTWARE.
NOTE:

NOTE:
21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3648
TIME ALLOWANCE:

> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set
NUMBER: 21-04-00
GROUP: Transmission
DATE: June 3O, 2000
High
99Cal14).
MODELS:
**1996** - 1999 (AB) Ram Van
**1996** - 1999 (AN) Dakota
**1996** - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
**1997** - 1999 (TJ) Wrangler
**1996** 1999 (XJ) Cherokee
NOTE:

December 18, 1998.
NOTE:
NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:

Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3654
1 CH7000/7001 J1962 Cable
1 MDS2
NOTE:
OR HIGHER.
REPAIR PROCEDURE:
SCREEN.
SCREEN.
NOTE:
BEGIN SESSION.
NOTE:
SOFTWARE.
NOTE:

NOTE:
Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3655
TIME ALLOWANCE:

> Control Module, A/T > Component Information > Technical Service Bulletins > Page 3656
> Transmission Control System Relay, A/T > Component Information > Locations

> Transmission Control System Relay, A/T > Component Information > Locations > Page 3660
8w-10-2
> Transmission Control System Relay, A/T > Component Information > Locations > Page 3661

Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 32RH 3-Speed
Seals and Gaskets: Service and Repair 32RH 3-Speed
REMOVAL
1. Raise vehicle. 2. Mark propeller shaft and axle yoke for alignment reference. 3. Disconnect and
remove propeller shaft.
Removing Extension Housing Yoke Seal
4. Remove old seal with Seal Remover C-3985-B from extension housing.
INSTALLATION
1. Place seal in position on extension housing.
Installing Extension Housing Yoke Seal
2. Drive seal into extension housing with Seal Installer C-3995-A or C-3972. 3. Carefully guide
propeller shaft slip yoke into housing and onto output shaft splines. Align marks made at removal
and connect propeller shaft to
rear axle pinion yoke.

Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 32RH 3-Speed > Page 3666
Seals and Gaskets: Service and Repair 46RE (A518) 4-Speed
REMOVAL
1. Raise vehicle. 2. Mark propeller shaft and axle yoke for alignment reference. 3. Disconnect and
remove propeller shaft.
Removing Overdrive Housing Yoke Seal
4. Remove old seal with Seal Remover C-3985-B from overdrive housing.
INSTALLATION
1. Place seal in position on overdrive housing.
Installing Overdrive Housing Yoke
2. Drive seal into overdrive housing with Seal Installer C-3995-A. 3. Carefully guide propeller shaft
slip yoke into housing and onto output shaft splines. Align marks
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches -
A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm
NO: 18-19-98
GROUP: Driveability
DATE: Apr. 10, 1998
MODELS: 1996 - 1998
(AB) Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
NOTE:

PARTS REQUIRED:
REPAIR PROCEDURE:

A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 3676
21-96-06-90 1.1 Hrs.

A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm
5,300 Rpm
NO: 18-19-98
GROUP: Driveability
DATE: Apr. 10, 1998
MODELS: 1996 - 1998
(AB) Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
NOTE:

PARTS REQUIRED:
REPAIR PROCEDURE:

A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page
3682
21-96-06-90 1.1 Hrs.

A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations
A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3686

A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation
A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations

Governor
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T >
Shift Interlock: Service and Repair
The column shift interlock is used to lock the transmission shifter in the Park position when the key
is in the Off position. The interlock device is located within the steering column assembly and is not
serviceable. If repair is necessary, the steering column assembly must be replaced.
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Shifter A/T: Service and Repair
REMOVAL
1. Remove the upper and lower column shroud. 2. Disconnect the over drive switch harness (if
equipped).
Gear Shift Lever Mounting Screw
3. Remove the gear shift lever mounting screw and remove the lever.
INSTALLATION
1. Install the lever and install the mounting screw and tighten to 20 Nm (177 inch lbs.). 2. Connect
the over drive switch harness (if equipped).
NOTE: Route and tie off harness to original location.
3. Install the upper and lower column shroud.

Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > 32RE 3-Speed
Shift Cable: Adjustments 32RE 3-Speed
SHIFT CABLE ADJUSTMENT
Check cable adjustment by starting the engine in Park and Neutral. Adjustment is correct if the
engine starts only in Park and Neutral.
Adjustment is incorrect if the engine starts in any other position, or does not start in either Park or
Neutral.
If the engine starts in any position other than Park or Neutral, or if the engine will not start at all, the
park/neutral position switch may be faulty.
Shift Cable Routing

Cable, A/T > Component Information > Adjustments > 32RE 3-Speed > Page 3707
Shift Cable Attachment At Steering Column And Transmission
The shift cable is attached to an arm on the steering column and to the transmission shift lever.
Brackets support and secure the cable at each end and clips are used to secure the cable to the
floor pan. The cable is operated by an arm on the steering column shaft.
The cable has a built-in adjuster mechanism at the transmission end. The mechanism consists of
an internal clamp and release button that allows the cable to be extended, or shortened for
adjustment.
SHIFT CABLE ADJUSTMENT CHECK
The ignition key should rotate from Off to Lock only when the shift lever is in Park.
Shifting out of Park should only be possible when the ignition key is in Off, Run, or Start positions.
It should not be possible when the key is in Accessory or Lock position.
Engine start should only occur in Park and Neutral position.
SHIFT CABLE ADJUSTMENT PROCEDURE
1. Place column shift lever in Park. 2. Raise vehicle. 3. Unsnap cable from transmission shift lever.
4. Move transmission shift lever all the way rearward to Park detent. 5. Release cable adjuster (at
transmission end of cable) to unlock cable. 6. Snap cable back onto pin on transmission shift lever.
7. Press cable lock inward to secure cable. 8. Lower vehicle and verify correct cable adjustment.
Shift Cable: Adjustments 46RE (A518) 4-Speed
SHIFT CABLE ADJUSTMENT
Check cable adjustment by starting the engine in Park and Neutral. Adjustment is correct if the
engine starts only in Park and Neutral.
Adjustment is incorrect if the engine starts in any other position, or does not start in either Park or
Neutral. If the engine starts in any position other than Park or Neutral, or if the engine will not start
at all, the park/neutral position switch may be faulty.
Shift Cable Routing
Shit Cable Attachemnt At Steering Column And Transmission

The shift cable is attached to an arm on the steering column and to the transmission shift lever.
Brackets support and secure the cable at each end and clips are used to secure the cable to the
floor pan. The cable is operated by an arm on the steering column shaft.
The cable has a built-in adjuster mechanism at the transmission end. The mechanism consists of
an internal clamp and release button that allows the cable to be extended, or shortened for
adjustment.
SHIFT CABLE ADJUSTMENT CHECK
The ignition key should rotate from Off to Lock only when the shift lever is in Park.
Shifting out of Park should only be possible when the ignition key is in Off, Run, or Start positions.
It should not be possible when the key is in Accessory or Lock position.
Engine start should only occur in Park and Neutral position.
SHIFT CABLE ADJUSTMENT PROCEDURE
1. Place column shift lever in Park. 2. Raise vehicle. 3. Unsnap cable from transmission shift lever.
4. Move transmission shift lever all the way rearward to Park detent. 5. Release cable adjuster (at
transmission end of cable) to unlock cable. 6. Snap cable back onto pin on transmission shift lever.
7. Press cable lock inward to secure cable. 8. Lower vehicle and verify correct cable adjust
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve
Cable/Linkage, A/T > Component Information > Adjustments > 32RE 3-Speed
Throttle Valve Cable/Linkage: Adjustments 32RE 3-Speed
TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT
Throttle Valve Cable Attachment-At Engine
The transmission throttle valve is operated by a cam on the valve body throttle lever. The throttle
lever is actuated by a cable connected to the engine throttle body lever. A retaining clip at the
engine-end of the cable is removed to provide for cable adjustment. The retaining clip is then
installed back onto the throttle valve cable to lock in the adjustment.
A correctly adjusted throttle valve cable, will cause the throttle lever on the transmission to move
simultaneously with the throttle body lever from the idle position. Proper adjustment allows
simultaneous movement without causing the transmission throttle lever to move ahead of, or lag
behind the throttle body lever.
THROTTLE VALVE CABLE ADJUSTMENT CHECK
1. Turn ignition key to OFF position. 2. Remove air cleaner. 3. Verify that throttle body lever is at
curb idle position. Then verify that transmission throttle lever is also at idle (full forward) position. 4.
Slide cable off attachment stud on throttle body lever. 5. Compare position of cable end to
attachment stud on throttle body lever:
a. Cable end and attachment stud should be aligned (or centered on one another) to within 1 mm
(0.039 inch) in either direction. b. If cable end and attachment stud are misaligned (off center),
cable will have to be adjusted as described in following procedure.
6. Reconnect cable end to attachment stud. Then with aid of a helper, observe movement of
transmission throttle lever and lever on throttle body.
a. If both levers move simultaneously from idle to half-throttle and back to idle position, adjustment
is correct. b. If transmission throttle lever moves ahead of, or lags behind throttle body lever, cable
adjustment will be necessary. Or, if throttle body lever
prevents transmission lever from returning to closed position, cable adjustment will be necessary.
THROTTLE VALVE CABLE ADJUSTMENT PROCEDURE
1. Turn ignition switch to OFF position and shift into Park. 2. Remove air cleaner. 3. Disconnect
cable end from attachment stud on throttle body Carefully slide cable off stud. Do not pull or pry
cable off. 4. Verify that transmission throttle lever is in idle (full forward) position. Then be sure
lever on throttle body is at curb idle position. 5. Insert a small screwdriver under edge of retaining
clip and remove retaining clip. 6. Center cable end on attachment stud to within 1 mm (0.039 inch).
7. Install retaining clip onto cable housing. 8. Check cable adjustment. Be sure transmission throttle
lever and lever on throttle body move simultaneously and as described in cable adjustment
checking procedure.
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve
Cable/Linkage, A/T > Component Information > Adjustments > 32RE 3-Speed > Page 3714
Throttle Valve Cable/Linkage: Adjustments 46RE (A518) 4-Speed
TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT
Throttle Valve Cable Attachment-At Engine
The transmission throttle valve is operated by a cam on the valve body throttle lever. The throttle
lever is actuated by a cable connected to the engine throttle body lever. A retaining clip at the
engine-end of the cable is removed to provide for cable adjustment. The retaining clip is then
installed back onto the throttle valve cable to lock in the adjustment.
A correctly adjusted throttle valve cable, will cause the throttle lever on the transmission to move
simultaneously with the throttle body lever from the idle position. Proper adjustment allows
simultaneous movement without causing the transmission throttle lever to move ahead of, or lag
behind the throttle body lever.
THROTTLE VALVE CABLE ADJUSTMENT CHECK
1. Turn ignition key to OFF position. 2. Remove air cleaner. 3. Verify that throttle body lever is at
curb idle position. Then verify that transmission throttle lever is also at idle (full forward) position. 4.
Slide cable off attachment stud on throttle body lever. 5. Compare position of cable end to
attachment stud on throttle body lever:
a. Cable end and attachment stud should be aligned (or centered on one another) to within 1 mm
(0.039 inch) in either direction. b. If cable end and attachment stud are misaligned-aligned (off
center), cable will have to be adjusted as described in following procedure.
6. Reconnect cable end to attachment stud. Then with aid of a helper, observe movement of
transmission throttle lever and lever on throttle body
a. If both levers move simultaneously from idle to half-throttle and back to idle position,, adjustment
is correct. b. If transmission throttle lever moves ahead of, or lags behind throttle body lever, cable
adjustment will be necessary. Or, if throttle body lever
prevents transmission lever from returning to closed position, cable adjustment will be necessary.
THROTTLE VALVE CABLE ADJUSTMENT PROCEDURE
1. Turn ignition switch to OFF position and shift into Park. 2. Remove air cleaner. 3. Disconnect
cable end from attachment stud on throttle body. Carefully slide cable off stud. Do not pull or pry
cable off. 4. Verify that transmission throttle lever is in idle (full forward) position. Then be sure
lever on throttle body is at curb idle position. 5. Insert a small screwdriver under edge of retaining
clip and remove retaining clip. 6. Center cable end on attachment stud to within 1 mm (0.039 inch).
7. Install retaining clip onto cable housing 8. Check cable adjustment. Be sure transmission throttle
lever and lever on throttle body move simultaneously and as described in cable adjustment
checking procedure.
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Torque Converter: Specifications
Bolt, Torque Converter ........................................................................................................................

..................................................... 31 Nm (23 ft. lbs.)
Component Information > Service and Repair > 32RH 3-Speed
Torque Converter: Service and Repair 32RH 3-Speed
REMOVAL
1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the
converter housing end of the transmission.
CAUTION: Verity that transmission is secure on the lifting device or work surface, the center of
gravity of the transmission will shift when the torque converter is removed creating an unstable
condition.
The torque converter is a heavy unit. Use caution when separating the torque converter from the
transmission.
3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the
torque converter from the transmission.
INSTALLATION
Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub
and notches with 320/400 grit paper or crocus cloth if necessary. The hub must be smooth to avoid
damaging the pump seal at installation. 1. Lubricate converter hub and oil pump seal lip with
transmission fluid. 2. Place torque converter in position on transmission.
CAUTION: Do not damage oil pump seal or bushing while inserting torque converter into the front
of the transmission.
3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5.
While pushing torque converter inward, rotate converter until converter is fully seated in the oil
pump gears.
Checking Torque Converter Seating
6. Check converter seating with a scale and straightedge. Surface of converter lugs should be 1/2
inch to rear of straightedge when converter is fully
seated.
7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8.
Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid.
Component Information > Service and Repair > 32RH 3-Speed > Page 3720
Torque Converter: Service and Repair 46RE (A518) 4-Speed
REMOVAL
1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the
converter housing end of the transmission.
CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of
gravity of the transmission will shift when the torque converter is removed creating an unstable
condition.
The torque converter is a heavy unit. Use caution when separating the torque converter from the
transmission.
3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the
torque converter from the transmission.
INSTALLATION
Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub
and notches with 320/400 grit paper or crocus cloth if necessary. The hub must be smooth to avoid
damaging the pump seal at installation. 1. Lubricate converter hub and oil pump seal lip with
transmission fluid. 2. Place torque converter in position on transmission.
CAUTION: Do not damage oil pump seal or bushing while inserting torque converter into the front
of the transmission.
3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5.
While pushing torque converter inward, rotate converter until converter is fully seated in the oil
pump gears.
Checking Torque Converter Seating
6. Check converter seating with a scale and straightedge. Surface of converter lugs should be 1/2
inch to rear of straightedge when converter is fully
seated.
7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8.
Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid.
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Locations > Component Locations
Solenoid, A/T > Component Information > Locations > Component Locations > Page 3725

Solenoid, A/T > Component Information > Locations > Page 3726

Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control
System Relay, A/T > Component Information > Locations

System Relay, A/T > Component Information > Locations > Page 3730
8w-10-2
System Relay, A/T > Component Information > Locations > Page 3731

Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Technical Service Bulletins > Customer Interest for Transmission Cooler: > 21-06-97A > Dec >
97 > A/T - Overdrive Unavailable in Cold Temperatures
NO: 21-06-97 Rev. A
GROUP: Transmission
DATE: Dec. 19, 1997
Programming
MODELS: 1996 - **1998**
(AB) Ram Van/Wagon
1996 (AN) Dakota
1996 - **1998** (BRIBE) Ram Truck
NOTE:

NOTE:
97 > A/T - Overdrive Unavailable in Cold Temperatures > Page 3740
1 CH7000/7001 J1962 Cable
NOTE:
INSTALLED.
Repair Procedure
NOTE:

NOTE:
a bypass adapter.
NOTE:
CAUTION:

CAUTION:
IDENTIFICATION.
application.
block.
block.
NOTE:
NOTE:
CAUTION:

assembly.
line routing.
CAUTION:


NOTE:
BE INSTALLED.
them up.
press NEXT MENU.
NOTE:
MAIN MENU.
MISCELLANEOUS.
NOTE:

TIME ALLOWANCE:

> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: >
NO: 21-06-97 Rev. A
GROUP: Transmission
DATE: Dec. 19, 1997
Programming
MODELS: 1996 - **1998**
(AB) Ram Van/Wagon
1996 (AN) Dakota
1996 - **1998** (BRIBE) Ram Truck
NOTE:

NOTE:
1 CH7000/7001 J1962 Cable
NOTE:
INSTALLED.
Repair Procedure
NOTE:

NOTE:
a bypass adapter.
NOTE:
CAUTION:

CAUTION:
IDENTIFICATION.
application.
block.
block.
NOTE:
NOTE:
CAUTION:

assembly.
line routing.
CAUTION:


NOTE:
BE INSTALLED.
them up.
press NEXT MENU.
NOTE:
MAIN MENU.
MISCELLANEOUS.
NOTE:

TIME ALLOWANCE:

> Component Information > Technical Service Bulletins > Page 3757
Transmission Cooler: Description and Operation
AUTOMATIC TRANSMISSION OIL COOLER
Top View Of Transmission Oil Cooling Circuit
Automatic Transmission Oil Cooler Lines
The automatic transmission oil is cooled when it passes through a cooler in the radiator lower tank.
In case of a leak in the transmission oil cooler, engine coolant may become mixed with
transmission fluid. Transmission fluid may also have entered the engine cooling system. Both
cooling system and transmission should be drained and inspected in the event cooler is leaking.
TRANSMISSION AUXILIARY COOLER
Transmission Auxiliary Cooler

Auxiliary transmission coolers are mounted ahead of the radiator. They operate in conjunction with
the main cooler located in the radiator lower tank. The transmission oil is routed through the main
cooler in the radiator lower tank first, then the auxiliary cooler before returning to the transmission.
Transmission Cooler: Service and Repair
Remove radiator. The servicing should be performed by a qualified repair facility. Once the
repaired or replacement radiator has been installed, fill the cooling system and inspect for leaks. If
the transmission operates properly after repairing the leak, drain the transmission and torque
converter while hot. Remove the transmission oil pan and inspect sludge and/or rust. Inspect for a
dirty or plugged inlet filter. If none of these conditions are found, the transmission may not require
reconditioning.
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T
Transmission Mount: Specifications
Insulator Bracket to Transmission (Rear) Bolts 50 ft.lb
Insulator to Transmission Bracket (Rear) Through Bolt/Nut 50 ft.lb
Insulator to Rear Support Nuts 30 ft.lb

Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T
Transmission Mount: Service and Repair
REMOVAL 1. Raise vehicle on a hoist. 2. Position transmission jack and raise rear of transmission
and engine SLIGHTLY. 3. Remove rear mount through-bolt and nut. 4. Remove U-shaped bracket
from the frame crossmember. Remove the insulator from the U-shaped bracket.
Rear Support
5. Remove rear engine support from the bottom face of transmission extension housing.
INSTALLATION 1. Attach the rear engine support to the bottom face of transmission extension
housing. Tighten the bolts to 68 Nm (50 ft. lbs.) torque. 2. Install insulator on the U-shaped bracket.
Tighten the nuts to 41 Nm (30 ft. lbs.) torque. 3. Install the through-bolt through the insulator and
U-bracket assembly and the rear engine support. Tighten the through-bolt nut to 68 Nm (50 ft.
lbs.) torque.
4. Attach the U-shaped bracket to the crossmember. Tighten the attaching bolts to 41 Nm (30 ft.
lbs.) torque. 5. Remove the transmission jack. 6. Lower the vehicle.
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 3767

Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure
Test Port, A/T > Component Information > Locations
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Description and Operation
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Locations

Governor
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Transmission Solenoids
Component Information > Adjustments > 32RE 3-Speed
Valve Body: Adjustments 32RE 3-Speed
CONTROL PRESSURE ADJUSTMENTS
There are two control pressure adjustments on the valve body; -
Line Pressure
- Throttle Pressure
Line and throttle pressures are interdependent because each affects shift quality and timing. As a
result, both adjustments must be performed properly and in the correct sequence. Adjust line
pressure first and throttle pressure last.
LINE PRESSURE ADJUSTMENT
Line Pressure Adjustment
Measure distance from the valve body to the inner edge of the adjusting screw with an accurate
steel scale.
Distance should be 33.4 mm (1-5/16 inch).
If adjustment is required, turn the adjusting screw in, or out, to obtain required distance setting.
NOTE: The 33.4 mm (1-5/16 inch) setting is an approximate setting. Manufacturing tolerances may
make it necessary to vary from this dimension to obtain desired pressure.
One complete turn of the adjusting screw changes line pressure approximately 1-2/3 psi (9 kPa).
Turning the adjusting screw counterclockwise increases pressure while turning the screw clockwise
decreases pressure.
THROTTLE PRESSURE ADJUSTMENT
Throttle Pressure Adjustment
Insert Gauge Tool C-3763 between the throttle lever cam and the kickdown valve stem.
Push the gauge tool inward to compress the kickdown valve against the spring and bottom the
throttle valve.
Component Information > Adjustments > 32RE 3-Speed > Page 3782
Maintain pressure against kickdown valve spring. Turn throttle lever stop screw until the screw
head touches throttle lever tang and the throttle lever cam touches gauge tool.
NOTE: The kickdown valve spring must be fully compressed and the kickdown valve completely
bottomed to obtain correct adjustment.
Valve Body: Adjustments 46RE (A518) 4-Speed
CONTROL PRESSURE ADJUSTMENTS
There are two control pressure adjustments on the valve body; -
Line Pressure
- Throttle Pressure
Line and throttle pressures are interdependent because each affects shift quality and timing. As a
result, both adjustments must be performed properly and in the correct sequence. Adjust line
pressure first and throttle pressure last.
LINE PRESSURE ADJUSTMENT
Line Pressure Adjustment
Measure distance from the valve body to the inner edge of the adjusting screw with an accurate
steel scale.
Distance should be 33.4 min (1-5/16 inch).
If adjustment is required, turn the adjusting screw in, or out, to obtain required distance setting.
NOTE: The 33.4 mm (1-5/16 inch) setting is an approximate setting. Manufacturing tolerances may
make it necessary to vary from this dimension to obtain desired pressure.
One complete turn of the adjusting screw changes line pressure approximately 1-2/3 psi (9 kPa).
Turning the adjusting screw counterclockwise increases pressure while turning the screw clockwise
decreases pressure.
THROTTLE PRESSURE ADJUSTMENT
Throttle Pressure Adjustment
Insert Gauge Tool C-3763 between the throttle lever cam and the kickdown valve stem.
Push the gauge tool inward to compress the kickdown valve against the spring and bottom the
throttle valve. Maintain pressure against kickdown valve spring. Turn throttle lever stop screw until
the screw head touches throttle lever tang and the throttle lever
cam touches gauge tool.
NOTE: The kickdown valve spring must be fully compressed and the kickdown valve completely
bottomed to obtain correct adjustment.
Valve Body: Service and Repair Removal and Installation

32RH 3-Speed
The valve body can be disassembled for cleaning and inspection of the individual components.
Refer to Disassembly and Assembly for proper procedures.
The only replaceable valve body components are: -
Manual lever.
- Manual lever washer, seal, E-clip, and shaft seal.
- Manual lever detent ball.
- Throttle lever.
- Fluid filter.
- Switch valve, spring, and pressure adjusting screw bracket.
- Converter clutch solenoid.
- Park rod and E-clip.
The remaining valve body components are serviced only as part of a complete valve body
assembly.
REMOVAL
1. Shift transmission into NEUTRAL. 2. Raise vehicle. 3. Remove gearshift and throttle levers from
shaft of valve body manual lever. 4. Position drain pan under transmission oil pan. 5. Remove
transmission oil pan and gasket. 6. Remove fluid filter from valve body. 7. Disconnect lock-up
solenoid wire, if necessary. 8. Remove bolts attaching valve body to transmission case.
Accumulator Piston And Springs
9. Lower valve body enough to remove accumulator piston and springs.
10. Work manual lever shaft out of transmission case.

Valve Body
11. Lower valve body, rotate valve body away from case, pull park rod out of sprag, and remove
valve body.
INSTALLATION
Manual Lever Shaft Seal
1. Check condition of manual lever shaft seal in transmission case. Replace seal if lip is cut or
worn. Install new seal with 15/16 deep well socket. 2. Check condition of seals on accumulator
piston. Install new piston seals, if necessary. 3. Place valve body manual lever in low (1 position)
so ball on park lock rod will be easier to install in sprag. 4. Lubricate shaft of manual lever with
petroleum jelly. This will ease inserting shaft through seal in case. 5. Position valve body in case
and work end of park lock rod into and through pawl sprag. Turn propeller shaft to align sprag and
park lock teeth if
necessary. The rod will click as it enters pawl. Move rod to check engagement.
CAUTION: It is possible for the park rod to displace into a cavity just above the pawl sprag during
installation. Make sure the rod is actually engaged in the pawl and has not displaced into this
cavity.
6. Install accumulator springs and piston into case. Then swing valve body over piston and outer
spring to hold it in place. 7. Align accumulator piston and outer spring and manual lever shaft in
case. 8. Then seat valve body in case and install one or two bolts to hold valve body in place. 9.
Tighten valve body bolts alternately and evenly to 11 Nm (100 inch lbs.) torque.
10. Connect lock-up solenoid wire, if necessary. 11. Install new fluid filter on valve body. Tighten
filter screws to 4 Nm (35 inch lbs.) torque. 12. Install throttle and gearshift levers on valve body
manual lever shaft. 13. Check and adjust front and rear bands if necessary. 14. Install oil pan and
new gasket. Tighten pan bolts to 17 Nm (13 ft. lbs.) torque. 15. Lower vehicle and fill transmission
with Mopar8 ATF+4, type 9602 fluid. 16. Check and adjust gearshift and throttle valve cables, if
necessary.
46RE (A518) 4-Speed
VALVE BODY
The valve body can be removed for service without having to remove the transmission assembly.
The valve body can be disassembled for cleaning and inspection of the individual components.
Refer to Disassembly and Assembly section for proper procedures.
The only replaceable valve body components are: -
Manual lever.
- Manual lever washer, seal, E-clip, and shaft seal.
- Manual lever detent ball.
- Throttle lever.
- Fluid filter.
- Pressure adjusting screw bracket.
- Governor pressure solenoid.
- Governor pressure sensor.
- Converter clutch/overdrive solenoid assembly and harness (includes sump temperature

thermistor).
- Governor housing gasket.
- Solenoid case connector O-rings.
The remaining valve body components are serviced only as part of a complete valve body
assembly.
REMOVAL
1. Shift transmission into NEUTRAL. 2. Raise vehicle. 3. Remove gearshift and throttle levers from
shaft of valve body manual lever.
Transmission Case Connector
4. Disconnect wires at solenoid case connector. 5. Position drain pan under transmission oil pan. 6.
Remove transmission oil pan and gasket. 7. Remove fluid filter from valve body. 8. Remove bolts
attaching valve body to transmission case. 9. Lower valve body enough to remove accumulator
piston and springs.
10. Work manual lever shaft and electrical connector out of transmission case.
Valve Body
11. Lower valve body, rotate valve body away from case, pull park rod out of sprag, and remove
valve body.
INSTALLATION
Valve Body Harness Connector O-Ring Seal
1. Check condition of O-ring seals on valve body harness connector. Replace seals on connector
body if cut or worn.
Manual Lever Shaft Seal
2. Check condition of manual lever shaft seal in transmission case. Replace seal if lip is cut or
worn. Install new seal with 15/16 deep well socket.
Accumulator Piston Components
3. Check condition of seals on accumulator piston. Install new piston seals, if necessary. 4. Place
valve body manual lever in low (1 position) so ball on park lock rod will be easier to install in sprag.
5. Lubricate shaft of manual lever with petroleum jelly. This will ease inserting shaft through seal in
case. 6. Lubricate seal rings on valve body harness connector with petroleum jelly. 7. Position
valve body in case and work end of park lock rod into and through pawl sprag. Turn propeller shaft
to align sprag and park lock teeth if
necessary. The rod will click as it enters pawl. Move rod to check engagement.
CAUTION: It is possible for the park rod to displace into a cavity just above the pawl sprag during
installation. Make sure the rod is actually engaged in the pawl and has not displaced into this
cavity.
8. Install accumulator springs and piston into case. Then swing valve body over piston and outer
spring to hold it in place. 9. Align accumulator piston and outer spring, manual lever shaft and
electrical connector in case.
10. Then seat valve body in case and install one or two bolts to hold valve body in place. 11.
Tighten valve body bolts alternately and evenly to 11 Nm (100 inch lbs.) torque. 12. Install new fluid
filter on valve body. Tighten filter screws to 4 Nm (35 inch lbs.) torque.
13. Install throttle and gearshift levers on valve body manual lever shaft. 14. Check and adjust front
and rear bands if necessary. 15. Connect solenoid case connector wires. 16. Install oil pan and
new gasket. Tighten pan bolts to 17 Nm (13 ft. lbs.) torque. 17. Lower vehicle and fill transmission
with MOPAR(r) ATF+4, type 9602 fluid. 18. Check and adjust gearshift and throttle valve cables, if
necessary.
Valve Body: Service and Repair Disassembly
Lower Housing Disassembly
1. Remove timing valve cover. 2. Remove 3-4 timing valve and spring. 3. Remove 3-4 quick fill
valve, spring and plug. 4. Remove 3-4 shift valve and spring.
Lower Housing Shift Valves And Springs
5. Remove converter clutch valve, spring and plug. 6. Remove converter clutch timing valve,
retainer and valve spring.
Main Component Body
CAUTION: Do not clamp any valve body component in a vise. This practice can damage the
component resulting in unsatisfactory operation after assembly and installation. Do not use pliers to
remove any of the valves, plugs or springs and do not force any of the components out or into
place. The valves and valve body housings will be damaged if force is used. Tag or mark the valve
body springs for reference as they are removed. Do not allow them to become intermixed.
1. Remove fluid filter.

Governor Pressure Solenoid And Sensor Wire Locations
2. Disconnect wires from governor pressure sensor and solenoid.
Governor Body And Retainer Plate Attaching Screw
3. Remove screws attaching governor body and retainer plate to transfer plate.
Governor Body And Gasket
4. Remove retainer plate, governor body and gasket from transfer plate. 5. Disconnect wires from
governor pressure sensor, if not done previously.
Governor Pressure Sensor
6. Remove governor pressure sensor from governor body. Sensor is retained in body with
M-shaped spring clip. Remove clip with small pointed tool
and slide sensor out of body.
Governor Pressure Solenoid
7. Remove governor pressure solenoid by pulling it straight out of bore in governor body. Remove
and discard solenoid O-rings if worn, cut, or torn. 8. Remove transmission fluid filter.
Solenoid Harness Case Connector Shoulder Bolt
9. Remove small shoulder bolt that secures solenoid harness case connector to 3-4 accumulator
housing. Retain shoulder bolt. Either tape it to
harness or thread it back into accumulator housing after connector removal.

Unhooking Solenoid Harness From Accumulator Cover Plate
10. Unhook overdrive/converter solenoid harness from 3-4 accumulator cover plate.
Solenoid Assembly Screws
11. Turn valve body over and remove screws that attach overdrive/converter solenoid assembly to
valve body.
Solenoid Assembly
12. Remove solenoid and harness assembly from valve body.

Boost Valve Cover Location
13. Remove boost valve cover.
Boost Valve Components
14. Remove boost valve retainer, valve spring and boost valve.
Detent Ball And Spring
15. Secure detent ball and spring with Retainer Tool 6583.
Park Rod
16. Remove park rod E-clip and separate rod from manual lever.
Throttle Lever E-Clip And Washer
17. Remove E-clip and washer that retains throttle lever shaft in manual lever.
Manual And Throttle Lever
18. Remove manual lever and throttle lever. Rotate and lift manual lever off valve body and throttle
lever shaft. Then slide throttle lever out of valve
body.
19. Position pencil magnet next to detent housing to catch detent ball and spring. Then carefully
remove Retainer Tool 6583 and remove detent ball
and spring.
Adjusting Screw Bracket Fastener
20. Remove screws attaching pressure adjusting screw bracket to valve body and transfer plate.
Hold bracket firmly against spring tension while
removing last screw.
Adjusting Screw Bracket And Spring
21. Remove adjusting screw bracket, line pressure adjusting screw, pressure regulator valve spring
and switch valve spring. Do not remove throttle
pressure adjusting screw from bracket and do not disturb setting of either adjusting screw during
removal.
Upper Housing Control Valve Locations
22. Turn upper housing over and remove switch valve, regulator valve and spring, and manual
valve. 23. Remove kickdown detent, kickdown valve, and throttle valve and spring.
Accumulator Housing Screw Locations
24. Loosen left-side 3-4 accumulator housing attaching screw about 2-3 threads. Then remove
center and right-side housing attaching screws.
Shift And Converter Clutch Valve Springs And Plug
25. Carefully rotate 3-4 accumulator housing upward and remove 3-4 shift valve spring and
converter clutch valve plug and spring.
Accumulator Housing, Valve Springs And Plug
26. Remove left-side screw and remove 3-4 accumulator housing from valve body.
Boost Valve Tube Brace
27. Bend back tabs on boost valve tube brace.
Boost Valve Tube
28. Remove boost valve connecting tube. Disengage tube from upper housing port first. Then rock
opposite end of tube back and forth to work it out
of lower housing.
CAUTION: Do not use tools to loosen or pry the connecting tube out of the valve body housings.
Loosen and remove the tube by hand only.
Lower Housing
29. Turn valve body over so lower housing is facing upward. In this position, the two check balls in
upper housing will remain in place and not fall out
when lower housing and separator plate are removed.
30. Remove screws attaching valve body lower housing to upper housing and transfer plate. Note
position of boost valve tube brace for assembly
reference.
31. Remove lower housing and overdrive separator plate from transfer plate.
ECE Check Ball
32. Remove the ECE check ball from the transfer plate. The ECE check ball is approximately 4.8
mm (3/16 inch) in diameter.
Transfer Plate
33. Remove transfer plate from upper housing. 34. Turn transfer plate over so upper housing
separator plate is facing upward.
Upperhousing Separator Plate
35. Remove upper housing separator plate from transfer plate. Note position of filter in separator
plate for assembly reference.
Rear Clutch And Rear Servo Check Ball Locations
36. Remove rear clutch and rear servo check balls from transfer plate. Note check ball location for
assembly reference.
Upper Housing Disassembly
Check Ball Locations In Upper Housing
1. Note location of check balls in valve body upper housing. Then remove the one large diameter
and the six smaller diameter check balls.
Shuttle Valve E-Clip And Secondary Spring Location
2. Remove governor plug and shuttle valve covers.

Shuttle And Boost Valve Components
3. Remove E-clip that secures shuttle valve secondary spring on valve stem. 4. Remove throttle
plug, primary spring, shuttle valve, secondary spring, and spring guides. 5. Remove boost valve
retainer, spring and valve if not previously removed.
6. Remove throttle plug and 1-2 and 2-3 governor plugs.

Upper Housing Shift Valve And Pressure Plug Locations
7. Turn upper housing around and remove limit valve and shift valve covers. 8. Remove limit valve
housing. Then remove retainer, spring, limit valve, and 2-3 throttle plug from limit valve housing. 9.
Remove 1-2 shift control valve and spring.
10. Remove 1-2 shift valve and spring. 11. Remove 2-3 shift valve and spring from valve body. 12.
Remove pressure plug cover. 13. Remove line pressure plug, sleeve, throttle pressure plug and
spring.
3-4 Accumulator
1. Remove end plate from housing. 2. Remove piston spring.

Accumulator Housing Components
3. Remove piston. Remove and discard piston seals.

Valve Body: Service and Repair Disassembly and Assembly
32RH 3-Speed
DISASSEMBLY
Valve Body Assembly
CAUTION: Do not clamp any part of the valve body assembly in a vise. This practice will distort the
valve body and transfer plate resulting in valve bind. Slide valves and plugs out carefully. Do not
use force at any time. The valves and valve body will be damaged if force is used. Also tag or mark
the valve body springs for reference as they are removed. Do not allow them to become
intermixed.
1. Remove screws attaching adjusting screw bracket to valve body and transfer plate. Hold bracket
firmly against spring force while removing last
screw.
Adjusting Screw Bracket And Spring Removal
2. Remove adjusting screw bracket, line pressure adjusting screw, pressure regulator spring and
switch valve spring. Do not remove throttle pressure
adjusting screw from bracket and do not disturb adjusting screw settings during removal.
Securing Detent Ball And Spring With Retainer Tool
3. Secure detent ball and spring in housing with retainer tool 6583.
Removing Manual And Throttle Levers
4. Remove manual shaft E-clip and washer. 5. Pull manual shaft and park rod assembly upward
out of valve body and off throttle lever. 6. Remove Retainer Tool 6583. Then remove and retain
detent ball and spring. 7. Remove throttle lever.
Clutch Module And Connecting Tube Removal/Installation
9. Remove screws attaching converter clutch module to valve body and remove module and
connecting tube.
Valve Body-To-Transfer Plate Screw Locations
10. Turn valve body over so transfer plate is facing upward. With valve body in this position, valve
body check balls will remain in place and not fall
out when transfer plate is removed.
11. Remove screws attaching transfer plate to valve body.
Transfer Plate Removal/Installation
12. Remove transfer plate and separator plate from valve body. Note position of filter and clutch
solenoid for reference. Remove valve body check
balls. Note that check balls may be steel or plastic.
13. Position transfer plate on bench so separator plate, filter and lockup solenoid are facing up.
This will avoid having rear clutch and rear servo check
balls fall out when plates are separated.
14. Remove screws attaching separator plate to transfer plate.

Converter Clutch Solenoid Removal
15. Remove converter clutch solenoid from separator plate.
Transfer And Separator Plates
16. Note position of filter, solenoid and rear clutch/rear servo check balls for assembly reference.
Clutch and servo check balls may be steel or plastic.
17. Remove shuttle valve end plate. 18. Remove shuttle valve E-clip and remove secondary spring
and spring guides from end of valve.
Control Valves And Governor Plugs
19. Remove governor valve end plate. 20. Remove switch valve and pressure regulator valve from
valve body. 21. Remove throttle valve and spring, kickdown valve and detent and manual valve
from valve body. 22. Remove 1-2 and 2-3 shift valve governor plugs from valve body. 23. Remove
shuttle valve throttle plug, primary spring and shuttle valve from valve body.
24. Remove 1-2 shift control valve and spring from valve body. 25. Remove 2-3 shift valve and
spring from valve body. 26. Remove 1-2 shift valve and spring from valve body. 27. Remove
regulator valve end plate. 28. Remove regulator valve line pressure plug, pressure plug sleeve,
throttle pressure plug and spring.
ASSEMBLY
CAUTION: Do not force valves or plugs into place during reassembly. If the valve body bores,
valves and plugs are free of distortion or burrs, the valve body components should all slide into
place easily. In addition, do not overtighten the transfer plate and valve body screws during
reassembly. Overtightening can distort the valve body resulting in valve sticking, cross leakage and
unsatisfactory operation. Tighten valve body screws to recommended torque only.
1. Lubricate valve body bores, valves and plugs with MOPAR(r) ATF+4, type 9602, transmission
fluid.
Valve Body Components

2. Insert rear clutch and rear servo check balls in transfer plate. 3. Install filter screen in separator
plate. 4. Align and install separator plate on transfer plate. Verify check ball position before
installing separator plate on transfer plate.
Installing Converter Cluch Solenoid-32RH
5. Install new O-ring on converter clutch solenoid and insert solenoid in separator plate. Then
secure solenoid in position with attaching screw.
Tighten screw to 4 Nm 35 inch lbs.) torque.
Correct Position Of Valve Body Check Balls
6. Position valve body so internal passages and check ball seats are facing upward. Then install
check balls in valve body. There are a total of seven
check balls; The one large check ball is approximately 11/32 inch in diameter. The remaining check
balls are approximately 1/4 inch in diameter.
7. Align and install assembled transfer and separator plates on valve body. Install and tighten valve
body screws alternately in a diagonal pattern to 4
Nm (35 inch lbs.) torque.

Converter Clutch Module Components
8. Assemble and install lockup module and components on valve body. 9. Assemble regulator
valve line pressure plug, sleeve, throttle plug and spring. insert assembly in valve body and install
end plate. Tighten end plate
screws to 4 Nm (35 inch lbs.) torque.
10. Install 1-2 and 2-3 shift valves and springs. 11. Install 1-2 shift control valve and spring. 12.
Install shuttle valve as follows:
a. Insert shuttle valve in bore. b. Insert plastic guides in shuttle valve secondary spring. c. Install
spring on end of valve. d. Hold shuttle valve in place. Then compress secondary spring and install
E-clip in groove at end of valve. e. Verify that spring and E-clip are properly seated before
proceeding.
13. Install shuttle valve cover plate. Tighten end plate screws to 4 Nm (35 inch lbs.) torque. 14.
Install 1-2 and 2-3 valve governor plugs in valve body. Then install shuttle valve primary spring and
throttle plug. 15. Align and install governor plug end plate on valve body and install end plate
screws. Tighten screws to 4 Nm (35 inch lbs.) torque. 16. Install manual valve. 17. Install throttle
valve and spring. Then install kickdown valve and detent. 18. Install pressure regulator valve and
switch valve in valve body.
Park Rod Install
19. Install manual lever detent spring in housing. Place detent ball on end of spring and push ball
and spring into housing. Secure ball and spring with
Detent Retainer 6583.
20. Insert line pressure adjusting screw in adjusting screw bracket. 21. Install spring on end of line
pressure regulator valve. 22. Install switch valve spring on tang at end of adjusting screw bracket.
23. Position adjusting screw bracket on valve body. Align valve springs and press bracket into
place. Install short, upper bracket screws first and long
bottom screw last. Verify that valve springs and bracket are properly aligned. Then tighten all three
bracket screws to 4 Nm (35 inch lbs.) torque.
24. Install module and connecting tube. Be sure long end of tube goes to module. Tighten module
screws to 4 Nm (35 inch lbs.) torque. 25. Install throttle lever in valve body. Then install manual
lever over throttle lever and start manual lever into valve body. 26. Align manual lever detent with
detent ball and align lever arm with manual valve. Hold throttle lever upward. Then press down on
manual lever
until lever is fully seated.
27. Install manual lever seal, washer and retaining E-clip. 28. Lubricate shaft of manual lever with
light coat of petroleum jelly. This will help protect seal lip when manual shaft seal is installed.
Manual And Throttle Lever Alignment
29. Verify that throttle lever is aligned with end of kickdown valve stem and that manual lever arm is
engaged in manual valve. 30. If line pressure and/or throttle pressure adjustment screw settings
were not disturbed, continue with overhaul or reassembly. However, if
adjustment screw settings were moved or changed, re-adjust as described in Valve Body Control
Pressure Adjustment procedure.
46RE (A518) 4-Speed
DISASSEMBLY
CAUTION: Do not clamp any valve body, component in a vise. This practice can damage the
component resulting in unsatisfactory operation after assembly and installation. Do not use pliers to
remove any of the valves, plugs or springs and do not force any of the components out or into
place. The valves and valve body housings will be damaged if force is used. Tag or mark the valve
body springs for reference as they are removed. Do not allow them to become intermixed.
1. Remove fluid filter.
Governor Pressure Solenoid And Sensor Wire Locations
2. Disconnect wires from governor pressure sensor and solenoid.

Governor Body And Retainer Plate Attaching Screw
3. Remove screws attaching governor body and retainer plate to transfer plate.
4. Remove retainer plate, governor body and gasket from transfer plate. 5. Disconnect wires from
governor pressure sensor, if not done previously.
6. Remove governor pressure sensor from governor body. Sensor is retained in body with
M-shaped spring clip. Remove clip with small pointed tool
and slide sensor out of body.

7. Remove governor pressure solenoid by pulling it straight out of bore in governor body. Remove
and discard solenoid O-rings if worn, cut, or torn. 8. Remove transmission fluid filter.
9. Remove small shoulder bolt that secures solenoid harness case connector to 3-4 accumulator
housing. Retain shoulder bolt. Either tape it to
harness or thread it back into accumulator housing after connector removal.
Unhooking Solenoid Harness From Accumulator Cover Plate
10. Unhook overdrive/converter solenoid harness from 3-4 accumulator cover plate.
Solenoid Assembly Screws
11. Turn valve body over and remove screws that attach overdrive/converter solenoid assembly to
valve body.
Solenoid Assembly
12. Remove solenoid and harness assembly from valve body.
Boost Valve Cover Location
13. Remove boost valve cover.

Boost Valve Components
14. Remove boost valve retainer, valve spring and boost valve.
15. Secure detent ball and spring with Retainer Tool 6583.
Park Rod
Throttle Lever E-Clip And Washer
17. Remove E-clip and washer that retains throttle lever shaft in manual lever.
Manual And Throttle Lever
18. Remove manual lever and throttle lever. Rotate and lift manual lever off valve body and throttle
lever shaft. Then slide throttle lever out of valve
body.
19. Position pencil magnet next to detent housing to catch detent ball and spring. Then carefully
remove Retainer Tool 6583 and remove detent ball
and spring.
Adjusting Screw Bracket Fastener
20. Remove screws attaching pressure adjusting screw bracket to valve body and transfer plate.
Hold bracket firmly against spring tension while
removing last screw.
Adjusting Screw Bracket And Spring
21. Remove adjusting screw bracket, line pressure adjusting screw, pressure regulator valve spring
and switch valve spring. Do not remove throttle
pressure adjusting screw from bracket and do not disturb setting of either adjusting screw during
removal.
22. Turn upper housing over and remove switch valve, regulator valve and spring, and manual
valve. 23. Remove kickdown detent, kickdown valve, and throttle valve and spring.
Accumulator Housing Screw Locations
24. Loosen left-side 3-4 accumulator housing attaching screw about 2-3 threads. Then remove
center and right-side housing attaching screws.
Shift And Converter Clutch Valve Springs And Plug
25. Carefully rotate 3-4 accumulator housing upward and remove 3-4 shift valve spring and
converter clutch valve plug and spring.
Accumulator Housing, Valve Springs And Plug
26. Remove left-side screw and remove 3-4 accumulator housing from valve body.
Boost Valve Tube Brace
27. Bend back tabs on boost valve tube brace.
Boost Valve Tube
28. Remove boost valve connecting tube. Disengage tube from upper housing port first. Then rock
opposite end of tube back and forth to work it out
of lower housing.
CAUTION: Do not use tools to loosen or pry the connecting tube out of the valve body housings.
Loosen and remove the tube by hand only.
Lower Housing
29. Turn valve body over so lower housing is facing upward. In this position, the two check balls in
upper housing will remain in place and not fall out
when lower housing and separator plate are removed.
30. Remove screws attaching valve body lower housing to upper housing and transfer plate. Note
position of boost valve tube brace for assembly
reference.
31. Remove lower housing and overdrive separator plate from transfer plate.
ECE Check Ball
32. Remove the ECE check ball from the transfer plate. The ECE check ball is approximately 4.8
mm (3/16 inch) in diameter.
Transfer Plate
33. Remove transfer plate from upper housing. 34. Turn transfer plate over so upper housing
separator plate is facing upward.
Upper Housing Separator Plate
35. Remove upper housing separator plate from transfer plate. Note position of filter in separator
plate for assembly reference.
36. Remove rear clutch and rear servo check balls from transfer plate. Note check ball location for
assembly reference.
VALVE BODY UPPER HOUSING
1. Note location of check balls in valve body upper housing. Then remove the one large diameter
and the six smaller diameter check balls.
2. Remove governor plug and shuttle valve covers.

3. Remove E-clip that secures shuttle valve secondary spring on valve stem. 4. Remove throttle
plug, primary spring, shuttle valve, secondary spring, and spring guides. 5. Remove boost valve
retainer, spring and valve if not previously removed. 6. Remove throttle plug and 1-2 and 2-3
governor plugs.
7. Turn upper housing around and remove limit valve and shift valve covers. 8. Remove limit valve
housing. Then remove retainer, spring, limit valve, and 2-3 throttle plug from limit valve housing. 9.
Remove 1-2 shift control valve and spring.
10. Remove 1-2 shift valve and spring. 11. Remove 2-3 shift valve and spring from valve body. 12.
Remove pressure plug cover. 13. Remove line pressure plug, sleeve, throttle pressure plug and
spring.
VALVE BODY LOWER HOUSING
1. Remove timing valve cover. 2. Remove 3-4 timing valve and spring. 3. Remove 3-4 quick fill
valve, spring and plug. 4. Remove 3-4 shift valve and spring.
5. Remove converter clutch valve, spring and plug. 6. Remove converter clutch timing valve,
retainer and valve spring.
3-4 ACCUMULATOR HOUSING
1. Remove end plate from housing. 2. Remove piston spring.
3. Remove piston. Remove and discard piston seals.
ASSEMBLY
reassembly. Overtightening can distort the housings resulting in valve sticking, cross leakage and
unsatisfactory operation. Tighten valve body screws to
recommended torque only.
LOWER HOUSING
1. Lubricate valves, springs, and the housing valve and plug bores with clean transmission fluid. 2.
Install 3-4 timing valve spring and valve in lower housing. 3. Install 3-4 quick fill valve in lower
housing. 4. Install 3-4 quick fill valve spring and plug in housing. 5. Install timing valve end plate.
Tighten end plate screws to 4 Nm (35 inch lbs.) torque.
3-4 ACCUMULATOR
1. Lubricate accumulator piston, seals and housing piston bore with clean transmission fluid. 2.
Install new seal rings on accumulator piston. 3. Install piston and spring in housing. 4. Install end
plate on housing.
TRANSFER PLATE
1. Install rear clutch and rear servo check balls in transfer plate.
Separator Plate Filter Screen Installation
2. Install filter screen in upper housing separator plate.

Brace Plate
3. Align and position upper housing separator plate on transfer plate. 4. Install brace plate. Tighten
brace attaching screws to 4 Nm (35 inch lbs.) torque. 5. Install remaining separator plate attaching
screws. Tighten screws to 4 Nm (35 inch lbs.) torque.
UPPER AND LOWER HOUSING
1. Position upper housing so internal passages and check ball seats are facing upward. Then
install check balls in housing. Eight check balls are used.
The single large check ball is approximately 8.7 mm (11/32 inch) diameter. The single small check
ball is approximately 4.8 mm (3/16 inch) in diameter. The remaining 6 check balls are
approximately 6.3 mm (1/4 inch) in diameter.
Installing Transfer Plate On Upper Housing

2. Position assembled transfer plate and upper housing separator plate on upper housing. Be sure
filter screen is seated in proper housing recess. 3. Install the ECE check ball into the transfer plate.
The ECE check ball is approximately 4.8 mm (3/16 inch) in diameter.
Lower Housing Separator Plate
4. Position lower housing separator plate on transfer plate.

5. Install lower housing on assembled transfer plate and upper housing. 6. Install and start all valve
body screws by hand except for the screws to hold the boost valve tube brace. Save those screws
for later installation.
Then tighten screws evenly to 4 Nm (35 inch lbs.) torque. Start at center and work out to sides
when tightening screws.
UPPER HOUSING VALVE AND PLUG

Installing Lower Housing On Transfer Plate And Upper Housing

Refer to images to perform the following steps:
1. Lubricate valves, plugs, springs with clean transmission fluid. 2. Assemble regulator valve line
pressure plug, sleeve, throttle plug and spring. Insert assembly in upper housing and install cover
plate. Tighten
cover plate screws to 4 Nm (35 inch lbs.) torque.
3. Install 1-2 and 2-3 shift valves and springs. 4. Install 1-2 shift control valve and spring. 5. Install
retainer, spring, limit valve, and 2-3 throttle plug from limit valve housing. 6. Install limit valve
housing and cover plate. Tighten screws to 4 Nm (35 inch lbs.). 7. Install shuttle valve as follows:
a. Insert plastic guides in shuttle valve secondary spring and install spring on end of valve. b. Install
shuttle valve into housing. c. Hold shuttle valve in place. d. Compress secondary spring and install
E-clip in groove at end of shuttle valve. e. Verify that spring and E-clip are properly seated before
proceeding.
8. Install shuttle valve cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 9.
Install 1-2 and 2-3 valve governor plugs in valve body.
10. Install shuttle valve primary spring and throttle plug. 11. Align and install governor plug cover.
Tighten cover screws to 4 Nm (35 inch lbs.) torque.
BOOST VALVE TUBE AND BRACE
Boost Valve Tube
1. Position valve body assembly so lower housing is facing upward. 2. Lubricate tube ends and
housing ports with transmission fluid or petroleum jelly.
3. Start tube in lower housing port first. Then swing tube downward and work opposite end of tube
into upper housing port. 4. Insert and seat each end of tube in housings.
Boost Valve Tube And Brace
5. Slide tube brace under tube and into alignment with valve body screw holes. 6. Install and finger
tighten three screws that secure tube brace to valve body housings.
Securing Boost Valve Tube With Brace Tabs
7. Bend tube brace tabs up and against tube to hold it in position. 8. Tighten all valve body housing
screws to 4 Nm (35 inch lbs.) torque after tube and brace are installed. Tighten screws in diagonal
pattern starting
at center and working outward.
3-4 ACCUMULATOR
Converter Clutch And 3-4 Shift Valve Springs

1. Position converter clutch valve and 3-4 shift valve springs in housing. 2. Loosely attach
accumulator housing with rightside screw. Install only one screw at this time as accumulator must
be free to pivot upward for ease
of installation.
3. Install 3-4 shift valve and spring. 4. Install converter clutch timing valve and spring. 5. Position
plug on end of converter clutch valve spring. Then compress and hold springs and plug in place
with fingers of one hand. 6. Swing accumulator housing upward over valve springs and plug.
Seating 3-4 Accumulator On Lower Housing
7. Hold accumulator housing firmly in place and install remaining two attaching screws. Be sure
springs and clutch valve plug are properly seated.
Tighten screws to 4 Nm (35 inch lbs.).
VALVE BODY FINAL
1. Install boost valve, valve spring, retainer and cover plate. Tighten cover plate screws to 4 Nm
(35 inch lbs.) torque. 2. Insert manual lever detent spring in upper housing.
Detent Ball Spring
3. Position detent ball on end of spring. Then hold detent ball and spring in detent housing with
Retainer Tool 6583. 4. Install throttle lever in upper housing. Then install manual lever over throttle
lever and start manual lever into housing. 5. Align manual lever with detent ball and manual valve.
Hold throttle lever upward. Then press down on manual lever until fully seated. Remove
detent ball retainer tool after lever is seated.
6. Then install manual lever seal, washer and E-clip.

engaged in manual valve. 8. Position line pressure adjusting screw in adjusting screw bracket. 9.
Install spring on end of line pressure regulator valve.
10. Install switch valve spring on tang at end of adjusting screw bracket. 11. Install manual valve.
12. Install throttle valve and spring. 13. Install kickdown valve and detent. 14. Install pressure
regulator valve. 15. Install switch valve. 16. Position adjusting screw bracket on valve body. Align
valve springs and press bracket into place. Install short, upper bracket screws first and long
17. Lubricate solenoid case connector O-rings and shaft of manual lever with light coat of
petroleum jelly. 18. Obtain new fluid filter for valve body but do not install filter at this time. 19. If
line pressure and/or throttle pressure adjustment screw settings were not disturbed, continue with
overhaul or reassembly. However, if
adjustment screw settings were moved or changed, readjust as described in Valve Body Control
20. Attach solenoid case connector to 3-4 accumulator with shoulder-type screw. Connector has
small locating tang that fits in dimple at top of
accumulator housing. Seat tang in dimple before tightening connector screw.
21. Install solenoid assembly and gasket. Tighten solenoid attaching screws to 8 Nm (72 inch lbs.)
torque.
Solenoid Harness Routing
22. Verify that solenoid wire harness is properly routed. Solenoid harness must be clear of manual
lever and park rod and not be pinched between
accumulator housing and cover.
GOVERNOR BODY, SENSOR AND SOLENOID
1. Turn valve body assembly over so accumulator side of transfer plate is facing down.
2. Install new O-rings on governor pressure solenoid and sensor. 3. Lubricate solenoid and sensor
O-rings with clean transmission fluid. 4. Install governor pressure sensor in governor body. Then
secure sensor with M-shaped retaining clip.
5. Install governor pressure solenoid in governor body. Push solenoid in until it snaps into place in
body.
6. Position governor body gasket on transfer plate.
Pressure Solenoid Retainer
7. Install retainer plate on governor body and around solenoid. Be sure solenoid connector is
positioned in retainer cutout. 8. Align screw holes in governor body and transfer plate. Then install
and tighten governor body screws to 4 Nm (35 inch lbs.) torque.
Governor Pressure Sensor And Solenoid Connectors
9. Connect harness wires to governor pressure solenoid and governor pressure sensor.
10. Perform Line Pressure and Throttle Pressure adjustments, refer to adjustment section of this
group for proper procedures. 11. Install fluid filter and pan. 12. Lower vehicle. 13. Fill transmission
with recommended fluid and road test vehicle to verify repair.
Valve Body: Service and Repair Cleaning and Inspection
Clean the valve housings, valves, plugs, springs, and separator plates with a standard parts
cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution.
Do not immerse any of the electrical components in cleaning solution. Clean the governor solenoid
and sensor and the dual solenoid and harness assembly by wiping them off with dry shop towels
only.
Dry all except the electrical parts with compressed air. Make sure all passages are clean and free
from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint
from these materials can stick to valve body parts, interfere with valve operation, and clog filters
and fluid passages.
Wipe the governor pressure sensor and solenoid valve with dry, lint free shop towels only. The
O-rings on the sensor and solenoid valve are the only serviceable components. Be sure the vent
ports in the solenoid valve are open and not blocked by dirt or debris. Replace the valve and/or
sensor only when DRB scan tool diagnosis indicates this is necessary. Or, if either part has
sustained physical damage (dented, deformed, broken, etc.).
CAUTION: Do not turn the small screw at the end of the solenoid valve for any reason. Turning the
screw in either direction will ruin solenoid calibration and result in solenoid failure. In addition, the
filter on the solenoid valve is NOT serviceable. Do not try to remove the filter as this will damage
the valve housing.
Upper Housing Valves, Plugs, Springs And Brackets
Inspect the throttle and manual valve levers and shafts. Do not attempt to straighten a bent shaft or
correct a loose lever. Replace these components if worn, bent, loose or damaged in any way.
Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a
straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using
only very light pressure.
Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a
sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally
flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be
replaced.
CAUTION: Many of the valves and plugs, such as the throttle valve, shuttle valve plug, 1-2 shift
valve and 1-2 governor plug, are made of coated aluminum. Aluminum components are identified
by the dark color of the special coating applied to the surface (or by testing with a magnet). Do not
sand aluminum valves or plugs under any circumstances. This practice could damage the special
coating causing the valves/plugs to stick and bind.
Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel
valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or
plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign
matter from lodging between the valves and plugs and the bore.
Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors.
Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs.
The springs must be free of distortion, warpage or broken coils.
Check the two separator plates for distortion or damage of any kind. Inspect the upper housing,
lower housing, 3-4 accumulator housing, and transfer plate carefully. Be sure all fluid passages are
clean and clear. Check condition of the upper housing and transfer plate check balls as well. The
check balls and ball seats must not be worn or damaged.
Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the
valves and plugs should drop freely into the bores.
Valve body bores do not change dimensionally with use. If the valve body functioned correctly
when new, it will continue to operate properly after cleaning and inspection. It should not be
necessary to replace a valve body assembly unless it is damaged in handling.
The only serviceable valve body components are listed below. The remaining valve body
components are serviced only as part of a complete valve body assembly. Serviceable parts are:
- dual solenoid and harness assembly
- solenoid gasket
- solenoid case connector O-rings and shoulder bolt
- switch valve and spring
- pressure adjusting screw and bracket assembly
- throttle lever
- manual lever and shaft seal
- throttle lever shaft seal, washer, and E-clip
- fluid filter and screws
- detent ball and spring
- valve body screws
- governor pressure solenoid
- governor pressure sensor and retaining clip
- park lock rod and E-clip

Valve Body: Service and Repair Assembly
Assembly Precaution
reassembly. Overtightening can distort the housings resulting in valve sticking, cross leakage and
unsatisfactory operation. Tighten valve body screws to recommended torque only.
NOTE: Follow assembly steps in order shown for proper valve body assembly.
Boost Valve and Brace Assembly
Boost Valve Tube
1. Position valve body assembly so lower housing is facing upward. 2. Lubricate tube ends and
housing ports with transmission fluid or petroleum jelly. 3. Start tube in lower housing port first.
Then swing tube downward and work opposite end of tube into upper housing port.
4. Insert and seat each end of tube in housings.
Boost Valve Tube And Brace
5. Slide tube brace under tube and into alignment with valve body screw holes. 6. Install and finger
tighten three screws that secure tube brace to valve body housings.
Securing Boost Valve Tube With Brace Tabs
7. Bend tube brace tabs up and against tube to hold it in position. 8. Tighten all valve body housing
screws to 4 Nm (35 inch lbs.) torque after tube and brace are installed. Tighten screws in diagonal
pattern starting
at center and working outward.
Governor Body, Sensor and Solenoid Assembly
1. Turn valve body assembly over so accumulator side of transfer plate is facing down.
2. Install new O-rings on governor pressure solenoid and sensor. 3. Lubricate solenoid and sensor
O-rings with clean transmission fluid. 4. Install governor pressure sensor in governor body. Then
secure sensor with M-shaped retaining clip.
5. Install governor pressure solenoid in governor body. Push solenoid in until it snaps into place in
body.
6. Position governor body gasket on transfer plate.
Pressure Solenoid Retainer
7. Install retainer plate on governor body and around solenoid. Be sure solenoid connector is
positioned in retainer cutout. 8. Align screw holes in governor body and transfer plate. Then install
and tighten governor body screws to 4 Nm (35 inch lbs.) torque.
Governor Pressure Sensor And Solenoid Connectors
9. Connect harness wires to governor pressure solenoid and governor pressure sensor.
10. Perform Line Pressure and Throttle Pressure adjustments, refer to adjustment section for
proper procedures. 11. Install fluid filter and pan. 12. Lower vehicle. 13. Fill transmission with
recommended fluid and road test vehicle to verify repair.
Lower Housing Disassembly

1. Lubricate valves, springs, and the housing valve and plug bores with clean transmission fluid. 2.
Install 3-4 timing valve spring and valve in lower housing. 3. Install 3-4 quick fill valve in lower
housing. 4. Install 3-4 quick fill valve spring and plug in housing. 5. Install timing valve end plate.
Tighten end plate screws to 4 Nm (35 inch lbs.) torque.
Transfer Plate Assembly
Rear Clutch And Rear Servo Sheck Ball Locations
1. Install rear clutch and rear servo check balls in transfer plate.
Seperator Plate Filter Screen Installation
2. Install filter screen in upper housing separator plate.
Brace Plate
3. Align and position upper housing separator plate on transfer plate. 4. Install brace plate. Tighten
brace attaching screws to 4 Nm (35 inch lbs.) torque. 5. Install remaining separator plate attaching
screws. Tighten screws to 4 Nm (35 inch lbs.) torque.
Upper and Lower Housing Assembly
1. Position upper housing so internal passages and check ball seats are facing upward. Then
install check balls in housing. Eight check balls are used.
The single large check ball is approximately 8.7 mm (11/32 inch) diameter. The single small check
ball is approximately 4.8 mm (3/16 inch) in diameter. The remaining 6 check balls are
approximately 6.3 mm (1/4 inch) in diameter.
Installing Transfer Plate On Upper Housing
2. Position assembled transfer plate and upper housing separator plate on upper housing. Be sure
filter screen is seated in proper housing recess.
ECE Check Ball
3. Install the ECE check ball into the transfer plate. The ECE check ball is approximately 4.8 mm
(3/16 inch) in diameter.
Lower Housing Separator Plate
4. Position lower housing separator plate on transfer plate.

Installing Lower Housing On Transfer Plate And Upper Housing

5. Install lower housing on assembled transfer plate and upper housing. 6. Install and start all valve
body screws by hand except for the screws to hold the boost valve tube brace. Save those screws
for later installation.
Then tighten screws evenly to 4 Nm (35 inch lbs.) torque. Start at center and work out to sides
when tightening screws.
Upper Housing Valve and Plug Assembly

Refer to figures to perform the following steps.

1. Lubricate valves, plugs, springs with clean transmission fluid. 2. Assemble regulator valve line
pressure plug, sleeve, throttle plug and spring. Insert assembly in upper housing and install cover
plate. Tighten
cover plate screws to 4 Nm (35 inch lbs.) torque.
3. Install 1-2 and 2-3 shift valves and springs. 4. Install 1-2 shift control valve and spring. 5. Install
retainer, spring, limit valve, and 2-3 throttle plug from limit valve housing. 6. Install limit valve
housing and cover plate. Tighten screws to 4 Nm (35 inch lbs.). 7. Install shuttle valve as follows:
a. Insert plastic guides in shuttle valve secondary spring and install spring on end of valve. b. Install
shuttle valve into housing. c. Hold shuttle valve in place. d. Compress secondary spring and install
E-clip in groove at end of shuttle valve. e. Verify that spring and E-clip are properly seated before
proceeding.
8. Install shuttle valve cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 9.
Install 1-2 and 2-3 valve governor plugs in valve body.
10. Install shuttle valve primary spring and throttle plug. 11. Align and install governor plug cover.
Tighten cover screws to 4 Nm (35 inch lbs.) torque.
Valve Body Final Assembly and Adjustment
1. Install boost valve, valve spring, retainer and cover plate. Tighten cover plate screws to 4 Nm
(35 inch lbs.) torque. 2. Insert manual lever detent spring in upper housing.
Detent Ball Spring
3. Position detent ball on end of spring. Then hold detent ball and spring in detent housing with
Retainer Tool 6583. 4. Install throttle lever in upper housing. Then install manual lever over throttle
lever and start manual lever into housing. 5. Align manual lever with detent ball and manual valve.
Hold throttle lever upward. Then press down on manual lever until fully seated. Remove
detent ball retainer tool after lever is seated.
6. Then install manual lever seal, washer and E-clip.
engaged in manual valve. 8. Position line pressure adjusting screw in adjusting screw bracket. 9.
Install spring on end of line pressure regulator valve.
10. Install switch valve spring on tang at end of adjusting screw bracket. 11. Install manual valve.
12. Install throttle valve and spring. 13. Install kickdown valve and detent. 14. Install pressure
regulator valve. 15. Install switch valve. 16. Position adjusting screw bracket on valve body. Align
valve springs and press bracket into place. Install short, upper bracket screws first and long
17. Lubricate solenoid case connector O-rings and shaft of manual lever with light coat of
petroleum jelly. 18. Obtain new fluid filter for valve body but do not install filter at this time. 19. If
line pressure and/or throttle pressure adjustment screw settings were not disturbed, continue with
overhaul or reassembly. However, if
adjustment screw settings were moved or changed, readjust as described in Valve Body Control
20. Attach solenoid case connector to 3-4 accumulator with shoulder-type screw. Connector has
small locating tang that fits in dimple at top of
accumulator housing. Seat tang in dimple before tightening connector screw.
21. Install solenoid assembly and gasket. Tighten solenoid attaching screws to 8 Nm (72 inch lbs.)
torque.
Solenoid Harness Routing
22. Verify that solenoid wire harness is properly routed. Solenoid harness must be clear of manual
lever and park rod and not be pinched between
accumulator housing and cover.
3-4 Accumulator Assembly Installation
Converter Clutch And 3-4 Shift Valve Springs
1. Position converter clutch valve and 3-4 shift valve springs in housing.
2. Loosely attach accumulator housing with right-side screw. Install only one screw at this time as
accumulator must be free to pivot upward for ease
of installation.
3. Install 3-4 shift valve and spring. 4. Install converter clutch timing valve and spring. 5. Position
plug on end of converter clutch valve spring. Then compress and hold springs and plug in place
with fingers of one hand. 6. Swing accumulator housing upward over valve springs and plug.
Seating 3-4 Accumulator On Lower Housing
7. Hold accumulator housing firmly in place and install remaining two attaching screws. Be sure
springs and clutch valve plug are properly seated.
Tighten screws to 4 Nm (35 inch lbs.).
3-4 Accumulator Reassembly
1. Lubricate accumulator piston, seals and housing piston bore with clean transmission fluid. 2.
Install new seal rings on accumulator piston. 3. Install piston and spring in housing. 4. Install end
plate on housing.
Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings >
Carrier Bearings: Specifications
Differential:
Bearing Preload ...................................................................................................................................

............................................ 0.38 mm (0.015 inch)
Component Information > Adjustments > Rear Axle - 8 1/4 and 9 1/4
Carrier Bearings: Adjustments Rear Axle - 8 1/4 and 9 1/4

DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH
The following must be considered when adjusting bearing pre-load and gear backlash: -
The maximum ring gear backlash variation is 0.003 inch (0.076 mm).
- Mark the gears so the same teeth are meshed during all backlash measurements.
- Maintain the torque while adjusting the bearing pre-load and ring gear backlash.
- Excessive adjuster torque will introduce a high bearing load and cause premature bearing failure.
Insufficient adjuster torque can result in excessive differential case free-play and ring gear noise.
- Insufficient adjuster torque will not support the ring gear correctly and can cause excessive
differential case free-play and ring gear noise.
NOTE: The differential bearing cups will not always immediately follow the threaded adjusters as
they are moved during adjustment. To ensure accurate bearing cup responses to the adjustments:
-
Maintain the gear teeth engaged (meshed) as marked.
- The bearings must be seated by rapidly rotating the pinion gear a half turn back and forth.
- Do this five to ten times each time the threaded adjusters are adjusted.
Threaded Adjuster Tool
1. Use Wrench C-4164 to adjust each threaded adjuster inward until the differential bearing
freeplay is eliminated. Allow some ring gear backlash
(approximately 0.01 inch/0.25 mm) between the ring and pinion gear. Seat the bearing cups with
the procedure described above.
Ring Gear Backlash Measurement
2. Install dial indicator and position the plunger against the drive side of a ring gear tooth. Measure
the backlash at 4 positions (90° apart) around the
ring gear. Locate and mark the area of minimum backlash.
3. Rotate the ring gear to the position of the least backlash. Mark the gear so that all future
backlash measurements will be taken with the same gear
teeth meshed.
4. Loosen the right-side, tighten the left-side threaded adjuster. Obtain backlash of 0.003 to 0.004
inch (0.076 to 0.102 mm) with each adjuster
tightened to 14 Nm (10 ft. lbs.). Seat the bearing cups with the procedure described above.
5. Tighten the differential bearing cap bolts; -
8 1/4 axles: 95 Nm (70 ft. lbs.)
- 9 1/4 axles: 136 Nm (100 ft. lbs.)
6. Tighten the right-side threaded adjuster to 102 Nm (75 ft. lbs.). Seat the bearing cups with the
procedure described above. Continue to tighten the
Component Information > Adjustments > Rear Axle - 8 1/4 and 9 1/4 > Page 3858
right-side adjuster and seat bearing cups until the torque remains constant at 102 Nm (75 ft. lbs.)
7. Measure the ring gear backlash. The range of backlash is 0.006 to 0.008 inch (0.15 to 0.203
mm). 8. Continue increasing the torque at the rightside threaded adjuster until the specified
backlash is obtained.
NOTE: The left-side threaded adjuster torque should have approximately 102 Nm (75 ft. lbs.). If the
torque is considerably less, the complete adjustment procedure must be repeated.
9. Tighten the left-side threaded adjuster until 102 Nm (75 ft. lbs.) torque is indicated. Seat the
bearing rollers with the procedure described above.
Do this until the torque remains constant.
10. Install the threaded adjuster locks and tighten the lock screws to 10 Nm (90 inch lbs.).
After the proper backlash is achieved, perform the Gear Contact Analysis procedure.
Carrier Bearings: Adjustments Rear Axle - 248RBI
INTRODUCTION
Axle Adjustment Shim Locations-248 RBI
Differential side bearing pre-load and gear backlash is achieved by selective shims positioned
behind the differential side bearing cones. The proper shim thickness can be determined using
slip-fit dummy bearings D-343 in place of the differential side bearings and a dial indicator C-3339.
Before proceeding with the differential bearing pre-load and gear backlash measurements,
measure the pinion gear depth and prepare the pinion gear for installation. Establishing proper
pinion gear depth is essential to establishing gear backlash and tooth contact patterns. After the
overall shim thickness to take up differential side play is measured, the pinion gear is installed, and
the gear backlash shim thickness is measured. The overall shim thickness is the total of the dial
indicator reading and the pre-load specification added together. The gear backlash measurement
determines the thickness of the shim used on the ring gear side of the differential case. Subtract
the gear backlash shim thickness from the total overall shim thickness and select that amount for
the pinion gear side of the differential. Differential shim measurements are performed with axle
spreader W-129-B removed.
SHIM SELECTION
NOTE: It is difficult to salvage the differential side bearings during the removal procedure. Install
replacement bearings if necessary.
1. Remove differential side bearings from differential case. 2. Remove factory installed shims from
differential case. 3. Install ring gear on differential case and tighten bolts to specification, if
necessary. 4. Install dummy side bearings D-343 on differential case. 5. Install differential case in
axle housing.
Tighten Bolts Holding Bearing Caps
6. Install the marked bearing caps in their correct positions. Install and snug the bolts.
Seat Pinion Gear Side Differential Dummy Side Bearing
Seat Ring Gear Side Differential Dummy Side Bearing
7. Using a dead-blow type mallet, seat the differential dummy bearings to each side of the axle
housing.
Differential Side Play Measurement
8. Thread guide stud C-3288-B into rear cover bolt hole below ring gear. 9. Attach a dial indicator
C-3339 to guide stud. Position the dial indicator plunger on a flat surface between the ring gear bolt
heads.
Hold Differential Case And Zero Dial Indicator
10. Push and hold differential case to pinion gear side of axle housing. 11. Zero dial indicator face
to pointer.
Hold Differential Case And Read Dial Indicator
12. Push and hold differential case to ring gear side of the axle housing. 13. Record dial indicator
reading. 14. Add 0.015 in. (0.38 mm) to the zero end play total. This new total represents the
thickness of shims to compress, or pre-load the new bearings
when the differential is installed.
15. Rotate dial indicator out of the way on the guide stud. 16. Remove differential case and dummy
bearings from axle housing. 17. Install the pinion gear in axle housing. Install the pinion yoke, or
flange, and establish the correct pinion rotating torque. 18. Install differential case and dummy
bearings D-343 in axle housing (without shims), install bearing caps and tighten bolts snug. 19.
Seat ring gear side dummy bearing. 20. Position the dial indicator plunger on a flat surface
between the ring gear bolt heads. 21. Push and hold differential case toward pinion gear.
Hold Differential Case And Zero Dial Indicator
22. Zero dial indicator face to pointer.
Hold Differential Case And Read Dial Indicator
23. Push and hold differential case to ring gear side of the axle housing. 24. Record dial indicator
reading. 25. This is the thickness shim required on the ring gear side of the differential case to
achieve proper backlash. 26. Subtract the backlash shim thickness from the total pre-load shim
thickness. The remainder is the shim thickness required on the pinion side of the
axle housing.
27. Rotate dial indicator out of the way on guide stud. 28. Remove differential case and dummy
bearings from axle housing. 29. Install side bearing shims on differential case hubs. 30. Install side
bearings and cups on differential case. 31. Install spreader W-129-B on axle housing and spread
axle opening enough to receive differential case. 32. Install differential case in axle housing. 33.
Remove spreader from axle housing. 34. Rotate the differential case several times to seat the side
bearings.
Ring Gear Backlash Measurement
35. Position the indicator plunger against a ring gear tooth. 36. Push and hold ring gear upward
while not allowing the pinion gear to rotate. 37. Zero dial indicator face to pointer.
Backlash Shim Adjustment
38. Push and hold ring gear downward while not allowing the pinion gear to rotate. Dial indicator
reading should be between 0.12 mm (0.005 inch)
and 0.20 mm (0.008 inch). If backlash is not within specifications transfer the necessary amount of
shim thickness from one side of the axle housing to the other.
39. Verify differential case and ring gear runout by measuring ring to pinion gear backlash at
several locations around the ring gear. Readings should
not vary more than 0.05 mm. (0.002 inch). If readings vary more than specified, the ring gear or the
differential case is defective.
After the proper backlash is achieved, perform Gear Contact Pattern Analysis procedure.
Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4
Carrier Bearings: Service and Repair Rear Axle - 8 1/4 and 9 1/4
REMOVAL
1. Remove differential case from axle housing. 2. Remove the bearings from the differential case
with Puller/Press C-293-PA and:
Differential Bearing Removal-8 1/4 Axle
- Adapters C-293-48 and Plug SP-3289 for the 8 1/4 axle.
Differential Bearing Removal-9 1/4 Axle

Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3866
- Adapters C-293-47 and Plug C-293-3 for the 9 1/4 axle.
INSTALLATION
1. Install differential side bearings. Use:
Install Differential Side Bearing-8 1/4 Axle
- Installer C-4340 with handle C-4171 for the 8 1/4 axle.
- Installer C-4213 and Handle C-4171 for the 9 1/4 axle.
2. Install differential case in axle housing.

Component Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3867
Carrier Bearings: Service and Repair Rear Axle - 248RBI
REMOVAL
1. Remove differential case from axle housing.
Differential Bearing Removal
2. Remove the bearings from the differential case with Puller/Press C-293-PA, Adapters C-293-62,
and Step Plate C-4487-1.
INSTALLATION
Install Differential Side Bearings
1. Using tool C-4190 with handle C-4171, install differential side bearings. 2. Install differential case
in axle housing.
Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears
Carrier Side Gears: Specifications
Differential:
Side Gear Clearance

..............................................................................................................................................................
0 - 0.18 mm (0 - 0.007 inch)
Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears
Carrier Side Gears: Adjustments
SIDE GEAR CLEARANCE
When measuring side gear clearance, check each gear independently. If it necessary to replace a
side gear, replace both gears as a matched set. 1. Install the axle shafts and C-clip locks and
pinion mate shaft.
Side Gear Clearance Measurement

2. Measure each side gear clearance. Insert a matched pair of feeler gauge blades between the
gear and differential housing on opposite sides of the
hub.
3. If side gear clearances is no more than 0.005 inch. Determine if the shaft is contacting the pinion
gear mate shaft. Do not remove the feeler gauges,
inspect the axle shaft with the feeler gauge inserted behind the side gear. If the end of the axle
shaft is not contacting the pinion gear mate shaft, the side gear clearance is acceptable.
Side Gear Calculations
4. If clearance is more than 0.005 inch (axle shaft not contacting mate shaft), record the side gear
clearance. Remove the thrust washer and measure
its thickness with a micrometer. Add the washer thickness to the recorded side gear clearance. The
sum of gear clearance and washer thickness will determine required thickness of replacement
thrust washer. In some cases, the end of the axle shaft will move and contact the mate shaft when
the feeler gauge is inserted. The C-clip lock is preventing the side gear from sliding on the axle
shaft.
5. If there is no side gear clearance, remove the C-clip lock from the axle shaft. Use a micrometer
to measure the thrust washer thickness. Record the
thickness and re-install the thrust washer. Assemble the differential case without the C-clip lock
installed and re-measure the side gear clearance.
6. Compare both clearance measurements. If the difference is less than 0.012 inch (0.305 mm),
add clearance recorded when the C-clip lock was
installed to thrust washer thickness measured. The sum will determine the required thickness of the
replacement thrust washer.
7. If clearance is 0.012 inch (0.305 mm) or greater, both side gears must be replaced (matched set)
and the clearance measurements repeated. 8. If clearance (above) continues to be 0.012 inch
(0.305 mm) or greater, the case must be replaced.
Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Differential Case: Specifications
Differential Case:
Clearance ............................................................................................................................................
............................................. 0.12 mm (0.005 inch) Flange Runout ....................................................
............................................................................................................................ 0.076 mm (0.003
inch)
Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4
Differential Case: Service and Repair Rear Axle - 8 1/4 and 9 1/4
REMOVAL
1. Remove the axle shafts. 2. Remove RWAL/ABS sensor from housing.
NOTE: Side play resulting from bearing races being loose on case hubs requires replacement of
the differential case.
Mark For Installation Reference
3. Mark the differential housing and the differential bearing caps for installation reference. 4.
Remove bearing threaded adjuster lock from each bearing cap. Loosen the bolts, but do not
remove the bearing caps.
Threaded Adjuster Tool
5. Loosen the threaded adjusters with Wrench C-4164. 6. Hold the differential case while removing
bearing caps and adjusters. 7. Remove the differential case.
NOTE: Each differential bearing cup and threaded adjuster must be kept with their respective
bearing.
INSTALLATION
1. Apply a coating of hypoid gear lubricant to the differential bearings, bearing cups, and threaded
adjusters. A dab of grease can be used to keep the
adjusters in position. Carefully position the assembled differential case in the housing.
Information > Service and Repair > Rear Axle - 8 1/4 and 9 1/4 > Page 3877
Bearing Caps & Bolts
2. Observe the reference marks and install the differential bearing caps at their original locations. 3.
Install bearing cap bolts and tighten the upper bolts to 14 Nm (10 ft. lbs.). Tighten the lower bolts
finger-tight until the bolt head is seated. 4. Perform the differential bearing pre-load and adjustment
procedure. 5. Install axle shafts and differential housing cover.
Differential Case: Service and Repair Rear Axle - 248RBI
REMOVAL
1. Remove axle shafts.
Bearing Cap Identification
2. Note the orientation of the installation reference letters stamped on the bearing caps and
housing machined sealing surface. 3. Remove the differential bearing caps.
Spread Differential Housing
4. Position Spreader W-129-B with the tool dowel pins seated in the locating holes. 5. Install the
hold down clamps and tighten the tool turnbuckle finger-tight. 6. Install a Guide Pin C-3288-B at the
left side of the differential housing. Attach dial indicator to housing pilot stud. Load the indicator
plunger
against the opposite side of the housing and zero the indicator.
7. Spread the housing enough to remove the case from the housing. Measure the distance with the
dial indicator.
CAUTION: Do not spread over 0.50 mm (0.020 in). If the housing is over-spread, it could be
distorted or damaged.
8. Remove the dial indicator.

Differential Removal
9. Pry the differential case loose from the housing. To prevent damage, pivot on housing with the
end of the pry bar against spreader.
10. Remove the case from housing. Mark or tag bearing cups to indicate which side they were
removed from.
INSTALLATION
1. Position Spreader W-129-B with the tool dowel pins seated in the locating holes. Install the hold
down clamps and tighten the tool turnbuckle
finger-tight.
2. Install a Guide Pin C-3288-B at the left side of the differential housing. Attach dial indicator to
housing pilot stud. Load the indicator plunger
against the opposite side of the housing and zero the indicator.
3. Spread the housing enough to install the case in the housing. Measure the distance with the dial
indicator.
CAUTION: Do not spread over 0.50 mm (0.020 inch). If the housing is over-spread, it could be
distorted or damaged.
4. Remove the dial indicator. 5. Install differential in housing.
Differential Installation
6. Install case in the housing. Tap the differential case with a rawhide or rubber mallet to ensure the
bearings are fully seated in the differential
housing.
7. Remove the spreader.

Differential Bearing Cap Reference Letters
8. Install the bearing caps at their original locations. Tighten the bearing cap bolts to 109 Nm (80 ft.
lbs.) torque. 9. Install axle shafts.
Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Information > Technical Service Bulletins > Differential Cover - Updated Sealer & Fluid
Differential Cover: Technical Service Bulletins Differential Cover - Updated Sealer & Fluid
NUMBER: 03-08-00
MODELS:
NOTE:
CORPORATE AXLE.
NOTE:
RTV.
NOTE:

Differential Cover: Service and Repair Rear Axle - 8 1/4 and 9 1/4
FINAL ASSEMBLY
Typical Housing Cover With Sealant
1. Scrape the residual sealant from the housing and cover mating surfaces. Clean the mating
surfaces with mineral spirits. Apply a bead of
MOPAR(r) Silicone Rubber Sealant, or equivalent, on the housing cover.
Install the housing cover within 5 minutes after applying the sealant.
2. Install the cover on the differential with the attaching bolts. Install the identification tag. Tighten
the cover bolts to 41 Nm (30 ft. lbs.) torque.
CAUTION: Overfilling the differential can result in lubricant foaming and overheating.
3. Refill the differential housing with gear lubricant. Refer to the Lubricant Specifications section for
the gear lubricant requirements. 4. Install the fill hole plug.
Differential Cover: Service and Repair Rear Axle - 248RBI
FINAL ASSEMBLY
Typical Housing Cover With Sealant
1. Scrape the residual sealant from the housing and cover mating surfaces. Clean the mating
surfaces with mineral spirits. Apply a bead of
MOPAR(R) Silicone Rubber Sealant, or equivalent, on the housing cover.
Install the housing cover within 5 minutes after applying the sealant. 2. Install the cover on the
differential with the attaching bolts. Install the identification tag. Tighten the cover bolts to 41 Nm
(30 ft. lbs.) torque.
CAUTION: Overfilling the differential can result in lubricant foaming and overheating.
3. Refill the differential housing with gear lubricant. Refer to the Lubricant Specifications section for
the gear lubricant requirements. 4. Install the fill hole plug.
Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Technical Service Bulletins > Differential Cover - Updated Sealer & Fluid
Fluid - Differential: Technical Service Bulletins Differential Cover - Updated Sealer & Fluid
NUMBER: 03-08-00
MODELS:
NOTE:
CORPORATE AXLE.
NOTE:
RTV.
NOTE:

Information > Technical Service Bulletins > Differential Cover - Updated Sealer & Fluid > Page 3892
Fluid - Differential: Technical Service Bulletins Differential - Lubricant & Sealing Requirements
NO: 03-02-98
GROUP: Axle And Propshaft
DATE: Apr. 3, 1996
SUBJECT: 8-1/4 - 9-1/4 Axle Lubricant And Sealing Requirements
MODELS: 1998 (AB) Ram Van 1998 (AN) Dakota 1998 (BR/BE) Ram Truck 1998 (DN) Durango
1998 (XJ) Cherokee
DISCUSSION:
With the introduction of the 1998 model year, the axle lubricant in the 8-1/4 and 9-1/4 axles was
changed in formulation to improve fuel economy. When adding lubricant or if service is performed
that requires new lubricant use 75W90 p/n 5010320AA.
This lubricant is more aggressive toward RTV sealants than previously used axle lubricants. When
resealing the axle cover, using the proper sealing material to minimize any potential fluid foaming
and/or seal breakdown is important. Currently the only recommended sealing material for mall axle
covers or transmission pans is MOPAR RTV Sealant (grey in color) p/n 82300234.

Fluid - Differential: Capacity Specifications
Differential Oil Capacity
8 1/4 .....................................................................................................................................................
........................................................ 2.22L (4.7 pints) With TRAC-LOK ..............................................
..................................................................................................................... include 5 oz. friction
modifier 9 1/4 .......................................................................................................................................
...................................................................... 2.32L (4.9 pints) With TRAC-LOK ................................
................................................................................................................................... include 5 oz.
friction modifier 248RBI .......................................................................................................................
............................................................................... 2.96L (6.25 pints) With TRAC-LOK .....................
.............................................................................................................................................. include 6
oz. friction modifier
Fluid - Differential: Fluid Type Specifications
Differential Fluid Type
Grade ...................................................................................................................................................
................................................................... API GL-5
Viscosity ..............................................................................................................................................
........................................................................... 90W
TRAC-LOK differentials require the specified amount of friction modifier.

Fluid - Differential: Service Precautions
DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur.
Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential >
Component Information > Specifications > 8 1/4 Axle
Pinion Bearing: Specifications 8 1/4 Axle
Pinion Bearing:
Preload ................................................................................................................................................
........................................ 1-2 Nm (10-20 inch lbs.)
Component Information > Specifications > 8 1/4 Axle > Page 3901
Pinion Bearing: Specifications 9 1/4 Axle
Pinion Bearing Preload:
Original ................................................................................................................................................
....................................... 1-2 Nm (10-20 inch lbs.) New ......................................................................
....................................................................................................................... 2-5 Nm (15-35 inch
lbs.)
Component Information > Specifications > 8 1/4 Axle > Page 3902
Pinion Bearing: Specifications Rear Axle - 248RBI
Pinion Bearing Preload:
Original Bearing ...................................................................................................................................

...................................... 1-3 Nm (10-20 inch lbs.) New Bearing .........................................................
...................................................................................................................... 2-5 Nm (20-40 inch lbs.)
Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Pinion Gear: Specifications
Pinion Std. Depth .................................................................................................................................

............................................. 127 mm (5.000 inch)
Pinion Nut ............................................................................................................................................

.............................. 292-447 Nm (215-330 ft. lbs.)
Information > Adjustments > 8 1/4 Axle
Pinion Gear: Adjustments 8 1/4 Axle
GENERAL INFORMATION
Pinion Gear ID Numbers
Ring and pinion gears are supplied as matched sets only. The identifying numbers for the ring and
pinion gear are marked on the face of each gear. A plus (+) number, minus (-) number or zero (0)
is marked on the face of the pinion gear. This number is the amount (in thousandths of an inch) the
depth varies from the standard depth setting of a pinion marked with a (0). The standard depth
provides the best teeth contact pattern. Refer to Backlash and Contact Pattern Analysis Paragraph
for additional information.
Shim Locations
Compensation for pinion depth variance is achieved with select shims. The shims are placed under
the rear pinion bearing cone.
If a new gear set is being installed, note the depth variance marked on both the original and
replacement pinion gear. Add or subtract the thickness of the original depth shims to compensate
for the difference in the depth variances. Refer to the Depth Variance charts.
Information > Adjustments > 8 1/4 Axle > Page 3908
Note where Old and New Pinion Marking columns intersect. Intersecting figure represents plus or
minus amount needed. Note the marked number on the face of the drive pinion gear (-1, -2, 0, +1,
+2, etc.). The numbers represent thousands of an inch deviation from the standard. If the number
is negative, add that value to the required thickness of the depth shim(s). If the number is positive,
subtract that value from the thickness of the depth shim(s). If the number is 0 no change is
necessary. Refer to the Pinion Gear Depth Variance Chart.
PINION DEPTH MEASUREMENT AND ADJUSTMENT
1. Install front pinion bearing cup. Use Installer D-130 and Handle C-4171. 2. Install rear pinion
bearing cup. Use Installer C-4308 and Handle C-4171.
8 1/4 Axle Pinion Adjustment Tools
3. Use Pinion Gear Adjustment Gauge Set C-3715-B. 4. Position Spacer SP-6030 over Shaft
SP-5385. 5. Position pinion rear bearing on shaft. 6. Position tools (with bearing) in the housing. 7.
Install Sleeve SP-5382. 8. Install pinion front bearing. 9. Install Spacer SP-6022.
10. Install Sleeve SP-3194-13, Washer SP-534, and Nut SP-3193. 11. Tighten the nut to seat the
pinion bearings in the housing. Allow the sleeve to turn several times during tightening to prevent
brinelling bearing
cups or bearings.
12. Loosen the compression nut tool. 13. Lubricate the pinion gear front and rear bearings with
gear lubricant. 14. Re-tighten the compression nut tool to 1-3 Nm (15-25 inch lbs.) torque. 15.
Rotate the pinion gear several complete revolutions to align the bearing rollers.
Gauge Block
16. Install Gauge Block. 17. Install Gauge Block SP-5383 at the end of SP-5385. 18. Install Cap
Screw SP-536 and tighten with Wrench SP-531.
Crossbore Arbor
19. Position Crossbore Arbor SP-6029 in the differential housing. 20. Center the arbor tool. 21.
Position the bearing caps on the arbor tool. 22. Install the attaching bolts. 23. Tighten the cap bolts
to 14 Nm (10 ft. lbs.).
Depth Shim(s) Selection
24. Trial fit depth shim(s) between the crossbore arbor and gauge block. The depth shim(s) fit must
be snug but not tight (drag friction of a feeler
gauge blade).
25. Select a shim equal to the shim selected above plus the drive pinion gear depth variance
number marked on the face of the pinion gear using the
opposite sign on the variance number. For example, if the depth variance is -2, add +0.002 inch to
the dial indicator reading.
NOTE: Depth shims are available in 0.001-inch increments from 0.020 inch to 0.038 inch.
26. Remove the tools from the differential housing.

Pinion Gear: Adjustments 9 1/4 Axle
GENERAL INFORMATION
pinion gear are marked on the face of each gear. A plus (+) number, minus (-) number or zero (0)
is marked on the face of the pinion gear. This number is the amount (in thousandths of an inch) the
depth varies from the standard depth setting of a pinion marked with a (0). The standard depth
provides the best teeth contact pattern. Refer to Backlash and Contact Pattern Analysis Paragraph
for additional information.
Shim Locations
the rear pinion bearing cone.
If a new gear set is being installed, note the depth variance marked on both the original and
minus amount needed. Note the marked number on the fan of the drive pinion gear (-1, -2, 0, +1,
+2, etc.). The numbers represent thousands of an inch deviation from the standard. If the number
is negative, add that value to the required thickness of the depth shim(s). If the number is positive,
subtract that value from the thickness of the depth shim(s). If the number is 0 no change is
necessary. Refer to the Pinion Gear Depth Variance Chart.
1. Install front bearing cup. Use Installer D-129 and Handle C-4171. 2. Install rear bearing cup. Use
Installer C-4310 and Handle C-4171.
9 1/4 Axle Pinion Adjustment Tools
3. Use Pinion Gear Adjustment Gauge Set C-758-D6. 4. Position Spacer SP-6017 over Shaft
SP-526. 5. Position pinion rear bearing on shaft. 6. Position tools (with bearing) in the housing. 7.
Install Sleeve SP-1730. 8. Install pinion front bearing. 9. Install Spacer SP-6022.
10. Install Sleeve SP-535A, Washer SP-534, and Nut SP-533. 11. Tighten the nut to seat the
pinion bearings in the housing. Allow the sleeve to turn several times during tightening to prevent
brinelling bearing
cups or bearings.
12. Loosen the compression nut tool. 13. Lubricate the pinion gear front and rear bearings with
gear lubricant. 14. Re-tighten the compression nut tool to 1-3 Nm (15-25 inch lbs.) torque. 15.
Rotate the pinion gear several complete revolutions to align the bearing rollers.
Gauge Block
16. Install Gauge Block. 17. Install Gauge Block SP-6020 at the end of SP-526. 18. Install Cap
Screw SP-536 and tighten with Wrench SP-531.
Crossbore Arbor
19. Position Crossbore Arbor SP-6018 in the differential housing. 20. Center the tool. 21. Position
the bearing caps on the arbor tool. 22. Install the attaching bolts. 23. Tighten the cap bolts to 14
Nm (10 ft. lbs.).
Depth Shim(s) Selection
24. Trial fit depth shim(s) between the crossbore arbor and gauge block. The depth shim(s) fit must
be snug but not tight (drag friction of a feeler
gauge blade).
25. Select a shim equal to the shim selected above plus the drive pinion gear depth variance
number marked on the face of the pinion gear using the
opposite sign on the variance number. For example, if the depth variance is -2, add +0.002 in. to
NOTE: Depth shims are available in 0.001-inch increments from 0.020 inch to 0.038 inch.
26. Remove the tools from the differential housing.

Pinion Gear: Adjustments Rear Axle - 248RBI
GENERAL INFORMATION
pinion gear are etched into the face of each gear. A plus (+) number, minus (-) number or zero (0)
is etched into the face of the pinion gear. This number is the amount (in thousandths of an inch) the
depth varies from the standard depth setting of a pinion etched with a (0). The standard setting
from the center line of the ring gear to the back face of the pinion is 127.00 mm (5.000 inch). The
standard depth provides the best teeth contact pattern. Refer to Backlash and Contact Pattern
Analysis Paragraph for additional information.
Shim Locations
the inner pinion bearing cone.
If a new gear set is being installed, note the depth variance etched into both the original and
minus amount needed.
Note the etched number on the face of the drive pinion gear (-1, -2, 0, +1, +2, etc.). The numbers
represent thousands of an inch deviation from the standard. If the number is negative, add that
value to the required thickness of the depth shim(s). If the number is positive, subtract that value
from the thickness of the depth shim(s). If the number is 0 no change is necessary. Refer to the
Pinion Gear Depth Variance Chart.
Pinion Gear Depth Gauge Tools-Typical
Measurements are taken with pinion cups and pinion bearings installed in housing. Take
measurements with a Pinion Gauge Set 6730 and Dial Indicator C-3339. 1. Assemble Pinion
Height Block 6739, Pinion Block 6736, and rear pinion bearing onto Screw 6741.
Pinion Height Block-Typical
2. Insert assembled height gauge components, rear bearing and screw into axle housing through
pinion bearing cups. 3. Install front pinion bearing and Cone 6740 hand tight.
Gauge Tools In Housing-Typical
4. Place Arbor Disc 6732 on Arbor D-115-3 in position in axle housing side bearing cradles. Install
differential bearing caps on Arbor Discs and
tighten cap bolts. Refer to the Torque Specifications.
NOTE: Arbor Discs 6732 have different step diameters to fit other axle sizes. Pick correct size step
for axle being serviced.
5. Assemble Dial Indicator C-3339 into Scooter Block D-115-2 and secure set screw. 6. Place
Scooter Block/Dial Indicator in position in axle housing so dial probe and scooter block are flush
against the surface of the pinion height
block. Hold scooter block in place and zero the dial indicator face to the pointer. Tighten dial
indicator face lock screw.
7. With scooter block still in position against the pinion height block, slowly slide the dial indicator
probe over the edge of the pinion height block.
Observe how many revolutions counterclockwise the dial pointer travels (approximately 0.125 inch)
to the out-stop of the dial indicator.
Pinion Gear Depth Measurement-Typical

8. Slide the dial indicator probe across the gap between the pinion height block and the arbor bar
with the scooter block against the pinion height
block. When the dial probe contacts the arbor bar, the dial pointer will turn clockwise. Bring dial
pointer back to zero against the arbor bar, do not turn dial face. Continue moving the dial probe to
the crest of the arbor bar and record the highest reading. If the dial indicator can not achieve the
zero reading, the rear bearing cup or the pinion depth gauge set is not installed correctly.
9. Select a shim equal to the dial indicator reading plus the drive pinion gear depth variance
number etched in the face of the pinion gear using the
opposite sign on the variance number. For example, if the depth variance is -2, add +0.002 in. to
10. Remove the pinion depth gauge components from the axle housing
Pinion Gear: Service and Repair Rear Axle - 8 1/4 and 9 1/4
NOTE: The ring and pinion gears are serviced in a matched set. Do not replace the pinion gear
without replacing the ring gear.
REMOVAL
1. Remove differential from the axle housing. 2. Mark pinion yoke and propeller shaft for installation
alignment. 3. Disconnect propeller shaft from pinion yoke. Using suitable wire, tie propeller shaft to
underbody. 4. Using Yoke Holder 6719 to hold yoke and remove the pinion yoke nut and washer.
Pinion Yoke Removal
5. Using Remover C-452, remove the pinion yoke from pinion shaft. 6. Partially install pinion nut
onto pinion to protect the threads.
Remove Pinion Gear
7. Remove the pinion gear from housing. Catch the pinion with your hand to prevent it from falling
and being damaged. 8. Remove the pinion shaft seal with suitable pry tool or slide-hammer
mounted screw. 9. Remove oil slinger, if equipped, and front pinion bearing.
10. Remove the front pinion bearing cup with:

Front Bearing Cup Removal-8 1/4 Axle
- Remover C-4345 and Handle C-4171 for the 8 1/4 axles.
- Bearing Removal Tool Set 6310 and Adapter Foot 6310-9 for the 9 1/4 axles.
Rear Bearing Cup Removal
11. Remove the rear bearing cup from housing. Use:
- Remover C-4307 and Handle C-4171 for the 8 1/4 axle.
- Remover C-4309 and Handle C-4171 for the 9 1/4 axle.

Collapsible Spacer
12. Remove the collapsible pre-load spacer.
Rear Bearing Removal
13. Remove the rear bearing from the pinion with:
- Puller/Press C-293-PA and Adapters C-293-47 for the 8 1/4 axle.
- Puller/Press C-293-PA and Adapters C-293-37 for the 9 1/4 axle.
Place 4 adapter blocks so they do not damage the bearing cage.
14. Remove the depth shims from the pinion gear shaft. Record the thickness of the depth shims.
INSTALLATION
1. Apply MOPAR(r) Door Ease, or equivalent, stick lubricant to outside surface of bearing cup.
Pinion Rear Bearing Cup Installation
2. Install the pinion rear bearing cup with: -
Installer C-4308 and Driver Handle C-4171 for the 8 1/4 axle.
- Installer C-4310 and Driver Handle C-4171 for the 9 1/4 axle.
3. Ensure cup is correctly seated. 4. Apply Mopar8 Door Ease, or equivalent, stick lubricant to
outside surface of bearing cup.
Pinion Front Bearing Cup Installation
5. Install the pinion front bearing cup with: -
Installer D-130 and Handle C-4171 for the 8 1/4 axle.
- Installer D-129 and Handle C-4171 for the 9 1/4 axle.
6. Install pinion front bearing, and oil slinger, if equipped. 7. Apply a light coating of gear lubricant
on the lip of pinion seal. Install seal with:
Pinion Seal Installation-8 1/4 Axle
- Installer C-4076-B and Handle C-4735-1 for the 8 1/4 axle.
- Installer C-3860-A and Handle C-4171 for the 9 1/4 axle.
NOTE: Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to
achieve proper ring and pinion gear mesh. If the factory installed ring and pinion gears are reused,
the pinion depth shim should not require replacement. If required, refer to Pinion Gear Depth to
select the proper thickness shim before installing rear pinion bearing.
8. Place the proper thickness depth shim on the pinion gear.
Shaft Rear Bearing Installation
9. Install the rear bearing and slinger, if equipped, on the pinion gear with: -
Installer 6448 for the 8 1/4 axle.
- Installer C-3095 for the 9 1/4 axle.

Collapsible Preload Spacer
10. Install a new collapsible pre-load spacer on pinion shaft and install pinion gear in housing. 11.
Install pinion gear in housing. 12. Install yoke with Installer C-3718 and Yoke Holder 6719. 13.
Install the yoke washer and a new nut on the pinion gear and tighten the pinion nut until there is
zero bearing end-play. It will not be possible at
this point to achieve zero bearing end-play if a new collapsible spacer was installed.
14. Tighten the nut to 285 Nm (210 ft. lbs.).
CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never
exceed specified pre-load torque. If pre-load torque or rotating torque is exceeded a new
collapsible spacer must be installed. The torque sequence will then have to be repeated.
15. Using Yoke Holder 6719, crush collapsible spacer until bearing end play is taken up.
Check Pinion Gear Rotating Torque
16. Slowly tighten the nut in 6.8 Nm (5 ft. lbs.) increments until the desired rotating torque is
achieved. Measure the rotating torque frequently to
avoid over crushing the collapsible spacer.
17. Check bearing rotating torque with an inch pound torque wrench. The torque necessary to
rotate the pinion gear should be:
- Original Bearings - 1 to 3 Nm (10 to 20 inch lbs.).
- New Bearings - 2 to 5 Nm (15 to 35 inch lbs.).
18. Install propeller shaft. 19. Install differential in housing.

Pinion Gear: Service and Repair Rear Axle - 248RBI
NOTE: The ring and pinion gears are service in a matched set. Do not replace the pinion gear
without replacing the ring gear.
REMOVAL
1. Remove differential assembly from axle housing. 2. Mark pinion yoke and propeller shaft for
installation alignment. 3. Disconnect propeller shaft from pinion yoke. Using suitable wire, tie
propeller shaft to underbody. 4. Using Yoke Holder 6719 to hold yoke, remove the pinion yoke nut
and washer.
Pinion Yoke Removal
5. Using Remover C-452 and Wrench C-3281, remove the pinion yoke from pinion shaft.
Remove Pinion Gear
6. Remove the pinion gear from housing. Catch the pinion with your hand to prevent it from falling
and being damaged. 7. Remove the pinion seal with a slide hammer or suitable pry bar. 8. Remove
oil slinger, if equipped, and the front pinion bearing.
Front Bearig Cup Removal
9. Remove the front pinion bearing cup with Remover D-158 and Handle C-4171.
Rear Bearing Cup Removal
10. Remove the rear bearing cup from housing. Use Remover D-162 and Handle C-4171.
Collapsible Spacer
11. Remove the collapsible pre-load spacer.
Inner Bearing Removal
12. Remove the rear bearing from the pinion with Puller/Press C-293-PA and Adapters C-293-37.
Place 4 adapter blocks so they do not damage the bearing cage.
13. Remove the pinion depth shims from the pinion gear shaft. Record the total thickness of the
depth shims.
INSTALLATION
Pinion Rear Bearing Cup Installation
1. Apply MOPAR(r) Door Ease stick lubricant to outside surface of bearing cup. Install the pinion
rear bearing cup with Installer D-111 and Handle
C-4171. Ensure cup is correctly seated.
Pinion Front Bearing Cup Installation
2. Apply MOPAR(r) Door Ease stick lubricant to outside surface of bearing cup. Install the pinion
front bearing cup with Installer D-146 and Handle
C-4171.
3. Install pinion front bearing and oil slinger, if equipped. Apply a light coating of gear lubricant on
the lip of pinion seal.
Pinion Seal Installation
4. Install seal with Installer 8108 and Handle C-4171.
NOTE: Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to
achieve proper ring and pinion gear mesh. If the
factory installed ring and pinion gears are reused, the pinion depth shim should not require
replacement or adjustment. Refer to Pinion Gear Depth paragraph to select the proper thickness
shim before installing rear pinion bearing cone.
5. Place the proper thickness pinion depth shim on the pinion gear.
Shaft Rear Bearing Installation
6. Install the rear bearing and oil slinger, if equipped, on the pinion gear with Installer C-3095-A.
Collapsible Preload Spacer
7. Install a new collapsible pre-load spacer on pinion shaft. 8. Install pinion gear in housing.
Pinion Yoke Installation
9. Install yoke with Installer C-3718 and Yoke Holder 6719.
10. Install the yoke washer and a new nut on the pinion gear. Tighten the nut to 292 Nm (215 ft.
lbs.) minimum. Do not over-tighten. Maximum
torque is 447 Nm (330 ft. lbs.).
CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing pre-load torque and
never exceed specified pre-load torque. If pre-load torque is exceeded a new collapsible spacer
must be installed. The torque sequence will have to be repeated.
Tightening Pinion Nut
11. Using Yoke Holder 6719, and a torque wrench set at 447 Nm (330 ft. lbs.), crush collapsible
spacer until bearing end play is taken up.
Check Pinion Gear Rotation Torque
12. Slowly tighten the nut in 6.8 Nm (5 ft. lbs.) increments until the rotating torque is achieved.
Measure the rotating torque frequently to avoid over
crushing the collapsible spacer.
13. Check bearing rotating torque with an inch pound torque wrench. The torque necessary to
rotate the pinion gear should be:
- Original Bearings - 1 to 3 Nm (10 to 20 inch lbs.).
- New Bearings - 2 to 5 Nm (15 to 35 inch lbs.).
14. Align previously made marks on Yoke and propeller shaft and install propeller shaft. 15. Install
differential housing into the axle housing.
Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Specifications > Rear Axle - 9 1/4
Ring Gear: Specifications Rear Axle - 9 1/4
Ring Gear:
Diameter ..............................................................................................................................................
........................................ 23.50 cm (9.25 inch) Backlash ...................................................................
............................................................................................... 0.12-0.20 mm (0.005-0.008 inch)
Runout .................................................................................................................................................
.................................... 0.127 mm (0.005 inch)
Ring Gear Bolt .....................................................................................................................................

............................................ 157 Nm (11.5 ft. lbs.)
Information > Specifications > Rear Axle - 9 1/4 > Page 3937
Ring Gear: Specifications Rear Axle - 248RBI
Ring Gear:
Diameter ..............................................................................................................................................
........................................ 24.76 cm (9.75 inch)
Ring Gear Bolt .....................................................................................................................................

.............................. 163-190 Nm (120-140 ft. lbs.)
Information > Specifications > Rear Axle - 9 1/4 > Page 3938
Ring Gear: Specifications 8 1/4 Axle
Ring Gear:
Diameter ..............................................................................................................................................
........................................ 20.95 cm (8.25 inch) Backlash ...................................................................
............................................................................................. 0.12-0.20 mm (0.005-01.008 inch)
Runout .................................................................................................................................................
.................................... 0.127 mm (0.005 inch)
Ring Gear Bolt .....................................................................................................................................

............................................... 102 Nm (75 ft. lbs.)
Information > Adjustments > Rear Axle - 8 1/4 and 9 1/4
Ring Gear: Adjustments Rear Axle - 8 1/4 and 9 1/4

GEAR CONTACT PATTERN ANALYSIS
The ring and pinion gear teeth contact patterns will show if the pinion gear depth is correct in the
axle housing. It will also show if the ring gear backlash has been adjusted correctly. The backlash
can be adjusted within specifications to achieve desired tooth contact patterns. 1. Apply a thin coat
of hydrated ferric oxide, or equivalent, to the drive and coast side of the ring gear teeth. 2. Wrap,
twist, and hold a shop towel around the pinion yoke to increase the turning resistance of the pinion
gear. This will provide a more distinct
contact pattern.
3. Using a boxed end wrench on a ring gear bolt, Rotate the differential case one complete
revolution in both directions while a load is being applied
from shop towel.

Information > Adjustments > Rear Axle - 8 1/4 and 9 1/4 > Page 3941
Gear Tooth Contact Patterns
The areas on the ring gear teeth with the greatest degree of contact against the pinion gear teeth
will squeegee the compound to the areas with the least amount of contact. Note and compare
patterns on the ring gear teeth to Gear Tooth Contact Patterns chart and adjust pinion depth and
gear backlash as necessary.
Ring Gear: Adjustments Rear Axle - 248RBI
GEAR CONTACT PATTERN ANALYSIS
The ring and pinion gear teeth contact patterns will show if the pinion gear depth is correct in the
axle housing. It will also show if the ring gear backlash has been adjusted correctly. The backlash
can be adjusted within specifications to achieve desired tooth contact patterns. 1. Apply a thin coat
of hydrated ferric oxide, or equivalent, to the drive and coast side of the ring gear teeth. 2. Wrap,
twist, and hold a shop towel around the pinion yoke to increase the turning resistance of the pinion
gear. This will provide a more distinct
contact pattern.
3. Using a boxed end wrench on a ring gear bolt, rotate the differential case one complete
revolution in both directions while a load is being applied
from shop towel.

Gear Tooth Contact Patterns
The areas on the ring gear teeth with the greatest degree of contact against the pinion gear teeth
will squeegee the compound to the areas with the least amount of contact. Note and compare
patterns on the ring gear teeth to Gear Tooth Contact Patterns chart and adjust pinion depth and
gear backlash as necessary.
Ring Gear: Service and Repair Rear Axle - 8 1/4 and 9 1/4
NOTE: The ring and pinion gears are serviced in a matched set. Do not replace the ring gear
without replacing the pinion gear.
REMOVAL
1. Remove differential from axle housing.
Ring Gear Removal
2. Place differential case in a suitable vise with soft metal jaw protectors. 3. Remove bolts holding
ring gear to differential case. 4. Using a soft hammer, drive ring gear from differential case. 5. Use
a brass drift and slowly tap the exciter ring from the differential case.
INSTALLATION
CAUTION: Do not reuse the bolts that held the ring gear to the differential case. The bolts can
fracture causing extensive damage.
1. Invert the differential case. 2. Position exciter ring on differential case. 3. Using a brass drift,
slowly and evenly tap the exciter ring into position. 4. Position ring gear on the differential case and
start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. 5. Invert the
differential case in the vise.
Ring Gear Bolt Installation
6. Install new ring gear bolts and alternately tighten to 157 Nm (115 ft. lbs.) torque. 7. Install
differential in axle housing and verify gear mesh and contact pattern.
Ring Gear: Service and Repair Rear Axle - 248RBI
The ring and pinion gears are service in a matched set. Do not replace the ring gear without
replacing the pinion gear.
REMOVAL
1. Remove differential from axle housing.
Ring Gear Removal
2. Place differential case in a suitable vise with soft metal jaw protectors. 3. Remove bolts holding
ring gear to differential case. 4. Using a soft hammer, drive ring gear from differential case. 5. Use
a brass drift and slowly tap the exciter ring from the differential case.
INSTALLATION
CAUTION: Do not reuse the bolts that held the ring gear to the differential case. The bolts can
fracture causing extensive damage.
1. Invert the differential case. 2. Position exciter ring on differential case. 3. Using a brass drift,
slowly and evenly tap the exciter ring into position. 4. Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt hole alignment. 5. Invert the differential case in
the vise.
Ring Gear Bolt Installation
6. Install new ring gear bolts and alternately tighten to 163-190 Nm (120-140 ft. lbs.) torque. 7.
Install differential in axle housing and verify gear mesh and contact pattern.
Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential >
System Information > Service and Repair > Rear Axle - 8 1/4 or 9 1/4
Seals and Gaskets: Service and Repair Rear Axle - 8 1/4 or 9 1/4
REMOVAL
1. Raise and support the vehicle. 2. Scribe a mark on the universal joint, pinion yoke, and pinion
shaft for reference. 3. Disconnect the propeller shaft from the pinion yoke. Secure the propeller
shaft in an upright position to prevent damage to the rear universal joint. 4. Remove the wheel and
tire assemblies. 5. Remove the brake drums to prevent any drag. The drag may cause a false
bearing rotating torque measurement. 6. Rotate the pinion yoke three or four times. 7. Measure the
amount of torque necessary to rotate the pinion gear with a (inch lbs.) dial-type torque wrench.
Record the torque reading for
installation reference.
8. Hold the yoke with Wrench 6719. Remove the pinion shaft nut and washer.
Yoke Removal
9. Remove the yoke with Remover C-452.
10. Remove the pinion shaft seal with suitable pry tool or slide-hammer mounted screw.
INSTALLATION
1. Clean the seal contact surface in the housing bore. 2. Examine the splines on the pinion shaft for
burrs or wear. Remove any burrs and clean the shaft. 3. Inspect pinion yoke for cracks, worn
splines and worn seal contact surface. Replace yoke if necessary.
NOTE: The outer perimeter of the seal is pre-coated with a special sealant. An additional
application of sealant is not required.
4. Apply a light coating of gear lubricant on the lip of pinion seal. 5. Install the new pinion shaft seal
with:
8 1/4 Axle Pinion Seal Installation
- 8 1/4 axle: Installer C-4076-B and Handle C-4735-1.
- 9 9 1/4 axle: Installer C-3860-A and Handle C-4171.
NOTE: The seal is correctly installed when the seal flange contacts the face of the differential
housing flange.
System Information > Service and Repair > Rear Axle - 8 1/4 or 9 1/4 > Page 3951
6. Position the pinion yoke on the end of the shaft with the reference marks aligned. 7. Seat yoke
on pinion shaft with Installer C-3718 and Wrench 6719. 8. Remove the tools and install the pinion
yoke washer. The convex side of the washer must face outward.
CAUTION: Do not exceed the minimum tightening torque when installing the pinion yoke retaining
nut at this point. Damage to collapsible spacer or bearings may result.
Tightening Pinion Shaft Nut
9. Hold pinion yoke with Yoke Holder 6719 and tighten shaft nut to 285 Nm (210 ft. lbs.). Rotate
pinion shaft several revolutions to ensure the
bearing rollers are seated.
Check Pinion Rotation Torque
10. Rotate the pinion shaft using an (inch lbs.) torque wrench. Rotating torque should be equal to
the reading recorded during removal, plus an
additional 0.56 Nm (5 inch lbs.) .
exceed specified pre-load torque. If pre-load torque is exceeded a new collapsible spacer must be
installed. The torque sequence will then have to be repeated.
11. If the rotating torque is low, use Yoke Holder 6719 to hold the pinion yoke and tighten the
pinion shaft nut in 6.8 Nm (5 ft. lbs.) increments until
proper rotating torque is achieved.

NOTE: The bearing rotating torque should be constant during a complete revolution of the pinion. If
the rotating torque varies, this indicates a binding condition.
12. The seal replacement is unacceptable if the final pinion nut torque is less than 285 Nm (210 ft.
lbs.). 13. Install the propeller shaft with the installation reference marks aligned. 14. Tighten the
universal joint yoke clamp screws to 19 Nm (14 ft. lbs.). 15. Install the brake drums. 16. Install
wheel and tire assemblies and lower the vehicle. 17. Check the differential housing lubricant level.
Seals and Gaskets: Service and Repair Rear Axle - 248RBI
REMOVAL
1. Raise and support the vehicle. 2. Scribe a mark on the universal joint, pinion yoke, and pinion
shaft for reference. 3. Disconnect the propeller shaft from the pinion yoke. Secure the propeller
shaft in an upright position to prevent damage to the rear universal joint. 4. Remove the wheel and
tire assemblies. 5. Remove the brake drums to prevent any drag. The drag may cause a false
bearing pre-load torque measurement. 6. Rotate the pinion yoke three or four times. 7. Measure
the amount of torque necessary to rotate the pinion gear with a (inch lbs.) dial-type torque wrench.
Record the torque reading for
installation reference.
8. Hold the yoke with Wrench 6719, Remove the pinion shaft nut and washer.
Yoke Removal
9. Remove the yoke with Remover C-452.
10. Remove the pinion shaft seal with suitable pry tool or slide-hammer mounted screw.
INSTALLATION
1. Clean the seal contact surface in the housing bore. 2. Examine the splines on the pinion shaft for
burrs or wear. Remove any burrs and clean the shaft. 3. Inspect pinion yoke for cracks, worn
splines and worn seal contact surface. Replace yoke if necessary.
NOTE: The outer perimeter of the seal is pre-coated with a special sealant. An additional
application of sealant is not required.
4. Apply a light coating of gear lubricant on the lip of pinion seal.
Pinion Seal Installation
5. Install the new pinion shaft seal with Installer 8108 and Handle 4171.
NOTE: The seal is correctly installed when the seal flange contacts the face of the differential
housing flange.
6. Position the pinion yoke on the end of the shaft with the reference marks aligned. 7. Seat yoke
on pinion shaft with Installer C-3718 and Wrench 6719.
8. Remove the tools and install the pinion yoke washer.
CAUTION: Do not exceed the minimum tightening torque when installing the pinion yoke retaining
nut at this point. Damage to collapsible spacer or bearings may result.
Tightening Pinion Shaft Nut
9. Hold pinion yoke with Yoke Holder 6719 and tighten shaft nut to 291.5 Nm (215 ft. lbs.). Rotate
pinion shaft several revolutions to ensure the
bearing rollers are seated.
Check Pinion Rotation Torque
10. Rotate the pinion shaft using a (inch lbs.) torque wrench. Rotating resistance torque should be
equal to the reading recorded during removal, plus
an additional 0.56 Nm (5 inch lbs.).
exceed specified pre-load torque. If pre-load torque is exceeded a new collapsible spacer must be
installed. The torque sequence will then have to be repeated.
11. If the rotating torque is low, use Yoke Holder 6719 to hold the pinion yoke and tighten the
pinion shaft nut in 6.8 Nm (5 ft. lbs.) increments until
proper rotating torque is achieved.
NOTE: The bearing rotating torque should be constant during a complete revolution of the pinion. If
the rotating torque varies, this indicates a binding condition.
12. Install the propeller shaft with the installation reference marks aligned. 13. Tighten the universal
joint yoke clamp screws to 19 Nm (14 ft. lbs.). 14. Install the brake drums. 15. Add gear lubricant to
the differential housing, if necessary. Refer to the Lubricant Specifications for gear lubricant
requirements. 16. Install wheel and tire assemblies and lower the vehicle.
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component
Information > Technical Service Bulletins > Customer Interest for Axle Bearing: > 05-07-98 > Feb > 99 > Brakes -
Vibration/Shudder on Application
Brakes - Vibration/Shudder on Application
NO: 05-07-98
GROUP: Brakes
DATE: Feb. 1, 1999
SUBJECT: Vehicle Vibrates/Shudders When Brakes Are Applied
MODELS:
1998 (AB) Ram Van/Wagon
NOTE:
THIS BULLETIN APPLIES TO 250013500 RAM VANS EQUIPPED WITH THE 9.25 HD AXLE
(SALES CODE DRG).
SYMPTOM/CONDITION:
Vehicle vibrates/shudders when the brakes are applied.
PARTS REQUIRED:
TIME ALLOWANCE:
Labor Operation No:
03-20-01-94 Remove and Install Axle Shafts, Measure Drum Diameter and Runout, Adjust Rear
Brakes, Adjust Parking Brake Brake
1.0 Hrs.
Related Operations:
NOTE:
OPERATIONS INCLUDE REPLACING BRAKE DRUMS WHEN NECESSARY.
03-20-20-50 Replace Axle Bearing and Seal, Right Side 0.2 Hrs.
03-20-20-51 Replace Axle Bearing and Seal, Left Side 0.2 Hrs.
03-20-26-50 Replace Axle Seal, Right Side 0.1 Hrs.
03-20-26-51 Replace Axle Seal, Left Side 0.1 Hrs.
05-70-06-59 Replace Brake Shoes And Linings 0.4 Hrs.
05-20-26-51 Resurface One Brake Drum 0.4 Hrs.

Vibration/Shudder on Application > Page 3965
05-20-26-52 Resurface Both Brake Drums 0.7 Hrs.
Diagnosis
1. Drive the vehicle at a safe speed and apply the service brakes. If the vehicle does not
vibrate/shudder until the brakes are applied, proceed to the next step. If the vehicle
vibrates/shudder regardless of service brake operation, refer to the 1998 Ram Van Service Manual
(Publication No. 81-370-8107) for noise and vibration diagnosis in Groups 02, 03, 05, 09, 11, 19,
and 22.
2. Drive the vehicle at a safe speed in area free of traffic. Lightly apply the parking brake. If the
vehicle vibrates/shudder while the parking brake is applied, proceed to the next step. If the vehicle
does not vibrate/shudder while the parking brake is applied, refer to the 1998 Ram Van Service
Manual (Publication No. 81-370-8107) for front brake vibration diagnosis in Group 05.
3. Raise the vehicle on a suitable hoist.
NOTE:
MAKE SURE THE PARKING BRAKE IS NOT APPLIED PRIOR TO LIFTING THE VEHICLE ON A
HOIST.
4. Remove both right and left rear tire/wheel assemblies.
5. Remove both right and left rear brake drums.
6. Using a 100 - 125 mm (4-5 in.) micrometer or vernier caliper, measure the diameter of the brake
drum pilot on the axle shaft (Figure 1).
7. If the brake drum pilot is less than 122.7 mm (4.830 in.) (Figure 2), perform the Repair
Procedure. If the brake drum pilot is equal to or greater than 122.7 mm (4.830 in.), refer to the 1998
Ram Van Service Manual (Publication No. 81-370- 8107), pages 5-5 through 5-11 for information
regarding brake system Diagnosis and Testing.
Repair Procedure
This bulletin involves installing revised axle shafts and if necessary brake linings and drums.
1. Clean all foreign material from the axle housing cover area.
2. Position a drain pan under the axle housing cover area.
3. Loosen housing cover bolts. Drain the lubricant from the housing and axle shaft tubes. Remove
the housing cover.
4. Remove the original sealant from the housing and cover surfaces then, clean the cover surfaces
with Mopar Brake parts Cleaner p/n 04549623.
5. Rotate the differential case so that the pinion mate gear shaft lock screw is accessible. Remove
the lock screw and pinion mate gear shaft from the differential case (Figure 3).
6. Push the axle shaft inward and remove the axle shaft C-clip lock from the axle shaft (Figure 4.).
7. Remove axle shaft. Use care to prevent damage to the axle shaft bearing and seal, which will
remain in the axle shaft tube.
CAUTION:
USE EXTREME CARE TO PREVENT SHAFT SPLINES FROM DAMAGING THE AXLE SHAFT
SEAL LIP.
8. Inspect the axle shaft seal for leakage or damage and inspect the roller bearing contact surface
on axle shaft for signs of brinelling, galling, and/or pitting. Replace the seal and/or bearing as
necessary using p/n 04137314 for the seal and p/n 04117858 for the bearing. Refer to the 1998
Ram Van Service Manual (Publication No. 81-370-8107), pages 3-20 and 3-21 for Axle Seal And
Bearing service.
9. Lubricate bearing bore and seal lip with gear lubricant p/n 05010320AA. Insert the new axle
shaft p/n 041 17897AB through the seal and bearing, then engage the axle shaft splines into the
side gear splines.
CAUTION:
SEAL LIP.
10. Insert the C-clip lock onto the end of the axle shaft. Push axle shaft outward to seat the C-clip
lock in the side gear.
11. Perform Steps 6 through 10 to the other axle shaft.
12. Insert pinion mate shaft into differential case and through thrust washers and pinion gears.
13. Align the hole in the shaft with the hole in the differential case. Apply Lock & Seal Adhesive p/n
04318031 to the threads of the pinion mate shaft lock screw and install the lock screw into the
differential case. Tighten the screw to 11 Nm (8 ft. lbs).
14. Apply a bead of Mopar Silicone Sealant p/n 82300234 to the housing cover (Figure 5). The
silicone sealant must be applied to all mating surfaces of the cover including around the cover bolt
holes.
NOTE:
INSTALL THE COVER WITHIN FIVE MINUTES AFTER APPLYING THE SEALANT.
15. Install the cover and any identification tag. Tighten the cover attaching bolts to 44 Nm (33 ft.
lbs.).
16. Fill the differential with 2.32 L (4.9 pts.) of Mopar 75W/90 Gear Lubricant p/n 0501 0320AA.
17. Inspect the brake linings on both sides of the vehicle. Replace the brake linings as necessary
using p/n 05003999AA. Refer to the 1998 Ram Van Service Manual (Publication No. 81-370-8107),
pages 5-21 through 5-22 for Rear Brake Shoes - 12 1/8 inch Removal and Installation. Anytime
brake linings are replaced, new brake adjusting lever pins p/n 03492671 must be installed.
18. Measure brake drum diameter and runout. Brake drum diameter must be checked using an
accurate brake drum micrometer. The maximum allowable diameter of the drum braking surface is
indicated on the drum outer edge. Brake drum runout must be checked by mounting the drum onto
a brake lathe and checking variation using a dial indicator. Variation in drum diameter should not
exceed 0.076 mm (0.003 in.). Drum runout should not exceed 0.20 mm (0.008 in.) out of round. If
the drum exceeds the variation/runout specification but does not exceed the maximum allowable
diameter, resurface the brake drum. If the brake drum exceeds the maximum allowable diameter,
replace the brake drum with p/n 5200951 9AC. If the brake drum is less than the maximum
allowable variation/runout and the diameter of the drum is less than the maximum specification and
there is not any major scoring in the drum, the drum can be reused.
19. Adjust brake shoes to brake drum using a brake gauge. Refer to the 1998 Ram Van Service
Manual (Publication No. 81-370-8107), pages 5-29
and 5-30 for information regarding proper brake shoe adjustment.
20. Install the brake drum onto the vehicle.
21. Install the tire and wheels onto the vehicle. Refer to the 1998 Ram Van Service Manual
(Publication No. 81-370-8107), pages 22-8 and 22-9 for proper tire/wheel installation.
22. Adjust the park brake cable tension. Refer to the 1998 Ram Van Service Manual (Publication
No. 81-370-8107), pages 5-30 and 5-31 for information regarding proper parking brake cable
tension adjustment.

Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Bearing: > 05-07-98 > Feb > 99 > Brakes
- Vibration/Shudder on Application
NO: 05-07-98
GROUP: Brakes
DATE: Feb. 1, 1999
MODELS:
NOTE:
(SALES CODE DRG).
SYMPTOM/CONDITION:
PARTS REQUIRED:
TIME ALLOWANCE:
Labor Operation No:
1.0 Hrs.
Related Operations:
NOTE:

- Vibration/Shudder on Application > Page 3974
Diagnosis
and 22.
NOTE:
HOIST.
Repair Procedure
the housing cover.
CAUTION:
SEAL LIP.
Bearing service.
side gear splines.
CAUTION:
SEAL LIP.
holes.
NOTE:
lbs.).
tension adjustment.

Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 05-07-98 > Feb > 99 >
NO: 05-07-98
GROUP: Brakes
DATE: Feb. 1, 1999
MODELS:
NOTE:
(SALES CODE DRG).
SYMPTOM/CONDITION:
PARTS REQUIRED:
TIME ALLOWANCE:
Labor Operation No:
1.0 Hrs.
Related Operations:
NOTE:

Brakes - Vibration/Shudder on Application > Page 3987
Diagnosis
and 22.
NOTE:
HOIST.
Repair Procedure
the housing cover.
CAUTION:
SEAL LIP.
Bearing service.
side gear splines.
CAUTION:
SEAL LIP.
holes.
NOTE:
lbs.).
tension adjustment.

Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: > 05-07-98 >
Feb > 99 > Brakes - Vibration/Shudder on Application
NO: 05-07-98
GROUP: Brakes
DATE: Feb. 1, 1999
MODELS:
NOTE:
(SALES CODE DRG).
SYMPTOM/CONDITION:
PARTS REQUIRED:
TIME ALLOWANCE:
Labor Operation No:
1.0 Hrs.
Related Operations:
NOTE:

Feb > 99 > Brakes - Vibration/Shudder on Application > Page 3996
Diagnosis
and 22.
NOTE:
HOIST.
Repair Procedure
the housing cover.
CAUTION:
SEAL LIP.
Bearing service.
side gear splines.
CAUTION:
SEAL LIP.
holes.
NOTE:
lbs.).
tension adjustment.

Shaft > Component Information > Service and Repair > 8-1/4 and 9-1/4 Axle
Axle Shaft: Service and Repair 8-1/4 and 9-1/4 Axle
REMOVAL
1. Raise and support vehicle. Ensure that the transmission is in neutral. 2. Remove wheel and tire
assembly. 3. Remove brake drum. Refer to Brakes, for proper procedure. 4. Clean all foreign
material from housing cover area. 5. Loosen housing cover bolts. Drain lubricant from the housing
and axle shaft tubes. Remove housing cover.
Mate Shaft Lock Screw
6. Rotate differential case so that pinion mate gear shaft lock screw is accessible. Remove lock
screw and pinion mate gear shaft from differential
case.
Axle Shaft C-Clip Lock
7. Push axle shaft inward and remove axle shaft C-clip lock from the axle shaft. 8. Remove axle
shaft. Use care to prevent damage to axle shaft bearing and seal, which will remain in axle shaft
tube. 9. Inspect axle shaft seal for leakage or damage.
10. Inspect roller bearing contact surface on axle shaft for signs of brinelling, galling and pitting. If
any of these conditions exist, the axle shaft and/or
bearing and seal must be replaced.
INSTALLATION
1. Lubricate bearing bore and seal lip with gear lubricant. Insert axle shaft through seal, bearing,
and engage it into side gear splines.
NOTE: Use care to prevent shaft splines from damaging axle shaft seal lip.
2. Insert C-clip lock in end of axle shaft. Push axle shaft outward to seat C-clip lock in side gear. 3.
Insert pinion mate shaft into differential case and through thrust washers and pinion gears. 4. Align
hole in shaft with hole in the differential case and install lock screw with Loctite(r) on the threads.
Tighten lock screw to 11 Nm (8 ft. lbs.)
torque.
5. Install cover and add fluid. Refer to Lubricant Change procedure in this section for procedure
and lubricant requirements. 6. Install brake drum. Refer to Brakes, for proper procedures. 7. Install
wheel and tire. 8. Lower vehicle.
Shaft > Component Information > Service and Repair > 8-1/4 and 9-1/4 Axle > Page 4002
Axle Shaft: Service and Repair Rear Axle - 248RBI
CAUTION: RAISE BOTH REAR WHEELS OFF THE SURFACE WHENEVER A REAR AXLE IS
BEING SERVICED.
REMOVAL
1. Remove the axle shaft flange bolts. 2. Slide the axle shaft out from the axle tube.
INSTALLATION
1. Clean the gasket contact surface area on the flange with an appropriate solvent. Install a new
flange gasket and slide the axle shaft into the tube. 2. Install the bolts and tighten to 122 Nm (90 ft.
lbs.).
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 05-07-98 > Feb >
99 > Brakes - Vibration/Shudder on Application
NO: 05-07-98
GROUP: Brakes
DATE: Feb. 1, 1999
MODELS:
NOTE:
(SALES CODE DRG).
SYMPTOM/CONDITION:
PARTS REQUIRED:
TIME ALLOWANCE:
Labor Operation No:
1.0 Hrs.
Related Operations:
NOTE:

99 > Brakes - Vibration/Shudder on Application > Page 4011
Diagnosis
and 22.
NOTE:
HOIST.
Repair Procedure
the housing cover.
CAUTION:
SEAL LIP.
Bearing service.
side gear splines.
CAUTION:
SEAL LIP.
holes.
NOTE:
lbs.).
tension adjustment.

Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: >
05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application
NO: 05-07-98
GROUP: Brakes
DATE: Feb. 1, 1999
MODELS:
NOTE:
(SALES CODE DRG).
SYMPTOM/CONDITION:
PARTS REQUIRED:
TIME ALLOWANCE:
Labor Operation No:
1.0 Hrs.
Related Operations:
NOTE:

05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on Application > Page 4020
Diagnosis
and 22.
NOTE:
HOIST.
Repair Procedure
the housing cover.
CAUTION:
SEAL LIP.
Bearing service.
side gear splines.
CAUTION:
SEAL LIP.
holes.
NOTE:
lbs.).
tension adjustment.

Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
4024
Seals and Gaskets: By Symptom
NO: 05-07-98
GROUP: Brakes
DATE: Feb. 1, 1999
MODELS:
NOTE:
(SALES CODE DRG).
SYMPTOM/CONDITION:
PARTS REQUIRED:
TIME ALLOWANCE:
Labor Operation No:

1.0 Hrs.
Related Operations:
NOTE:

4025
Diagnosis
and 22.
NOTE:
HOIST.
4026
Repair Procedure
the housing cover.
4027
CAUTION:
SEAL LIP.
Bearing service.
side gear splines.
CAUTION:
SEAL LIP.
holes.
NOTE:
lbs.).
4028
tension adjustment.
NO: 05-07-98
GROUP: Brakes
DATE: Feb. 1, 1999
MODELS:
NOTE:
(SALES CODE DRG).
SYMPTOM/CONDITION:
PARTS REQUIRED:
TIME ALLOWANCE:
Labor Operation No:
1.0 Hrs.
Related Operations:
NOTE:

4029
Diagnosis
and 22.
NOTE:
HOIST.
4030
Repair Procedure
the housing cover.
4031
CAUTION:
SEAL LIP.
Bearing service.
side gear splines.
CAUTION:
SEAL LIP.
holes.
NOTE:
lbs.).
4032
tension adjustment.

Axles > System Information > Service and Repair > Rear Axle - 8 1/4 or 9 1/4 Light duty
Seals and Gaskets: Service and Repair Rear Axle - 8 1/4 or 9 1/4 Light duty
REMOVAL
Axle Seal Removal
INSTALLATION
Axles > System Information > Service and Repair > Rear Axle - 8 1/4 or 9 1/4 Light duty > Page 4035
depth.
the axle shaft.
Seals and Gaskets: Service and Repair Rear Axle - 9 1/4 Heavy Duty
REMOVAL
Axle Seal Removal
INSTALLATION
the correct depth.
the axle shaft.
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension
- Wander Diagnosis/Repair
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
- Wander Diagnosis/Repair > Page 4046
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-002-01A >
Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-07-00 > Sep
> 00 > Steering Wander - Diagnosis and Correction Revised
Revised
NUMBER: 19-07-00
GROUP: Steering

following:
NOTE:
DIAGNOSIS:
box).
NOTE:
NOTE:
ROADS, ETC.).

> 00 > Steering Wander - Diagnosis and Correction Revised > Page 4061
NOTE:

new cotter pin.
> 00 > Steering Wander - Diagnosis and Correction Revised > Page 4062
specifications.
NOTE:
VAN/WAGONS.

Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Bearing: > 19-07-00 > Sep >
00 > Steering Wander - Diagnosis and Correction Revised
Revised
NUMBER: 19-07-00
GROUP: Steering

following:
NOTE:
DIAGNOSIS:
box).
NOTE:
NOTE:
ROADS, ETC.).

00 > Steering Wander - Diagnosis and Correction Revised > Page 4068
NOTE:

new cotter pin.
00 > Steering Wander - Diagnosis and Correction Revised > Page 4069
specifications.
NOTE:
VAN/WAGONS.

Lubricant Type

Component Information > Service and Repair > Front
REMOVAL
during removal).
INSTALLATION
Component Information > Service and Repair > Front > Page 4073
8 1/4 and 9 1/4 Axles
REMOVAL
Axle Seal Removal
INSTALLATION
depth.
the axle shaft.
With 9 1/4 Axle
REMOVAL
Axle Seal Removal

INSTALLATION
the correct depth.
the axle shaft.
248 RBI Axle
REMOVAL
INSTALLATION
adjustment nut.
Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 03-07-98 >
Dec > 98 > Axle - Noise/Whine Between 35 and 55 MPH
Drive/Propeller Shaft: Customer Interest Axle - Noise/Whine Between 35 and 55 MPH
NO: 03-07-98
GROUP: Axle And Propshafts
DATE: Dec. 11, 1998
SUBJECT: Axle Noise/Whine Between 35 And 55 MPH
MODELS:
1998 - 1999 (AB) Ram Van
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 9-1/4 OR DANA 60 (248RBI)

AXLE BUILT PRIOR TO OCT. 1, 1998 (MDH1001XX).
SYMPTOM/CONDITION:
Some vehicles may exhibit axle noise in the 35 to 55 mile per hour range.
DIAGNOSIS:
Drive the vehicle on a smooth road and listen for axle noise in the 35 to 55 mile per hour range.
Note if the noise is heard during drive or coast. The 9-1/4 axle noise may be heard during coast
conditions and the Dana 60 (248RBI) may be heard during drive conditions. If noise is heard,
PARTS REQUIRED:
AR 82300234 Sealant, Adhesive (Grey)
AR 05010320AA Lube, 75W90 Gear
AR(1) 52105679AB Shaft, Prop (9-1/4 Axle)
AR(1) 52105678AB Shaft, Prop (Dana 60/248 RBI)
REPAIR PROCEDURE:
This bulletin involves checking gearset backlash, gear pattern, and replacing the prop shaft with a
new torsionally damped part.
1. Drain the axle lube and remove the axle cover. Following service manual procedures, check the
gearset for backlash and gear pattern. If proper backlash and gear pattern is found, proceed with
the remaining steps. If improper backlash or gear pattern is found, make adjustments following
standard procedures.
2. Following service manual procedures, remove the prop shaft.
3. Install p/n 52105679AB (9-1/4) or 52105678AB (Dana 60/248RBI) into the vehicle.
4. Road test the vehicle to confirm that the noise is minimized or gone.
5. If the noise is still heard, further axle diagnosis and repair will be required.
TIME ALLOWANCE:

Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
03-07-98 > Dec > 98 > Axle - Noise/Whine Between 35 and 55 MPH
Drive/Propeller Shaft: All Technical Service Bulletins Axle - Noise/Whine Between 35 and 55 MPH
NO: 03-07-98
GROUP: Axle And Propshafts
DATE: Dec. 11, 1998
SUBJECT: Axle Noise/Whine Between 35 And 55 MPH
MODELS:
1998 - 1999 (AB) Ram Van
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 9-1/4 OR DANA 60 (248RBI)

AXLE BUILT PRIOR TO OCT. 1, 1998 (MDH1001XX).
SYMPTOM/CONDITION:
Some vehicles may exhibit axle noise in the 35 to 55 mile per hour range.
DIAGNOSIS:
Drive the vehicle on a smooth road and listen for axle noise in the 35 to 55 mile per hour range.
Note if the noise is heard during drive or coast. The 9-1/4 axle noise may be heard during coast
conditions and the Dana 60 (248RBI) may be heard during drive conditions. If noise is heard,
PARTS REQUIRED:
AR 82300234 Sealant, Adhesive (Grey)
AR 05010320AA Lube, 75W90 Gear
AR(1) 52105679AB Shaft, Prop (9-1/4 Axle)
AR(1) 52105678AB Shaft, Prop (Dana 60/248 RBI)
REPAIR PROCEDURE:
This bulletin involves checking gearset backlash, gear pattern, and replacing the prop shaft with a
new torsionally damped part.
1. Drain the axle lube and remove the axle cover. Following service manual procedures, check the
gearset for backlash and gear pattern. If proper backlash and gear pattern is found, proceed with
the remaining steps. If improper backlash or gear pattern is found, make adjustments following
standard procedures.
2. Following service manual procedures, remove the prop shaft.
3. Install p/n 52105679AB (9-1/4) or 52105678AB (Dana 60/248RBI) into the vehicle.
4. Road test the vehicle to confirm that the noise is minimized or gone.
5. If the noise is still heard, further axle diagnosis and repair will be required.
TIME ALLOWANCE:

Shaft > Component Information > Service and Repair > Procedures
Drive/Propeller Shaft: Procedures
PROPELLER SHAFT
1. Clean all universal joint bores with cleaning solvent and a wire brush. 2. Inspect the yokes for
distortion, cracks, and worn bearing cap bores.
Shaft > Component Information > Service and Repair > Procedures > Page 4092
Drive/Propeller Shaft: Removal and Replacement
REMOVAL
1. Raise and support vehicle on safety stands. 2. Shift the transmission to the Neutral position. 3.
Using a suitable marker, mark a line across the axle pinion yoke and the propeller shaft yoke for
installation reference. 4. Remove the bolts holding the universal joint clamps to the pinion yoke.
Rear Propeller Shaft
5. Slide the slip yoke off of the transmission output shaft and remove the propeller shaft.
INSTALLATION
1. Slide the slip yoke onto the transmission output shaft. 2. Align the installation reference marks
made on the propeller shaft and pinion yoke. 3. Position universal joint into pinion yoke. 4. Install
the universal joint clamp and clamp bolts to the pinion yoke. Tighten bolts to 19 Nm (14 ft. lbs.). 5.
Lower the vehicle.
Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Removal and Replacement
Universal Joint: Removal and Replacement
UNIVERSAL JOINT REPLACEMENT
Single cardan universal joint components are not serviceable. If worn or leaking, they must be
replaced as a unit.
REMOVAL
Reference Marks On Yoke
1. Scribe reference marks on the propeller shaft yokes, axle yoke, and transmission yoke before
removal or component service. This will ensure
correct phasing and eliminate possible vibration.
2. Remove the propeller shaft. 3. Using a soft drift, tap the outside of the bearing assembly to
loosen snap ring.
Remove Snap Ring
4. Remove snap rings from both sides of yoke.

Drive/Propeller Shaft > Component Information > Service and Repair > Removal and Replacement > Page 4097
Press Out Bearing
5. Set the yoke in an arbor press or vise with a large socket beneath it. If joint is a replacement with
a lube fitting position the yoke with the lube
fitting pointing up. Place a smaller socket on the upper bearing assembly and press it through to
release the lower bearing assembly.
6. If the bearing assembly will not pull out by hand after pressing, tap the base of the lug near it to
dislodge.
Press Out Remaining Bearing
7. To remove the opposite bearing, turn the yoke over and straighten the cross in the open hole.
Then carefully press the end of the cross until the
remaining bearing can be removed.
CAUTION: If the cross or bearing assembly are cocked when being pressed, the bearing assembly
will score the walls of the yoke bore and ruin the yoke.
INSTALLATION
1. Clean all the universal joint yoke bores with cleaning solvent and a wire brush. 2. Inspect the
yokes for distortion, cracks and worn bearing assembly bores. 3. Apply Extreme Pressure (EP)
N.L.G.I. Grade 1 or 2 grease to aid in installation.
Install Cross In Yoke
4. If the replacement joint has a lube fitting position the cross in the yoke with the fitting pointing up.
Install Bearing On Trunnion
5. Place a bearing assembly over the trunnion and align it with the cross hole. Keep the needle
bearings upright in the bearing assembly. A needle
roller lying at the bottom will prevent proper assembly.
6. Press the bearing assembly into the cross hole enough to install a snap ring. Install a snap ring.
7. Place opposite bearing assembly over the trunnion and align it with the cross hole. 8. Press the
bearing assembly into the cross hole enough to install a snap ring. Install a snap ring. 9. Add
grease to lube fitting, if equipped.
10. Install the propeller shaft.

Universal Joint: Overhaul
DISASSEMBLY
Individual components of cardan universal joints are not serviceable. If worn or leaking, they must
be replaced as an assembly. 1. Remove the propeller shaft. 2. Using a soft drift, tap the outside of
the bearing cap to loosen snap-ring.
Remove Snap-Ring
3. Remove snap-rings from both sides of yoke. 4. Set the yoke in an arbor press or vise with a
socket whose inside diameter is large enough to receive the bearing cap positioned beneath the
yoke. 5. Position the yoke with the grease fitting, if equipped, pointing up.
Press Out Bearing
6. Place a socket with an outside diameter smaller than the upper bearing cap on the upper
bearing cap and press the cap through the yoke to release
the lower bearing cap.
7. If the bearing cap will not pull out of the yoke by hand after pressing, tap the yoke ear near the
bearing cap to dislodge the cap.
Press Out Remaining Bearing
8. To remove the opposite bearing cap, turn the yoke over and straighten the cross in the open
hole. Then, carefully press the end of the cross until
the remaining bearing cap can be removed.
CAUTION: If the cross or bearing cap are not straight during installation, the bearing cap will score
the walls of the yoke bore and damage can occur.
ASSEMBLY
1. Apply Extreme Pressure (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores to aid in
installation.
Install Cross In Yoke
2. Position the cross in the yoke with its lube fitting, if equipped, pointing up.
Install Bearing On Trunnion
3. Place a bearing cap over the trunnion and align the cap with the yoke bore. Keep the needle
bearings upright in the bearing cap. A needle bearing
lying at the bottom of the cap will prevent proper assembly.
4. Press the bearing cap into the yoke bore enough to install a snap ring. 5. Install a snap ring. 6.
Repeat Step 4 and Step 5 to install the opposite bearing cap. If the joint is stiff or binding, strike the
yoke with a soft hammer to seat the needle
bearings.
7. Add grease to lube fitting, if equipped. 8. Install the propeller shaft

Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications
Bolt, Driveplate-to-Crankshaft .............................................................................................................

.................................................... 75 Nm (55 ft. lbs.)
Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps
and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation
SYSTEM OPERATION
Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps
and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Page 4110

INJURY.
as required.
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set
NUMBER: 21-04-00
GROUP: Transmission
DATE: June 3O, 2000
High
99Cal14).
MODELS:
**1996** - 1999 (AB) Ram Van
**1996** - 1999 (AN) Dakota
**1996** - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
**1997** - 1999 (TJ) Wrangler
**1996** 1999 (XJ) Cherokee
NOTE:

December 18, 1998.
NOTE:
NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:

1 CH7000/7001 J1962 Cable
1 MDS2
NOTE:
OR HIGHER.
REPAIR PROCEDURE:
SCREEN.
SCREEN.
NOTE:
BEGIN SESSION.
NOTE:
SOFTWARE.
NOTE:

NOTE:
TIME ALLOWANCE:

and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set
NUMBER: 21-04-00
GROUP: Transmission
DATE: June 3O, 2000
High
99Cal14).
MODELS:
**1996** - 1999 (AB) Ram Van
**1996** - 1999 (AN) Dakota
**1996** - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
**1997** - 1999 (TJ) Wrangler
**1996** 1999 (XJ) Cherokee
NOTE:

December 18, 1998.
NOTE:
NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:

1 CH7000/7001 J1962 Cable
1 MDS2
NOTE:
OR HIGHER.
REPAIR PROCEDURE:
SCREEN.
SCREEN.
NOTE:
BEGIN SESSION.
NOTE:
SOFTWARE.
NOTE:

NOTE:
TIME ALLOWANCE:

and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 4130
and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations

and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4134
8w-10-2
and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4135

Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins >
Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm
NO: 18-19-98
GROUP: Driveability
DATE: Apr. 10, 1998
MODELS: 1996 - 1998
(AB) Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
NOTE:

PARTS REQUIRED:
REPAIR PROCEDURE:

and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins >
Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm >
Page 4146
21-96-06-90 1.1 Hrs.

and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at
5,300 Rpm
5,300 Rpm
NO: 18-19-98
GROUP: Driveability
DATE: Apr. 10, 1998
MODELS: 1996 - 1998
(AB) Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
NOTE:

PARTS REQUIRED:
REPAIR PROCEDURE:

and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at
5,300 Rpm > Page 4152
21-96-06-90 1.1 Hrs.

and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4156

and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations

Governor
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids -



A/T - Buzz/Whining in Reverse When Cold
NUMBER: 21-08-99
GROUP: Transmission
Is Selected.
MODELS: 1996 - 1999
(AB) Ram Van
1996 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
NOTE:

TRANSMISSION.
August 1, 1995.
DIAGNOSIS:
PARTS REQUIRED:

A/T - Buzz/Whining in Reverse When Cold > Page 4180
EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
TIME ALLOWANCE:

Apr > 99 > A/T - Buzz/Whining in Reverse When Cold
Cold
NUMBER: 21-08-99
GROUP: Transmission
Is Selected.
MODELS: 1996 - 1999
(AB) Ram Van
1996 - 1999 (AN) Dakota
1998 - 1999 (DN) Durango
NOTE:

TRANSMISSION.
August 1, 1995.
DIAGNOSIS:
PARTS REQUIRED:

Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 4186
EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
TIME ALLOWANCE:

Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations


Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators -
SYSTEM OPERATION
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators -

INJURY.
as required.
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules -
Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set
NUMBER: 21-04-00
GROUP: Transmission
DATE: June 3O, 2000
High
99Cal14).
MODELS:
**1996** - 1999 (AB) Ram Van
**1996** - 1999 (AN) Dakota
**1996** - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
**1997** - 1999 (TJ) Wrangler
**1996** 1999 (XJ) Cherokee
NOTE:

December 18, 1998.
NOTE:
NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:

Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page
4212
1 CH7000/7001 J1962 Cable
1 MDS2
NOTE:
OR HIGHER.
REPAIR PROCEDURE:
SCREEN.
SCREEN.
NOTE:
BEGIN SESSION.
NOTE:

SOFTWARE.
NOTE:

NOTE:
Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page
4213
TIME ALLOWANCE:

Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763
Set
NUMBER: 21-04-00
GROUP: Transmission
DATE: June 3O, 2000
High
99Cal14).
MODELS:
**1996** - 1999 (AB) Ram Van
**1996** - 1999 (AN) Dakota
**1996** - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
**1997** - 1999 (TJ) Wrangler
**1996** 1999 (XJ) Cherokee
NOTE:

December 18, 1998.
NOTE:
NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:

Set > Page 4219
1 CH7000/7001 J1962 Cable
1 MDS2
NOTE:
OR HIGHER.
REPAIR PROCEDURE:
SCREEN.
SCREEN.
NOTE:
BEGIN SESSION.
NOTE:

SOFTWARE.
NOTE:

NOTE:
Set > Page 4220
TIME ALLOWANCE:


8w-10-2

Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches -
Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine
Bucking/Surging at 5,300 Rpm
NO: 18-19-98
GROUP: Driveability
DATE: Apr. 10, 1998
MODELS: 1996 - 1998
(AB) Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
NOTE:

PARTS REQUIRED:
REPAIR PROCEDURE:

Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine
Bucking/Surging at 5,300 Rpm > Page 4237
21-96-06-90 1.1 Hrs.

Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T
- Engine Bucking/Surging at 5,300 Rpm
5,300 Rpm
NO: 18-19-98
GROUP: Driveability
DATE: Apr. 10, 1998
MODELS: 1996 - 1998
(AB) Ram Van
1996 - 1998 (AN) Dakota
1998 (DN) Durango
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
NOTE:

PARTS REQUIRED:
REPAIR PROCEDURE:

Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T
- Engine Bucking/Surging at 5,300 Rpm > Page 4243
21-96-06-90 1.1 Hrs.


Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component

Governor
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > 4WD Switch >
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light >
ABS Light: Description and Operation General Information
SYSTEM OPERATION
The Anti-Lock Brake System (ABS)lamp gives an indication when the ABS system is faulty or
inoperative. The lamp is controlled by the instrument cluster circuitry based upon messages
received from the Controller Anti-lock Brake (CAB) on the Chrysler Collision Detection (CCD) data
bus. The lamp is turned on by the CAB for about two seconds when the ignition switch is turned to
the On position as a bulb test.
After the bulb test, the CAB turns the lamp on or off based upon the results of the ABS self-tests.
The CAB continually monitors the ABS circuits and sensors to decide whether the system is in
good operating condition. The CAB then sends the proper messages to the instrument cluster on
the CCD data bus to turn the lamp on or off. If the CAB turns the lamp on after the bulb test, it
indicates that the CAB has detected a system malfunction and/or that the ABS system has become
inoperative. If only the amber ABS lamp is illuminated, and the red brake warning lamp remains off,
the base brake system will operate normally.
Each time the instrument cluster circuitry receives a lamp-on message from the CAB, it will light the
lamp for the duration of the ABS malfunction. The CAB will also flash this lamp during the
diagnostic mode, unless a hard fault is present. If a hard fault is present, the ABS lamp will
illuminate without flashing.
ABS Light: Description and Operation Rear Wheel Antilock Brakes
The amber ABS warning lamp is used to alert the driver of an RWAL problem and identify
Diagnostic Trouble Codes (DTCs) stored in the Controller Antilock Brake (CAB's) memory.
ABS Light: Description and Operation Four Wheel Antilock Brakes
The amber ABS warning lamp is located in the instrument cluster. The lamp illuminates at start-up
to perform a self check. The lamp goes out when the self check program determines the system is
operating normal. If an ABS component exhibits a fault the Controller Antilock Brake (CAB) will
illuminate the lamp and register a trouble code in the microprocessor. The lamp is controlled by the
CAB. The CAB controls the lamp sending a message to the instrument cluster.
Component Information > Testing and Inspection > Pinpoint Tests
ABS Light: Pinpoint Tests
Component Information > Testing and Inspection > Pinpoint Tests > Page 4267
Component Information > Testing and Inspection > Pinpoint Tests > Page 4268
ABS Light: Component Tests and General Diagnostics
The diagnosis found here addresses an inoperative Anti-lock Brake System (ABS) lamp condition.
If the ABS lamp stays on with the ignition switch in the On position, or comes on and stays on while
driving.

COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
If the ABS lamp fails to light when the ignition switch is turned to the On position, replace the ABS
lamp bulb with a known good unit. If the ABS lamp still fails to operate, diagnosis of the ABS
system and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan
tool as described in the proper Diagnostic Procedures. For further diagnosis of the ABS lamp and
the instrument cluster circuitry, see Instrument Cluster in the Diagnosis and Testing.
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic
Connector - ABS > Component Information > Locations
Diagnostic Connector - ABS: Locations
NOTE: Chrysler does not provide a procedrure to retrieve ABS diagnostic trouble codes without a
scan tool
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic
Connector - ABS > Component Information > Locations > Page 4275
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Corrosion
September 2004
Models
NOTE:
IMPORTANT:
Subject
Repair
Corrosion > Page 4284
Parts Information

NOTE:
Parts Return
Not required.
letter.
repair.
1. Open the hood.
off.
3).
3).
tray (Figure 4).

WARNING:
worn.
(Figure 5).
panel (Figure 5).
NOTE:
replacement.
following process:
CAUTION:
housing.
spliced.
(Figure 10).
CAUTION:
tubing (Figure 11).
NOTE:
13).
control unit.
NOTE:
control module.
drain tube grommet.
lbs. (7.9 N.m).
in. lbs. (7.9 N.m).
Control Module > Component Information > Technical Service Bulletins > Recalls: > NHTSA04V185000 > Apr > 04 > Recall
04V185000: ABS Control Module Corrosion
Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-002-02 > Jan > 02 > Rear
Axle - Vehicle Speed Is Inaccurate
NUMBER: 18-002-02
MODELS:
NOTE:
REAR AXLE.
DISCUSSION:
NOTE:

September 2004
Models
NOTE:
IMPORTANT:
Subject
Repair
Parts Information

NOTE:
Parts Return
Not required.
letter.
repair.
1. Open the hood.
off.
3).
3).
tray (Figure 4).

WARNING:
worn.
(Figure 5).
panel (Figure 5).
NOTE:
replacement.
following process:
CAUTION:
housing.
spliced.
(Figure 10).
CAUTION:
tubing (Figure 11).
NOTE:
13).
control unit.
NOTE:
control module.
drain tube grommet.
lbs. (7.9 N.m).
in. lbs. (7.9 N.m).
Module Corrosion
Inaccurate
NUMBER: 18-002-02
MODELS:
NOTE:
REAR AXLE.
DISCUSSION:
NOTE:

Control Module: > 18-002-02 > Jan > 02 > Rear Axle - Vehicle Speed Is Inaccurate
Inaccurate
NUMBER: 18-002-02
MODELS:
NOTE:
REAR AXLE.
DISCUSSION:
NOTE:

Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion
September 2004
Models
NOTE:
IMPORTANT:
Subject
Repair
Parts Information

NOTE:
Parts Return
Not required.
letter.
repair.
1. Open the hood.
off.
3).
3).
tray (Figure 4).

WARNING:
worn.
(Figure 5).
panel (Figure 5).
NOTE:
replacement.
following process:
CAUTION:
housing.
spliced.
(Figure 10).
CAUTION:
tubing (Figure 11).
NOTE:
13).
control unit.
NOTE:
control module.
drain tube grommet.
lbs. (7.9 N.m).
in. lbs. (7.9 N.m).
Control Module: > NHTSA04V185000 > Apr > 04 > Recall 04V185000: ABS Control Module Corrosion
Module Corrosion
Control Module > Component Information > Specifications > With RWAL Brakes
Mounting Screws .................................................................................................................................

....................................................... 4 Nm (36 ft. lbs.)
Control Module > Component Information > Specifications > With RWAL Brakes > Page 4358
Screws .................................................................................................................................................
................................................. 4.4 Nm (39 inch lbs.)
Control Module > Component Information > Locations > EBC 2
Control Module > Component Information > Locations > EBC 2 > Page 4361
(CAB)
Brake (CAB)
and circuits that:
- (72) ROM Checksum
- (73) Watchdog
(CAB) > Page 4364
braking.
(CAB) > Page 4365
CAB/HCU
scan tool.
(CAB) > Page 4366
GENERAL INFORMATION
SYSTEM SELF-TEST
CAB INPUTS
- Brake Lamp Switch
- Reset Switch
CAB OUTPUTS
RWAL Valve
- ABS Warning Lamp

Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System
REMOVAL
CAB.

10. Remove the CAB.
INSTALLATION
REMOVAL
INSTALLATION
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications > With Four Wheel Antilock Brakes
Hydraulic Control Assembly - Antilock Brakes: Specifications With Four Wheel Antilock Brakes
Bracket Nuts ........................................................................................................................................

................................................ 12 Nm (102 inch lbs.) Mounting Bolts .................................................
........................................................................................................................................ 15 Nm (11 ft.
lbs.)
Assembly - Antilock Brakes > Component Information > Specifications > With Four Wheel Antilock Brakes > Page 4375
Hydraulic Control Assembly - Antilock Brakes: Specifications With Rear Wheel Antilock Brakes
Bracket Nuts ........................................................................................................................................

................................................ 12 Nm (102 inch lbs.) Valve Bolt ........................................................
......................................................................................................................................... 24 Nm (18
ft. lbs.)
Assembly - Antilock Brakes > Component Information > Description and Operation > General Information
Hydraulic Control Assembly - Antilock Brakes: Description and Operation General Information
The controller-antilock brake module is used to monitor wheel speeds and modulates (control)
hydraulic pressure in each brake channel. The modulated hydraulic pressure is used to prevent
wheel lock up during braking. The CAB also provides a vehicle speed signal (VSS) to the
powertrain control module.
Assembly - Antilock Brakes > Component Information > Description and Operation > General Information > Page 4378
Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Control Unit
(HCU)
Description
The HCU on the EBC 2 has only a separate rear valve body.
The HCU on the EBC 325 has two integral valve bodies for controlling the front and rear brakes.
Within the HCU are solenoids, valves, check valves, and a reset switch necessary to apply and
release brake pressure as required to avoid wheel lockup, keep the wheels rolling, and maintain
optimum deceleration.
The isolation valve is normally open, allowing unrestricted flow from the master cylinder to the
wheels. When the CAB determines antilock intervention is required, the valve closes to isolate the
master cylinder hydraulic circuit. Fluid is trapped in the circuit and then prevented from reaching the
wheels.
The dump valve is pulsed on and off by the CAB. This valve cycles only if the isolation valve is
closed. When dump is on, it allows fluid to the low pressure accumulator for temporary storage.
This causes the pressure to the wheel to decrease. When the valve is off, fluid is allowed to the
wheel.
The brake return check valve allows the HCU to drain faster after the ABS stop, when the brake is
released.
The Reset Switch is positioned in the HCU to monitor the master cylinder (input), rear brake
(output) and accumulator pressure. During normal braking, pressure is equal for input and output
and the switch remains open. During an Antilock stop the switch will close as the isolation valve is
cycled and pressure becomes unequal between input and output. At the end of an ABS stop the
isolation valve will open as master cylinder pressure and rear pressure equalize. The switch is
used to monitor correct operation of the HCU and to set a diagnostic trouble code if incorrect
pressure is detected.
When the brakes are applied, fluid is forced from the master cylinder outlet ports to the HCU inlet
ports. This pressure is transmitted through three normally open isolation valves inside the HCU,
then through the outlet ports of the HCU to the wheels. If the CAB senses that a wheel is about to
lock, based on wheel speed sensor data, it pulls the normally open isolation valve closed for that
circuit. This prevents any more fluid from entering that circuit. The CAB continues to look at the
sensor signal to determine if the wheel is still decelerating. If deceleration is still taking place, the
normally closed dump valve for that circuit is opened. This dumps any pressure that is trapped
between the normally open valve and the brake back into an accumulator. Once the affected circuit
comes back up to speed, the CAB returns the valves to their normal condition allowing the affected
brake to be reapplied. On the EBC 325 system, the pump and accumulators are used to provide
rapid response during the reapply sequence and to minimize pedal feedback.
GENERAL INFORMATION
CAB/HCU
The Hydraulic Control Unit (HCU) consists of a valve body, pump, accumulator and motor.
The pump, motor, and accumulator are combined into an assembly attached to the valve body. The
accumulator store the extra fluid which had to be dumped from the brakes. This is done to prevent
the wheels from locking up. The pump provides the fluid volume needed and is operated by a DC
type motor. The motor is controlled by the Controller Antilock Brake (CAB).
The valve body contains the solenoid valves. The valves modulate brake pressure during antilock
braking and are controlled by the CAB.
Assembly - Antilock Brakes > Component Information > Description and Operation > General Information > Page 4379
The HCU provides three channel pressure control to the front and rear brakes. One channel
controls the rear wheel brakes in tandem. The two remaining channels control the front wheel
brakes individually.
During antilock braking, the solenoid valves are opened and closed as needed. The valves are not
static. They are cycled rapidly and continuously to modulate pressure and control wheel slip and
deceleration.
During normal braking, the HCU solenoid valves and pump are not activated. The master cylinder
and power booster operate the same as a vehicle without an ABS brake system.
During antilock braking, solenoid valve pressure modulation occurs in three stages, pressure
decrease, pressure hold, and pressure increase. The valves are all contained in the valve body
portion of the HCU.
Pressure Decrease The inlet valve is closed and the outlet valve is opened during the pressure
decrease cycle.
A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or
more wheels. At this point, the CAB closes the inlet to prevent the driver from further increasing the
brake pressure and locking the brakes. The CAB then opens the outlet valve, which also opens the
return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed to
prevent wheel lock.
Once the period of high wheel slip has ended, the CAB closes the outlet valve and begins a
pressure increase or hold cycle as needed.
Pressure Hold Both solenoid valves are closed in the pressure hold cycle. Fluid apply pressure in
the control channel is maintained at a constant rate. The CAB maintains the hold cycle until sensor
inputs indicate a pressure change is necessary.
Pressure Increase The inlet valve is open and the outlet valve is closed during the pressure
increase cycle. The pressure increase cycle is used to counteract unequal wheel speeds. This
cycle controls re-application of fluid apply pressure due to changing road surfaces or wheel speed.
If the Controller Antilock Brake (CAB) senses that rear wheel speed deceleration is excessive, it
will energize a isolation solenoid by providing battery voltage to the solenoid. This prevents a
further increase of driver induced brake pressure to the rear wheels. If this initial action is not
enough to prevent rear wheel lock-up, the CAB will momentarily energize a dump solenoid (the
CAB energizes the dump solenoid by providing battery voltage to the solenoid). This opens the
dump valve to vent a small amount of isolated rear brake pressure to an accumulator. The action of
fluid moving to the accumulator reduces the isolated brake pressure at the wheel cylinders. The
dump (pressure venting) cycle is limited to very short time periods (milliseconds). The CAB will
pulse the dump valve until rear wheel deceleration matches the vehicle deceleration rate or the
desired slip rate programmed into the CAB. The system will switch to normal braking once wheel
locking tendencies are no longer present.
A predetermined maximum number of consecutive dump cycles can be performed during any one
antilock stop. If excessive dump cycles occur, a DTC will be set and stored in the CAB memory. If
during an antilock stop, the driver releases the brake pedal, the reset switch contacts will open.
This signal to the CAB is an indication that pressure has equalized across the RWAL valve. The
CAB will then reset the dump cycle counter in anticipation of the next antilock stop. Additionally,
any fluid stored in the accumulator will force its way past the dump valve, back into the hydraulic
circuit and return to the master cylinder.
A fuse internal to the CAB, provides a fail-safe device which prevents unwanted control over the
isolation and dump solenoids. The fuse is in series with the isolation and dump solenoids output
circuits. If the internal fuse is open, the CAB cannot provide voltage to energize either solenoid and
antilock stops are prevented. If the fuse is open, the braking system will operate normally but
without antilock control over rear brake pressure.
Assembly - Antilock Brakes > Component Information > Service and Repair > Front Antilock Valve Replacement
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Front Antilock Valve
Replacement
NOTE: If the antilock control assembly needs to be replaced, the rear axle type and tire revolutions
per mile must be programed into the new Controller Antilock Brake (CAB).
REMOVAL
1. Remove left turn signal housing. 2. Remove the extension panel under the left turn signal
housing opening.
Access Cover
3. Disconnect the horn connector and remove the access cover. 4. Remove the washer reservoir
hose. 6. Remove the reservoir from the engine compartment. 7. Disconnect battery cables and
remove the battery. 8. Remove the power distribution center. 9. Remove the battery and power
distribution center mount.
10. Push the harness connectors locks to release the locks, then remove the connectors from the
CAB.
Assembly - Antilock Brakes > Component Information > Service and Repair > Front Antilock Valve Replacement > Page
4382
HCU Brake Lines
11. Disconnect brake lines from Hydraulic Control Unit (HCU). 12. Remove the front mounting bolt
through access opening. 13. Remove the rear mounting bolt from the engine compartment. 14. Tilt
the assembly upward were the brake lines attach and remove the assembly from the mounting
bracket.
INSTALLATION
1. Install the assembly into the mounting bracket. 2. Install mounting bolts and tighten to 15 Nm (11
ft. lbs.). 3. Install the brake lines to HCU and tighten to 13 Nm (115 inch lbs.). 4. Connect the CAB
harness connectors and lock in place. 5. Install the reservoir in the engine compartment. Connect
the pump motor connector and pump hose. 6. Install the washer reservoir mounting screws. 7.
Install the battery and power distribution center mount. 8. Install the power distribution center. 9.
Install the battery and battery cables.
10. Connect the horn connector and install the access cover. 11. Install the extension panel. 12.
Install left turn signal housing. 13. Bleed the brake system.
Assembly - Antilock Brakes > Component Information > Service and Repair > Front Antilock Valve Replacement > Page
4383
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Rear Antilock Valve
Replacement
REMOVAL
housing opening.
Access Cover
3. Disconnect the horn connector and remove the access cover. 4. Remove one brake line from the
rear antilock valve through the access cover opening. 5. From the engine compartment, disconnect
antilock valve harness connector from the controller. 6. Remove the other brake line and mounting
bolt from the antilock valve. 7. Remove rear antilock valve.
INSTALLATION
1. Position rear antilock valve on the valve bracket. 2. Install the mounting bolt and tighten to 24
Nm (18 ft. lbs.). 3. Install the brake lines and tighten to 15 Nm (130 inch lbs.). 4. Connect wiring
harness wires to the controller. 5. Connect the horn connector and install the access cover. 6.
Install the extension panel. 7. Install left turn signal housing. 8. Fill and bleed brake system.
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Specifications > With Four Wheel Antilock Brakes
Front Bolt 11 ft.lb
Rear Bolt 18 ft.lb

Sensor > Component Information > Specifications > With Four Wheel Antilock Brakes > Page 4388

Sensor > Component Information > Locations > Component Locations
Sensor > Component Information > Diagrams > Front
Sensor > Component Information > Diagrams > Front > Page 4395
Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes
OPERATION
CIRCUIT OPERATION
Each sensor has:
AN, DN, BE and BR:
AB, AN and DN:
BE and BR:
cold.)
proper part.

Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement
Front
REMOVAL
Wheel Speed Sensor
steering knuckle.
INSTALLATION
REMOVAL
sensor stud.

INSTALLATION
REMOVAL
INSTALLATION
Front Tone Wheel
Tone Wheel
wheel is damaged.
Rear Tone Wheel
procedures.
Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Bleeding Procedures
GENERAL INFORMATION
master cylinder
- combination valve
- left rear wheel
- right rear wheel
- right front wheel
- left front wheel
MANUAL BLEEDING
PRESSURE BLEEDING
Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Bleeding Procedures > Page 4408
GENERAL INFORMATION
fluid as needed.
master cylinder
- combination valve
- right rear wheel
- left rear wheel
- right front wheel

- left front wheel
MANUAL BLEEDING
Bleed Hose Setup
immersed in fluid.
PRESSURE BLEEDING
6921 or equivalent.
Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications
Brake Pedal Assy: Specifications
Shaft Nut ..............................................................................................................................................

..................................................... 54 Nm (40 ft. lbs.)
Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications >
Page 4412
Brake Pedal Assy: Description and Operation
A suspended-type brake pedal is used for all applications. The pedal is attached to the pedal
support bracket with a pivot bolt, sleeve and bushings. The pedal, bolt, sleeve and bushings are all
serviceable components.
Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications >
Page 4413
Brake Pedal Assy: Service and Repair
REMOVAL
1. Remove the knee blocker under the steering column, to access the pedal.
Push Rod
2. Remove clip securing push rod to pedal. 3. Remove brake pedal shaft nut. 4. Slide brake pedal
shaft out and remove the brake pedal. 5. Remove and inspect pedal bushings. Replace bushings if
worn or damaged.
INSTALLATION
1. Lubricate pedal shaft and bushings with Mopar multi-mileage grease. 2. Install pedal bushings in
pedal, sleeve and support. 3. Position pedal in support and install the pedal shaft. 4. Apply Mopar
Lock N' Seal, or 242 Loctite to threads of pedal shaft and shaft retaining nut. 5. Install washer and
nut on the pedal shaft. Tighten shaft nut to 54 Nm (40 ft. lbs.). 6. Check and adjust stop lamp
switch, if necessary.
Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical
Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions
Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark 20 ABS System Test
Revisions
NUMBER: 26-12-97I
Models: 1998 Teves Mark 20 ABS Diagnostic Manual - Publication Number - 81-699-97013
Revisions to the ABS warning lamp test

Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 4418
94
95
Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark IV/Teves Mark 20 ABS
Revisions
NUMBER: 26-12-97F
Models: 1997-1998 Teves Mark IV, Teves Mark 20 ABS Diagnostic Manual - Publication Number -
81-699-97012
Revisions to the ABS warning light procedure

244
245
Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information >
Description and Operation > General Information
Brake Warning Indicator: Description and Operation General Information
SYSTEM OPERATION
The brake warning lamp gives an indication when the parking brake is applied, when the pressures
in the two halves of the split brake hydraulic system are unequal, if the Anti-lock Brake System
(ABS) lamp has failed and an ABS fault occurs, and during ABS diagnostics. The lamp is turned on
by the instrument cluster circuitry for about two seconds when the ignition switch is moved to the
Start position as a bulb test. After the bulb test, the lamp is controlled by a hard wired input from
the parking brake switch and/or by the instrument cluster circuitry based upon messages received
from the Controller Anti-lock Brake (CAB) on the Chrysler Collision Detection (CCD) data bus.
The CAB turns the lamp on or off based upon the results of the ABS self-tests. The CAB
continually monitors the ABS circuits and sensors, including the brake warning switch and the ABS
lamp, to decide whether the system is in good operating condition. The CAB then sends the proper
messages to the instrument cluster on the CCD data bus to turn the lamp on or off. If the CAB turns
the lamp on after the bulb test, it indicates that the CAB has detected a system malfunction.
The parking brake switch is hard wired to the instrument cluster and closes to ground when the
parking brake is applied. The brake warning switch is hard wired to the CAB and closes to ground
when it senses unequal hydraulic pressures in the two halves of the split brake hydraulic system,
possibly due to low brake fluid level or brake fluid leakage.
After the bulb test, if the red brake warning lamp remains illuminated with the parking brake
released, the base brake system may not be operational. The vehicle should never be operated
while the red brake warning lamp is illuminated.
Description and Operation > General Information > Page 4425
Brake Warning Indicator: Description and Operation Brake Warning Lamp Description
The red brake warning lamp is used to alert the driver of a hydraulic fault or that the parking brake
is applied. For the RWAL system, the red brake warning lamp also is used to alerts the driver of a
problem with the RWAL system.
The brake warning lamp illuminates when a message is sent over the bus to the cluster to
illuminate the bulb. A ground for the bulb is provided when:
- The brakes are applied and the park brake switch is actuated.
- A hydraulic fault has occurred and the pressure differential switch is actuated.
- A RWAL fault has occurred.

Brake Warning Indicator: Testing and Inspection
The diagnosis found here addresses an inoperative brake warning lamp condition. If the brake
warning lamp stays on with the ignition switch in the On position and the parking brake released, or
comes on while driving,

INJURY.
component and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for
battery voltage at the fuse in the junction block. If OK, go to Step 4. If not OK, repair the
Unplug the wire harness connector at the park brake
switch. With the park brake released, check for continuity between the park brake switch terminal
and a good ground. There should be no continuity If OK, go to Step 5. If not OK, adjust or replace
the faulty park brake switch.
4. Remove the instrument cluster. With the park brake switch wire harness connector still
unplugged, check for continuity between the park brake
switch wire harness connector cavity and a good ground. There should be no continuity. If OK, go
to Step 6. If not OK, repair the short circuit as required.
5. Check for continuity between the park brake switch sense circuit cavities of the instrument
cluster wire harness connector (connector A) and the
park brake switch wire harness connector, There should be continuity. If OK, see Instrument
Cluster in the Diagnosis and Testing for further testing of the brake warning lamp and the
instrument cluster circuitry. If not OK, repair the open circuit as required.
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Specifications
Brake Caliper: Specifications
Piston Diameter LD 2.126 in
Piston Diameter HD 2.205 in
Mounting Bolts 24 ft.lb
Adapter Bolts 210 ft.lb

Brake Caliper: Testing and Inspection
CLEANING
Clean the caliper components with clean brake fluid or brake clean only. Wipe the caliper and
piston dry with lint free towels or use low pressure compressed air.
CAUTION: Do not use gasoline, kerosene, thinner, or similar solvents. These products may leave a
residue that could damage the piston and seal.
INSPECTION
The piston is made from a phenolic resin (plastic material) and should be smooth and clean.
The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface
by sanding or polishing.
CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never
interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore
and piston tolerances are different.
Polishing Piston Bore
The bore can be lightly polished with a brake hone to remove very minor surface imperfections.
The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would
increase bore diameter more than 0.025 mm (0.001 inch).
Service and Repair > Removal and Installation
Brake Caliper: Service and Repair Removal and Installation
REMOVAL
1. Raise and support vehicle. 2. Remove front wheel and tire assembly.
Caliper
3. Remove caliper brake hose bolt, washers and hose. 4. Remove caliper mounting bolts. 5. Tilt the
bottom of the caliper up and remove it from the adapter. 6. Remove anti-rattle springs.
NOTE: Upper and lower anti-rattle springs are not interchangeable.
INSTALLATION
1. Clean caliper mounting adapter and anti-rattle springs. Then lubricate anti-rattle springs and
mounting bolts with Mopar high temperature or
multi-mileage grease.
2. Install anti-rattle springs. 3. Tilt the top of the caliper over rotor and under adapter. Then push
the bottom of the caliper down onto the adapter. 4. Install caliper mounting bolts and tighten to 33
Nm (24 ft. lbs.). 5. Install brake hose to caliper with new seal washers and tighten fitting bolt to 24
Nm (18 ft. lbs.).
CAUTION: Be sure the front hose is free of kinks or bends and is clear of all chassis and
suspension components.
6. Fill master cylinder with Mopar brake fluid or equivalent. 7. Fill and bleed brake system. 8. Install
wheel and tire assembly and lower vehicle. 9. Apply brakes several times to seat caliper pistons
and brake shoes. Be sure firm pedal is obtained before moving vehicle.
Service and Repair > Removal and Installation > Page 4434
Brake Caliper: Service and Repair Disassembly and Assembly
DISASSEMBLY
1. Drain the brake fluid from caliper.
C-Clamp One Piston
2. C-clamp a block of wood over one piston.
Protect Caliper Piston
3. Take another piece of wood and pad it with one-inch thickness of shop towels. Place this piece
in the outboard shoe side of the caliper in front of
the other piston. This will cushion and protect caliper piston during removal.
4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the
caliper brake hose port. Use only enough air
pressure to ease the piston out.
CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a
cracked piston.
WARNING: Never attempt to catch the piston as it leaves the bore. This could result in personal
injury.
5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the
first piston removed. This will seal the empty
piston bore.
6. Move the padded piece of wood in front of the other piston. 7. Remove the second piston using
the same procedure with short bursts of low pressure air.
Piston Dust Boot Removal
8. Remove piston dust boots with a suitable pry tool.
Piston Seal
9. Remove piston seals from caliper.
CAUTION: Do not scratch piston bore while removing the seals.
Disc Brake Caliper
10. Push caliper mounting bolt bushings out of the boot seals and remove the boot seals from the
caliper. 11. Remove caliper bleed screw.
ASSEMBLY
CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry.
1. Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid.
Piston Seal
2. Install new piston seals into caliper bores.
NOTE: Verify seal is fully seated and not twisted.
3. Lightly lubricate lip of new boot with silicone grease. Install boot on piston and work boot lip into
the groove at the top of piston. 4. Stretch boot rearward to straighten boot folds, then move boot
forward until folds snap into place.
Caliper Piston Installation
5. Install piston into caliper bore and press piston down to the bottom of the caliper bore by hand or
with hammer handle.
Seating Dust Boot

6. Seat dust boot in caliper with Handle C-4171 or equivalent and Installer:
- HD 56 mm caliper: Installer C-4340
- LD 54 mm caliper: Installer C-3716-A
7. Install the second piston and dust boot. 8. Lubricate caliper mounting bolt bushings, boot seals
and bores with silicone grease. 9. Install the boot seals into the caliper seal bores and center the
seals in the bores.
10. Install mounting bolt bushings into the boot seals and insure seal lip is engaged into the
bushing groves at either end of the bushing. 11. Install caliper bleed screw.
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications
Brake Pad: Specifications
As a general rule, riveted brake shoes should be replaced when worn to within 0.78 mm (1/32 inch)
of the rivet heads.
Bonded lining should be replaced when worn to a thickness of 1.6 mm (1/16 inch).
Brake Pad: Service and Repair
NOTE: If brake shoes are to be replaced, remove 1/4 of the fluid from master cylinder with suction
gun.
REMOVAL
1. Raise and support vehicle. 2. Remove front wheel and tire assemblies. 3. Remove caliper
mounting bolts.
Caliper
4. Remove caliper by tilting the bottom up and off the caliper adapter.
NOTE: Do not allow brake hose to support caliper assembly.
Inboard Brake Shoe
5. Remove inboard brake shoe from the caliper adapter.

Outboard Brake Shoe
6. Remove outboard brake shoe from caliper adapter.
Top Anti-Rattle Spring
Bottom Anti-Rattle Spring
7. Remove the anti-rattle springs from the caliper adapter.
INSTALLATION
1. Bottom pistons in caliper bore with C-clamp. Place an old brake shoe between a C-clamp and
caliper piston. 2. Clean caliper adapter and anti-rattle springs. Then lubricate anti-rattle springs and
mounting bolts with Mopar high temperature or multi-mileage
grease.
3. Install anti-rattle springs.
NOTE: Anti-rattle springs are not interchangeable.
4. Install inboard brake shoe in adapter. 5. Install outboard brake shoe in adapter. 6. Tilt the top of
the caliper over rotor and under adapter. Then push the bottom of the caliper down onto the
adapter. 7. Install caliper mounting bolts and tighten to 33 Nm (24 ft. lbs.). 8. Install wheel and tire
assemblies and lower vehicle. 9. Apply brakes several times to seat caliper pistons and brake
shoes and obtain firm pedal.
10. Top off master cylinder fluid level.

Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Brake Rotor/Disc: Specifications
Disc Brake Rotor
Type......................................................................................................................................................
....................................................................Ventilated
Diameter 1500/2500.............................................................................................................................
.......................................................298 mm (11.75 in)
Diameter 3500......................................................................................................................................
....................................................325.6 mm (12.82 in)
Max. Runout.........................................................................................................................................
....................................................0.102 mm (0.004 in)
Max. Thickness Variation.....................................................................................................................

.................................................0.013 mm (0.0005 in)
Min. Thickness......................................................................................................................................
.....................................................30.0 mm (1.181 in)
Brake Rotor/Disc: Testing and Inspection
GENERAL INFORMATION
The rotor braking surfaces should not be refinished unless necessary
Light surface rust and scale can be removed with a lathe equipped with dual sanding discs. The
rotor surfaces can be restored by machining in a disc brake lathe if surface scoring and wear are
light.
Replace the rotor under the following conditions: -
severely scored
- tapered
- hard spots
- cracked
- below minimum thickness
ROTOR MINIMUM THICKNESS
Measure rotor thickness at the center of the brake shoe contact surface. Replace the rotor if worn
below minimum thickness, or if machining would reduce thickness below the allowable minimum.
Rotor minimum thickness is usually specified on the rotor hub. The specification is either stamped
or cast into the hub surface.
ROTOR RUNOUT
Checking Rotor Runout And Thickness Variation
Check rotor lateral runout with dial indicator C-3339 or equivalent. Excessive lateral runout will
cause brake pedal pulsation and rapid, uneven wear of the brake shoes. Position the dial indicator
plunger approximately 25.4 min (1 inch) inward from the rotor edge. Maximum allowable rotor
runout is 0.102 mm (0.004 inch).
ROTOR THICKNESS VARIATION
Variations in rotor thickness will cause pedal pulsation, noise and shudder.
Measuring Rotor Thickness

Measure rotor thickness at 6 to 12 points around the rotor face.
Position the micrometer approximately 25.4 mm (1 inch) from the rotor outer circumference for
each measurement.
Thickness should not vary by more than 0.013 mm (0.0005 inch) from point-to-point on the rotor.
Machine or replace the rotor if necessary.
Information > Service and Repair > Rotor Removal and Installation
Brake Rotor/Disc: Service and Repair Rotor Removal and Installation
REMOVAL
1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove caliper.
NOTE: Do not allow brake hose to support caliper assembly.
Caliper Adapter
4. Remove caliper adapter bolts from the steering knuckle and remove adapter.
Disc Brake Rotor
5. Remove grease cap, cotter pin, nut lock, nut, washer and outer wheel bearing. 6. Remove the
rotor from the spindle.
INSTALLATION
1. Inspect and repack wheel bearings if necessary. Install new grease seals if inner bearing was
removed. 2. On models with all-wheel antilock system (ABS), check condition of tone wheel in rotor
hub. If teeth on wheel are damaged, rotor and hub
assembly will have to be replaced (tone wheel is not serviced separately).
3. Install rotor on spindle. 4. Install outer bearing, thrust washer and nut. 5. Tighten wheel bearing
adjusting nut to 27 - 34 Nm (240 - 300 inch lbs.) while turning rotor. 6. Loosen wheel bearing
adjusting nut completely. Then retighten nut finger tight. Wheel bearing end play should not exceed
0.076 mm (0.003 inch)
7. Install nut lock on bearing adjusting nut. Align lock slots with cotter pin hole and secure nut and
lock with new cotter pin.
Information > Service and Repair > Rotor Removal and Installation > Page 4451
8. Clean grease cap and coat interior of cap with wheel bearing grease. 9. Install caliper adapter
and tighten adapter bolts to:
- LD 1500: 176 Nm (130 ft. lbs.)
- HD 2500/3500: 285 Nm (210 ft. lbs.)
10. Install caliper and tighten bolts to 33 Nm (24 ft. lbs.). 11. Install wheel and tire assembly and
lower vehicle. 12. Apply brakes several times to seat brake shoes. Be sure to obtain firm pedal
before moving vehicle.
Information > Service and Repair > Rotor Removal and Installation > Page 4452
Brake Rotor/Disc: Service and Repair Rotor Refinishing
Rotor braking surfaces can be sanded or machined in a disc brake lathe.
Fig 6 Refacing Brake Disc
The lathe must machine both sides of the rotor simultaneously with dual (two) cutter heads.
Equipment capable of machining only one side at a time will produce a tapered rotor.
Fig 7 Refacing Brake Disc -- Final Finish
The lathe should also be equipped with a grinder attachment or dual sanding discs for final cleanup
or light refinishing.
If the rotor surfaces only need minor cleanup of rust, scale, or minor scoring, use abrasive discs to
clean up the rotor surfaces. However, when a rotor is scored or worn, machining with cutting tools
will be required.
CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum allowable
thickness.
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Specifications
Backing Plate: Specifications
Bolts .....................................................................................................................................................
.................................................. 115 Nm (85 ft. lbs.)
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
Backing Plate: Service and Repair
REMOVAL
1. Remove wheel and tire assembly and brake drum. 2. Remove brake shoe assembly. 3. Remove
parking brake cable from parking brake lever. 4. Compress parking brake cable retainer tabs. Then
push retainer and cable through and out of support plate. 5. Disconnect brake line at wheel
cylinder. 6. Remove wheel cylinder from support plate. 7. Remove axle shaft, refer to Transmission
and Drivetrain for procedures. 8. Remove bolts attaching support Plate to axle and remove support
plate.
INSTALLATION
1. Apply bead of silicone sealer around axle mounting surface of support plate. 2. Install support
plate on axle flange. Tighten attaching bolts to 115 Nm (85 ft. lbs.). 3. Apply bead of silicone sealer
around wheel cylinder mounting surface and install wheel cylinder. 4. Install brake line in wheel
cylinder. 5. Install parking brake cable in support plate. 6. Install axle shaft, refer to Transmission
and Drivetrain for procedure. 7. Connect parking brake cable to lever on secondary shoe and install
brake shoes on support plate. 8. Adjust brake shoes to drum with brake gauge. 9. Install brake
drum and wheel and tire assembly.
10. Bleed brake system.

Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Technical Service Bulletins > Customer Interest for Brake Drum: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on
Application
NO: 05-07-98
GROUP: Brakes
DATE: Feb. 1, 1999
MODELS:
NOTE:
(SALES CODE DRG).
SYMPTOM/CONDITION:
PARTS REQUIRED:
TIME ALLOWANCE:
Labor Operation No:
1.0 Hrs.
Related Operations:
NOTE:

Application > Page 4466
Diagnosis
and 22.
NOTE:
HOIST.
Repair Procedure
the housing cover.
CAUTION:
SEAL LIP.
Bearing service.
side gear splines.
CAUTION:
SEAL LIP.
holes.
NOTE:
lbs.).
tension adjustment.

Technical Service Bulletins > All Technical Service Bulletins for Brake Drum: > 05-07-98 > Feb > 99 > Brakes -
NO: 05-07-98
GROUP: Brakes
DATE: Feb. 1, 1999
MODELS:
NOTE:
(SALES CODE DRG).
SYMPTOM/CONDITION:
PARTS REQUIRED:
TIME ALLOWANCE:
Labor Operation No:
1.0 Hrs.
Related Operations:
NOTE:

Diagnosis
and 22.
NOTE:
HOIST.
Repair Procedure
the housing cover.
CAUTION:
SEAL LIP.
Bearing service.
side gear splines.
CAUTION:
SEAL LIP.
holes.
NOTE:
lbs.).
tension adjustment.

Brake Drum: Specifications
Rear Drum Specifications
11" Rear Drum
Nominal Diameter ................................................................................................................................

........................................................... 11.030"
Maximum Machine Limit ......................................................................................................................

.......................................................... 11.090"
Discard Diameter .................................................................................................................................

...................................................................... *
Runout Limit ........................................................................................................................................

............................................................. 0.008"
12" Rear Drum
Nominal Diameter ................................................................................................................................

........................................................... 12.125"
Maximum Machine Limit ......................................................................................................................

.......................................................... 12.185"
Discard Diameter .................................................................................................................................

...................................................................... *
Runout Limit ........................................................................................................................................

............................................................. 0.008"
* - Discard when diameter is greater than Maximum Machine

Brake Drum: Testing and Inspection
GENERAL INFORMATION
The maximum allowable diameter of the drum braking surface is indicated on the drum outer edge.
Generally, a drum can be machined to a maximum of 1.52 mm (0.060 inch) oversize. Always
replace the drum if machining would cause drum diameter to exceed the size limit indicated on the
drum.
BRAKE DRUM RUNOUT
Measure drum diameter and runout with an accurate gauge. The most accurate method of
measurement involves mounting the drum in a brake lathe and checking variation and runout with a
dial indicator.
Variations in drum diameter should not exceed 0.076 mm (0.003 inch). Drum runout should not
exceed 0.20 mm (0.008 inch) out of round. Machine the drum if runout or variation exceed these
values. Replace the drum if machining causes the drum to exceed the maximum allowable
diameter.
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Customer Interest for Brake Shoe: > 05-07-98 > Feb > 99 > Brakes - Vibration/Shudder on
Application
NO: 05-07-98
GROUP: Brakes
DATE: Feb. 1, 1999
MODELS:
NOTE:
(SALES CODE DRG).
SYMPTOM/CONDITION:
PARTS REQUIRED:
TIME ALLOWANCE:
Labor Operation No:
1.0 Hrs.
Related Operations:
NOTE:

Diagnosis
and 22.
NOTE:
HOIST.
Repair Procedure
the housing cover.
CAUTION:
SEAL LIP.
Bearing service.
side gear splines.
CAUTION:
SEAL LIP.
holes.
NOTE:
lbs.).
tension adjustment.

Technical Service Bulletins > All Technical Service Bulletins for Brake Shoe: > 05-07-98 > Feb > 99 > Brakes -
NO: 05-07-98
GROUP: Brakes
DATE: Feb. 1, 1999
MODELS:
NOTE:
(SALES CODE DRG).
SYMPTOM/CONDITION:
PARTS REQUIRED:
TIME ALLOWANCE:
Labor Operation No:
1.0 Hrs.
Related Operations:
NOTE:

Diagnosis
and 22.
NOTE:
HOIST.
Repair Procedure
the housing cover.
CAUTION:
SEAL LIP.
Bearing service.
side gear splines.
CAUTION:
SEAL LIP.
holes.
NOTE:
lbs.).
tension adjustment.

Brake Shoe: Specifications
As a general rule, riveted brake shoes should be replaced when worn to within 0.78 mm (1/32 inch)
of the rivet heads.
Bonded linings should be replaced when worn to a thickness of 1.6 mm (1/16 inch).
Brake Shoe: Service and Repair
REMOVAL
1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove clip nuts securing
brake drum to wheel studs. 4. Remove brake drum. 5. Vacuum brake components to remove brake
lining dust. 6. Unhook adjusting lever return spring from lever. 7. Remove lever and return spring
from lever pivot pin. 8. Unhook adjuster lever from adjuster cable assembly.
9. Remove shoe-to-shoe upper spring.
10. Remove shoe hold-down springs. 11. Disconnect parking brake cable from parking brake lever.
12. Remove lower spring and adjuster assembly.
13. Remove brake shoes.
INSTALLATION
NOTE: Pivot screw and adjusting nut have left hand threads on left side brake and right hand
threads on right side brake. Verify that adjusting nuts are installed on correct side of vehicle.
1. Coat contact pads on support plate with Mopar high temperature grease, multi-mileage grease,
or equivalent. 2. Assemble adjuster, lower spring and tooth brake shoes. Then position the
assembled components on the support plate.
NOTE: Primary shoe is installed toward the front of the vehicle and secondary toward the rear of
the vehicle.
3. Install brake shoe hold-down springs and pins. Be sure hold-down pins are seated in support
plate and springs are connected. 4. Insert parking brake cable through parking brake cable guide
spring to parking brake lever. Be sure cable end is properly secured in lever. 5. Install upper spring.
6. Position adjuster lever return spring on pivot. 7. Install adjuster lever. 8. Attach adjuster cable to
adjuster lever. Be sure cable is properly routed. 9. Adjust brake shoes to drum with brake gauge.
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Wheel Cylinder: Specifications
Bolts/Nuts 15 ft.lb
Wheel Cylinder Components-Typical

Information > Service and Repair > Wheel Cylinder Removal and Installation
Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation
REMOVAL
1. Remove wheel and tire assembly. 2. Remove brake drum. 3. Disconnect wheel cylinder brake
line. 4. Remove brake shoe return springs and move shoes out of engagement with cylinder push
rods. 5. Remove cylinder attaching bolts and remove cylinder from support plate.
INSTALLATION
1. Apply bead of silicone sealer around cylinder mounting surface of support plate. 2. Install
cylinder mounting bolts and tighten to 20 Nm (15 ft. lbs.). 3. Connect brake line to cylinder. 4. Install
brake shoe return spring. 5. Install brake drum. 6. Install wheel and tire assembly. 7. Bleed brake
system.
Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4511
Wheel Cylinder: Service and Repair Cleaning and Inspection
CLEANING
Clean the cylinder and pistons with clean brake fluid or brake cleaner only. Do not use any other
cleaning agents.
Dry the cylinder and pistons with compressed air. Do not use rags or shop towels to dry the
cylinder components. Lint from cloth material will adhere to the cylinder bores and pistons.
INSPECTION
Inspect the cylinder bore. Light discoloration and dark stains in the bore are normal and will not
impair cylinder operation.
The cylinder bore can be lightly polished but only with crocus cloth. Replace the cylinder if the bore
is scored, pitted or heavily corroded. Honing the bore to restore the surface is not recommended.
Inspect the cylinder pistons. The piston surfaces should be smooth and free of scratches, scoring
and corrosion. Replace the pistons if worn, scored, or corroded. Do attempt to restore the surface
Discard the old piston cups and the spring and expander. These parts are not reusable. The
original dust boots may be reused but only if they are in good condition.
Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul
DISASSEMBLY
1. Remove push rods and boots. 2. Press pistons, cups and spring and expander out of cylinder
bore. 3. Remove bleed screw.
ASSEMBLY
1. Lubricate wheel cylinder bore, pistons, piston cups and spring and expander with clean brake
fluid. 2. Install first piston in cylinder bore. Then install first cup in bore and against piston. Be sure
lip of piston cup is facing inward (toward spring and
expander) and flat side is against piston.
3. Install spring and expander followed by remaining piston cup and piston. 4. Install boots on each
end of cylinder and insert push rods in boots. 5. Install cylinder bleed screw.
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Antilock Brake System Bleeding Procedures
GENERAL INFORMATION
master cylinder
- combination valve
- left rear wheel
- right rear wheel
- right front wheel
- left front wheel
MANUAL BLEEDING
PRESSURE BLEEDING
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 4518
GENERAL INFORMATION
fluid as needed.
master cylinder
- combination valve
- right rear wheel
- left rear wheel
- right front wheel

- left front wheel
MANUAL BLEEDING
Bleed Hose Setup
immersed in fluid.
PRESSURE BLEEDING
6921 or equivalent.
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Brake Caliper: Specifications
Piston Diameter LD 2.126 in
Piston Diameter HD 2.205 in
Mounting Bolts 24 ft.lb
Adapter Bolts 210 ft.lb

Brake Caliper: Testing and Inspection
CLEANING
Clean the caliper components with clean brake fluid or brake clean only. Wipe the caliper and
piston dry with lint free towels or use low pressure compressed air.
CAUTION: Do not use gasoline, kerosene, thinner, or similar solvents. These products may leave a
residue that could damage the piston and seal.
INSPECTION
The piston is made from a phenolic resin (plastic material) and should be smooth and clean.
The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface
CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never
interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore
and piston tolerances are different.
Polishing Piston Bore
The bore can be lightly polished with a brake hone to remove very minor surface imperfections.
The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would
increase bore diameter more than 0.025 mm (0.001 inch).
Brake Caliper: Service and Repair Removal and Installation
REMOVAL
1. Raise and support vehicle. 2. Remove front wheel and tire assembly.
Caliper
3. Remove caliper brake hose bolt, washers and hose. 4. Remove caliper mounting bolts. 5. Tilt the
bottom of the caliper up and remove it from the adapter. 6. Remove anti-rattle springs.
NOTE: Upper and lower anti-rattle springs are not interchangeable.
INSTALLATION
1. Clean caliper mounting adapter and anti-rattle springs. Then lubricate anti-rattle springs and
mounting bolts with Mopar high temperature or
multi-mileage grease.
2. Install anti-rattle springs. 3. Tilt the top of the caliper over rotor and under adapter. Then push
the bottom of the caliper down onto the adapter. 4. Install caliper mounting bolts and tighten to 33
Nm (24 ft. lbs.). 5. Install brake hose to caliper with new seal washers and tighten fitting bolt to 24
Nm (18 ft. lbs.).
CAUTION: Be sure the front hose is free of kinks or bends and is clear of all chassis and
suspension components.
6. Fill master cylinder with Mopar brake fluid or equivalent. 7. Fill and bleed brake system. 8. Install
wheel and tire assembly and lower vehicle. 9. Apply brakes several times to seat caliper pistons
and brake shoes. Be sure firm pedal is obtained before moving vehicle.
Brake Caliper: Service and Repair Disassembly and Assembly
DISASSEMBLY
1. Drain the brake fluid from caliper.
C-Clamp One Piston
2. C-clamp a block of wood over one piston.
Protect Caliper Piston
3. Take another piece of wood and pad it with one-inch thickness of shop towels. Place this piece
in the outboard shoe side of the caliper in front of
the other piston. This will cushion and protect caliper piston during removal.
4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the
caliper brake hose port. Use only enough air
pressure to ease the piston out.
CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a
cracked piston.
WARNING: Never attempt to catch the piston as it leaves the bore. This could result in personal
injury.
5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the
first piston removed. This will seal the empty
piston bore.
6. Move the padded piece of wood in front of the other piston. 7. Remove the second piston using
the same procedure with short bursts of low pressure air.
Piston Dust Boot Removal
8. Remove piston dust boots with a suitable pry tool.
Piston Seal
9. Remove piston seals from caliper.
CAUTION: Do not scratch piston bore while removing the seals.
Disc Brake Caliper
10. Push caliper mounting bolt bushings out of the boot seals and remove the boot seals from the
caliper. 11. Remove caliper bleed screw.
ASSEMBLY
CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry.
1. Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid.
Piston Seal
2. Install new piston seals into caliper bores.
NOTE: Verify seal is fully seated and not twisted.
3. Lightly lubricate lip of new boot with silicone grease. Install boot on piston and work boot lip into
the groove at the top of piston. 4. Stretch boot rearward to straighten boot folds, then move boot
forward until folds snap into place.
Caliper Piston Installation
5. Install piston into caliper bore and press piston down to the bottom of the caliper bore by hand or
with hammer handle.
Seating Dust Boot

6. Seat dust boot in caliper with Handle C-4171 or equivalent and Installer:
- HD 56 mm caliper: Installer C-4340
- LD 54 mm caliper: Installer C-3716-A
7. Install the second piston and dust boot. 8. Lubricate caliper mounting bolt bushings, boot seals
and bores with silicone grease. 9. Install the boot seals into the caliper seal bores and center the
seals in the bores.
10. Install mounting bolt bushings into the boot seals and insure seal lip is engaged into the
bushing groves at either end of the bushing. 11. Install caliper bleed screw.
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component
Brake Fluid: Specifications
BRAKE FLUID
Specification ........................................................................................................................................
.................................................................. DOT 3
Standard ..............................................................................................................................................
........................................................... SAE J1703
NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703
standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake
system. Use only Mopar brake fluid or an equivalent from a tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An
open container of brake fluid will absorb moisture from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission
fluid, power steering fluid, etc.
Brake Fluid: Testing and Inspection
CAUTION:
The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic
fluid tends to absorb moisture from the atmosphere over periods of time. As hydraulic brake fluid
absorbs moisture, it effects the function of the vehicles hydraulic brake system. For this reason, the
vehicle's hydraulic brake fluid should be drained and replaced using fresh clean hydraulic brake
fluid every two years. When replacing hydraulic brake fluid, use only Mopar brake fluid or an
equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications.
BRAKE FLUID CONTAMINATION
Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the
presence of petroleum in the brake fluid.
To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid
separates into layers, there is mineral oil or other fluid contamination of the brake fluid.
If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the
rubber parts or components containing rubber coming into contact with the brake fluid. This
includes the master cylinder, proportioning valves, caliper seals, wheel cylinder seals, ABS
hydraulic control unit (HCU), and all hydraulic fluid hoses.
Brake Fluid: Service and Repair
Always clean the master cylinder filler caps before checking fluid level. If not cleaned, dirt from the
caps could enter the fluid.
Correct fluid level is to the bottom of the ring indicators on the reservoir. If necessary, add fluid to
correct the level. With disc brake equipped vehicles, fluid level in the front brake reservoir will
decrease slightly in proportion to normal lining wear.
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Brake Hose/Line: Description and Operation
Flexible rubber hose is used at both front brakes and at the rear axle junction block. Double walled
steel tubing is used to connect the master cylinder to the major hydraulic braking components and
then to he flexible rubber hoses.
Brake Hose/Line: Testing and Inspection
Flexible rubber hose is used at both front brakes and at the rear axle junction block. Inspect the
hoses whenever the brake system is serviced, at every engine oil change, or whenever the vehicle
is in for service. Inspect the hoses for surface cracking, scuffing, or worn spots. Replace any brake
hose immediately if the fabric casing of the hose is exposed due to cracks or abrasions.
Also check brake hose installation. Faulty installation can result in kinked, twisted hoses, or contact
with the wheels and tires or other chassis components. All of these conditions can lead to scuffing,
cracking and eventual failure.
The steel brake lines should be inspected periodically for evidence of corrosion, twists, kinks,
leaks, or other damage. Heavily corroded lines will eventually rust through causing leaks. In any
case, corroded or damaged brake lines should be replaced.
Factory replacement brake lines and hoses are recommended to ensure quality, correct length and
superior fatigue life. Care should be taken to make sure that brake line and hose mating surfaces
are clean and free from nicks and burrs. Also remember that right and left brake hoses are not
interchangeable.
Use new copper seal washers at all caliper connections. Be sure brake line connections are
properly made (not cross threaded) and tightened to recommended torque.
Brake Hose/Line: Service and Repair
GENERAL INFORMATION
Mopar preformed metal brake line is recommended and preferred for all repairs. However,
double-wall steel line can be used for emergency repair when factory replacement parts are not
readily available.
Inverted Flare And ISO Flare
Special, heavy duty tube bending and flaring equipment is required to prepare double wall brake
line. Special bending tools are needed to avoid kinking or twisting metal brake line. In addition,
special flaring tools are needed for a double inverted flare/ISO flare.
DOUBLE INVERTED FLARING
1. Cut off damaged tube with Tubing Cutter. 2. Ream cut edges of tubing to ensure proper flare. 3.
Install replacement tube nut on the tube. 4. Insert tube in flaring tool. 5. Place gauge form over the
end of the tube. 6. Push tubing through flaring tool jaws until tube contacts recessed notch in
gauge that matches tube diameter. 7. Tighten the tool bar on the tube
Cutting And Flaring Of Brake Fluid Tubing
8. Insert plug on gauge in the tube. Then swing compression disc over gauge and center tapered
flaring screw in recess of compression disc. 9. Tighten tool handle until plug gauge is squarely
seated on jaws of flaring tool. This will start the inverted flare.
10. Remove the plug gauge and complete the inverted flare.
ISO FLARING
To make a ISO flare use Snap-On Flaring Tool TFM-428 or equivalent. 1. Cut off damaged tube
with Tubing Cutter. 2. Remove any burrs from the inside of the tube. 3. Install tube nut on the tube.
4. Position the tube in the flaring tool flush with the top of the tool bar. Then tighten the tool bar on
the tube.
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 Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Description and Operation
Brake Proportioning/Combination Valve: Description and Operation
GENERAL INFORMATION
The combination valve contains a pressure differential valve and switch, metering valve and a
proportioning valve on 1500 models. The combination valve/ rear brake proportioning valve are not
repairable and must be replaced as an assembly.
PRESSURE DIFFERENTIAL SWITCH
The pressure differential switch is connected to the brake warning lamp. The switch is triggered by
movement of the switch valve. The purpose of the switch is to monitor fluid pressure in the
separate front/rear brake hydraulic circuits.
A decrease or loss of fluid pressure in either hydraulic circuit will cause the switch valve to shuttle
forward or rearward in response to the pressure differential. Movement of the switch valve will push
the switch plunger upward. This closes the switch internal contacts completing the electrical circuit
to the warning lamp. The switch valve may remain in an actuated position until repair restores
system pressures to normal levels.
METERING VALVE
The metering valve is used to balance brake action between the front disc and rear drum brakes.
The valve holds-off the initial pressure to the front disc brakes until the rear brake shoes retracting
springs are overcome. The valve is designed to maintain front brake fluid pressure at 241 - 517
kPa (35 - 75 psi) until the hold-off limit of 310 - 689 kPa (100 psi) is reached. At this point, the
metering valve opens completely permitting full fluid apply pressure to the front disc brakes. This
reduces front brake lining wear during low deceleration stops.
PROPORTIONING VALVE
The proportioning valve is used to balance front-rear brake action at high decelerations. The valve
allows normal fluid flow during moderate braking. The valve only controls fluid flow during high
decelerations brake stops, when a percentage of rear weight is transferred to the front wheels.
Valve > Component Information > Description and Operation > Page 4544
Brake Proportioning/Combination Valve: Testing and Inspection
METERING VALVE
Metering valve operation can be checked visually with the aid of a helper. Observe the metering
valve stem while a helper applies and releases the brakes. If the valve is operating correctly, the
stem will extend slightly when the brakes are applied and retract when the brakes are released. If
the valve is faulty, replace the entire combination valve as an assembly.
PRESSURE DIFFERENTIAL SWITCH
1. Have helper sit in drivers seat to apply brake pedal and observe red brake warning light. 2.
Raise vehicle on hoist. 3. Connect bleed hose to a rear wheel cylinder and immerse hose end in
container partially filled with brake fluid. 4. Have helper press and hold brake pedal to floor and
observe warning light.
a. If warning light illuminates, switch is operating correctly. b. If light fails to illuminate, check circuit
fuse, bulb, and wiring. The parking brake switch can be used to aid in identifying whether or not the
brake light bulb and fuse is functional. Repair or replace parts as necessary and test differential
pressure switch operation again.
5. If warning light still does not illuminate, switch is faulty. Replace combination valve assembly,
bleed brake system and verify proper switch and
valve operation.
PROPORTIONING VALVE
Road test the vehicle and make several hard brake applications. If a premature rear wheel skid
occurs this could be an indication the proportioning valve has malfunctioned. 1. Inspect and verify
the rear brakes are clean, adjusted and operating properly. 2. Check the pressure in and out of the
valve. The pressure should be equal up to the 250 psi. split point. 3. Above 250 psi. the output
pressure should decrease on a 0.43 slope.
Brake Proportioning/Combination Valve: Service and Repair
REMOVAL
housing opening.
Access Cover
Pressure Differential Switch
7. From the engine compartment disconnect the pressure differential switch wire from the
combination valve. Then remove the brake lines from the
switch side of the valve.

Combination Valve Brake Lines
8. Through the access cover opening, remove the other two brake lines from the valve. 9. Remove
the valve mounting bolt and remove the valve through access cover opening.
INSTALLATION
1. Position the valve on the mounting bracket. 2. Install the mounting bolt and tighten to 24 Nm (18
ft. lbs.). 3. Install the brake lines and tighten to 13 Nm (115 inch lbs.). 4. Install the reservoir in the
engine compartment. Connect the pump motor connector and pump hose. 5. Install the washer
reservoir mounting screws. 6. Connect the horn connector and in-stall the access cover. 7. Install
the extension panel. 8. Install left turn signal housing. 9. Fill and bleed brake system.
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly -
Antilock Brakes > Component Information > Specifications > With Four Wheel Antilock Brakes
Hydraulic Control Assembly - Antilock Brakes: Specifications With Four Wheel Antilock Brakes
Bracket Nuts ........................................................................................................................................

................................................ 12 Nm (102 inch lbs.) Mounting Bolts .................................................
........................................................................................................................................ 15 Nm (11 ft.
lbs.)
Antilock Brakes > Component Information > Specifications > With Four Wheel Antilock Brakes > Page 4551
Hydraulic Control Assembly - Antilock Brakes: Specifications With Rear Wheel Antilock Brakes
Bracket Nuts ........................................................................................................................................

................................................ 12 Nm (102 inch lbs.) Valve Bolt ........................................................
......................................................................................................................................... 24 Nm (18
ft. lbs.)
Antilock Brakes > Component Information > Description and Operation > General Information
Hydraulic Control Assembly - Antilock Brakes: Description and Operation General Information
The controller-antilock brake module is used to monitor wheel speeds and modulates (control)
hydraulic pressure in each brake channel. The modulated hydraulic pressure is used to prevent
wheel lock up during braking. The CAB also provides a vehicle speed signal (VSS) to the
powertrain control module.
Antilock Brakes > Component Information > Description and Operation > General Information > Page 4554
Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Control Unit
(HCU)
Description
The HCU on the EBC 2 has only a separate rear valve body.
The HCU on the EBC 325 has two integral valve bodies for controlling the front and rear brakes.
Within the HCU are solenoids, valves, check valves, and a reset switch necessary to apply and
release brake pressure as required to avoid wheel lockup, keep the wheels rolling, and maintain
optimum deceleration.
The isolation valve is normally open, allowing unrestricted flow from the master cylinder to the
wheels. When the CAB determines antilock intervention is required, the valve closes to isolate the
master cylinder hydraulic circuit. Fluid is trapped in the circuit and then prevented from reaching the
wheels.
The dump valve is pulsed on and off by the CAB. This valve cycles only if the isolation valve is
closed. When dump is on, it allows fluid to the low pressure accumulator for temporary storage.
This causes the pressure to the wheel to decrease. When the valve is off, fluid is allowed to the
wheel.
The brake return check valve allows the HCU to drain faster after the ABS stop, when the brake is
released.
The Reset Switch is positioned in the HCU to monitor the master cylinder (input), rear brake
(output) and accumulator pressure. During normal braking, pressure is equal for input and output
and the switch remains open. During an Antilock stop the switch will close as the isolation valve is
cycled and pressure becomes unequal between input and output. At the end of an ABS stop the
isolation valve will open as master cylinder pressure and rear pressure equalize. The switch is
used to monitor correct operation of the HCU and to set a diagnostic trouble code if incorrect
pressure is detected.
When the brakes are applied, fluid is forced from the master cylinder outlet ports to the HCU inlet
ports. This pressure is transmitted through three normally open isolation valves inside the HCU,
then through the outlet ports of the HCU to the wheels. If the CAB senses that a wheel is about to
lock, based on wheel speed sensor data, it pulls the normally open isolation valve closed for that
circuit. This prevents any more fluid from entering that circuit. The CAB continues to look at the
sensor signal to determine if the wheel is still decelerating. If deceleration is still taking place, the
normally closed dump valve for that circuit is opened. This dumps any pressure that is trapped
between the normally open valve and the brake back into an accumulator. Once the affected circuit
comes back up to speed, the CAB returns the valves to their normal condition allowing the affected
brake to be reapplied. On the EBC 325 system, the pump and accumulators are used to provide
rapid response during the reapply sequence and to minimize pedal feedback.
GENERAL INFORMATION
CAB/HCU
The Hydraulic Control Unit (HCU) consists of a valve body, pump, accumulator and motor.
The pump, motor, and accumulator are combined into an assembly attached to the valve body. The
accumulator store the extra fluid which had to be dumped from the brakes. This is done to prevent
the wheels from locking up. The pump provides the fluid volume needed and is operated by a DC
type motor. The motor is controlled by the Controller Antilock Brake (CAB).
The valve body contains the solenoid valves. The valves modulate brake pressure during antilock
braking and are controlled by the CAB.
Antilock Brakes > Component Information > Description and Operation > General Information > Page 4555
The HCU provides three channel pressure control to the front and rear brakes. One channel
controls the rear wheel brakes in tandem. The two remaining channels control the front wheel
brakes individually.
During antilock braking, the solenoid valves are opened and closed as needed. The valves are not
static. They are cycled rapidly and continuously to modulate pressure and control wheel slip and
deceleration.
During normal braking, the HCU solenoid valves and pump are not activated. The master cylinder
and power booster operate the same as a vehicle without an ABS brake system.
During antilock braking, solenoid valve pressure modulation occurs in three stages, pressure
decrease, pressure hold, and pressure increase. The valves are all contained in the valve body
portion of the HCU.
Pressure Decrease The inlet valve is closed and the outlet valve is opened during the pressure
decrease cycle.
A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or
more wheels. At this point, the CAB closes the inlet to prevent the driver from further increasing the
brake pressure and locking the brakes. The CAB then opens the outlet valve, which also opens the
return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed to
prevent wheel lock.
Once the period of high wheel slip has ended, the CAB closes the outlet valve and begins a
pressure increase or hold cycle as needed.
Pressure Hold Both solenoid valves are closed in the pressure hold cycle. Fluid apply pressure in
the control channel is maintained at a constant rate. The CAB maintains the hold cycle until sensor
inputs indicate a pressure change is necessary.
Pressure Increase The inlet valve is open and the outlet valve is closed during the pressure
increase cycle. The pressure increase cycle is used to counteract unequal wheel speeds. This
cycle controls re-application of fluid apply pressure due to changing road surfaces or wheel speed.
If the Controller Antilock Brake (CAB) senses that rear wheel speed deceleration is excessive, it
will energize a isolation solenoid by providing battery voltage to the solenoid. This prevents a
further increase of driver induced brake pressure to the rear wheels. If this initial action is not
enough to prevent rear wheel lock-up, the CAB will momentarily energize a dump solenoid (the
CAB energizes the dump solenoid by providing battery voltage to the solenoid). This opens the
dump valve to vent a small amount of isolated rear brake pressure to an accumulator. The action of
fluid moving to the accumulator reduces the isolated brake pressure at the wheel cylinders. The
dump (pressure venting) cycle is limited to very short time periods (milliseconds). The CAB will
pulse the dump valve until rear wheel deceleration matches the vehicle deceleration rate or the
desired slip rate programmed into the CAB. The system will switch to normal braking once wheel
locking tendencies are no longer present.
A predetermined maximum number of consecutive dump cycles can be performed during any one
antilock stop. If excessive dump cycles occur, a DTC will be set and stored in the CAB memory. If
during an antilock stop, the driver releases the brake pedal, the reset switch contacts will open.
This signal to the CAB is an indication that pressure has equalized across the RWAL valve. The
CAB will then reset the dump cycle counter in anticipation of the next antilock stop. Additionally,
any fluid stored in the accumulator will force its way past the dump valve, back into the hydraulic
circuit and return to the master cylinder.
A fuse internal to the CAB, provides a fail-safe device which prevents unwanted control over the
isolation and dump solenoids. The fuse is in series with the isolation and dump solenoids output
circuits. If the internal fuse is open, the CAB cannot provide voltage to energize either solenoid and
antilock stops are prevented. If the fuse is open, the braking system will operate normally but
without antilock control over rear brake pressure.
Antilock Brakes > Component Information > Service and Repair > Front Antilock Valve Replacement
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Front Antilock Valve
Replacement
NOTE: If the antilock control assembly needs to be replaced, the rear axle type and tire revolutions
per mile must be programed into the new Controller Antilock Brake (CAB).
REMOVAL
housing opening.
Access Cover
hose. 6. Remove the reservoir from the engine compartment. 7. Disconnect battery cables and
remove the battery. 8. Remove the power distribution center. 9. Remove the battery and power
distribution center mount.
10. Push the harness connectors locks to release the locks, then remove the connectors from the
CAB.
Antilock Brakes > Component Information > Service and Repair > Front Antilock Valve Replacement > Page 4558
HCU Brake Lines
11. Disconnect brake lines from Hydraulic Control Unit (HCU). 12. Remove the front mounting bolt
through access opening. 13. Remove the rear mounting bolt from the engine compartment. 14. Tilt
the assembly upward were the brake lines attach and remove the assembly from the mounting
bracket.
INSTALLATION
1. Install the assembly into the mounting bracket. 2. Install mounting bolts and tighten to 15 Nm (11
ft. lbs.). 3. Install the brake lines to HCU and tighten to 13 Nm (115 inch lbs.). 4. Connect the CAB
harness connectors and lock in place. 5. Install the reservoir in the engine compartment. Connect
the pump motor connector and pump hose. 6. Install the washer reservoir mounting screws. 7.
Install the battery and power distribution center mount. 8. Install the power distribution center. 9.
Install the battery and battery cables.
10. Connect the horn connector and install the access cover. 11. Install the extension panel. 12.
Install left turn signal housing. 13. Bleed the brake system.
Antilock Brakes > Component Information > Service and Repair > Front Antilock Valve Replacement > Page 4559
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Rear Antilock Valve
Replacement
REMOVAL
housing opening.
Access Cover
3. Disconnect the horn connector and remove the access cover. 4. Remove one brake line from the
rear antilock valve through the access cover opening. 5. From the engine compartment, disconnect
antilock valve harness connector from the controller. 6. Remove the other brake line and mounting
bolt from the antilock valve. 7. Remove rear antilock valve.
INSTALLATION
1. Position rear antilock valve on the valve bracket. 2. Install the mounting bolt and tighten to 24
Nm (18 ft. lbs.). 3. Install the brake lines and tighten to 15 Nm (130 inch lbs.). 4. Connect wiring
harness wires to the controller. 5. Connect the horn connector and install the access cover. 6.
Install the extension panel. 7. Install left turn signal housing. 8. Fill and bleed brake system.
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Specifications > With Antilock Brakes
Brake Master Cylinder: Specifications With Antilock Brakes
Mounting Nuts .....................................................................................................................................

..................................................... 23 Nm (17 ft. lbs.)
Component Information > Specifications > With Antilock Brakes > Page 4564
Brake Master Cylinder: Specifications Without Antilock Brakes
Mounting Nuts .....................................................................................................................................

..................................................... 23 Nm (17 ft. lbs.)
Brake Master Cylinder: Description and Operation
A two-piece master cylinder is used on all models. The cylinder body containing the primary and
secondary pistons is made of aluminum. The removable fluid reservoir is made of nylon reinforced
with glass fiber. The reservoir is the only serviceable component.
The fluid compartments of the nylon reservoir are interconnected to permit fluid level equalization.
However, the equalization feature does not affect circuit separation in the event of a front or rear
brake malfunction. The reservoir compartments will retain enough fluid to operate the functioning
hydraulic circuit.
Care must be exercised when removing/installing the master cylinder connecting lines. The threads
in the cylinder fluid ports can be damaged if care is not exercised. Start all brake line fittings by
hand to avoid cross threading.
The cylinder reservoir can be replaced when necessary. However, the aluminum body section of
the master cylinder is not a repairable component.
NOTE: If diagnosis indicates that an internal malfunction has occurred, the aluminum body section
must be replaced as an assembly.
Brake Master Cylinder: Testing and Inspection
1. Start engine and check booster vacuum hose connections. A hissing noise indicates vacuum
leak. Correct any vacuum leak before proceeding. 2. Stop engine and shift transmission into
Neutral. 3. Pump brake pedal until all vacuum reserve in booster is depleted. 4. Press and hold
brake pedal under light foot pressure. The pedal should hold firm, if the pedal falls away master
cylinder is faulty (internal
leakage).
5. Start engine and note pedal action it should fall away slightly under light foot pressure then hold
firm. If no pedal action is discernible, power
booster, vacuum supply, or vacuum check valve is faulty. Proceed to the POWER BOOSTER
VACUUM TEST.
6. If the POWER BOOSTER VACUUM TEST passes, rebuild booster vacuum reserve as follows:
Release brake pedal. Increase engine speed to
1500 rpm, close the throttle and immediately stop turn off ignition to stop engine.
7. Wait a minimum of 90 seconds and try brake action again. Booster should provide two or more
vacuum assisted pedal applications. If vacuum
assist is not provided, booster is faulty.

Component Information > Service and Repair > Master Cylinder Bleeding
Brake Master Cylinder: Service and Repair Master Cylinder Bleeding
GENERAL INFORMATION
A new master cylinder should be bled before installation on the vehicle. Required bleeding tools
include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from
brake line.
BLEEDING PROCEDURE
1. Mount master cylinder in vise.
Master Cylinder Bleeding - Typical
2. Attach bleed tubes to cylinder outlet ports. Then position each tube end into the reservoir. 3. Fill
reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release
pistons and allow them to return under spring pressure. Continue bleeding operations
until air bubbles are no longer visible in fluid.

Component Information > Service and Repair > Master Cylinder Bleeding > Page 4569
Brake Master Cylinder: Service and Repair Master Cylinder Replacement
REMOVAL
Master Cylinder
1. Remove brake lines from master cylinder. 2. Remove master cylinder mounting nuts. 3. Remove
master cylinder from mounting studs.
INSTALLATION
NOTE: If master cylinder is replaced, bench bleed before installation.
1. Position master cylinder on mounting studs. 2. Install mounting nuts and tighten to 23 Nm (17 ft.
lbs.). 3. Install brake lines and tighten to 16 Nm (145 inch lbs.). 4. Bleed brake system.
Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement
REMOVAL
1. Remove the master cylinder. 2. Remove reservoir cap and empty fluid into drain container.
Reservoir Retaining Pins
3. Remove pins that retain reservoir to master cylinder. Use hammer and pin punch to remove
pins. 4. Clamp cylinder body in vise with brass protective jaws.
Loosening Reservoir
5. Loosen reservoir from grommets with pry tool.

6. Remove reservoir by rocking it to one side and pulling free of grommets.
7. Remove old grommets from cylinder body.
INSTALLATION
CAUTION: Install the grommets using fingers only. Installation with tools may cut or tear the
grommets.
1. Lubricate new grommets with clean brake fluid and Install new grommets in cylinder body. Use
finger pressure to install and seat grommets. 2. Position the reservoir into the grommets. Then rock
reservoir back and forth while pressing downward to seat it in grommets. 3. Install the reservoir
retaining pins into the cylinder body. 4. Bleed master cylinder on bench before installation.
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Wheel Cylinder: Specifications
Bolts/Nuts 15 ft.lb
Wheel Cylinder Components-Typical

Information > Service and Repair > Wheel Cylinder Removal and Installation
Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation
REMOVAL
1. Remove wheel and tire assembly. 2. Remove brake drum. 3. Disconnect wheel cylinder brake
line. 4. Remove brake shoe return springs and move shoes out of engagement with cylinder push
rods. 5. Remove cylinder attaching bolts and remove cylinder from support plate.
INSTALLATION
1. Apply bead of silicone sealer around cylinder mounting surface of support plate. 2. Install
cylinder mounting bolts and tighten to 20 Nm (15 ft. lbs.). 3. Connect brake line to cylinder. 4. Install
brake shoe return spring. 5. Install brake drum. 6. Install wheel and tire assembly. 7. Bleed brake
system.
Wheel Cylinder: Service and Repair Cleaning and Inspection
CLEANING
Clean the cylinder and pistons with clean brake fluid or brake cleaner only. Do not use any other
cleaning agents.
Dry the cylinder and pistons with compressed air. Do not use rags or shop towels to dry the
cylinder components. Lint from cloth material will adhere to the cylinder bores and pistons.
INSPECTION
Inspect the cylinder bore. Light discoloration and dark stains in the bore are normal and will not
impair cylinder operation.
The cylinder bore can be lightly polished but only with crocus cloth. Replace the cylinder if the bore
is scored, pitted or heavily corroded. Honing the bore to restore the surface is not recommended.
Inspect the cylinder pistons. The piston surfaces should be smooth and free of scratches, scoring
and corrosion. Replace the pistons if worn, scored, or corroded. Do attempt to restore the surface
Discard the old piston cups and the spring and expander. These parts are not reusable. The
original dust boots may be reused but only if they are in good condition.
Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul
DISASSEMBLY
1. Remove push rods and boots. 2. Press pistons, cups and spring and expander out of cylinder
bore. 3. Remove bleed screw.
ASSEMBLY
1. Lubricate wheel cylinder bore, pistons, piston cups and spring and expander with clean brake
fluid. 2. Install first piston in cylinder bore. Then install first cup in bore and against piston. Be sure
lip of piston cup is facing inward (toward spring and
expander) and flat side is against piston.
3. Install spring and expander followed by remaining piston cup and piston. 4. Install boots on each
end of cylinder and insert push rods in boots. 5. Install cylinder bleed screw.
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement
Parking Brake Cable: Service and Repair Front Cable Replacement
NOTE: To compress tabs on cable housing retainers use a 1/2 inch boxed end wrench.
REPLACEMENT
1. Raise and support vehicle. 2. Loosen adjusting nut to create slack in front cable. 3. Remove the
front cable from the cable connector. 4. Compress cable housing retainer tabs at underbody
bracket and remove the cable from the bracket. 5. Lower vehicle. 6. Push ball end of cable out of
pedal clevis with small screwdriver.
Parking Brake Pedal
7. Compress cable housing retainer tabs at the pedal bracket and remove the cable. 8. Remove
the left cowl trim and sill plate. 9. Pull up the carpet and remove the cable from the body clip.
10. Pull up on the cable and remove the cable with the body grommet.
INSTALLATION
1. From inside vehicle, insert cable housing retainer into hole in pedal assembly. 2. Seat cable
retainer in pedal assembly. 3. Engage cable ball end in clevis on pedal assembly. 4. Route cable
along the top of the wheel well and clip in place. 5. Route cable through the floorpan and install
body grommet. 6. Place carpet down and install the left cowl trim and sill plate. 7. Raise and
support vehicle. 8. Route cable through the underbody bracket and seat cable housing retainer in
bracket. 9. Connect cable to the cable connector.
10. Perform park brake adjustment procedure. 11. Lower vehicle.

Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement > Page 4585
Parking Brake Cable: Service and Repair Rear Cable Replacement
NOTE: To compress tabs on cable housing retainers use a 1/2 inch boxed end wrench.
REMOVAL
1. Release parking brakes. 2. Raise and support vehicle. 3. Loosen cable adjuster nut.
Rear Park Brake Cables
4. Remove the rear cables from the cable tensioner bracket. 5. Remove the right rear cable
retainer clip from the frame bracket. Then pull the cable through the bracket. 6. Compress tabs on
them left cable housing retainer. Then pull the cable through the frame bracket. 7. Pull the right
rear cable through the brake hose bracket and remove the cable retainers from the axle. 8.
Remove rear wheels and brake drums. 9. Disconnect each cable from the park brake lever.
10. Remove cable guide spring. 11. Compress cable tabs on each cable housing retainer at the
brake support plate. 12. Remove the cables from the brake support plates.
INSTALLATION
1. Install cable guide spring. 2. Install the brake drums. 3. Push each cable housing through the
brake support plate hole until the cable housing retainer tabs lock into place.
NOTE: Pull on the cable housing to ensure it is locked into place.
4. Pull back on the cable. Then push the cable in to engage the cable in the park brake lever.
NOTE: Pull on the cable end to ensure it is attached to the park brake lever.
5. Install the right cable retainers on the axle. The push the right cable through the hole in the brake
hose bracket. 6. Push both cables through the frame bracket. Push the left cable until the cable
housing retainer tabs lock into place. Install the retainer clip on the
right cable.
NOTE: The right cable must be installed in the top hole of the bracket and left cable in the bottom
hole.
7. Install the cables onto the cable tensioner bracket and install the cables into the cable
connectors. 8. Install the wheel and tire assemblies. 9. Perform park brake adjustment procedure.
10. Remove supports and lower vehicle.

Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component
Parking Brake Pedal: Service and Repair
REMOVAL
1. Raise and support vehicle. 2. Loosen adjuster nut at the tensioner. 3. Remove front cable from
the cable connector. 4. Lower vehicle. 5. Push ball end of cable out of pedal clevis on the pedal
assembly with small screwdriver. 6. Compress cable housing retainer at pedal bracket and remove
cable. Compress cable housing retainer with 1/2 boxed end wrench. 7. Disconnect the park brake
lamp switch. 8. Remove the park brake release from the knee blocker.
Parking Brake Pedal
9. Remove mounting bolts.
10. Remove assembly.
INSTALLATION
1. Install park brake pedal assembly and install mounting bolts. 2. Tighten mounting bolts to 54 Nm
(40 ft. lbs.). 3. Seat cable housing retainer into pedal bracket. 4. Install ball end of cable into clevis
on the pedal assembly. 5. Raise vehicle and install front cable into the cable connector. 6. Perform
park brake adjustment procedure. 7. Lower vehicle.
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Vacuum Brake Booster: Specifications
DIMENSIONS:
Type .....................................................................................................................................................
...................................... 250 mm Dual Diaphragm
TIGHTENING TORQUES:
Mounting Nuts .....................................................................................................................................

................................................. 18 Nm (13 ft. lbs.)
Vacuum Brake Booster: Description and Operation
Power assisted brakes are standard on all models. A dual diaphragm, vacuum operated power
brake booster is used to provide assist.
The booster unit consists of a single housing divided into separate chambers by two internal
diaphragms. The outer edge of the diaphragm is secured to the housing.
The booster push rod, which connects the booster to the brake pedal and master cylinder, is
attached to the center of the diaphragm. A check valve is used in the booster inlet and is connected
to the engine intake manifold. Power assist is generated utilizing a combination of vacuum and
atmospheric pressure to boost brake assist.
NOTE: The power brake booster is not a repairable component. The booster must be replaced as
an assembly if diagnosis indicates a malfunction has occurred.
Information > Testing and Inspection > Operational Test
Vacuum Brake Booster: Testing and Inspection Operational Test
1. Start engine and check booster vacuum hose connections. A hissing noise indicates vacuum
leak. Correct any vacuum leak before proceeding. 2. Stop engine and shift transmission into
Neutral. 3. Pump brake pedal until all vacuum reserve in booster is depleted. 4. Press and hold
brake pedal under light foot pressure. The pedal should hold firm, if the pedal falls away master
cylinder is faulty (internal
leakage).
5. Start engine and note pedal action it should fall away slightly under light foot pressure then hold
firm. If no pedal action is discernible, power
booster, vacuum supply, or vacuum check valve is faulty. Proceed to the POWER BOOSTER
VACUUM TEST.
6. If the POWER BOOSTER VACUUM TEST passes, rebuild booster vacuum reserve as follows:
Release brake pedal. Increase engine speed to
1500 rpm, close the throttle and immediately stop turn off ignition to stop engine.
7. Wait a minimum of 90 seconds and try brake action again. Booster should provide two or more
vacuum assisted pedal applications. If vacuum
assist is not provided, booster is faulty.

Information > Testing and Inspection > Operational Test > Page 4596
Vacuum Brake Booster: Testing and Inspection Vacuum Test
Typical Booster Vacuum Test Connections
1. Connect vacuum gauge to booster check valve with short length of hose and T-fitting. 2. Start
and run engine at curb idle speed for one minute. 3. Observe the vacuum supply. If vacuum supply
is not adequate, repair vacuum supply. 4. Clamp hose shut between vacuum source and check
valve. 5. Stop engine and observe vacuum gauge. 6. If vacuum drops more than one inch HG (33
millibars) within 15 seconds, booster diaphragm or check valve is faulty.
Vacuum Brake Booster: Service and Repair
REMOVAL
1. Remove vacuum hoses from booster check valve. 2. Remove the master cylinder. 3. Inside
vehicle, remove steering column lower cover and knee blocker for access to brake pedal.
Booster Push Rod
4. Remove clip that attaches booster push rod to brake pedal pin.
Power Brake Booster
5. Remove booster mounting nuts. 6. Remove booster and booster dash seal.
INSTALLATION
1. Position seal on booster. 2. Mount booster on dash panel. 3. Slide booster push rod onto brake
pedal pin. Then secure push rod with retaining clip. 4. Install booster mounting nuts and tighten to
18 Nm (13 ft. lbs.). 5. Install knee blocker and lower column cover. 6. Install the master cylinder. 7.
Install booster vacuum hose. 8. Fill and bleed brake system.
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve >
Component Information > Testing and Inspection
Vacuum Brake Booster Check Valve: Testing and Inspection
1. Disconnect vacuum hose from check valve. 2. Remove check valve and valve seal from booster.
3. Use a hand operated vacuum pump for test.
Vacuum Check Valve And Seal
4. Apply 15 - 20 inches vacuum at large end of check valve. 5. Vacuum should hold steady. If
gauge on pump indicates vacuum loss, check valve is faulty and should be replaced.
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS
Wiring Corrosion
September 2004
Models
NOTE:
IMPORTANT:
Subject
Repair
Wiring Corrosion > Page 4610
Parts Information

NOTE:
Parts Return
Not required.
letter.
repair.
1. Open the hood.
off.
3).
3).
tray (Figure 4).

WARNING:
worn.
(Figure 5).
panel (Figure 5).
NOTE:
replacement.
following process:
CAUTION:
housing.
spliced.
(Figure 10).
CAUTION:
tubing (Figure 11).
NOTE:
13).
control unit.
NOTE:
control module.
drain tube grommet.
lbs. (7.9 N.m).
in. lbs. (7.9 N.m).
Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > NHTSA04V185000 > Apr > 04 >
Recall 04V185000: ABS Control Module Corrosion
Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-002-02 > Jan > 02
> Rear Axle - Vehicle Speed Is Inaccurate
NUMBER: 18-002-02
MODELS:
NOTE:
REAR AXLE.
DISCUSSION:
NOTE:

Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion
September 2004
Models
NOTE:
IMPORTANT:
Subject
Repair
Electronic Brake Control Module: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 4636
Parts Information

NOTE:
Parts Return
Not required.
letter.
repair.
1. Open the hood.
off.
3).
3).
tray (Figure 4).

WARNING:
worn.
(Figure 5).
panel (Figure 5).
NOTE:
replacement.
following process:
CAUTION:
housing.
spliced.
(Figure 10).
CAUTION:
tubing (Figure 11).
NOTE:
13).
control unit.
NOTE:
control module.
drain tube grommet.
lbs. (7.9 N.m).
in. lbs. (7.9 N.m).
Electronic Brake Control Module: > NHTSA04V185000 > Apr > 04 > Recall 04V185000: ABS Control Module Corrosion
Module Corrosion
Electronic Brake Control Module: > 18-002-02 > Jan > 02 > Rear Axle - Vehicle Speed Is Inaccurate
Inaccurate
NUMBER: 18-002-02
MODELS:
NOTE:
REAR AXLE.
DISCUSSION:
NOTE:

Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Inaccurate
NUMBER: 18-002-02
MODELS:
NOTE:
REAR AXLE.
DISCUSSION:
NOTE:

September 2004
Models
NOTE:
IMPORTANT:
Subject
Repair
Parts Information

NOTE:
Parts Return
Not required.
letter.
repair.
1. Open the hood.
off.
3).
3).
tray (Figure 4).

WARNING:
worn.
(Figure 5).
panel (Figure 5).
NOTE:
replacement.
following process:
CAUTION:
housing.
spliced.
(Figure 10).
CAUTION:
tubing (Figure 11).
NOTE:
13).
control unit.
NOTE:
control module.
drain tube grommet.
lbs. (7.9 N.m).
in. lbs. (7.9 N.m).
Module Corrosion
Brake Control Module > Component Information > Specifications > With RWAL Brakes
Mounting Screws .................................................................................................................................

....................................................... 4 Nm (36 ft. lbs.)
Brake Control Module > Component Information > Specifications > With RWAL Brakes > Page 4684
Screws .................................................................................................................................................
................................................. 4.4 Nm (39 inch lbs.)
Brake Control Module > Component Information > Locations > EBC 2
Brake Control Module > Component Information > Locations > EBC 2 > Page 4687
Brake Control Module > Component Information > Description and Operation > Kelsey-Hayes EBC Controller Antilock
Brake (CAB)
Brake (CAB)
and circuits that:
- (72) ROM Checksum
- (73) Watchdog
Brake (CAB) > Page 4690
braking.
CAB/HCU
scan tool.
GENERAL INFORMATION
SYSTEM SELF-TEST
CAB INPUTS
- Brake Lamp Switch
- Reset Switch
CAB OUTPUTS
RWAL Valve
- ABS Warning Lamp

Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System
REMOVAL
CAB.

Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 4695
10. Remove the CAB.
INSTALLATION
Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 4696
REMOVAL
INSTALLATION
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > 4WD
Switch > Component Information > Description and Operation
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Specifications > With Four Wheel Antilock Brakes
Front Bolt 11 ft.lb
Rear Bolt 18 ft.lb

Speed Sensor > Component Information > Specifications > With Four Wheel Antilock Brakes > Page 4708

Speed Sensor > Component Information > Locations > Component Locations
Speed Sensor > Component Information > Locations > Component Locations > Page 4711
Speed Sensor > Component Information > Locations > Component Locations > Page 4712
Speed Sensor > Component Information > Diagrams > Front
Speed Sensor > Component Information > Diagrams > Front > Page 4715
Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes
OPERATION
CIRCUIT OPERATION
Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 4718
Each sensor has:
AN, DN, BE and BR:
AB, AN and DN:
BE and BR:
cold.)
proper part.

Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 4719
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement
Front
REMOVAL
Wheel Speed Sensor
steering knuckle.
INSTALLATION
REMOVAL
sensor stud.

Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4722
INSTALLATION
REMOVAL
INSTALLATION
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4723
Front Tone Wheel
Tone Wheel
wheel is damaged.
Rear Tone Wheel
procedures.
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature
Sensor > Component Information > Locations

.
SYSTEM OPERATION
Sensor > Component Information > Testing and Inspection > Testing
Sensor > Component Information > Testing and Inspection > Page 4734
on battery tray.
REMOVAL
INSTALLATION
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Description and Operation
SYSTEM OPERATION
REMOVAL
Lower Shroud Screws
Shroud Pivot Point

Upper Shroud Screws
removal.
removal.
INSTALLATION
position.

Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Specifications

..................................................... 34 Nm (25 ft. lbs.)


Switch > Component Information > Service and Repair > 32RH Transmission
REMOVAL
from case.
INSTALLATION
Switch > Component Information > Service and Repair > 32RH Transmission > Page 4751
REMOVAL
from case.
INSTALLATION
Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
8w-10-2


SYSTEM OPERATION
operation.
Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information >
Locations

.
SYSTEM OPERATION
Testing and Inspection > Testing
Testing and Inspection > Page 4769
on battery tray.
REMOVAL
INSTALLATION
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Voltage
Alternator: Specifications Voltage
Powertrain Control Module (PCM) regulates charging system voltage by controlling the generator
field source (+) circuit.
The voltage range is 12.9 to 15.0 volts

Specifications > Voltage > Page 4775
Alternator: Specifications Rated Amps
Denso Part # 56027912 Rated SAE Amps ..........................................................................................

.......................................................................................................... 117 amps
Minimum Test Amps ............................................................................................................................

..................................................................... 90 amps
Denso Part # 56027913 Rated SAE Amps ..........................................................................................

.......................................................................................................... 136 amps
Minimum Test Amps ............................................................................................................................

................................................................... 120 amps
B+terminal,ground Terminal,generator Field Connections

Alternator: Description and Operation
SYSTEM OPERATION
The generator is belt-driven by the engine using a serpentine type drive belt. It is serviced only as a
complete assembly. If the generator fails for any reason, the entire assembly must he replaced.
As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a
current into the windings of the stator coil. Once the generator begins producing sufficient current. it
also provides the current needed to energize the rotor.
The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative
diodes for rectification. From the diodes, rectified DC current is delivered to the vehicle electrical
system through the generator battery and ground terminals.
Although the generators appear the same externally, different generators with different output
ratings are used on this vehicle. Be certain that the replacement generator has the same output
rating and part number as the original unit. Refer to Generator Ratings in the Specifications for
amperage ratings and part numbers.
Noise emitting from the generator may be caused by: worn, loose or defective bearings; a loose or
defective drive pulley; incorrect, worn, damaged or misadjusted fan drive belt; loose mounting
bolts; a misaligned drive pulley or a defective stator or diode.
Alternator: Service and Repair
REMOVAL
WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING

BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT
IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM.
1. Disconnect negative battery cable at battery 2. Remove generator drive belt.
Remove/Install Generator
3. Remove generator pivot and mounting bolts/nut. Position generator for access to wire
connectors.
Remove/Install Generator Connectors - Typical
4. Remove nuts from harness holddown, battery terminal, ground terminal and 2 field terminals.
Remove wire connectors. A typical generator wiring
harness is shown. Wiring harness routing as shown may be slightly different depending on vehicle
model and/or engine.
5. Remove generator from vehicle.
INSTALLATION
1. Position generator to engine and install wiring to rear of generator. Tighten all wiring fasteners as
follows:
- Battery terminal nut 8.5 N.m (75 in. lbs.)
- Ground terminal nut-8.5 N.m (75 in. lbs.)
- Field terminal nuts 2.8 N.m (25 iii. lbs.)
2. Install generator mounting fasteners and tighten as follows:
- Generator mounting bolt-41 N.m (30 ft. lbs.)

- Generator pivot bolt/nut-41 N.m (30 ft. lbs.)
CAUTION: -
Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be
damaged.
- When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water
pump will be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to
overheat.
3. Install generator drive belt. 4. Install negative battery cable to battery

Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information >
Voltage Regulator: Description and Operation
SYSTEM OPERATION
The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage
regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced
separately. If replacement is necessary, the PCM must be replaced.
Operation: The amount of DC current produced by the generator is controlled by EVR circuitry
contained within the PCM. This circuitry is connected in series with the generators second rotor
field terminal and its ground.
Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field.
The EVR circuitry monitors system line voltage and battery temperature (refer to Battery
Temperature Sensor for more information). It then compensates and regulates generator current
output accordingly. Also refer to Charging System Operation for additional information.
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
SYSTEM OPERATION
REMOVAL
Lower Shroud Screws
Shroud Pivot Point

Upper Shroud Screws
removal.
removal.
INSTALLATION
position.

Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Specifications

..................................................... 34 Nm (25 ft. lbs.)


Service and Repair > 32RH Transmission
REMOVAL
from case.
INSTALLATION
Service and Repair > 32RH Transmission > Page 4800
REMOVAL
from case.
INSTALLATION
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Starter Motor: Description and Operation
SYSTEM OPERATION
The starter motor incorporates several features to create a reliable, efficient, compact, and
lightweight unit. A planetary gear system (intermediate transmission) is used between the electric
motor and the pinion gear. This feature makes it possible to reduce the dimensions of the starter.
At the same time, it allows higher armature rotational speed and delivers increased torque through
the pinion gear to the starter ring gear on the automatic transmission torque converter.
The starter motors for all engines are activated by a solenoid mounted to the overrunning clutch
housing. However, the starter motor and solenoid are serviced only as a complete assembly If
either component is faulty or damaged, the entire starter assembly must be replaced.
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Starter Motor: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Raise and support the vehicle.
Starter Remove/Install
3. Remove the nut and lock washer from the starter mounting stud. Slide the automatic
transmission cooler tube bracket forward on the tubes far
enough for clearance.
4. Remove the screw from the upper starter mounting flange hole. 5. Move the starter towards the
front & the vehicle until the starter gear housing nose clears the bell-housing. Then tilt the nose
downwards and tower
the starter far enough to access the starter solenoid wire harness connection
6. Remove the two nuts that secure the battery cable and solenoid feed wire to the terminals on the
starter solenoid. Remove the starter solenoid wire
harness connector from the solenoid terminals.
7. Remove the starter motor from the vehicle. 8. Reverse the removal procedures to install. Tighten
the starter hardware as follows:
- Lower mounting nut - 68 N.m (50 ft. lbs.)

- Upper mounting screw - 68 N.m (50 ft. lbs.)
- Battery cable terminal nut - 14 N.m (120 in. lbs.)
- Solenoid wire harness terminal nut - 6 N.m (55 in. lbs.).

Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
8w-10-2
> Page 4808

> Page 4809

> Page 4810
SYSTEM OPERATION
> Page 4811
operation.
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Auxiliary Power Outlet: Diagram Information and Instructions
Introduction
8w-01-002
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

Auxiliary Power Outlet: Diagnostic Aids
position
problem

Testing For Voltage
Testing For Voltage


Probing Tool
Auxiliary Power Outlet: Description and Operation
SYSTEM OPERATION
An accessory power outlet is optional equipment on this model. The power outlet is installed in the
instrument panel accessory switch plate, which is located near the center of the instrument panel,
inboard of the radio. The power outlet base is secured by a snap fit within the instrument panel
accessory switch plate. A plastic protective cap snaps into the power outlet base when the power
outlet is not being used.
The power outlet base or receptacle shell is connected to ground, and an insulated contact in the
bottom of the shell is connected to battery current. The power outlet receives battery voltage from a
fuse in the Power Distribution Center (PDC) at all times.
While the power outlet is very similar to a cigar lighter base unit, it does not include the two small
spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar
lighter heating element to the insulated contact.
The power outlet receptacle unit and the accessory power outlet protective cap are available for
service. The power outlet receptacle cannot be repaired and, if faulty or damaged, it must be
replaced.
Auxiliary Power Outlet: Testing and Inspection

INJURY.
1. Check the fuse in the Power Distribution Center (PDC). If OK, go to Step 3. If not OK, repair the
shorted circuit or component as required and
replace the faulty fuse.
2. Check for battery voltage at the fuse in the PDC. If OK, go to Step 4. If not OK, repair the open
circuit to the battery as required. 3. Remove the plastic protective cap from the power outlet
receptacle. Check for continuity between the inside circumference of the power outlet
receptacle and a good ground. There should be continuity. If OK, go to Step 5. If not OK, go to
Step 6.
4. Check for battery voltage at the insulated contact located at the back of the power outlet
receptacle. If not OK, go to Step 6. 5. Disconnect and isolate the battery negative cable. Remove
the instrument panel accessory switch plate. Check for continuity between the ground
circuit cavity of the power outlet wire harness connector and a good ground. There should be
continuity. If OK, go to Step 7. If not OK, repair the open circuit to ground as required.
6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of
the power outlet wire harness connector. If OK,
replace the faulty power outlet receptacle. If not OK, repair the open circuit to the PDC fuse as
required.
Auxiliary Power Outlet: Service and Repair
REMOVAL

INJURY.
Cigar Lighter And Power Outlet
2. Unsnap the power outlet protective cap from the power outlet receptacle base.
Power Outlet Remove/Install - Typical
3. Look inside the power outlet receptacle base and note the position of the rectangular retaining
bosses of the mount that secures the receptacle base
to the instrument panel accessory switch plate.
4. Insert a pair of external snap ring pliers into the power outlet receptacle base and engage the
tips of the pliers with the retaining bosses of the
mount.
5. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using
a gentle rocking motion, pull the pliers and the
receptacle base out of tile mount.
6. Remove the power outlet mount from the instrument panel accessory switch plate. 7. Reverse
the removal procedures to install.
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
SYSTEM OPERATION

required.
Junction Block
Cap.
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Electronic Noise Suppressor: Description and Operation
SYSTEM OPERATION
Radio Frequency Interference (RFI) and ElectroMagnetic Interference (EMI) noise suppression is
accomplished primarily through circuitry internal to the radio receivers. These internal suppression
devices are only serviced as part of the radio receiver. External suppression devices that are
serviced, and should be checked in the case of RFI or EMI noise complaints, include the following:
-
Radio antenna base ground
- Radio chassis ground wire, strap, or bracket
- Engine-to-body ground strap (if the vehicle is so equipped)
- Cab-to-bed ground strap (if the vehicle is so equipped)
- Heater core ground strap (if the vehicle is so equipped)
- Resistor-type spark plugs
- Radio suppression-type secondary ignition wiring.
In addition, if the source of RFI or EMI noise is identified as a component on the vehicle (i.e.,
generator, blower motor, etc.), the ground path for that component should be checked. If excessive
resistance is found in that circuit, repair that circuit as required before considering any component
replacement.
If the source of the noise is identified as two-way mobile radio or telephone equipment, check the
equipment installation for the following: -
Power connections should be made directly to the battery, and fused as closely to the battery as
possible.
- The antenna should be mounted on the roof or toward the rear of the vehicle. Remember that
magnetic antenna mounts on the roof panel can adversely affect the operation of an overhead
console compass, if the vehicle is so equipped.
- The antenna cable should be fully shielded coaxial cable, should be as short as is practical, and
should be routed away from the factory-installed vehicle wire harnesses whenever possible.
- The antenna and cable must be carefully matched to ensure a low Standing Wave Ratio (SWR).
Fleet vehicles are available with an extra-cost RFI suppressed Powertrain Control Module (PCM).
This unit reduces interference generated by the PCM on some radio frequencies used in two-way
radio communications. However, this unit will not resolve complaints of RFI in the commercial AM
or FM radio frequency ranges
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Locations > Power Distribution Center
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Locations > Power Distribution Center > Page 4850
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Multiple Junction Connector: Diagram Information and Instructions
Introduction
8w-01-002
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

Multiple Junction Connector: Diagnostic Aids
position
problem

Testing For Voltage
Testing For Voltage


Probing Tool
Multiple Junction Connector: Electrical Diagrams
8w-12-2
8w-12-3
Diagrams
8w-12-6
8w-12-7
8w-12-8
8w-12-9
8w-12-10
8w-12-11
8w-12-12
8w-12-13
8w-12-14
8w-12-15
Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number
Multiple Junction Connector: Service and Repair
Junction Block
REMOVAL

INJURY.
1. Disconnect and isolate the battery negative cable. 2. Remove the knee blocker from the
instrument panel. See Knee Blocker Replacement. 3. Reach through the outboard side of the
instrument panel steering column opening to access and unplug all of the wire harness connectors
from the
junction block cavities.
Junction Block Remove/Install
4. With the driver side front door open, remove the two screws that secure the junction block to the
left instrument panel end bracket. 5. Reach through the outboard side of the instrument panel
steering column opening to remove the junction block from the left instrument panel end
bracket.
6. Reverse the removal procedures to install. Tighten the mounting screws to 2.8 N.m (25 in. lbs.).
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ignition Off Draw (IOD) Fuse <-->
[Power Interrupt Connector/Switch] > Component Information > Description and Operation
Ignition Off Draw (IOD) Fuse: Description and Operation
Ignition-Off Draw Fuse
SYSTEM OPERATION
All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is removed when the vehicle is
shipped from the factory. This fuse feeds various accessories that require battery current when the
ignition switch is in the Off position, including the clock. The fuse is removed to prevent battery
discharge during vehicle storage.
When removing or installing the IOD fuse, it is important that the ignition switch be in the Off
position. Failure to place the ignition switch in the Off position can cause the radio display to
become scram-bled when the IOD fuse is removed and replaced. Removing and replacing the IOD
fuse again, with the ignition switch in the Off position, will correct the scrambled display condition.
The IOD fuse should be checked if the radio or clock displays are inoperative. The IOD fuse is
located in the junction block. Refer to the label on the back of the junction block fuse access panel
for IOD fuse identification and location.
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations

Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information
> Locations

Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and
Ground Distribution > Ignition Off Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information >
SYSTEM OPERATION
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions
Auxiliary Power Outlet: Diagram Information and Instructions
Introduction
8w-01-002
> Diagram Information and Instructions > Page 4905
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

Auxiliary Power Outlet: Diagnostic Aids
position
problem

Testing For Voltage
Testing For Voltage


Probing Tool
> Page 4923
Auxiliary Power Outlet: Description and Operation
SYSTEM OPERATION
An accessory power outlet is optional equipment on this model. The power outlet is installed in the
instrument panel accessory switch plate, which is located near the center of the instrument panel,
inboard of the radio. The power outlet base is secured by a snap fit within the instrument panel
accessory switch plate. A plastic protective cap snaps into the power outlet base when the power
outlet is not being used.
The power outlet base or receptacle shell is connected to ground, and an insulated contact in the
bottom of the shell is connected to battery current. The power outlet receives battery voltage from a
fuse in the Power Distribution Center (PDC) at all times.
While the power outlet is very similar to a cigar lighter base unit, it does not include the two small
spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar
lighter heating element to the insulated contact.
The power outlet receptacle unit and the accessory power outlet protective cap are available for
service. The power outlet receptacle cannot be repaired and, if faulty or damaged, it must be
replaced.
> Page 4924
Auxiliary Power Outlet: Testing and Inspection

INJURY.
circuit to the battery as required. 3. Remove the plastic protective cap from the power outlet
receptacle. Check for continuity between the inside circumference of the power outlet
receptacle and a good ground. There should be continuity. If OK, go to Step 5. If not OK, go to
Step 6.
4. Check for battery voltage at the insulated contact located at the back of the power outlet
receptacle. If not OK, go to Step 6. 5. Disconnect and isolate the battery negative cable. Remove
the instrument panel accessory switch plate. Check for continuity between the ground
circuit cavity of the power outlet wire harness connector and a good ground. There should be
continuity. If OK, go to Step 7. If not OK, repair the open circuit to ground as required.
the power outlet wire harness connector. If OK,
replace the faulty power outlet receptacle. If not OK, repair the open circuit to the PDC fuse as
required.
> Page 4925
Auxiliary Power Outlet: Service and Repair
REMOVAL

INJURY.
2. Unsnap the power outlet protective cap from the power outlet receptacle base.
Power Outlet Remove/Install - Typical
3. Look inside the power outlet receptacle base and note the position of the rectangular retaining
bosses of the mount that secures the receptacle base
to the instrument panel accessory switch plate.
4. Insert a pair of external snap ring pliers into the power outlet receptacle base and engage the
tips of the pliers with the retaining bosses of the
mount.
5. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using
a gentle rocking motion, pull the pliers and the
receptacle base out of tile mount.
6. Remove the power outlet mount from the instrument panel accessory switch plate. 7. Reverse
Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Description and
Operation
SYSTEM OPERATION

required.
Junction Block
Cap.
Dodge Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Electronic Noise Suppressor: Description and Operation
SYSTEM OPERATION
Radio Frequency Interference (RFI) and ElectroMagnetic Interference (EMI) noise suppression is
accomplished primarily through circuitry internal to the radio receivers. These internal suppression
devices are only serviced as part of the radio receiver. External suppression devices that are
serviced, and should be checked in the case of RFI or EMI noise complaints, include the following:
-
Radio antenna base ground
- Radio chassis ground wire, strap, or bracket
- Engine-to-body ground strap (if the vehicle is so equipped)
- Cab-to-bed ground strap (if the vehicle is so equipped)
- Heater core ground strap (if the vehicle is so equipped)
- Resistor-type spark plugs
- Radio suppression-type secondary ignition wiring.
In addition, if the source of RFI or EMI noise is identified as a component on the vehicle (i.e.,
generator, blower motor, etc.), the ground path for that component should be checked. If excessive
resistance is found in that circuit, repair that circuit as required before considering any component
replacement.
If the source of the noise is identified as two-way mobile radio or telephone equipment, check the
equipment installation for the following: -
Power connections should be made directly to the battery, and fused as closely to the battery as
possible.
- The antenna should be mounted on the roof or toward the rear of the vehicle. Remember that
magnetic antenna mounts on the roof panel can adversely affect the operation of an overhead
console compass, if the vehicle is so equipped.
- The antenna cable should be fully shielded coaxial cable, should be as short as is practical, and
should be routed away from the factory-installed vehicle wire harnesses whenever possible.
- The antenna and cable must be carefully matched to ensure a low Standing Wave Ratio (SWR).
Fleet vehicles are available with an extra-cost RFI suppressed Powertrain Control Module (PCM).
This unit reduces interference generated by the PCM on some radio frequencies used in two-way
radio communications. However, this unit will not resolve complaints of RFI in the commercial AM
or FM radio frequency ranges
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Power
Distribution Center
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Power
Distribution Center > Page 4938
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Multiple Junction Connector: Diagram Information and Instructions
Introduction
8w-01-002
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

Multiple Junction Connector: Diagnostic Aids
position
problem

Testing For Voltage
Testing For Voltage


Probing Tool
Multiple Junction Connector: Electrical Diagrams
8w-12-2
8w-12-3
Diagrams
8w-12-6
8w-12-7
8w-12-8
8w-12-9
8w-12-10
8w-12-11
8w-12-12
8w-12-13
8w-12-14
8w-12-15
Multiple Junction Connector: Service and Repair
Junction Block
REMOVAL

INJURY.
1. Disconnect and isolate the battery negative cable. 2. Remove the knee blocker from the
instrument panel. See Knee Blocker Replacement. 3. Reach through the outboard side of the
instrument panel steering column opening to access and unplug all of the wire harness connectors
from the
junction block cavities.
Junction Block Remove/Install
4. With the driver side front door open, remove the two screws that secure the junction block to the
left instrument panel end bracket. 5. Reach through the outboard side of the instrument panel
steering column opening to remove the junction block from the left instrument panel end
bracket.
Dodge Workshop Manuals > Power and Ground Distribution > Ignition Off Draw (IOD) Fuse <--> [Power Interrupt
Connector/Switch] > Component Information > Description and Operation
SYSTEM OPERATION
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Relay Box > Component Information > Locations

Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations

Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution >
Ignition Off Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation
SYSTEM OPERATION
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 4997
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:

NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
Technical Service Bulletins for Alignment: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair >
Page 5005
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:

NOTE:
Page 5006
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

Page 5007
NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Technical Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised
NUMBER: 19-07-00
GROUP: Steering

following:
NOTE:
DIAGNOSIS:
box).
NOTE:
NOTE:
ROADS, ETC.).

Technical Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised >
Page 5012
NOTE:

new cotter pin.
Technical Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised >
Page 5013
specifications.
NOTE:
VAN/WAGONS.

Other Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised
NUMBER: 19-07-00
GROUP: Steering

following:
NOTE:
DIAGNOSIS:
box).
NOTE:
NOTE:
ROADS, ETC.).

Other Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised >
Page 5019
NOTE:

new cotter pin.
Other Service Bulletins for Alignment: > 19-07-00 > Sep > 00 > Steering Wander - Diagnosis and Correction Revised >
Page 5020
specifications.
NOTE:
VAN/WAGONS.

Other Service Bulletins for Alignment: > Page 5021
Alignment: By Symptom
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:
NOTE:
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
CAUSE STEERING WANDER. HOWEVER,
THE AIR LEVELING SYSTEM MAY BE INSTALLED ON THE VEHICLE TO ADJUST VEHICLE
ATTITUDE. IF THE VEHICLE IS EQUIPPED WITH AN AIR LEVELING SYSTEM, ENSURE THE
SYSTEM IS INFLATED TO THE MANUFACTURERS SPECIFICATIONS PRIOR TO
PROCEEDING.
NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
GROUP: Steering

OVERVIEW:
This bulletin provides a diagnostic procedure for steering sensitivity.
MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:
NOTE:
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:
NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Page 5032
Alignment: Specifications
CASTER:
Preferred ..............................................................................................................................................
...................................................................... +2.5° Range .................................................................
..................................................................................................................................................... ±
............................................................................. 1.25°
CAMBER:
Preferred ..............................................................................................................................................
........................................................................... 0° Range .................................................................
....................................................................................................................................................... ±
0.6° Maximum Right/Left Difference ....................................................................................................
................................................................................ 0°
TOTAL TOE-IN:
Preferred ..............................................................................................................................................
........................................................................... 0° Range .................................................................
..................................................................................................................................................... ±
............................................................................. 0.05°
THRUST ANGLE
Preferred ..............................................................................................................................................
........................................................................... 0° Range .................................................................
....................................................................................................................................................... ±
0.4°
Page 5033
Alignment: Description and Operation
GENERAL INFORMATION
Wheel Alignment Measurements
Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The
positioning is accomplished through suspension and steering linkage adjustments. An alignment is
considered essential for efficient steering, good directional stability and to minimize tire wear. The
most important measurements of an alignment are caster, camber and toe.
Caster - is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the
knuckle forward provides negative caster. Tilting the top of the knuckle rearward provides positive
caster. Positive caster promotes directional stability. This angle enables the front wheels to return
to a straight ahead position after turns.
Camber - is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the
top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides
positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire.
Toe - is the difference between the leading inside edges and trailing inside edges of the front tires.
Uneven wheel toe position cause's unstable steering, uneven tire near and steering wheel
off-center. The wheel toe position is the final front wheel alignment adjustment.
Thrust Angle - is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust
angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged
component(s) must be replaced to correct the thrust angle.
Page 5034
Alignment: Testing and Inspection
PRE-ALIGNMENT INSPECTION
Before starting wheel alignment, the following inspection and necessary corrections must be
completed. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for
wear or adjustment. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4.
Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5.
Inspect suspension components for wear and noise.
Page 5035
Alignment: Service and Repair
GENERAL INFORMATION
The front wheel alignment angles should be set to preferred specifications. This will prevent
abnormal tire tread wear.
Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each
bumper at the center and jounce the vehicle up and down several times. Always release the
bumper in the down position.
CAMBER AND CASTER
Camber and caster angle adjustments involve repositioning the upper suspension arm pivot bar.
Alignment adjustments are accomplished by changing the position of the pivot bar.
Adjuster Tool 8199, or equivalent is used to adjust the camber and caster angles.
Tools Attached To Frame
1. Clamp the tool on the upper suspension arm frame bracket. Use the two clamp bolts to attach
the tool to the bracket. 2. With the adjustment tools installed, loosen both upper suspension arm
bolts completely. 3. Tighten or loosen the tool adjustment bolts to move the upper suspension arm
inward or outward to obtain the proper camber and caster
angles.
Caster: Move the rear position of the pivot bar in or out. This will change the caster angle
significantly and camber angle only slightly. To retain the camber while adjusting caster, move the
rear pivot bar in or out. Move the forward pivot very slightly in the opposite direction.
NOTE: For example, to increase a positive caster angle move the rear position of the pivot bar
inward. Move the front of pivot bar outward until the original camber angle is obtained.
Camber: Move the forward position of the pivot bar in or out. This will change the camber angle
significantly and caster angle only slightly. The camber angle should be adjusted to the service
specifications. Tighten the pivot bar bolts to 298 Nm (220 ft. lbs.).
Page 5036
TOE POSITION
The wheel toe position is the final adjustment procedure. 1. Secure the steering wheel with the
front wheels in the straight ahead position. For power steering vehicles, start the engine before
straightening
the wheels.
2. Loosen the tie rod adjustment sleeve clamp bolts.
3. Adjust the wheel toe position by rotating the tie rod adjustment sleeve. 4. Position the adjustment
sleeve clamps so the ends are not located at the sleeve slot. Tighten the tie rod sleeve clamps to:
- Standard Duty: 23 Nm (17 ft. lbs.)
- Heavy Duty: 35 Nm (26 ft. lbs.)
Ensure the clamp bolts are located at the underside of the sleeve.
5. Verify camber, caster and toe position.

Page 5037
Adjuster, Caster & Camber 8119

Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Specifications
Center Link: Specifications
To Idler Arm Nut ..................................................................................................................................

.................................................... 64 Nm (47 ft. lbs.)
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Front Steering Knuckle: Description and Operation
The steering knuckles are used to steer the vehicle. The knuckles are mounted to the ball studs at
the end of the suspension arms.
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Front Steering Knuckle: Service and Repair
REMOVAL
1. Raise and support the vehicle. Place a jack under outer end of lower suspension arm. 2.
Remove wheel and tire assembly. 3. Remove disc brake caliper and rotor. 4. Remove tie rod from
steering knuckle arm.
5. Remove cotter pins and nuts from upper and lower ball joints. 6. Use Ball Stud Remover
C-3564-A, or equivalent to free upper and lower ball joints from steering knuckle. 7. Remove tool
and steering knuckle assembly. 8. Remove the rotor dust shield and steering arm from steering
knuckle.
INSTALLATION
1. Install brake rotor dust shield on steering knuckle and tighten bolts to 24 Nm (18 ft. lbs.). 2.
Install steering arm on knuckle and tighten nuts to;
- LD 5/8-18 nut: 294 Nm (217 ft. lbs.)
- HD 3/4-16 nut: 330 Nm (225 ft. lbs.)
3. Position steering knuckle on upper and lower ball joints and install nuts. Tighten upper nut to 183
Nm (135 ft. lbs). Install new cotter pins. 4. Tighten the lower nut to:
- LD 11/16-16 nut: 183 Nm (135 ft. lbs.)
- HD 3/4-16 nut: 237 Nm (175 ft. lbs.)
5. Install tie rod to steering knuckle arm. 6. Install rotor and disc brake caliper. 7. Install wheel and
tire assembly and lower the vehicle.
Dodge Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Technical Service
Bulletins > Customer Interest for Idler Arm: > 02-08-98 > Aug > 98 > Front Suspension - Knocking Noise on Turns
Idler Arm: Customer Interest Front Suspension - Knocking Noise on Turns
NO: 02-08-98
GROUP: Suspension
DATE: Aug. 21, 1998
SUBJECT: Knocking Noise In The Front Suspension When The Steering Wheel Is Rotated To The
Full Left/Right
MODELS: 1998 - 1999 (AB) Ram Van
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT ON MAY 20, 1998 (MDH 0520XX) THROUGH
AUGUST 03, 1998 (MDH 0803XX).
SYMPTOM/CONDITION:
A knocking noise may be heard in the front suspension when the steering wheel is rotated to the
full left or right steering positions. The noise may be more prevalent when the steering wheel is
rotated to the full right or left positions with the vehicle moving over bumps in the road.
DIAGNOSIS:
With the vehicle sitting at curb height and the vehicle weight resting on the tires of the vehicle,
rotate the steering wheel to a full left or right lock turn. Inspect the position of the idler arm relative
to the front stabilizer bar. If there is an interference condition between the idler arm and the
stabilizer bar, perform the Repair Procedure.
PARTS REQUIRED:
1 52039336AC Bar, Stabilizer
REPAIR PROCEDURE:
This bulletin involves installing a revised stabilizer bar.
2. Remove the stabilizer bar link bolt nuts, retainers, and insulators from the strut bar (Figure 1).
3. Remove the stabilizer bar link bolts, retainers, insulators, and spacers from the stabilizer bar.
4. Remove the stabilizer bar retaining bolts and remove the stabilizer bar.
Bulletins > Customer Interest for Idler Arm: > 02-08-98 > Aug > 98 > Front Suspension - Knocking Noise on Turns > Page
5054
5. Remove the bushings from the stabilizer bar.
6. Install the bushings onto the new stabilizer bar p/n 52039336AC.
7. Position the new stabilizer bar p/n 52039336AC onto the frame rails.
NOTE:
ENSURE THE STABILIZER BAR IS CENTERED WITH EQUAL SPACING ON BOTH SIDES.
8. Install stabilizer retainers and bolts. Tighten the bolts to 23 Nm (200 in. lbs.).
9. Install the link bolts, retainers, spacers, and insulators onto the stabilizer bar and onto the strut
bar.
10. Install the link bolt nuts. Tighten the nuts to 11 N.m (100 in. lbs.).
11. Remove the support and lower the vehicle.
TIME ALLOWANCE:

Bulletins > All Technical Service Bulletins for Idler Arm: > 02-08-98 > Aug > 98 > Front Suspension - Knocking Noise on
Turns
Idler Arm: All Technical Service Bulletins Front Suspension - Knocking Noise on Turns
NO: 02-08-98
GROUP: Suspension
DATE: Aug. 21, 1998
SUBJECT: Knocking Noise In The Front Suspension When The Steering Wheel Is Rotated To The
Full Left/Right
MODELS: 1998 - 1999 (AB) Ram Van
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT ON MAY 20, 1998 (MDH 0520XX) THROUGH
AUGUST 03, 1998 (MDH 0803XX).
SYMPTOM/CONDITION:
A knocking noise may be heard in the front suspension when the steering wheel is rotated to the
full left or right steering positions. The noise may be more prevalent when the steering wheel is
rotated to the full right or left positions with the vehicle moving over bumps in the road.
DIAGNOSIS:
With the vehicle sitting at curb height and the vehicle weight resting on the tires of the vehicle,
rotate the steering wheel to a full left or right lock turn. Inspect the position of the idler arm relative
to the front stabilizer bar. If there is an interference condition between the idler arm and the
stabilizer bar, perform the Repair Procedure.
PARTS REQUIRED:
1 52039336AC Bar, Stabilizer
REPAIR PROCEDURE:
This bulletin involves installing a revised stabilizer bar.
2. Remove the stabilizer bar link bolt nuts, retainers, and insulators from the strut bar (Figure 1).
3. Remove the stabilizer bar link bolts, retainers, insulators, and spacers from the stabilizer bar.
4. Remove the stabilizer bar retaining bolts and remove the stabilizer bar.
Bulletins > All Technical Service Bulletins for Idler Arm: > 02-08-98 > Aug > 98 > Front Suspension - Knocking Noise on
Turns > Page 5060
5. Remove the bushings from the stabilizer bar.
6. Install the bushings onto the new stabilizer bar p/n 52039336AC.
7. Position the new stabilizer bar p/n 52039336AC onto the frame rails.
NOTE:
ENSURE THE STABILIZER BAR IS CENTERED WITH EQUAL SPACING ON BOTH SIDES.
8. Install stabilizer retainers and bolts. Tighten the bolts to 23 Nm (200 in. lbs.).
9. Install the link bolts, retainers, spacers, and insulators onto the stabilizer bar and onto the strut
bar.
10. Install the link bolt nuts. Tighten the nuts to 11 N.m (100 in. lbs.).
11. Remove the support and lower the vehicle.
TIME ALLOWANCE:

Idler Arm: Specifications
Mounting Bolts .....................................................................................................................................

................................................ 155 Nm (115 ft. lbs.)
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage
Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage
NUMBER: 19-005-03
GROUP: Steering
DATE: Aug. 29, 2003
MODELS:
1993 - 2003 (AB) Ram Van
1994 - 2004 (AN) Dakota
2004 (CS) Pacifica
2002 - 2004 (KJ) Liberty
1995-2004 (PL) Neon
1997 - 2003 (PR) Prowler


Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5067
2003 - 2004 (ZB) Viper
2004 (ZH) Crossfire
DISCUSSION:
NOTE:

Power Steering Fluid: Capacity Specifications
Capacity ...............................................................................................................................................
....................................................... 1.28 L (2.7 pints)
Power Steering Fluid: Fluid Type Specifications
The recommended lubricant is Mopar Power Steering Fluid.

Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Power Steering Fluid Cooler: Specifications
To Block Bolts ......................................................................................................................................

.................................................... 41 Nm (30 ft. lbs.)
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
Power Steering Fluid Reservoir: Specifications
Attaching Bolts .....................................................................................................................................

.................................................... 48 Nm (35 ft. lbs.)
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Power Steering Line/Hose: Specifications
Pressure Line ......................................................................................................................................

...................................................... 35 Nm (25 ft. lbs.) Return Line .....................................................
.......................................................................................................................................... 35 Nm (25
ft. lbs.)
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
MODELS:
1993 - 2003 (AB) Ram Van
1994 - 2004 (AN) Dakota
2004 (CS) Pacifica
2002 - 2004 (KJ) Liberty
1995-2004 (PL) Neon
1997 - 2003 (PR) Prowler


2003 - 2004 (ZB) Viper
2004 (ZH) Crossfire
DISCUSSION:
NOTE:

Information > Specifications > Mechanical Specifications
Power Steering Pump: Mechanical Specifications
Bracket Bolts .......................................................................................................................................

..................................................... 28 Nm (21 ft. lbs.) Pump Bolts .......................................................
........................................................................................................................................ 54 Nm (40 ft.
lbs.) Flow Control Valve .......................................................................................................................
........................................................... 75 Nm (55 ft. lbs.)
Information > Specifications > Mechanical Specifications > Page 5091
Power Steering Pump: Pressure, Vacuum and Temperature Specifications
Relief Pressure ± 50 ............................................................................................................................

................................................... 9653 kPa (1400 psi) Flow Rate At 1500 RPM .................................
................................................................................................................................................ 2.4 -
2.8 GPM
Power Steering Pump: Description and Operation
The P-Series pump is used on these vehicles.
Hydraulic pressure is provided for the power steering gear by the belt driven power steering pump.
The power steering pump is a constant flow rate and displacement, vane-type pump.
The pump is connected to the steering gear via the pressure hose and the return hose. The pump
shaft has a pressed-on pulley that is belt driven by the crankshaft pulley.
Trailer tow option vehicles are equipped with a power steering pump oil cooler. The oil cooler is
mounted to the radiator support.
NOTE: Power steering pumps are not interchangeable with pumps installed on other vehicles.
Power Steering Pump: Testing and Inspection
Pump Leakage
Refer to illustration for areas to inspect for leakage.

Information > Service and Repair > Power Steering Pump Initial Operation
Power Steering Pump: Service and Repair Power Steering Pump Initial Operation
WARNING: The fluid level should be checked with engine off to prevent injury from moving
components.
CAUTION: Use Mopar (R) Power Steering Fluid or equivalent. Do not use automatic transmission
fluid and do not overfill.
Wipe filler cap clean, then check the fluid level. The dipstick should indicate COLD when the fluid is
at normal temperature.
1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes.
2. Start the engine and let run for a few seconds then turn engine off. 3. Add fluid if necessary.
Repeat the above procedure until the fluid level remains constant after running the engine. 4. Raise
the front wheels off the ground. 5. Slowly turn the steering wheel right and left, lightly contacting the
wheel stops at least 20 times. 6. Check the fluid level add if necessary. 7. Lower the vehicle, start
the engine and turn the steering wheel slowly from lock to lock. 8. Stop the engine and check the
fluid level and refill as required. 9. If the fluid is extremely foamy or milky looking, allow the vehicle
to stand a few minutes and repeat the procedure.
CAUTION: Do not run a vehicle with foamy fluid for an extended period. This may cause pump
damage.
Information > Service and Repair > Power Steering Pump Initial Operation > Page 5096
Power Steering Pump: Service and Repair Power Steering Pump Pulley Replacement
REMOVAL
1. Remove pump assembly. 2. Remove pulley from pump with Puller C-4333, or equivalent.
INSTALLATION
1. Replace pulley if bent, cracked, or loose. 2. Install pulley on pump with Installer C-4063-B, or
equivalent flush with the end of the shaft. Ensure the tool and pulley remain aligned with the
pump shaft.
3. Install pump assembly. 4. With Serpentine Belts; Run engine until warm (5 min.) and note any
belt chirp. If chirp exists, move pulley outward approximately 0.5 mm (0.020
inch). If noise increases, press on 1.0 mm (0.040 inch). Be careful that pulley does not contact
mounting bolts.
Power Steering Pump: Service and Repair Power Steering Pump Removal and Installation
WARNING: Do not attempt to remove the pump without removing the belt first. the automatic
tensioner is under a high spring load.
REMOVAL
1. Remove drive belt by rotating tensioner clockwise and sliding belt off tensioner pulley. 2.
Disconnect hoses from the power steering pump and cap fittings.
3. Remove bracket bolts and remove pump assembly. 4. Remove the pump pulley.
5. Remove pump attaching screws.
INSTALLATION
1. Install pump bracket to pump and tighten the bolts to 28 Nm (21 ft. lbs.). 2. Install the pump
pulley. 3. Install pump assembly on engine block and tighten bolts to 41 Nm (30 ft. lbs.). 4. Connect
hoses to pump and tighten fitting to 35 Nm (25 ft. lbs.). 5. Install serpentine belt. 6. Fill pump
reservoir with power steering fluid only, and perform Pump Initial Operation.
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Arm > Component Information > Specifications
Steering Arm: Specifications
LD 5/8 Bolt ...........................................................................................................................................

................................................ 294 Nm (217 ft. lbs.) HD 3/4 Bolt ........................................................
.................................................................................................................................. 330 Nm (225 ft.
lbs.)
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service Precautions
.
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service Precautions > Page 5106
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover >
Steering Column Cover: Service and Repair
REMOVAL

INJURY.
1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, move the tilt
steering column to the fully raised position. 3. Remove the end cap from the left end of the
instrument panel. See Instrument Panel End Cap Replacement.
Steering Column Opening Cover Remove/Install
4. Remove the three screws that secure the lower edge of the steering column opening cover to
the knee blocker. 5. Remove the two screws that secure the out board end of the steering column
opening cover to the left instrument panel end bracket. 6. Using a trim stick or another suitable
wide flat-bladed tool, gently pry the upper edge of the steering column opening cover away from
the
instrument panel just below the cluster bezel to release the four snap clip retainers that secure the
cover to the instrument panel.
7. Remove the steering column opening cover from the instrument panel. 8. Reverse the removal
procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.).
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Customer Interest for Steering Gear: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander
Diagnosis/Repair
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
Diagnosis/Repair > Page 5118
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-002-01A > Sep > 01 > Steering/Suspension -
Wander Diagnosis/Repair
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Steering Gear: Specifications
GEAR CODE & RATIO:
HF ........................................................................................................................................................
................................................................ 16 - 13:1
WORM-SHAFT BEARING:
Preload ................................................................................................................................................
.......................... 0.45 - 1.13 Nm (10 - 15 inch lbs.)
PITMAN SHAFT OVERCENTER DRAG:
New (Under 400 Miles)

.................................................................................................................................. 0.45 - 0.90 Nm
(6 - 10 inch lbs.) + preload Used (Over 400 Miles)
......................................................................................................................................... 0.5 - 0.6 Nm
(4 - 5 inch lbs.) + preload
TIGHTENING TORQUES:
Adjustment Cap Locknut .....................................................................................................................

............................................... 108 Nm (80 ft. lbs.) Adjustment Screw Locknut ..................................
................................................................................................................................. 27 Nm (20 ft.
lbs.) Gear To Bracket Bolts .................................................................................................................
..................................................... 142 Nm (105 ft. lbs.) Bracket To Frame Bolts ...............................
..................................................................................................................................... 136 Nm (100
ft. lbs.) Pitman Shaft Nut ......................................................................................................................
......................................................... 251 Nm (185 ft. lbs.) Rack Piston Plug ......................................
........................................................................................................................................... 102 Nm
(75 ft. lbs.) Side Cover Bolts ................................................................................................................
................................................................... 61 Nm (45 ft. lbs.) Return Guide Clamp Bolts .................
................................................................................................................................................. 5 Nm
(48 inch lbs.)
Steering Gear: Description and Operation
The power steering gear is a recirculating ball type gear. The gear acts as a rolling thread between
the worm shaft and rack piston. The worm shaft is supported by a thrust bearing at the lower end
and a bearing assembly at the upper end. When the worm shaft is turned the rack piston moves.
The rack piston teeth mesh with the pitman shaft. Turning the worm shaft turns the pitman shaft,
which turns the steering linkage.
Steering Gear: Testing and Inspection
Refer to illustrations for areas to inspect for leakage.

Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments
> Worm Thrust Bearing
Steering Gear: Adjustments Worm Thrust Bearing
CAUTION: Steering gear must be adjusted in the proper order. If adjustments are not performed in
order, gear damage and improper steering response may result.
NOTE: Adjusting the steering gear in the vehicle is not recommended. Remove gear from the
vehicle and drain the fluid. Then mount gear in a vise to perform adjustments.
1. Mount the gear carefully into a vise.
CAUTION: Do not overtighten the vise on the gear case. This may affect the adjustment.
2. Remove adjuster plug locknut. 3. Rotate the stub shaft back and forth with a 12 point socket to
drain the remaining fluid. 4. Turn the adjuster in with Spanner Wrench C-4381, or equivalent.
Tighten the plug and thrust bearing in the housing until firmly bottomed in
housing about 34 Nm (25 ft. lbs.).
5. Place an index mark on the housing even with one of the holes in adjuster plug.
> Worm Thrust Bearing > Page 5135
6. Measure back (counterclockwise) 5.08 mm (0.20 inch) and mark housing.
7. Rotate adjustment cap back (counterclockwise) with spanner wrench until hole is aligned with
the second mark. 8. Install and tighten locknut to 108 Nm (80 ft. lbs.). Be sure adjustment cap does
not turn while tightening the locknut.
Steering Gear: Adjustments Sector Shaft Over Center
NOTE: Before performing this procedure, the worm bearing preload adjustment must be
preformed.
1. Rotate the stub shaft with a 12 point socket from stop to stop and count the number of turns.
2. Starting at either stop turn the stub shaft back 1/2 the total number of turns. This is the center of
the gear travel.
3. Place the torque wrench in the vertical position on the stub shaft. Rotate the wrench 45 degrees
each side of the center and record the highest
rotational torque in this range. This is the Over-Center Rotating Torque.
NOTE: The stub shaft must rotate smoothly without sticking or binding.
4. Rotate the stud shaft between 90° and 180° to the left of center and record the left off-center
preload. Repeat this to the right of center and record
the right off-center preload. The average of these two recorded readings is the Preload Rotating
Torque.
5. The Over-Center Rotating Torque should be 0.45 - 0.9 Nm (4 - 8 inch lbs.) higher than the
Preload Rotating Torque. 6. If an adjustment to the Over-Center Rotating Torque is necessary, first
loosen the adjuster lock nut. Then turn the pitman shaft adjuster screw back
(Counterclockwise) until fully extended, then turn back in (Clockwise) one full turn.
7. Remeasure Over-Center Rotating Torque. If necessary turn the adjuster screw and repeat
measurement until correct Over-Center Rotating Torque
is reached.
NOTE: To increase the preload turn the screw CLOCKWISE.

8. Prevent the adjuster screw from turning while tightening adjuster lock nut. Tighten the adjuster
lock nut to 49 Nm (36 ft. lbs.).
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Steering Gear Replacement
Steering Gear: Service and Repair Steering Gear Replacement
REMOVAL
1. Position the front wheels straight-ahead. 2. Raise and support the vehicle. 3. Remove and cap
fluid hoses from steering gear. 4. Remove the coupler retaining bolt and slide the coupler off the
steering gear stub shaft.
5. Mark the pitman shaft and pitman arm for installation reference. Remove the pitman arm from
the shaft with Puller C-4150A, or equivalent.
6. Remove the steering gear bracket retaining bolts and nuts. 7. Remove the steering gear and
bracket from the vehicle. 8. Remove the gear from the mounting bracket.
INSTALLATION
1. Position steering gear mounting bracket on the gear. Install mounting bolts and tighten to 142
Nm (105 ft. lbs.). 2. Position the steering gear and bracket on the frame rail. Install the bolts and
nuts. Tighten bolts and nuts to 136 Nm (100 ft. lbs.). 3. Align the coupler shaft index marks to the
steering gear and steering shaft. 4. Install the steering coupler and install new bolts. Tighten bolts
to 49 Nm (36 ft. lbs.). 5. Align and install the pitman arm. 6. Install the washer and retaining nut on
the pitman shaft. Tighten the nut to 251 Nm (185 ft. lbs.). 7. Connect fluid hoses to steering gear.
Tighten hose fittings to 28 Nm (21 ft. lbs.). 8. Remove support and lower vehicle. 9. Add fluid,
perform Power Steering Pump/Service and Repair/Initial Operation.
Repair > Steering Gear Replacement > Page 5140
Steering Gear: Service and Repair Overhaul
Housing End Plug
DISASSEMBLY
1. Unseat and remove retaining ring from groove with a punch through the hole in the end of the
housing. 2. Rotate stub shaft slowly COUNTER-CLOCKWISE to force the end plug out from
housing.
CAUTION: Do not turn stub shaft any further than necessary. The rack piston balls will drop out of
the rack piston circuit if the stub shaft is turned too far.
3. Remove O-ring seal.
ASSEMBLY
1. Lubricate O-ring with power steering fluid. 2. Install into the housing. 3. Install plug, tap lightly
with a plastic mallet to seat it.
4. Install retaining ring with open end 25 mm (1 inch) from access hole. 5. Adjust pitman arm shaft,
refer to Adjustments/Over-Center Rotational Torque.
Pitman Shaft/Seals/Bearing
DISASSEMBLY
1. Clean exposed end of pitman shaft and housing with a wire brush.
2. Remove preload adjuster nut. 3. Rotate stub shaft with a 12 point socket from stop to stop and
count the number of turns. 4. Center the stub shaft by rotating it from the stop 1/2 of the total
amount of turns. 5. Remove side cover bolts and remove side cover, gasket and pitman shaft as an
assembly.
NOTE: The pitman shaft will not clear the housing if it is not centered.
6. Remove pitman shaft from the side cover.
7. Remove dust seal from the housing with a seal pick.
CAUTION: Use care not to score the housing bore when prying out seals and washer.
8. Remove retaining ring with snap ring pliers. 9. Remove washer from the housing.
10. Remove oil seal from the housing with a seal pick.
11. Remove pitman shaft bearing from housing with a bearing driver and handle.
ASSEMBLY
1. Install pitman shaft bearing into housing with a bearing driver and handle. 2. Coat the oil seals
and washer with grease. 3. Install the oil seal with a driver and handle. 4. Install backup washer. 5.
Install the retainer ring with snap ring pliers.
6. Install dust seal with a driver and handle. 7. Install pitman shaft to side cover by screwing shaft in
until it fully seats to side cover. 8. Install preload adjuster nut. Do not tighten nut until after
Over-Center Rotation Torque adjustment has been made. 9. Install gasket to side cover and bend
tabs around edges of side cover.
10. Install pitman shaft assembly and side cover to housing. 11. Install side cover bolts and tighten
to 60 Nm (44 ft. lbs.). 12. Adjust Over-Center Rotation Torque. Refer to Adjustments.
Spool Valve
DISASSEMBLY
1. Remove lock nut. 2. Remove adjuster nut with Spanner Wrench C-4381, or equivalent.
3. Remove thrust support assembly out of the housing.

4. Pull stub shaft and valve assembly from the housing.
5. Remove stub shaft from valve assembly by lightly tapping on a block of wood to loosen shaft.
Then disengage stub shaft pin from hole in spool
valve and separate the valve assembly from stub shaft.

6. Remove spool valve from valve body by pulling and rotating the spool valve from the valve body.
7. Remove spool valve O-ring and valve body teflon and O-rings underneath the teflon rings. 8.
Remove the O-ring between the worm shaft and the stub shaft.
ASSEMBLY
NOTE: Clean and dry all components, then lubricate with power steering fluid.
1. Install spool valve spool O-ring. 2. Install spool valve in valve body by pushing and rotating. Hole
in spool valve for stub shaft pin must be accessible from opposite end of valve
body.
3. Install stub shaft in valve spool and engage locating pin on stub shaft into spool valve hole.
NOTE: Notch in stub shaft cap must fully engage valve body pin and seat against valve body
shoulder.
4. Install O-rings and teflon rings over the O-rings on valve body.
5. Install O-ring into the back of the stub shaft. 6. Install stub shaft and valve assembly in the
housing. Line up worm shaft to slots in the valve assembly. 7. Install thrust support assembly.
NOTE: The thrust support is serviced as an assembly. If any component of the thrust support is
damaged the assembly must be replaced.
8. Install adjuster nut and lock nut. 9. Adjust Thrust Bearing Preload and Over-Center Rotating
Torque.
Rack Piston and Worm Shaft
DISASSEMBLY
1. Remove side cover and pitman shaft. 2. Remove housing end plug.
3. Remove rack piston plug. 4. Turn stub shaft COUNTERCLOCKWISE until the rack piston begins
to come out of the housing.
5. Insert Arbor C-4175, or equivalent into bore of rack piston and hold tool tightly against worm
shaft. 6. Turn the stub shaft COUNTERCLOCKWISE, this will force the rack piston onto the tool
and hold the rack piston balls in place. 7. Remove the rack piston and tool together from housing.
8. Remove tool from rack piston. 9. Remove rack piston balls.
10. Remove clamp bolts, clamp and ball guide.
11. Remove teflon ring and O-ring from the rack piston. 12. Remove the adjuster lock nut and
adjuster nut. 13. Pull the stub shaft with the spool valve and thrust support assembly out of the
housing.
14. Remove the worm shaft from the housing.
ASSEMBLY
NOTE: Clean and dry all components and lubricate with power steering fluid.
1. Check for scores, nicks or burrs on the rack piston finished. Slight wear is normal on the worm
gear surfaces. 2. Install O-ring and teflon ring on the rack piston.
3. Install worm shaft in the rack piston and align worm shaft spiral groove with rack piston ball
guide hole.
CAUTION: The rack piston balls must be installed alternately into the rack piston and ball guide.
This maintains worm shaft preload. There are 12 black balls and 12 silver (Chrome) balls. The
black balls are smaller than the silver balls.
4. Lubricate and install rack piston balls through return guide hole while turning worm shaft
COUNTERCLOCKWISE.
5. Install remaining balls in guide using grease to hold the balls in place. 6. Install the guide onto
rack piston and install clamp and clamp bolts. Tighten bolts to 58 Nm (43 ft. lbs.). 7. Insert Arbor
C-4175, or equivalent into bore of rack piston and hold tool tightly against worm shaft. 8. Turn the
worm shaft COUNTERCLOCKWISE while pushing on the arbor. This will force the rack piston onto
the arbor and hold the rack piston
balls in place.
9. Install the races and thrust bearing on the worm shaft and install shaft in the housing.
10. Install the stub shaft with spool valve, thrust support assembly and adjuster nut in the housing.
11. Install the rack piston and arbor tool into the housing. 12. Hold arbor tightly against worm shaft
and turn stub shaft CLOCKWISE until rack piston is seated on worm shaft. 13. Install pitman shaft
and side cover in the housing. 14. Install rack piston plug and tighten to 150 Nm (111 ft. lbs.). 15.
Install housing end plug. 16. Adjust worm shaft thrust bearing preload and over-center rotating
torque.
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information >
Specifications
Steering Wheel: Specifications
Retaining Nut .......................................................................................................................................

..................................................... 47 Nm (35 ft. lbs.)
Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Specifications
Tie Rod End: Specifications
LD Clamp Nut ......................................................................................................................................

............................................... 22 Nm (200 inch lbs.) HD Clamp Nut ..................................................
........................................................................................................................................ 35 Nm (26 ft.
lbs.) LD 9/16 Ball Stud Nut ..................................................................................................................
............................................................ 75 Nm (55 ft. lbs.) HD 5/8 Ball Stud Nut .................................
............................................................................................................................................ 102 Nm
(75 ft. lbs.)
Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Tie Rod End: Service and Repair
NOTE: Only the outer tie-rod end can be removed from heavy duty tie rods.
REMOVAL
1. Raise and support the vehicle. 2. Remove cotter pin and retaining nut from the tie-rod end ball
stud. 3. Remove tie-rod end at the steering knuckle or center link with Puller C-3894-A, or
equivalent. 4. Loosen tie-rod sleeve clamp bolts and unthread the tie-rod end from the sleeve.
INSTALLATION
1. Thread the tie-rod end into sleeve. 2. Install tie-rod end on steering knuckle arm or enter link. 3.
Install nut and tighten to:
- 9/16-18 ball stud: 75 Nm (55 ft. lbs.)
- 5/8-18 (HD) ball stud: 102 Nm (75 ft. lbs.)
4. Install a new cotter pin. 5. Remove supports and lower vehicle. 6. Adjust the wheel toe position,
refer to Alignment.
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications
> Lower Ball Joint
Ball Joint: Specifications Lower Ball Joint
LD 11/16 Nut .......................................................................................................................................

................................................. 183 Nm (135 ft. lbs.) HD 3/4 Nut .......................................................
.................................................................................................................................... 237 Nm (175 ft.
lbs.) Joint To Suspension Arm .............................................................................................................
......................................................... 170 Nm (125 ft. lbs.)
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications
> Lower Ball Joint > Page 5164
Ball Joint: Specifications Upper Ball Joint
Ball Joint Nut .......................................................................................................................................

................................................. 183 Nm (135 ft. lbs.)
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Lower Ball Joint
Ball Joint: Testing and Inspection Lower Ball Joint
1. Raise the front of the vehicle. Install safety floor stands under both lower suspension arms as far
outboard as possible. Lower the vehicle onto the
stands to support some of all of the vehicle weight.
NOTE: The upper suspension arms must not contact the rebound bumpers.
2. Install a dial indicator and clamp assembly to the lower suspension arm. 3. Position indicator
plunger against knuckle arm and zero indicator. 4. Raise and lower the wheel with a pry bar under
the center of the tire. Measure the axial movement of the knuckle with respect to the suspension
arm.
5. If the travel of the suspension arm is 0.51 mm (0.020 inch) or more, replace the ball joint.
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Lower Ball Joint > Page 5167
Ball Joint: Testing and Inspection Upper Ball Joint
1. Position a floor jack under the lower suspension arm. Raise the wheel and allow the tire to lightly
contact the floor (vehicle weight relieved from the
tire).
2. Mount a dial indicator on the upper suspension arm. Position the indicator plunger against the
upper ball stud boss of the steering knuckle. 3. Grasp the top of the tire and apply force in and out.
Look for movement at the ball joint between the upper suspension arm and steering knuckle. 4. If
lateral movement is greater than 0.8 mm (0.030 inch), replace the ball joint.
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Repair > Lower Ball Joint Replacement
Ball Joint: Service and Repair Lower Ball Joint Replacement
REMOVAL
1. Raise and support the vehicle. 2. Remove the front wheel and tire assembly 3. Remove disc
brake caliper and rotor from steering knuckle. 4. Remove shock absorber. 5. Remove the strut bar.
6. Install Spring Compressor DD-1278, or equivalent. Use a piece of pipe to fabricate a spacer
positioned between the tool and suspension arm. 7. Tighten tool nut against bell-shaped adapter
tool finger-tight and loosen 1/2 of a turn. 8. Remove cotter pins and nuts from ball studs. 9. Position
Ball Stud Remover C-3564-A, or equivalent and rotate threaded portion of tool to apply force to the
lower ball stud.
10. Strike steering knuckle sharply with a hammer to loosen ball stud from knuckle. Do not force
ball stud out from knuckle with the tool.
11. Remove ball stud seal. Use Remover/Installer C-4212F, or equivalent to press the ball stud
from lower suspension arm bore.
Lower Ball Stud Installation
INSTALLATION
Repair > Lower Ball Joint Replacement > Page 5170
1. Press new ball stud in lower suspension arm with Remover/Installer C-4212F, or equivalent. 2.
Position new seal over ball stud and use a socket to force lip of seal until securely in place. 3.
Position lower ball stud in steering knuckle. 4. Install retaining nut on the lower ball stud and tighten
to:
- 11/16-16 bolt: 183 Nm (135 ft. lbs.)
- 3/4-16 bolt: 237 Nm (175 ft. lbs.)
5. Install new cotter pins. 6. Install the strut bar. 7. Remove spring compressor tool. Install shock
absorber. 8. Install rotor and disc brake caliper. 9. Install wheel and tire assemble and lower the
vehicle.
Repair > Lower Ball Joint Replacement > Page 5171
Ball Joint: Service and Repair Upper Ball Joint Replacement
REMOVAL
1. Place a jack under outer end of lower suspension arm. Raise and support the vehicle. 2.
Remove wheel and tire assembly. 3. Remove cotter pin and nut from upper ball stud. 4. Position
Ball Stud Remover C-3564-A, or equivalent between ball studs. Rotate threaded portion of tool to
apply force to the upper ball stud. 5. Strike steering knuckle sharply with a hammer to loosen ball
stud from knuckle. Do not force ball stud out from knuckle with the tool. 6. Remove ball stud seal.
7. Use Tool C-3561, or equivalent to unthread ball stud from suspension arm.
INSTALLATION
1. Thread new ball stud in with Tool C-3561, or equivalent and tighten to 170 Nm (125 ft. lbs.). The
gap between ball stud Hex and suspension arm
bore is 0.25 - 1.25 mm (0.01 - 0.05 inch).
2. Install new seal over ball stud and securely locked in place. 3. Position steering knuckle on
upper ball stud tighten nut to 183 Nm (135 ft. lbs.). Install a new cotter pin. 4. Install wheel and tire
assembly and lower the vehicle.
Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component
Control Arm Bushing: Service and Repair
REMOVAL
1. Remove lower control arm. 2. Use an arbor press and an appropriate size sleeve (driver) to force
out old bushing.
INSTALLATION
1. Use an arbor press and an appropriate size sleeve (driver) to install the new bushing. Ensure
bushing is completely seated. 2. Install lower control arm.
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Front Steering Knuckle: Description and Operation
The steering knuckles are used to steer the vehicle. The knuckles are mounted to the ball studs at
the end of the suspension arms.
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Front Steering Knuckle: Service and Repair
REMOVAL
1. Raise and support the vehicle. Place a jack under outer end of lower suspension arm. 2.
Remove wheel and tire assembly. 3. Remove disc brake caliper and rotor. 4. Remove tie rod from
steering knuckle arm.
5. Remove cotter pins and nuts from upper and lower ball joints. 6. Use Ball Stud Remover
C-3564-A, or equivalent to free upper and lower ball joints from steering knuckle. 7. Remove tool
and steering knuckle assembly. 8. Remove the rotor dust shield and steering arm from steering
knuckle.
INSTALLATION
1. Install brake rotor dust shield on steering knuckle and tighten bolts to 24 Nm (18 ft. lbs.). 2.
Install steering arm on knuckle and tighten nuts to;
- LD 5/8-18 nut: 294 Nm (217 ft. lbs.)
- HD 3/4-16 nut: 330 Nm (225 ft. lbs.)
3. Position steering knuckle on upper and lower ball joints and install nuts. Tighten upper nut to 183
Nm (135 ft. lbs). Install new cotter pins. 4. Tighten the lower nut to:
- LD 11/16-16 nut: 183 Nm (135 ft. lbs.)
- HD 3/4-16 nut: 237 Nm (175 ft. lbs.)
5. Install tie rod to steering knuckle arm. 6. Install rotor and disc brake caliper. 7. Install wheel and
tire assembly and lower the vehicle.
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut Bar <--> [Radius Arm] > Component
Strut Bar: Specifications
Rear Nut ..............................................................................................................................................

..................................................... 71 Nm (52 ft. lbs.) Front Nuts ........................................................
..................................................................................................................................... 136 Nm (100
ft. lbs.)
Strut Bar: Description and Operation
The strut bar is used to control the movement of the lower control arm. The bar is mounted
between the lower control arm and a frame bracket. The bar uses replaceable bushings to isolated
it from the frame bracket.
Strut Bar: Service and Repair
REMOVAL
1. Raise and support the vehicle. 2. Remove front tire and wheel assembly. 3. Remove the roll pin
from the rear of the strut bar with a small punch and hammer.
Strut Bar
4. Remove the nut, retainer and bushing from the rear of the strut bar. 5. Remove the stabilizer bar
link from the strut bar. 6. Remove the jounce bumper/strut bar mounting nuts and bolts. 7. Remove
the strut bar from the vehicle. Remove the bushing and inner retainer from the strut bar.
INSTALLATION
1. Position the inner retainer and bushing on the strut bar. 2. Install strut through the frame rail
hole. 3. Install jounce bumper/strut bar mounting bolts and nuts. Tighten the nuts to 136 Nm (100 ft.
lbs.). 4. Install the rear bushing, retainer and nut on the strut bar. Tighten the nut to 71 Nm (52 ft.
lbs.). 5. Install the stabilizer bar link to the strut bar. 6. Install the spring pin in the strut bar. 7. Install
wheel and tire assembly. 8. Remove support and lower the vehicle.
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Stabilizer Link: Specifications
Link Nuts ..............................................................................................................................................

............................................... 11 Nm (100 inch lbs.)
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 19-002-01A > Sep >
01 > Steering/Suspension - Wander Diagnosis/Repair
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5197
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-04-00A > May > 00
> Squeaking/Clicking Noises From Rear Leaf Springs
Suspension Spring ( Coil / Leaf ): Customer Interest Squeaking/Clicking Noises From Rear Leaf
Springs
NUMBER: 02-04-00 Rev. A
GROUP: Suspension
DATE: May 12, 2000
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CORRECTION TO A PART NUMBER.
SUBJECT: Squeaking/Clicking Noise From Rear Leaf Springs
OVERVIEW: This bulletin involves replacing the spring tip liners and installing spring clinch clip
isolators.
MODELS: 1994 - 2000
(AB) Ram Van/Wagon
SYMPTOM/CONDITION: Squeaking/clicking noise coming from the rear of the vehicle.
DIAGNOSIS: If the customer indicates that the vehicle has a squeaking/clicking noise coming from
the rear of the vehicle, verify that the noise is coming from the rear springs as the vehicle's
suspension goes through jounce and rebound. If a squeaking/clicking noise is coming from the rear
springs, perform the Repair Procedure.
NOTE:
PERFORM THE REPAIR PROCEDURE ON ANY VEHICLE THAT HAS MISSING TIP LINERS OR
MISSING CLINCH CLIP ISOLATORS AND A SQUEAKING/CLICKING NOISE IS COMING FROM
THE REAR SPRINGS.
NOTE:
RAM TRUCKS WERE NOT ORIGINALLY EQUIPPED WITH SPRING CLINCH CLIP ISOLATORS.
PARTS REQUIRED:
EQUIPMENT REQUIRED:
Large C-Clamp (5-6 in.) Large Pry Bar Large Adjustable Pliers
REPAIR PROCEDURE:
1. Raise the vehicle on an appropriate frame support style lift (rear axle must be allowed to extend
fully).
2. On Ram Vans, remove both rear tire/wheel assemblies.
3. Position a large C-Clamp adjacent to the spring clinch clip and clamp the leaves of the spring
together.
> Squeaking/Clicking Noises From Rear Leaf Springs > Page 5204
Figure 1
4. Use an appropriate pry bar to bend open the rear spring clinch clip (Figure 1). If necessary,
remove the existing spring clinch clip isolators.
Figure 2
5. Use the pry bar to spread apart the leaf (Figure 2). The clearance between the leaves should be
enough to remove the old liner (if necessary) and install the replacement liner.
Figure 3
6. If necessary, remove the old spring tip liner (Figure 3).
7. With the prybar still inserted between the leaves, install a new spring tip liner (see Parts
Required section) onto the leaf.
Figure 4
8. Firmly seat the spring tip liner onto the leaf. A C-Clamp can be used to compress the adjacent
leaves together (Figure 4) which will seat the liner retaining pin into the hole.
NOTE:
THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINTING
TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING.
9. Apply a small amount of lubricant p/n 05018626AA onto the tip liner wear pad.
10. Repeat Steps 5 through 9 to remove and install all rear spring tip liners.
Figure 5
11. Place one spring clinch clip isolator p/n **52113142AA** onto the outboard side of the spring
clinch clip (Figure 5) and one isolator on the inboard side of the spring clinch clip.
Figure 6
12. Using large adjustable pliers, close the spring clinch clip until the isolator contacts the leaf
spring (Figure 6).
CAUTION:
DO NOT USE A HAMMER TO CLOSE THE SPRING CLINCH CLIP. DAMAGE TO THE
ISOLATOR MAY RESULT.
13. Use an appropriate pry bar to bend open the front spring clinch clip. If necessary, remove the
existing spring clinch clip isolators.
14. Perform Steps 5 through 12 to the front portion of the rear leaf spring assembly.
15. Perform Steps 4 through 14 to the other side of the vehicle.
16. On Ram Van/Wagons, install the tire wheel assemblies.
TIME ALLOWANCE:
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): >
19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair > Page 5213
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-04-00A
> May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs
Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Squeaking/Clicking Noises From
Rear Leaf Springs
GROUP: Suspension
DATE: May 12, 2000
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CORRECTION TO A PART NUMBER.
SUBJECT: Squeaking/Clicking Noise From Rear Leaf Springs
OVERVIEW: This bulletin involves replacing the spring tip liners and installing spring clinch clip
isolators.
MODELS: 1994 - 2000
(AB) Ram Van/Wagon
SYMPTOM/CONDITION: Squeaking/clicking noise coming from the rear of the vehicle.
DIAGNOSIS: If the customer indicates that the vehicle has a squeaking/clicking noise coming from
the rear of the vehicle, verify that the noise is coming from the rear springs as the vehicle's
suspension goes through jounce and rebound. If a squeaking/clicking noise is coming from the rear
springs, perform the Repair Procedure.
NOTE:
PERFORM THE REPAIR PROCEDURE ON ANY VEHICLE THAT HAS MISSING TIP LINERS OR
MISSING CLINCH CLIP ISOLATORS AND A SQUEAKING/CLICKING NOISE IS COMING FROM
THE REAR SPRINGS.
NOTE:
RAM TRUCKS WERE NOT ORIGINALLY EQUIPPED WITH SPRING CLINCH CLIP ISOLATORS.
PARTS REQUIRED:
EQUIPMENT REQUIRED:
Large C-Clamp (5-6 in.) Large Pry Bar Large Adjustable Pliers
REPAIR PROCEDURE:
1. Raise the vehicle on an appropriate frame support style lift (rear axle must be allowed to extend
fully).
2. On Ram Vans, remove both rear tire/wheel assemblies.
3. Position a large C-Clamp adjacent to the spring clinch clip and clamp the leaves of the spring
together.
> May > 00 > Squeaking/Clicking Noises From Rear Leaf Springs > Page 5220
Figure 1
4. Use an appropriate pry bar to bend open the rear spring clinch clip (Figure 1). If necessary,
remove the existing spring clinch clip isolators.
Figure 2
5. Use the pry bar to spread apart the leaf (Figure 2). The clearance between the leaves should be
enough to remove the old liner (if necessary) and install the replacement liner.
Figure 3
6. If necessary, remove the old spring tip liner (Figure 3).
7. With the prybar still inserted between the leaves, install a new spring tip liner (see Parts
Required section) onto the leaf.
Figure 4
8. Firmly seat the spring tip liner onto the leaf. A C-Clamp can be used to compress the adjacent
leaves together (Figure 4) which will seat the liner retaining pin into the hole.
NOTE:
THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINTING
TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING.
9. Apply a small amount of lubricant p/n 05018626AA onto the tip liner wear pad.
10. Repeat Steps 5 through 9 to remove and install all rear spring tip liners.
Figure 5
11. Place one spring clinch clip isolator p/n **52113142AA** onto the outboard side of the spring
clinch clip (Figure 5) and one isolator on the inboard side of the spring clinch clip.
Figure 6
12. Using large adjustable pliers, close the spring clinch clip until the isolator contacts the leaf
spring (Figure 6).
CAUTION:
DO NOT USE A HAMMER TO CLOSE THE SPRING CLINCH CLIP. DAMAGE TO THE
ISOLATOR MAY RESULT.
13. Use an appropriate pry bar to bend open the front spring clinch clip. If necessary, remove the
existing spring clinch clip isolators.
14. Perform Steps 5 through 12 to the front portion of the rear leaf spring assembly.
15. Perform Steps 4 through 14 to the other side of the vehicle.
16. On Ram Van/Wagons, install the tire wheel assemblies.
TIME ALLOWANCE:
Suspension Spring ( Coil / Leaf ): Specifications
U-Bolts Nuts ........................................................................................................................................

................................................... 115 Nm (85 ft. lbs.) Shackle Eye Nut ..............................................
..................................................................................................................................... 149 Nm (110
ft. lbs.) Shackle Bracket Bolts ..............................................................................................................
................................................................. 47 Nm (35 ft. lbs.) Front Spring Eye Nut ...........................
................................................................................................................................................... 122
Nm (90 ft. lbs.) Rear Spring Eye Nut ...................................................................................................
.......................................................................... 149 Nm (110 ft. lbs.)
Information > Description and Operation > Coil Springs
Suspension Spring ( Coil / Leaf ): Description and Operation Coil Springs
The coil springs control ride quality and maintain proper ride height. The coil springs mount
between the frame and lower control arm. An isolator is located between the spring and frame to
help isolate noise.
Information > Description and Operation > Coil Springs > Page 5227
Suspension Spring ( Coil / Leaf ): Description and Operation Leaf Springs
The rear suspension system uses a multi-leaf springs and a solid drive axle. The forward end of the
springs are mounted to the body rail hangers through rubber bushings. The rearward end of the
springs are attached to the body by the use of shackles. The spring and shackles use rubber
bushings. The bushing help to isolate road noise. The shackles allow the springs to change their
length as the vehicle moves over various road conditions.
Suspension Spring ( Coil / Leaf ): Testing and Inspection
If the vehicle is used for severe, off-road operation. the springs should be examined periodically.
Check for broken and shifted leafs, loose and missing clips, and broken center bolts.
Information > Service and Repair > Coil Springs
Suspension Spring ( Coil / Leaf ): Service and Repair Coil Springs
REMOVAL
1. Raise and support vehicle. 2. Remove front wheel and tire assembly. 3. Remove disc brake
caliper from steering knuckle. 4. Disconnect the stabilizer bar and strut bar from the lower
suspension arm. 5. Remove the shock absorber.
Coil Spring
6. Install Spring Compressor DD-1278, or equivalent up through the lower suspension arm, coil
spring and shock hole in the frame. 7. Tighten the spring compressor to compress spring.
NOTE: This will hold the spring in place until the lower suspension arm is separated from the
steering knuckle.
8. Remove the cotter pin and lower ball joint nut at the steering knuckle.
9. Install Ball Joint Remover C-3564-A, or equivalent on the lower ball joint. Turn the threaded
portion of the tool and lock securely against the
lower joint.
10. Expand the tool enough to place force on the lower ball joint. Strike the steering knuckle
sharply with a hammer to loosen the joint. Do not attempt
to force the joint out of the steering knuckle with the loosening tool.
11. Remove the spring compressor tool and pivot the lower suspension arm downward. 12.
Remove coil spring and isolator pad from the vehicle.
INSTALLATION
1. Tape the isolator pad to the tap of the coil spring. Position the spring in the lower suspension
arm well. Be sure that the coil spring is seated in the
well. The flat or closed end of the coil spring is the top. The ramped or open end of the coil spring is
the bottom.
2. Install Spring Compressor DD-1278, or equivalent up through the lower suspension arm, coil
spring and shock hole in frame. 3. Tighten the tool nut to compress the coil spring 4. Position the
lower ball joint in steering knuckle.
Information > Service and Repair > Coil Springs > Page 5231
5. Install the retaining nut on the lower ball joint and tighten to:
- LD 11/16-16 bolt: 183 Nm (135 ft. lbs.).
- HD 3/4-16 bolt: 237 Nm (175 ft. lbs.).
6. Install new cotter pins. 7. Install the strut bar. 8. Remove the spring compressor tool. 9. Install
the stabilizer bar.
10. Install the shock absorber. 11. Install disc brake caliper. 12. Install wheel and tire assembly and
lower the vehicle.
Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Bushing
DISASSEMBLE
1. Remove the spring from the vehicle. 2. Position the spring eye in a press. 3. Press the bushing
out with an appropriate size driver.
ASSEMBLE
1. Press new bushing into the spring eye with an appropriate size driver.
NOTE: Bushing must be centered in the spring eye.
2. Install the spring on the vehicle.

Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Replacement
CAUTION: The rear of the vehicle must be lifted only with a jack or hoist. The lift must be placed
under the frame rail crossmember located aft of the rear axle. Use care to avoid bending the side
rail flange.
REMOVAL
1. Raise the vehicle at the frame. 2. Use a hydraulic jack to relieve the axle weight. 3. Remove
wheel and tire assembly.
Rear Spring
4. Remove the U-bolt nuts, spring plate, U-bolts and spring seat from the axle. 5. Remove the nut
and bolt from the shackle mounting bracket. 6. Remove the nut and bolt from the rear spring eye.
7. Remove the spring from the vehicle. 8. Remove the nut and bolt from the rear spring eye and
remove the shackle.
INSTALLATION
1. Install the spring shackle to the rear spring eye. Install the bolt and nut and tighten the nut finger
tight. 2. Position the spring on the rear axle pad. Make sure the spring center bolt is inserted in the
pad locating hole. 3. Align the spring front eye attaching nut finger tight. 4. Align the spring shackle
eye with the bolt hole in the shackle bracket. Install the bolt and nut and tighten the nut finger tight.
NOTE: When installing a rear spring, ensure rear spring eye is located above the shackle bracket
pivot bolt.
5. Install the spring seat, U-bolts, spring plate and nuts. Tighten the U-bolt nuts to 115 Nm (85 ft.
lbs.). 6. Install wheel and tire assembly. 7. Remove the support stands and lower the vehicle. 8.
Tighten the front spring eye nut to 122 Nm (90 ft. lbs.). 9. Tighten the shackle nuts to 149 Nm (110
ft. lbs.).
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 19-002-01A > Sep >
01 > Steering/Suspension - Wander Diagnosis/Repair
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: >
19-002-01A > Sep > 01 > Steering/Suspension - Wander Diagnosis/Repair
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Suspension Strut / Shock Absorber: Specifications
FRONT:
Upper Nut ............................................................................................................................................

................................................. 34 Nm (25 ft. lbs.) Lower Bolts ..........................................................
................................................................................................................................ 23 Nm (17 ft. lbs.)
REAR:
Lower Bolt ............................................................................................................................................

................................................ 75 Nm (55 ft. lbs.) Upper Bolt .............................................................
............................................................................................................................... 75 Nm (55 ft. lbs.)
Information > Description and Operation > Front
Suspension Strut / Shock Absorber: Description and Operation Front
The shock absorbers dampen the jounce and rebound motion of the vehicle over various road
conditions. The shock is mounted to the upper and lower suspension arm through the center of the
spring.
Information > Description and Operation > Front > Page 5256
Suspension Strut / Shock Absorber: Description and Operation Rear
Ride control is accomplished through the use of dual-action shock absorbers. The shocks dampen
the jounce and rebound as the vehicle travels over various road conditions. The top of the shock
absorbers are bolted to the body crossmember. The bottom of the shocks are bolted to the axle
bracket.
Suspension Strut / Shock Absorber: Testing and Inspection
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 spring eye and 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.
Information > Service and Repair > Front
Suspension Strut / Shock Absorber: Service and Repair Front
REMOVAL
Front Shock Absorber
1. Remove nut and bushing from the shock absorber upper stud. 2. Raise vehicle, remove the
lower attaching bolts and remove shock absorber.
INSTALLATION
1. Install the lower retainer and bushing on the upper stud. Insert the shock absorber stud through
the frame hole. 2. Install the lower shock bolts and tighten to 23 Nm (17 ft. lbs.). 3. Install the upper
grommet and retainer on the shock absorber stud. Install the nut and tighten to 34 Nm (25 ft. lbs.).
Information > Service and Repair > Front > Page 5260
Suspension Strut / Shock Absorber: Service and Repair Rear
REMOVAL
1. Raise and support the vehicle. 2. Remove the lower shock absorber mounting nut and bolt from
the axle bracket.
Rear Shock Absorber
3. Remove the upper mounting nut, retainers and bolt. 4. Remove the shock absorber from the
vehicle. If necessary, remove the spacer tube from the upper shock absorber eye.
INSTALLATION
1. Install the shock absorber in the axle bracket and install the bolt and nut. 2. Install the spacer
tube in the upper shock absorber eye. 3. Position the shock absorber to the frame rail bracket.
Install the inner retainer, bolt, outer retainer and nut. 4. Tighten the shock absorber mounting nuts
to 75 Nm (55 ft. lbs.). 5. Remove the supports and lower the vehicle.
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Description and Operation > Front
Suspension Travel Bumper: Description and Operation Front
The jounce bumpers are used to limit the travel of the suspension jounce and rebound motion. The
replaceable bumpers are mounted to the upper and lower suspension arm.
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Description and Operation > Front > Page 5265
Suspension Travel Bumper: Description and Operation Rear
The jounce bumpers are used to limit the spring and axle travel. They are bolted to the body rail
above the axle.
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Technical Service Bulletins > Customer Interest: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander
Diagnosis/Repair
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-002-01A > Sep > 01 >
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
Steering/Suspension - Wander Diagnosis/Repair > Page 5282
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander -
Diagnosis and Correction Revised
Revised
NUMBER: 19-07-00
GROUP: Steering

following:
NOTE:
DIAGNOSIS:
box).
NOTE:
NOTE:
ROADS, ETC.).

Diagnosis and Correction Revised > Page 5289
NOTE:

new cotter pin.
specifications.
NOTE:
VAN/WAGONS.

Technical Service Bulletins > All Other Service Bulletins for Wheel Bearing: > 19-07-00 > Sep > 00 > Steering Wander -
Revised
NUMBER: 19-07-00
GROUP: Steering

following:
NOTE:
DIAGNOSIS:
box).
NOTE:
NOTE:
ROADS, ETC.).

NOTE:

new cotter pin.
specifications.
NOTE:
VAN/WAGONS.

Lubricant Type

Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front
REMOVAL
during removal).
INSTALLATION
and Repair > Front > Page 5301
8 1/4 and 9 1/4 Axles
REMOVAL
Axle Seal Removal
INSTALLATION
depth.
the axle shaft.
With 9 1/4 Axle
REMOVAL
Axle Seal Removal

INSTALLATION
the correct depth.
the axle shaft.
248 RBI Axle
REMOVAL
INSTALLATION
adjustment nut.
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information >
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest for Wheels: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander
Diagnosis/Repair
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Service Bulletins > All Technical Service Bulletins for Wheels: > 19-002-01A > Sep > 01 > Steering/Suspension - Wander
Diagnosis/Repair
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Wheels: Description and Operation
The rim size is on the safety certification label located on the drivers door shut face. The size of the
rim is determined by the drivetrain package. Original equipment wheels are designed for operation
up to the specified maximum vehicle capacity.
Fig. 1
All models use stamped steel, cast aluminum or forged aluminum wheels. Every wheel has raised
sections between the rim flanges and rim drop well called safety humps.
Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air
pressure, the raised sections help hold the tire on the wheel.
The wheel studs and nuts are designed for specific applications. All aluminum and some steel
wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure
proper retention of the wheels. Do not use replacement studs or nuts with a different design or
lesser quality.
Wheels: Testing and Inspection
Inspect wheels for:
- Excessive run out
- Dents or cracks
- Damaged wheel lug nut holes
- Air leaks from any area or surface of the rim
NOTE: Do not attempt to repair a wheel by hammering, heating or welding.
If a wheel is damaged an original equipment replacement wheel should be used. When obtaining
replacement wheels, they should be equivalent in load carrying capacity. The diameter, width,
offset, pilot hole and bolt circle of the wheel should be the same as the original wheel.
WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and
handling of the vehicle. Used wheels are not recommended. The service history of the wheel may
have included severe treatment or very high mileage. The rim could fail without warning.
Wheels: Service and Repair
REPLACEMENT NOTES:
Wheels must be replaced if they have: -
Excessive runout
- Bent or dented
- Leak air through welds
- Have damaged bolt holes
Wheel repairs employing hammering, heating, or welding are not allowed.
Original equipment wheels are available through your dealer. Replacement wheels from any other
source should be equivalent in: -
Load carrying capacity
- Diameter
- Width
- Offset
- Mounting configuration
Failure to use equivalent replacement wheels may affect the safety and handling of your vehicle.
Replacement with used wheels is not recommended. Their service history may have included
severe treatment.
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Diagnosis/Repair
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
GROUP: Steering

MODELS:
NOTE:
SYMPTOM/CONDITION:

the following:

NOTE:
PARTS REQUIRED:
TIME ALLOWANCE:
FAILURE CODE:
NOTE:
NOTE:

NOTE:
NOTE:
pin.
NOTE:
NOTE:
NOTE:
CAUTION:
**52106320A0 **
WHEEL ALIGNMENT
NOTE:

NOTE:
NOTE:
VAN/WAGONS.
CAUTION:
Revised
NUMBER: 19-07-00
GROUP: Steering

following:
NOTE:
DIAGNOSIS:
box).
NOTE:
NOTE:
ROADS, ETC.).

NOTE:

new cotter pin.
specifications.
NOTE:
VAN/WAGONS.

Revised
NUMBER: 19-07-00
GROUP: Steering

following:
NOTE:
DIAGNOSIS:
box).
NOTE:
NOTE:
ROADS, ETC.).

NOTE:

new cotter pin.
specifications.
NOTE:
VAN/WAGONS.

Lubricant Type

Service and Repair > Front
REMOVAL
during removal).
INSTALLATION
Service and Repair > Front > Page 5366
8 1/4 and 9 1/4 Axles
REMOVAL
Axle Seal Removal
INSTALLATION
depth.
the axle shaft.
With 9 1/4 Axle
REMOVAL
Axle Seal Removal

INSTALLATION
the correct depth.
the axle shaft.
248 RBI Axle
REMOVAL
INSTALLATION
adjustment nut.
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Specifications > Wheel Tightening Sequence
Wheel Fastener: Specifications Wheel Tightening Sequence
Wheel Torque Sequence - Master

Specifications > Wheel Tightening Sequence > Page 5373
Wheel Fastener: Specifications Lug Nut Torque
15 Inch 5 Stud Wheel

...........................................................................................................................................................
109 - 150 Nm (80 - 110 ft. lbs.) 16 Inch 8 Stud Wheel
.........................................................................................................................................................
163 - 203 Nm (120 - 150 ft. lbs.)
Wheel Fastener: Service and Repair
REMOVAL
1. Remove wheel and tire assembly. 2. Remove disc brake rotor. 3. Place rotor on flat surface and
drive studs out of the with a hammer and punch.
INSTALLATION
1. Turn the rotor over and place in a vise. 2. Drive new studs into the rotor with hammer and punch.
3. Install rotor. 4. Install wheel and tire assembly.
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Air Door Actuator / Motor: Description and Operation
SYSTEM OPERATION
Blend-Air Door Motor The blend-air door on heater-only and heater-A/C models is connected with a
short mechanical link to an electronic blend-air door actuator motor. The blend-air door motor
controls the positioning of the blend-air door in the heater-A/C housing. The blend- air door motor is
mounted to the top of the right end of the distribution duct under the instrument panel in the
A mechanical link is attached to the end of the blend-air door motor lever in the passenger
compartment and passes through a bellows-type boot and a small hole in the dash panel to the
engine compartment. In the engine compartment, the link is attached to the end of the blend air
door lever on the top cover of the heater-A/C housing.
The blend-air door motor is controlled by a potentiometer that is integral to the heater-only or
heater-A/C control. The rotary-type temperature control knob positions the potentiometer, and the
potentiometer controls the voltage to the blend-air door motor. The blend-air door motor moves the
blend-air door based upon the voltage level of the signal received from the potentiometer.
The blend-air door motor is accessible for service through the instrument panel glove box opening.
The blend-air door motor cannot be repaired and, if faulty or damaged, it must be replaced. The
mechanical link and boot are available for service replacement.
Air Door Actuator / Motor: Testing and Inspection
The blend-air door in the heater-A/C housing is controlled by a combination of mechanical linkage
and electronic controls. The mechanical linkage is connected to the blend-air door pivot shaft lever
in the engine compartment on one end, and to the blend-air door servo motor lever in the
passenger compartment on the other end. The blend-air door motor is controlled by the
temperature control knob through a potentiometer that is integral to the heater-only or heater-A/C
control assembly.

INJURY.
Roll down the glove box from the instrument panel.
Refer to Glove Box - Roll Down in the Removal and Installation Instrument Panel, Gauges and
Warning Indicators/Instrument Panel Systems for the procedures.
4. Connect the battery negative cable. Turn the ignition switch to the On position. Look through the
instrument panel glove box opening to locate the
blend-air door motor on the top of the distribution duct. Check that the blend-air door link is
connected to the blend-air door motor lever. If OK, go to Step 6. If not OK, see Blend-Air Door
Motor in the Removal and Installation.
5. While observing the blend-air door motor, slowly rotate the temperature control knob from stop to
stop. The motor lever movement should
correspond to the movements of the temperature control knob. If OK, check the blend-air door in
the heater-A/C housing for damage. If not OK, go to Step 7.
Unplug the wire harness connector from the
blend-air door motor. Check for continuity between the blend air door driver circuit cavity of the
blend-air door motor wire harness connector and a good ground. There should be continuity. If OK,
go to Step 8. If not OK, repair the open circuit to ground as required.
voltage at the ignition feed circuit cavity of the
blend-air door motor wire harness connector. If OK, go to Step 9. If not OK, repair the open circuit
to the junction block fuse as required.
Check the resistance between the blend air door
driver circuit cavity and the ignition feed circuit cavity of the blend-air door motor wire harness
connector. The resistance should be from 8.5 to 11.5 kilohms. If OK, go to Step 10. If not OK, go to
Step 13.
9. Move the temperature control knob to the full counterclockwise (Cool) position. Measure the
resistance between the ignition feed circuit cavity
and the blend door feedback signal circuit cavity of the blend-air door motor wire harness
connector. The resistance should not be more than 100 ohms. If OK, go to Step 11. If not OK, go to
Step 13.
10. Move the temperature control knob to the full clockwise (Warm) position. Measure the
resistance between the ignition feed circuit cavity and the
blend door feedback signal circuit cavity of the blend-air door motor wire harness connector. The
resistance should be less than 10 ohms. If OK, go to Step 12. If not OK, go to Step 13.
11. Measure the resistance between the ignition feed circuit cavity and the blend door feedback
signal circuit cavity of the blend-air door motor wire
harness connector while slowly rotating the temperature control knob from stop to stop. There
should be no spikes greater than 11.5 kilohms. If OK, replace the faulty blend-air door motor. If not
OK, replace the faulty heater-only or heater-A/C control unit.
12. Remove the heater-only or heater-A/C control from the instrument panel. See Heater-A/C
Control Replacement for the procedures. Check for
continuity between the blend air door driver circuit cavity of the blend-air controller wire harness
connector and a good ground. There should be continuity. If OK, go to Step 14. If not OK, repair
the open circuit to ground as required.
13. Connect the battery negative cable. Turn the ignition switch to the On position. Check for
battery voltage at the ignition feed circuit cavity of the
blend-air controller wire harness connector. If OK, go to Step 15. If not OK, repair the open circuit
to the junction block fuse as required.
Check the resistance between the blend air door
driver circuit terminal and the ignition feed circuit terminal in the blend-air controller receptacle on
the back of the heater-A/C control. The resistance should be from 8.5 to 11.5 kilohms. If OK, go to
Step 16. If not OK, replace the faulty heater-A/C control unit.
15. Move the temperature control knob to the full counterclockwise (Cool) position. Measure the
resistance between the ignition feed circuit terminal
and the blend door feedback signal circuit terminal in the blend-air controller receptacle on the back
of the heater-A/C control. The resistance should not be more than 100 ohms. If OK, go to Step 17.
If not OK, replace the faulty heater-A/C control unit.
16. Move the temperature control knob to the full clockwise (Warm) position. Measure the
resistance between the ignition feed circuit terminal and
the blend door feedback signal circuit terminal in the blend-air controller receptacle on the back of
the heater-A/C control. The resistance should be less than 10 ohms. If OK, repair the blend door
feedback signal circuit to the blend-air door motor as required. If not OK, replace the faulty
heater-A/C control unit.
Component Information > Service and Repair > Blend Door Actuator Replacement
Air Door Actuator / Motor: Service and Repair Blend Door Actuator Replacement
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, FAILURE TO TAKE THE PROPER

PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAGS DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box from the
instrument panel. 3. Reach through the instrument panel glove box opening to access and unplug
the wire harness connector from the blend-air door motor.
Blend-Air Door Motor Remove/Install
4. Reach through the instrument panel glove box opening to unlatch the link retainer on the end of
the blend-air door motor lever. Remove the link
from the retainer.
5. Remove the three screws that secure the blend-air door motor to the top of the distribution duct.
6. Remove the blend-air door motor from the distribution duct.
INSTALLATION 1. Position the blend-air door motor on the top of the distribution duct. 2. Secure
the blend-air door motor to the distribution duct with three screws. Tighten the mounting screws to
2.2 N.m (20 in. lbs.).
Blend-Air Door Linkage
3. Install the link to the retainer on the end of the blend-air door lever. Be certain that the retainer is
positioned between the two sets of nubs on the
link, then snap the retainer closed.
4. Plug in the blend-air door motor wire harness connector. 5. Reinstall the glove box in the
instrument panel. 6. Connect the battery negative cable.
Component Information > Service and Repair > Blend Door Actuator Replacement > Page 5383
Air Door Actuator / Motor: Service and Repair Mode Door Actuator Replacement
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, FAILURE TO TAKE THE PROPER

PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
REMOVAL
Recirculation Air Door Actuator
WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE

FOLLOWING OPERATION.
1. Disconnect and isolate the battery negative cable. 2. if the vehicle is not equipped with air
conditioning, go to Step 5. if the vehicle is equipped with air conditioning, disconnect the suction
line
jumper at the expansion valve.
3. Remove the screws that secure the filter-drier and its mounting bracket to the heater-A/C
housing and the cowl side panel. Swing the filter-drier,
mounting bracket and refrigerant plumbing as a unit out of the way towards the center of the
vehicle.
Recirculation Air Door Actuator Remove/Install
4. Unplug the vacuum harness connector from the recirculation air door actuator located on the top
of the recirculation housing near the cowl side
panel in the engine compartment.
5. Unsnap the retaining clip that secures the recirculation air door actuator link to the recirculation
air door lever. 6. Loosen the two nuts that secure the recirculation air door actuator to the bracket
molded into the upper forward edge of the recirculation housing. 7. Disengage the actuator link
from the recirculation air door lever. 8. Lift the recirculation air door actuator upwards far enough to
disengage the two mounting studs from the slotted holes in the molded bracket on the
upper forward edge of the recirculation housing.
9. Remove the recirculation air door actuator from the engine compartment.
10. Reverse the removal procedures to install. Tighten the mounting nuts to 2.2 N.m (20 in. lbs.).
Floor-defrost Door Actuator 1. Disconnect and isolate the battery negative cable. 2. Remove the
instrument panel assembly from the vehicle. Refer to: "Instrument Panel Gauges and Warning
Indicators : Instrument Panel :
Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster /
Carrier/Service and Repair
Floor-Defrost Door Actuator
3. Unplug the two vacuum harness connectors from the floor-defrost door actuator located on a
mount between the two defroster outlets on the left
side of the distribution duct.
Vacuum Actuator Remove/Install - Typical
4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the actuator latch while
pulling firmly upward on the actuator to remove the
actuator from the mount on the distribution duct.
5. Lift the actuator upward until the actuator link is almost parallel with the floor-defrost door lever,
then disengage the hole on the end of the link
from the pin on the end of the lever.
6. Remove the floor-defrost door actuator from the distribution duct. 7. Reverse the removal
procedures to install.
Floor-panel Door Actuator 1. Disconnect and isolate the battery negative cable. 2. Remove the
instrument panel assembly from the vehicle. Refer to: "Instrument Panel Gauges and Warning
Indicators : Instrument Panel :
Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster /
Carrier/Service and Repair
Floor-panel Door Actuator
3. Unplug the two vacuum harness connectors from the floor-panel door actuator located on a
mount outboard of the demister outlet on the right side
of the distribution duct.

Recirculation Air Door Remove/Install
4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the actuator latch while
pulling firmly outward on the actuator to remove the
actuator from the mount on the distribution duct.
5. Swing the actuator around the floor-panel door lever about 1800, or until the actuator link is at
almost a right angle on the opposite side of the
lever, then disengage the hole on the end of the link from the pin on the end of the lever.
6. Remove the floor-panel door actuator from the distribution duct. 7. Reverse the removal
procedures to install.
Air Door Actuator / Motor: Service and Repair Rear Heat A/C
The rear mode control motor is used only on models with the optional rear heater-A/C unit. The
rear mode control motor can be removed without removing the rear heater-A/C unit from the
vehicle.
REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the rear
heater-A/C unit. 3. Remove the vertical duct from the rear heater- A/C unit. 4. Remove the
horizontal duct from the rear heater-A/C unit.
Rear Mode Control Motor Remove/Install
5. Unplug the wire harness connector from the rear mode control motor, located on the outboard
side of the upper housing near the front of the rear
heater-A/C unit.
6. Remove the three screws that secure the rear mode control motor to the rear heater-A/C unit
upper housing. 7. Move the rear mode control motor outboard far enough to disengage the motor
hub from the water valve control cable adaptor. 8. Remove the rear mode control motor from the
rear heater-A/C unit.
INSTALLATION 1. Install the rear mode control motor hub over the water valve control cable
adaptor. Be certain to index the flats in the motor hub to the flats on the
adaptor.
2. Install three screws to secure the rear mode control motor to the mounting bosses on the rear
heater-A/C unit upper housing. Tighten the mounting

3. Plug in the wire harness connector to the rear mode control motor. 4. Reinstall the horizontal
duct to the rear heater-A/C unit. 5. Reinstall the vertical duct on the rear heater-A/C unit. 6.
Reinstall the cover on the rear heater-A/C unit. 7. Connect the battery negative cable.
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair >
Distribution Duct Replacement
Air Duct: Service and Repair Distribution Duct Replacement
The distribution duct can be removed from the vehicle without disconnecting the refrigerant lines or
discharging the refrigerant system. The distribution duct assembly must be removed from the
vehicle and disassembled for service access of the floor-defrost door or the floor-panel door.
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS /

AIR BAG SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND
REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel
from the vehicle. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument
Panel/Instrument Panel
Assembly Replacement.
3. Remove the blend-air door motor from the distribution duct. See Blend-Air Door Motor
Replacement procedures. 4. Unplug the two vacuum harness connections from each of the two
vacuum actuators on the upper half of the distribution duct. 5. Remove the one screw that secures
the vacuum harness retaining strap to the left end of the distribution duct. 6. Remove the vacuum
harness from the distribution duct.
Distribution Duct Remove/Install

7. Remove the one screw that secures the left floor outlet of the distribution duct to the instrument
panel support on the left side of the dash panel
engine housing extension.
8. Remove the five screws that secure the distribution duct to the dash panel. 9. Remove the
distribution duct from the dash panel.
Disassembly 1. Remove the seals from the inlet flange and the panel outlet flange of the
distribution duct. 2. Remove the fifteen remaining screws that secure the upper half of the
distribution duct to the lower half. 3. Carefully separate the two halves of the distribution duct.
Inspection Examine all of the distribution duct seals for damage. Replace all damaged or deformed
seals. Clean all of the upper and lower distribution duct mating flanges prior to reassembly.
Inspect the distribution duct components for damage. Repair or replace any faulty or damaged
components as required. Remove any foreign material or other restrictions to air flow.
Distribution Duct Replacement > Page 5391
Assembly 1. Position the upper half of the distribution duct over the lower half. Be certain that the
pivot shafts for both mode doors are in their proper
positions.
2. Install fifteen of the screws that secure the upper half of the distribution duct to the lower half
leaving out the screw on the left rear corner of
the duct that also secures the vacuum harness retaining strap. Tighten the mounting screws to 2.2
N.m (20 in. lbs.).
3. Install new seals on the inlet flange and the panel outlet flange of the distribution duct.
INSTALLATION 1. Position the distribution duct to the dash panel. 2. Install the four screws that
secure the distribution duct to the right side of the dash panel. Tighten the mounting screws to 2.7
N.m (24 in. lbs.). 3. Install the one screw that secures the left floor outlet of the distribution duct to
the instrument panel support on the left side of the dash panel
engine housing extension, and the one screw that secures the distribution duct to the dash panel
between the two defroster outlets. Tighten the mounting screws to 4.5 N.m (40 in. lbs.).
4. Position and route the vacuum harness over the distribution duct. 5. Install the one screw that
secures the vacuum harness retaining strap near the left end of the distribution duct. Tighten the
mounting screw to 2.2
N.m (20 in. lbs.).
6. Plug in the two vacuum harness connections to each of the two vacuum actuators on the upper
half of the distribution duct. 7. Reinstall the blend-air door motor to the distribution duct. See
Blend-Air Door Motor Replacement. 8. Reinstall the instrument panel to the vehicle. Refer to
Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Panel
Assembly Replacement.

Air Duct: Service and Repair Duct and Outlet Replacement

COULD RESULT IN ACCIDENTAL AIRBAGS DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
Outlet Barrels In addition to the panel outlet barrels in the instrument panel, models equipped with
the optional rear heater-A/C unit have outlets for the rear seat passengers located in the left rear
side panel lower trim and in the headliner. The service procedures for all of the instrument panel
outlet barrels is the same. The outlets in the left rear side panel and in the headliner are serviced
as a unit with the outlet bezels.
Outlet Barrels
1. Using a trim stick or another suitable wide flat-bladed tool, gently pry at the sides of the outlet
barrels to release the snap-fit pivots on the barrel
from the pivot pins in the outlet housings of the instrument panel or the instrument cluster bezel.
2. Once the outlet barrel is released from the pivots, tilt the top of the barrel out from the housing to
disengage the travel limiter pin on the bottom of
the barrel that is inserted into a slot in the bottom of the housing.
3. To install the outlet barrel, insert the travel limiter pin on the bottom of the barrel into the slot in
the bottom of the housing. Position the top of the
barrel in the outlet housing and press inward firmly and evenly on both sides of the barrel until the
pivots snap into place.
Outlet Housings 1. Remove the passenger side airbag module from the instrument panel. Refer to
Airbag Module - Passenger Side replacement procedures. 2. Remove the barrel(s) from the outlet
housing. See Ducts and Outlets - Outlet Barrels replacement procedures.
Outlet Housings
3. Remove the screws that secure the outlet housing to the instrument panel. 4. Remove the outlet
housing from the instrument panel. 5. Reverse the removal procedures to install. Tighten the
mounting screws to 2.2 N.m (20 in. lbs.).
Defroster Duct Extensions 1. Remove The Instrument Panel from the passenger compartment.
Refer to Instrument Panel, Gauges and Warning Indicators/Instrument
Panel/Instrument Panel/Instrument Panel Assembly replacement.

Defroster Duct Extensions
3. Remove the defroster duct extension from below the top of the instrument panel. 4. Reverse the
Demister Duct
Both side window demister ducts and both outboard panel ducts are integral to the demister duct
unit. The inboard panel ducts are integral to the instrument panel distribution duct unit. 1. Remove
the base trim from the instrument panel. Refer to Instrument Panel, Gauges and Warning
Indicators/Instrument Panel/Instrument
Panel Base Trim replacement procedures.
Demister Duct And Instrument Panel Distribution Duct
2. Remove the screws that secure the demister duct to the instrument panel armature. 3. Separate
the demister duct from the instrument panel distribution duct. 4. Remove the demister duct from the
instrument panel armature. 5. Reverse the removal procedures to install. Tighten the mounting
Instrument Panel Distribution Duct
The inboard panel ducts are integral to the instrument panel distribution duct unit. Both side
window demister ducts and both outboard panel ducts are integral to the demister duct unit. 1.
Remove the base trim from the instrument panel. Refer to Instrument Panel, Gauges and Warning
Panel/Instrument Panel Base Trim replacement
2. Remove the screws that secure the distribution duct to the instrument panel armature. 3.
Separate the instrument panel distribution duct from the demister duct. 4. Remove the instrument
panel distribution duct from the instrument panel armature. 5. Reverse the removal procedures to
Rear Overhead Duct
A rear overhead duct is only used on models equipped with the optional rear heater-A/C unit. The
rear overhead duct is integral to the rear headliner. If either the duct or the headliner is faulty or
damaged, the rear headliner unit must be replaced.
Rear Overhead Outlet Bezels
Rear overhead outlets are only used on models equipped with the optional rear heater-A/C unit.
1. Using a trim stick or another suitable wide flat-bladed tool, gently pry around the perimeter edges
of the outlet bezel to release it from the
overhead duct outlet.
2. Remove the overhead outlet bezel from the rear headliner. 3. To install the outlet bezel, position
the bezel in the outlet opening of the rear overhead duct and press inward firmly and evenly on
both sides
of the bezel until it snaps into place.
Rear Side Panel Outlet Bezels
Rear side panel outlet bezels are only used on models equipped with the optional rear heater-A/C
unit.
1. Using a trim stick or another suitable wide flat-bladed tool, gently pry between the edge of the
outlet bezel and the rear side panel lower trim
panel to release the snap clips that secure the bezel to the horizontal duct.
2. Remove the outlet bezel from the rear side panel lower trim panel. 3. To install the outlet bezel,
position the bezel to the holes on the horizontal duct and press inward firmly and evenly on both
sides of the bezel
until the retaining clips snap into place.
Vertical Duct
The vertical duct is only used on models equipped with the optional rear heater-A/C unit.
Rear Heater-A/C Unit Ducts Remove/Install
1. Using a trim stick or another suitable wide flat-bladed tool, gently pry out the plug that covers the
vertical duct mounting screw. 2. Loosen but do not remove the screw that secures the vertical duct
to the rear side panel strainer. Only loosen the screw far enough to disengage
the vertical duct from the side panel. Gently pull the vertical duct away from the rear side panel
while loosening the screw so that it can be determined when the screw is disengaged from the side
panel.
3. Grasp the top of the vertical duct firmly with one hand and press upward on the inboard side of
the duct opening in the headliner with the other
hand. Pull the top of the duct downward and inboard until it unsnaps from the headliner duct
opening.
4. Lift the vertical duct off of the rear heater-A/C unit duct outlet. 5. Reverse the removal
procedures to install. Tighten the mounting screw to 2.2 N.m (20 in. lbs.).
Horizontal Duct
The horizontal duct is only used on models equipped with the optional rear heater-A/C unit. 1.
Remove the outlet bezels from the rear side panel lower trim panel. See Ducts and Outlets - Rear
Side Panel Outlet Bezels replacement
procedures.
2. Remove the lower trim panels from the left rear side panel. 3. Remove the two retainers that
secure the horizontal duct to the left rear side panel. 4. Lift the horizontal duct off of the rear
heater-A/C unit duct outlet. 5. Reverse the removal procedures to install.
Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
Air Register: Service and Repair

COULD RESULT IN ACCIDENTAL AIRBAGS DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
Outlet Barrels In addition to the panel outlet barrels in the instrument panel, models equipped with
the optional rear heater-A/C unit have outlets for the rear seat passengers located in the left rear
side panel lower trim and in the headliner. The service procedures for all of the instrument panel
outlet barrels is the same. The outlets in the left rear side panel and in the headliner are serviced
as a unit with the outlet bezels.
Outlet Barrels
1. Using a trim stick or another suitable wide flat-bladed tool, gently pry at the sides of the outlet
barrels to release the snap-fit pivots on the barrel
from the pivot pins in the outlet housings of the instrument panel or the instrument cluster bezel.
2. Once the outlet barrel is released from the pivots, tilt the top of the barrel out from the housing to
disengage the travel limiter pin on the bottom of
the barrel that is inserted into a slot in the bottom of the housing.
3. To install the outlet barrel, insert the travel limiter pin on the bottom of the barrel into the slot in
the bottom of the housing. Position the top of the
barrel in the outlet housing and press inward firmly and evenly on both sides of the barrel until the
pivots snap into place.
Outlet Housings 1. Remove the passenger side airbag module from the instrument panel. Refer to
Airbag Module - Passenger Side replacement procedures. 2. Remove the barrel(s) from the outlet
housing. See Ducts and Outlets - Outlet Barrels replacement procedures.
Outlet Housings
3. Remove the screws that secure the outlet housing to the instrument panel. 4. Remove the outlet
housing from the instrument panel. 5. Reverse the removal procedures to install. Tighten the
Defroster Duct Extensions 1. Remove The Instrument Panel from the passenger compartment.
Refer to Instrument Panel, Gauges and Warning Indicators/Instrument
Panel/Instrument Panel/Instrument Panel Assembly replacement.

Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair >
Page 5399
Defroster Duct Extensions
3. Remove the defroster duct extension from below the top of the instrument panel. 4. Reverse the
Demister Duct
Both side window demister ducts and both outboard panel ducts are integral to the demister duct
unit. The inboard panel ducts are integral to the instrument panel distribution duct unit. 1. Remove
the base trim from the instrument panel. Refer to Instrument Panel, Gauges and Warning
Panel Base Trim replacement procedures.
Demister Duct And Instrument Panel Distribution Duct
2. Remove the screws that secure the demister duct to the instrument panel armature. 3. Separate
the demister duct from the instrument panel distribution duct. 4. Remove the demister duct from the
instrument panel armature. 5. Reverse the removal procedures to install. Tighten the mounting
Instrument Panel Distribution Duct
The inboard panel ducts are integral to the instrument panel distribution duct unit. Both side
window demister ducts and both outboard panel ducts are integral to the demister duct unit. 1.
Remove the base trim from the instrument panel. Refer to Instrument Panel, Gauges and Warning
Panel/Instrument Panel Base Trim replacement
2. Remove the screws that secure the distribution duct to the instrument panel armature. 3.
Separate the instrument panel distribution duct from the demister duct. 4. Remove the instrument
panel distribution duct from the instrument panel armature. 5. Reverse the removal procedures to
Rear Overhead Duct
A rear overhead duct is only used on models equipped with the optional rear heater-A/C unit. The
rear overhead duct is integral to the rear headliner. If either the duct or the headliner is faulty or
damaged, the rear headliner unit must be replaced.
Rear overhead outlets are only used on models equipped with the optional rear heater-A/C unit.
Page 5400
1. Using a trim stick or another suitable wide flat-bladed tool, gently pry around the perimeter edges
of the outlet bezel to release it from the
overhead duct outlet.
2. Remove the overhead outlet bezel from the rear headliner. 3. To install the outlet bezel, position
the bezel in the outlet opening of the rear overhead duct and press inward firmly and evenly on
both sides
of the bezel until it snaps into place.
Rear side panel outlet bezels are only used on models equipped with the optional rear heater-A/C
unit.
1. Using a trim stick or another suitable wide flat-bladed tool, gently pry between the edge of the
outlet bezel and the rear side panel lower trim
panel to release the snap clips that secure the bezel to the horizontal duct.
2. Remove the outlet bezel from the rear side panel lower trim panel. 3. To install the outlet bezel,
position the bezel to the holes on the horizontal duct and press inward firmly and evenly on both
sides of the bezel
until the retaining clips snap into place.
Vertical Duct
The vertical duct is only used on models equipped with the optional rear heater-A/C unit.
Page 5401
Rear Heater-A/C Unit Ducts Remove/Install
1. Using a trim stick or another suitable wide flat-bladed tool, gently pry out the plug that covers the
vertical duct mounting screw. 2. Loosen but do not remove the screw that secures the vertical duct
to the rear side panel strainer. Only loosen the screw far enough to disengage
the vertical duct from the side panel. Gently pull the vertical duct away from the rear side panel
while loosening the screw so that it can be determined when the screw is disengaged from the side
panel.
3. Grasp the top of the vertical duct firmly with one hand and press upward on the inboard side of
the duct opening in the headliner with the other
hand. Pull the top of the duct downward and inboard until it unsnaps from the headliner duct
opening.
4. Lift the vertical duct off of the rear heater-A/C unit duct outlet. 5. Reverse the removal
procedures to install. Tighten the mounting screw to 2.2 N.m (20 in. lbs.).
Horizontal Duct
The horizontal duct is only used on models equipped with the optional rear heater-A/C unit. 1.
Remove the outlet bezels from the rear side panel lower trim panel. See Ducts and Outlets - Rear
Side Panel Outlet Bezels replacement
procedures.
2. Remove the lower trim panels from the left rear side panel. 3. Remove the two retainers that
secure the horizontal duct to the left rear side panel. 4. Lift the horizontal duct off of the rear
heater-A/C unit duct outlet. 5. Reverse the removal procedures to install.
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and
Operation
Blower Motor: Description and Operation
SYSTEM OPERATION
Front
The front blower motor and blower wheel are located in the blower housing in the engine
compartment. The blower housing is integral to the recirculation housing, which is secured to the
dash panel and the right cowl side inner panel below the heater-A/C housing. The blower motor
controls the velocity of air flowing through the heater-A/C system by spinning a squirrel cage-type
blower wheel within the housing at the selected speed. The blower motor and blower wheel can be
accessed for service from the engine compartment.
The front blower motor will only operate when the ignition switch is in the On position, and when
the heater-only or heater-A/C mode control switch knob is in any position, except Off. The blower
motor receives a fused battery feed through the blower motor relay whenever the ignition switch is
in the On position. The blower motor battery feed circuit is protected by a fuse in the Power
Distribution Center (PDC). The blower motor relay control circuit is protected by a fuse in the
junction block.
Blower speed is controlled by regulating the blower motor ground path through the heater-A/C
mode control switch, the front blower motor switch, the blower motor resistor, and the high speed
blower motor relay. When the blower motor switch is placed in the highest speed position it
energizes the high speed blower motor relay, which then provides a direct ground feed to the
blower motor and bypasses the remainder of the blower motor control circuit.
The blower motor and blower motor wheel cannot be repaired and, if faulty or damaged, they must
be replaced. The blower motor and blower wheel are each serviced separately.
Rear
The rear blower motor and blower wheel are located in the optional rear heater-A/C unit housing in
the passenger compartment. The rear heater-A/C unit is secured to the floor panel between the
fuel filler inlet housing and the left rear wheel house against the left side panel. The blower motor
controls the velocity of air flowing through the rear heater-A/C system by spinning a squirrel
cage-type blower wheel within the housing at the selected speed. The blower motor and blower
wheel can be accessed for service from the passenger compartment.
The rear blower motor will only operate when the ignition switch is in the On position. The blower
motor receives a fused battery feed through the blower motor relay whenever the ignition switch is
in the On position. The blower motor battery feed circuit is protected by a fuse in the Power
Distribution Center (PDC). The blower motor relay control circuit is protected by a fuse in the
junction block.
Blower speed is controlled by regulating the blower motor ground path through the blower motor
switch, the blower motor resistor, and the high speed blower motor relay. When the rear blower
motor switch is placed in the highest speed position it energizes the high speed blower motor relay,
which then provides a direct ground feed to the blower motor and bypasses the remainder of the
blower motor control circuit.
The rear blower motor and blower motor wheel cannot be repaired and, if faulty or damaged, they
must be replaced. The blower motor and blower wheel are each serviced separately.
Blower Motor: Testing and Inspection
WARNING: ON VEHICLES EQUIPPED WITH AIR BAGS, REFER TO AIRBAGS BEFORE

INJURY.
Possible causes of an inoperative front or rear blower motor include:
- Faulty fuse
of Faulty blower motor circuit wiring or wire harness connectors -
Faulty blower motor resistor
- Faulty blower motor relay
- Faulty blower motor switch
- Faulty heater-A/C mode control switch (front only)
- Faulty high speed blower motor relay
- Faulty blower motor.
Possible causes of the front or rear blower motor not operating in all speeds include:
- Faulty fuse
- Faulty blower motor switch
- Faulty blower motor resistor
- Faulty blower motor relay
- Faulty blower motor circuit wiring or wire harness connectors
- Faulty high speed blower motor relay.
Vibration Possible causes of front or rear blower motor vibration include: -
Improper blower motor mounting
- Improper blower wheel mounting
- Blower wheel out of balance or deformed
- Blower motor faulty.
Noise To verify that the blower is the source of the noise, unplug the blower motor wire harness
connector and operate the heater-A/C system. If the noise goes away, possible causes include: -
Foreign material in the front or rear heater-A/C housing
- Improper blower motor mounting
- Improper blower wheel mounting
- Blower motor faulty.

Blower Motor: Service and Repair
Front
REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the upper half of the
radiator fan shroud.
Front Blower Motor Remove/Install
3. Unplug the wire harness connector from the blower motor. 4. Remove the blower motor cooling
tube from the nipple on the blower housing cover below the blower motor. 5. Remove the three
screws that secure the blower motor mounting plate to the blower housing cover. 6. Remove the
blower motor assembly from the blower housing. 7. If the vehicle is equipped with air conditioning,
move the suction and discharge lines as required to remove the blower motor assembly from the
engine compartment.
8. Remove the retainer clip from the hub of the blower wheel. 9. Remove the wheel from the blower
motor shaft.
INSTALLATION 1. Press the hub of the blower wheel onto the blower motor shaft. Be sure the flat
on the blower motor shaft is indexed to the flat on the inside of the
hub.
2. Install the retainer clip over the blower wheel hub. The ears of the retainer clip must be indexed
over the flats on the blower motor shaft and
blower wheel hub.
3. Apply a small bead of RTV rubber sealant to the blower motor side of the rubber seal and
isolator unit. This will help to secure the seal to the
blower mounting plate during installation.
4. Position the rubber seal and isolator unit to the blower motor mounting plate. 5. Position the
blower motor and seal to the three mounting bosses on the blower housing cover and press the
isolators over the mounting bosses. 6. Secure the blower motor mounting plate to the blower
housing cover with the three mounting screws. Tighten the mounting screws to 2.2 N.m (20
in. lbs.).
7. Reinstall the blower motor cooling tube to the nipple on the blower housing cover.
Blower Motor Wheel Remove/Install
8. Plug in the blower motor wire harness connector.

9. Reinstall the upper radiator fan shroud.
REAR
The rear blower motor is used only on models with the optional rear heater-A/C unit. The blower
motor can be removed without removing the rear heater-A/C unit from the vehicle.
REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the rear
heater-A/C unit. See Rear Heater-A/C Cover Replacement for the procedures. 3. Remove the
vertical duct from the rear heater-A/C unit. See Ducts and Outlets - Vertical Duct. 4. Remove the
horizontal duct from the rear heater-A/C unit. See Ducts and Outlets - Horizontal Duct. 5. Remove
the upper housing from the rear heater-A/C unit. See Rear Heater-A/C Unit - Disassembly.
6. Remove the three screws that secure the blower motor mounting plate to the rear heater-A/C
unit upper housing. 7. Remove the blower motor assembly from the rear heater-A/C unit upper
housing. 8. Remove the retainer clip from the hub of the blower wheel. 9. Remove the wheel from
the blower motor shaft.
INSTALLATION 1. Press the hub of the blower wheel onto the blower motor shaft. Be sure the flat
on the blower motor shaft is indexed to the flat on the inside of the
hub.
2. Install the retainer clip over the blower wheel hub. The ears of the retainer clip must be indexed
over the flats on the blower motor shaft and
blower wheel hub.
3. Position the rubber seal and isolator unit to the blower motor mounting plate. 4. Position the
blower motor and seal to the three mounting bosses on the rear heater-A/C unit upper housing and
press the isolators over the
mounting bosses.
5. Secure the blower motor mounting plate to the rear heater-A/C unit upper housing with the three
mounting screws. Tighten the mounting screws to
2.2 N.m (20 in. lbs.).
6. Reinstall the upper housing onto the rear heater-A/C unit. See Rear Heater-A/C Unit - Assembly
Replacement for the procedures. 7. Reinstall the horizontal duct to the rear heater-A/C unit. See
Ducts and Outlets - Horizontal Duct. 8. Reinstall the vertical duct to the rear heater-A/C unit. See
Ducts and Outlets - Vertical Duct. 9. Reinstall the cover to the rear heater-A/C unit. See Rear
Heater-A/C Cover Replacement for the procedures.

Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations
8w-10-2
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description
and Operation > Blower Motor Relay
SYSTEM OPERATION
Front
Rear
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description
and Operation > Blower Motor Relay > Page 5413
SYSTEM OPERATION
Front
replaced.
Rear
location.
replaced.
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > Blower Motor Relay
Blower Motor Relay
Relay Test

relay.
Relay Circuit Test
Inspection > Blower Motor Relay > Page 5416
Blower Motor Relay
Relay Test

relay.
Relay Circuit Test
Front
Rear
unit.
place.
relay operation.

firmly into place.
relay operation.
Rear
heater-A/C unit.
firmly into place.
relay operation.
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description
and Operation
Blower Motor Resistor: Description and Operation
SYSTEM OPERATION
Front
The front blower motor resistor is mounted to the inboard side of the heater-A/C housing in the
engine compartment. It can be accessed for service from the engine compartment. It is secured to
the housing with two screws and is connected to the headlamp and dash wire harness. See Blower
Motor Resistor - Front in the Removal and Installation for more information.
The blower motor resistor has multiple resistor wires, each of which will change the resistance in
the blower motor ground path to change the blower motor speed. The blower motor switch directs
the ground path through the correct resistor wire to obtain the selected blower motor speed.
With the blower motor switch in the lowest speed position the ground path for the motor is applied
through all of the resistor wires. Each higher speed selected with the blower motor switch applies
the blower motor ground path through fewer of the resistor wires, increasing the blower motor
speed. When the blower motor switch is in the highest speed position, the blower motor resistor is
bypassed and the blower motor receives a direct path to ground through the high speed blower
motor relay.
The front blower motor resistor cannot be repaired and, if faulty or damaged, it must be replaced.
Rear
The optional rear heater-A/C unit has a blower motor resistor mounted to the inside of the unit
lower housing in the passenger compartment. It can be accessed for service through the horizontal
duct opening in the rear heater-A/C unit upper housing. It is secured to the inside of the lower
housing by two mounting tabs and a snap feature that are molded into the lower housing, and it is
connected to the rear heater-A/C unit wire harness. See Blower Motor Resistor - Rear in the
Removal and Installation for more information.
The blower motor resistor has multiple resistor wires, each of which will change the resistance in
the blower motor ground path to change the blower motor speed. The blower motor switch directs
the ground path through the correct resistor wire to obtain the selected blower motor speed.
With the blower motor switch in the lowest speed position the ground path for the motor is applied
through all of the resistor wires. Each higher speed selected with the blower motor switch applies
the blower motor ground path through fewer of the resistor wires, increasing the blower motor
speed. When the blower motor switch is in the highest speed position, the blower motor resistor is
bypassed and the blower motor receives a direct path to ground through the high speed blower
motor relay
The rear blower motor resistor cannot be repaired and, if faulty or damaged, it must be replaced.
and Operation > Page 5422
Blower Motor Resistor: Testing and Inspection
The blower motor resistors used for the front heater-only or heater-A/C systems and for the
optional rear heater-A/C unit can be tested in the same manner. The front blower motor resistor is
located in the engine compartment on the inboard side of the heater-A/C housing. The rear blower
motor resistor is located in lower housing of the rear heater-A/C unit in the passenger
compartment.
The front blower motor resistor can be tested without removing it from its mounting position. The
rear blower motor resistor must be removed from its mounting position to be tested. See Blower
Motor Resistor - Rear in the Removal and Installation procedures.

INJURY.
the blower motor resistor. 3. Check for continuity between each of the blower motor switch input
terminals of the resistor and the resistor output terminal. In each case there
should be continuity. If OK, repair the wire harness circuits between the blower motor switch and
the blower motor resistor or blower motor as required. If not OK, replace the faulty blower motor
resistor.
Blower Motor Resistor: Service and Repair
Front
REMOVAL 1. Disconnect and isolate the battery negative cable.
Front Blower Motor Resistor Remove/Install
2. Unplug the wire harness connector from the blower motor resistor, which is located on the
inboard side of the heater-A/C housing. 3. Remove the two screws that secure the blower motor
resistor to the heater-A/C housing. 4. Remove the front blower motor resistor from the heater-A/C
housing.
INSTALLATION 1. Position the front blower motor resistor to the mounting hole on the inboard side
of the heater-A/C housing. 2. Secure the front blower motor resistor to the heater-A/C housing with
two screws. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). 3. Plug the wire harness
connector into the front blower motor resistor. 4. Connect the battery negative cable.
Rear
The rear blower motor resistor is used only on models with the optional rear heater-A/C unit.
REMOVAL 1. Before beginning this procedure, place the rear heater-A/C unit in the heat mode by
turning the ignition switch to the On position and placing the
temperature control knob on the heater-A/C control in the full hot position.
2. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. 3.
Remove the cover from the rear heater-A/C unit. 4. Reach under the front of the rear heater-A/C
unit to access and unplug the wire harness connector from the rear blower motor resistor. 5.
Remove the horizontal duct from the rear heater-A/C unit.
Rear Blower Motor Resister Remove/Install
6. Reach through the horizontal duct outlet in the rear heater-A/C unit upper housing with a small
hand or use large pliers to access the blower motor
resistor.
7. Push firmly against the inboard side of the blower motor resistor shield toward the outboard side
of the vehicle until the resistor unsnaps from the
retainer in the lower housing.
8. Pull the blower motor resistor out of the rear heater-A/C housing through the horizontal duct
outlet.
INSTALLATION 1. Lower the blower motor resistor into the rear heater-A/C unit upper housing
horizontal duct outlet. 2. Slide the outboard edge of the blower motor resistor mounting flange
under the two tabs on the outboard edge of the resistor mounting hole in the
lower housing.
3. Reach under the front of the rear heater-A/C unit to hold the blower motor resistor against the
outboard side of the mounting hole with one hand.
Then, use the other hand to reach through the horizontal duct outlet from above and press firmly
downward on the inboard side of the resistor shield until the inboard side of the resistor mounting
flange snaps under the retainer on the inboard side of the mounting hole in the lower housing.
4. Reach under the front of the rear heater-A/C unit to access and plug in the wire harness
connector to the rear blower motor resistor. 5. Reinstall the horizontal duct to the rear heater- A/C
unit. 6. Reinstall the cover over the rear heater-A/C unit. 7. Connect the battery negative cable.
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description
and Operation
SYSTEM OPERATION
Front
Rear
an Off position.
blower motor speed.

INJURY.
as required.
ground as required.
switch.
Instrument Panel,

Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Compressor Clutch: Specifications
Clutch Air Gap .....................................................................................................................................

.......................... 0.35 - 0.65 mm (0.013 to 0.025 in.)
8w-80-4
Compressor Clutch: Description and Operation
SYSTEM OPERATION
Compressor Clutch - Typical
The compressor clutch assembly consists of a stationary electromagnetic coil, a hub bearing and
pulley assembly, and a clutch plate. The electromagnetic coil unit and the hub bearing and pulley
assembly are each retained on the nose of the compressor front housing with snap rings. The
clutch plate is mounted on the compressor shaft and secured with a nut.
These components provide the means to engage and disengage the compressor from the engine
serpentine accessory drive belt. When the clutch coil is energized, it magnetically draws the clutch
into contact with the pulley and drives the compressor shaft. When the coil is not energized, the
pulley freewheels on the clutch hub bearing, which is part of the pulley. The compressor clutch and
coil are the only serviced parts on the compressor.
The compressor clutch is controlled by several components: the heater-A/C mode control switch,
the low pressure cut-off switch, the high pressure cut-off switch, the fin sensing cycling clutch
switch, the thermal limiter switch, the compressor clutch relay, and the Powertrain Control Module
(PCM). The PCM may delay compressor clutch engagement for up to thirty seconds.
Compressor Clutch: Service and Repair
The refrigerant system can remain fully-charged during compressor clutch, pulley, or coil
replacement. The compressor clutch can be serviced in the vehicle.
REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the serpentine drive
belt. 3. Unplug the compressor clutch coil wire harness connector.
Clutch Nut Remove
4. install two 6 millimeter screws into the threaded holes in the front of the clutch plate. Use two
box-end wrenches over the screws to hold the clutch
plate stationary and remove the hex nut.
CAUTION: Do not pry between the clutch plate and the clutch pulley to remove the plate. Failure to
observe this caution may result in damage to the compressor clutch assembly.
5. Remove the clutch plate and the clutch shims. If necessary, tap the clutch plate lightly with a
plastic hammer to loosen it. 6. Remove the compressor clutch pulley retaining snap ring with snap
ring pliers. 7. Remove the clutch pulley assembly from the compressor. If necessary, tap the clutch
pulley lightly with a plastic hammer to loosen it. 8. Remove the screw and retainer from the clutch
coil lead wire harness on the compressor front housing. 9. Unplug the compressor clutch wire
harness connectors from the thermal limiter switch.
10. Note the alignment of the clutch field coil assembly on the compressor before removing it for
correct reinstallation.
Clutch/Pulley/Coil Remove/Install
11. Remove the snap ring that secures the clutch field coil assembly to the compressor front
housing.
12. Remove the clutch field coil assembly from the compressor front housing.
Inspection Examine the friction surfaces of the clutch pulley and the front plate for wear. The pulley
and front plate should be replaced if there is excessive wear or scoring.
If the friction surfaces are oily, inspect the shaft and nose area of the compressor for oil. If
excessive oil is present, the shaft seal is leaking and the compressor must be replaced.
Check the clutch pulley bearing for roughness or excessive leakage of grease. Replace the
bearing, if required.
INSTALLATION 1. Position the back of the clutch field coil against the compressor front housing.
Be certain that the locating pin on the back of the coil lines up with
the indentation on the compressor front housing. This ensures the proper orientation of the coil and
the wire harness.
2. Install the clutch field coil snap ring (bevel side outward) with snap ring pliers. Be certain that the
snap ring is properly seated into the groove.
CAUTION: If the snap ring is not fully seated in the groove it will vibrate out, resulting in a clutch
failure and severe damage to the front housing of the compressor.
3. Install the clutch coil lead wire harness retaining clip on the compressor front housing and tighten
the retaining screw. 4. Plug in the compressor clutch wire harness connectors to the thermal limiter
switch. 5. Position the clutch pulley assembly onto the compressor.
CAUTION: Do not mar or contaminate the clutch pulley friction surface.
6. Install the clutch pulley assembly snap ring (bevel side outward) with snap ring pliers. Be certain
that the snap ring is properly seated in the
groove.
7. Place a trial stack of shims, 2.54 millimeters (0.10 inch) thick, on the compressor shaft.
Aligning Clutch Plate Splines
8. Note the machined mating splines on the compressor shaft and in the clutch plate hub. 9. Align
the mating splines and install the clutch plate on the compressor shaft.
10. Install the external front rotor snap ring with snap ring pliers. The bevel side of the snap ring
must be facing outward. Press the snap ring to make
sure it is properly seated in the groove.
Check Clutch Air Gap
11. With the front clutch plate assembly tight against the shims, measure the air gap between the
clutch plate and the pulley face with a feeler gauge.
The air gap should be from 0.35 to 0.65 millimeter (0.013 to 0.025 inch). If the proper air gap is not
obtained, add or subtract shims until the desired air gap is obtained.
12. Install the compressor shaft nut. Tighten the nut to 14.4 N.m (10.5 ft. lbs.).
13. The shims may compress after tightening the compressor shaft nut. Check the air gap in four or
more places to verify that the air gap is still
correct. Spin the pulley for a final check.
14. Reverse the remaining removal procedures to complete the installation.
Clutch Break-In After a new compressor clutch has been installed, cycle the compressor clutch
approximately twenty times (five seconds on, then five seconds off). During this procedure, set the
heater-A/C control to the recirculation mode (Max-A/C), the blower motor switch in the highest
speed position, and the engine speed at 1500 to 2000 rpm. This procedure (burnishing) will seat
the opposing friction surfaces and provide a higher compressor clutch torque capability
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Compressor Clutch Coil: Testing and Inspection
The battery must be fully-charged before performing the following tests. Refer to Starting and
Charging/Battery for more information.
1. Connect an ammeter (0 to 10 ampere scale) in series with the clutch coil terminal. Use a
voltmeter (0 to 20 volt scale) with clip-type leads for
measuring the voltage across the battery and the compressor clutch coil.
2. With the heater-A/C mode control switch in any A/C mode, and the blower motor switch in the
lowest speed position, start the engine and run it at
normal idle.
3. The compressor clutch coil voltage should read within two volts of the battery voltage. If there is
voltage at the clutch coil, but the reading is not
within Two Volts of the battery voltage, test the clutch coil feed circuit for excessive voltage drop
and repair as required. If there is no voltage reading at the clutch coil, use a DRB scan tool and the
proper Diagnostic Procedures for testing of the compressor clutch circuit. The following
components must be checked and repaired as required before you can complete testing of the
clutch coil: -
Fuses in the junction block and the Power Distribution Center
- Heater-A/C mode control switch
- Compressor clutch relay
- Fin sensing cycling clutch switch
- High pressure cut-off switch
- Low pressure cut-off switch
- Thermal limiter switch
- Powertrain Control Module.
4. The compressor clutch coil is acceptable if the current draw measured at the clutch coil is 2.0 to
3.9 amperes with the electrical system voltage at
11.5 to 12.5 volts. This should only be checked with the work area temperature at 210 C (700 F). If
system voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories
until the system voltage drops below 12.5 volts. a. If the clutch coil current reading is four amperes
or more, the coil is shorted and should be replaced. b. If the clutch coil current reading is zero, the
coil is open and should be replaced.
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information >
8w-10-2


SYSTEM OPERATION
Relay Test

Relay Circuit Test
relay operation.
Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation
Condenser HVAC: Description and Operation
SYSTEM OPERATION
The condenser is located in the air flow in front of the engine cooling radiator. The condenser is a
heat exchanger that allows the high-pressure refrigerant gas being discharged by the compressor
to give up its heat to the air passing over the condenser fins. When the refrigerant gas gives up its
heat, it condenses. When the refrigerant leaves the condenser, it has become a high-pressure
liquid refrigerant.
The volume of air flowing over the condenser fins is critical to the proper cooling performance of
the air conditioning system. Therefore, it is important that there are no objects placed in front of the
radiator grille openings in the front of the vehicle or foreign material on the condenser fins that
might obstruct proper air flow. Also, any factory-installed air seals or shrouds must be properly
reinstalled following radiator or condenser service.
The condenser cannot be repaired and, if faulty or damaged, it must be replaced.

Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Condenser HVAC: Service and Repair

CAUTION: Before removing the condenser, note the location of each of the radiator and condenser
air seals. These seals are used to direct air through the condenser and radiator. The air seals must
be reinstalled in their proper locations in order for the air conditioning and engine cooling systems
to perform as designed.
refrigerant system. 3. Remove the radiator grille from the vehicle. 4. Disconnect the discharge line
from the condenser inlet. Install plugs in, or tape over all of the opened refrigerant line fittings. 5.
Disconnect the liquid line from the condenser outlet. Install plugs in, or tape over all of the opened
refrigerant line fittings. 6. Remove the upper radiator support from the vehicle.
Condenser Remove/Install
7. Remove the nuts that secure the condenser to the front of the right and left radiator core
supports.
INSTALLATION 1. Carefully position the condenser mounting brackets over the screws on the right
and left radiator core supports. 2. Reinstall the nuts that secure the condenser mounting brackets
to the radiator core supports. Tighten the mounting nuts to 11.8 N.m (105 in. lbs.). 3. Reinstall the
upper radiator support in the vehicle. 4. Remove the plugs or tape from the refrigerant line fittings
on the liquid line and the condenser outlet. Connect the liquid line to the condenser
outlet. See Liquid Line Replacement for the procedures.

5. Remove the plugs or tape from the refrigerant line fittings on the discharge line and the
condenser inlet. Connect the discharge line to the
condenser inlet. See Suction and Discharge Line Replacement for the procedures.
6. Check that all of the condenser and radiator air seals are in their proper locations. 7. Reinstall
the radiator grille in the vehicle. 8. Connect the battery negative cable. 9. Evacuate the refrigerant
system.
NOTE: If the condenser is replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the
vehicle.
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Diagrams
8w-80-4
Control Assembly: Testing and Inspection
Heater System Diagnosis
Mode Control
Satisfactory heater and air conditioner performance depends upon proper operation and
adjustment of all operating controls and refrigeration system components.
Operation must be tested as described in the following sequence:
1. Inspect and adjust the serpentine drive belt. 2. Start the engine and set the engine speed to
1,300 rpm. 3. Move the temperature control knob to the full counterclockwise (Cool) position and
place the mode control knob in the Bi-Level position. The
outside (recirculation) air door should be open to outside air. If not OK, see Vacuum System.
4. With the temperature control knob in the full counterclockwise (Cool) position, the air being
discharged from the outlets should be near ambient
temperature. As the temperature control knob is rotated clockwise beyond the third detent, a
gradual warming of the air being discharged should be noticed. If OK, go to Step 7. If not OK, go to
Step 6.
5. Roll down the glove box from the instrument panel. Refer to Glove Box - Roll Down in the
Removal and Installation Instrument Panel, Gauges
and Warning Indicators/Instrument Panel for the procedures. Look through the instrument panel
glove box opening to locate the blend-air door motor on the top of the distribution duct. While
rotating the temperature control knob through its travel, check that the blend-air door motor lever is
moving and that the blend-air door link is connected to the lever. If OK, see Heater Performance. If
not OK, see Blend-Air Door Control.
6. Open the vehicle windows. Test the blower motor operation in all speeds. If not OK, see the
tests for the individual blower motor components.
Leave the blower motor switch in the highest speed position.
7. On vehicles with air conditioning, the compressor should be running and the air conditioning
system in operation. If not OK, see A/C Performance
in the Diagnosis and Testing.
8. Check the heater-only or heater-A/C mode control switch operation. The systems should
respond as shown in the Mode Control chart. Reduce the
engine speed to normal idle. The vacuum will be high at low idle and the actuators should respond
quickly. If not OK, see Vacuum System - Heater-A/C Controls.
9. If the vacuum tests, and the electrical component and circuit tests reveal no problems,
disassemble the heater-A/C housing, the recirculation
housing and the distribution duct to inspect for mechanical misalignment or binding of the mode
doors.
Control Assembly: Service and Repair

INJURY.
the passenger compartment. 3. Reach between the upper dash panel engine housing extension
and the bottom of the instrument panel to access and unplug the vacuum harness
connector, which is located near the left defroster outlet of the distribution duct.
4. Remove the cluster bezel from the instrument panel. Refer to Instrument Panel, Gauges and
Warning Indicators/Instrument Panel/Cluster Bezel
Replacement.
Heater-A/C Control Remove/Install
5. Remove the three screws that secure the heater-A/C control to the instrument panel. 6. Pull the
heater-A/C control assembly away from the instrument panel far enough to access the connections
on the back of the control.
Heater-A/C Control Connections
7. Unplug the wire harness connectors from the back of the heater-A/C control. 8. Remove the
heater-A/C control from the instrument panel.
INSTALLATION 1. Plug in the wire harness connectors to the back of the heater-A/C control. 2.
Position the heater-A/C control in the instrument panel and secure it with three screws. Tighten the
screws to 2.2 N.m (20 in. lbs.). 3. Reinstall the cluster bezel to the instrument panel. Refer to
Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Cluster Bezel
Replacement.
4. Reach between the upper dash panel engine housing extension and the bottom of the
instrument panel to access and plug in the two halves of the
vacuum harness connector.
5. Reinstall the engine cover in the passenger compartment. 6. Connect the battery negative cable.
Dodge 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
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
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
1999 - 2004 (WJ/WG) Grand Cherokee

2005 - **2007** (WK/WH) Grand Cherokee
2006 - **2007** (XK**/XH)** Commander
SYMPTOM/CONDITION:
Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page
5469
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:

5470
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
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.
5471
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.
5472
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.
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:
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.
5473
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.
CAUTION:
51. Remove the drain tube cap/clamp.
60. Allow the engine to run for 20 minutes.
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.
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.
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

5474
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.
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.
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.
NOTE:
Technician must use eye protection, rubber gloves, and protective clothing.
NOTE:
No occupants should be in the vehicle during material application.
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.
vehicle.
CAUTION:
23. Remove the drain tube clamp/cap/plug.
the vehicle.
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.
5475
28. Install the blower motor and connect the blower motor wire harness connector.
32. Set the blower to HIGH - A/C OFF.
36. With the engine running, allow the blower to operate for 20 minutes.
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.
the vehicle.
CAUTION:
44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto
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.
the vehicle.
CAUTION:
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.


5476
60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by
the vehicle.
CAUTION:
63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat
the vehicle.
65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower
right under panel duct.
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
the drain.
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.
NOTE:
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).
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.
5477
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.
24. Open windows slightly (about 1/2 inch opening).
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:
30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto
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.
40. Turn the ignition switch to the off position.
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.

5478
45. Install outer glove box.
VA Vehicle Procedure
the drain.
3. Clamp off the drain tube using a suitable clamp.
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.
CAUTION:
9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool.
11. Insert the applicator tool into the HVAC filter opening.
CAUTION:
15. Remove the clamp from the drain tube.
21. Install the HVAC filter cover (do not install the HVAC filter at this time).
25. Set the A/C switch to NC OFF.

5479
CAUTION:
35. Remove the HVAC filter cover.
39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary.
40. Install the HVAC filter cover.
CAUTION:
42. Remove the drain tube clamp.
51. With the engine running, allow the blower motor to operate for 20 minutes.

5480
CAUTION:

Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When
Hot/Humid
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
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
1999 - 2004 (WJ/WG) Grand Cherokee
2005 - **2007** (WK/WH) Grand Cherokee

2006 - **2007** (XK**/XH)** Commander
SYMPTOM/CONDITION:
Hot/Humid > Page 5486
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:

TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
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.
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.
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.
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.
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).
CAUTION:
21. Insert the applicator tool into the blower resistor/power module opening.
CAUTION:
25. Remove the cap/clamp from the drain tube.
29. Insert the applicator tool into the blower resistor opening.
39. Allow the blower to operate for 20 minutes.
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:
45. Remove the blower motor resistor/power module.
CAUTION:
51. Remove the drain tube cap/clamp.
60. Allow the engine to run for 20 minutes.
CAUTION:
65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK**
vehicles proceed to Step # 66.
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.
71. Install the floor mat.
72. Close the hood.
AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure

1. Open the hood.
vehicle on a suitable hoist.
4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat
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.

the vehicle.
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.
NOTE:
Technician must use eye protection, rubber gloves, and protective clothing.
NOTE:
No occupants should be in the vehicle during material application.
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).
vehicle.
CAUTION:
23. Remove the drain tube clamp/cap/plug.
the vehicle.
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.
the vehicle.
39. Install the drain tube clamp/cap/plug.
the vehicle.
CAUTION:
44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto
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.
the vehicle.
CAUTION:
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.


the vehicle.
CAUTION:
63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat
the vehicle.
65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower
right under panel duct.
67. If applicable, install the silencer pad under the right side of the instrument panel.
69. Close the hood.
ST Vehicle Procedure
the drain.
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.
NOTE:
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).
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.
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.
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:
30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto
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.
40. Turn the ignition switch to the off position.
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.

45. Install outer glove box.
VA Vehicle Procedure
the drain.
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.
CAUTION:
9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool.
CAUTION:
15. Remove the clamp from the drain tube.
21. Install the HVAC filter cover (do not install the HVAC filter at this time).
25. Set the A/C switch to NC OFF.

CAUTION:
35. Remove the HVAC filter cover.
39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary.
40. Install the HVAC filter cover.
CAUTION:
42. Remove the drain tube clamp.
51. With the engine running, allow the blower motor to operate for 20 minutes.

CAUTION:

Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Operation > Combination Coil
Evaporator Core: Description and Operation Combination Coil
SYSTEM OPERATION
rear unit housing. It is called a combination coil because it combines the functions of a heater core
and an evaporator coil into a single heat exchanger unit.
The combination coil features six rows of tube and fin construction. The two rows located toward
the outboard side of the vehicle serve as the heater core and have engine coolant circulated
through them whenever the rear water valve is open. The four rows toward the inboard side of the
vehicle serve as the evaporator and have refrigerant circulated through them whenever the air
conditioning compressor is operating. The amount of refrigerant flowing through the combination
coil is controlled by a dedicated rear thermal expansion valve.
The combination coil can be accessed for service by removing the rear heater-A/C unit upper
housing. The combination coil cannot be repaired and, if faulty or damaged, it must be replaced.
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Operation > Combination Coil > Page 5500
Evaporator Core: Description and Operation Evaporator Coil
SYSTEM OPERATION
Front
The evaporator coil is located in the heater-A/C housing, on the right side of the engine
compartment. The evaporator coil is positioned in the heater-A/C housing so that all air that enters
the housing must pass over the fins of the evaporator before it is distributed through the system
ducts and outlets. However, air passing over the evaporator coil fins will only be conditioned when
the compressor is engaged and circulating refrigerant through the evaporator coil tubes.
Refrigerant enters the evaporator from the expansion valve as a low-temperature, low-pressure
mixture of liquid and gas. As air flows over the fins of the evaporator, the humidity in the air
condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption
causes the refrigerant to boil and vaporize. The refrigerant becomes a hightemperature,
low-pressure gas before it leaves the evaporator.
The evaporator coil cannot be repaired and, if faulty or damaged, it must be replaced.
Rear
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Combination Coil Removal and Installation
Evaporator Core: Service and Repair Combination Coil Removal and Installation
The combination coil is used only on models with the optional rear heater-A/C unit. The
combination coil can be removed without removing the rear heater-A/C unit from the vehicle.

REMOVAL 1. Disconnect and isolate the battery negative cable.
2. Remove the expansion valve from the combination coil.
3. Drain the engine cooling system. Refer to: "Engine, Cooling and Exhaust : Service and Repair"
See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair
4. Disconnect the rear heater-A/C unit heater hoses from the combination coil heater tubes. Install
plugs in, or tape over the opened combination coil
heater tubes and hoses.
5. Remove the vertical duct from the rear heater-A/C unit.
6. Remove the horizontal duct from the rear heater-A/C unit.
7. Remove the upper housing from the rear heater-A/C unit.
Evaporator Coil Remove/Install
8. Lift the combination coil out of the rear heater-A/C unit lower housing.
INSTALLATION 1. Insert the combination coil into the bottom of the rear heater-A/C unit lower
housing.
2. Reinstall the upper housing onto the rear heater-A/C unit.

3. Reinstall the horizontal duct to the rear heater- A/C unit.
4. Reinstall the vertical duct to the rear heater-A/C unit.
5. Unplug or remove the tape from the rear heater-A/C unit combination coil heater tubes and
hoses. Connect the heater hoses to the combination coil
heater tubes and fill the engine cooling system.
6. Reinstall the expansion valve to the combination coil.
NOTE: If the combination coil is replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the
vehicle.
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Combination Coil Removal and Installation > Page 5503
Evaporator Core: Service and Repair Evaporator Core Replacement

Front
Assembly HVAC : Service and Repair" See: Housing
Assembly HVAC/Service and Repair
2. Remove the top cover from the heater-A/C housing. 3. Remove the expansion valve from the
evaporator coil. 4. Remove the fin sensing cycling clutch switch probe from the evaporator coil.
Evaporative Coil Remove/Install
5. Lift the evaporator coil out of the heater-A/C housing.
INSTALLATION 1. Insert the evaporator coil into the bottom of the heater-A/C housing. 2. Reinstall
the expansion valve to the evaporator coil. 3. Reinstall the fin sensing cycling clutch switch probe to
the evaporator coil. 4. Reinstall the top cover onto the heater-A/C housing. 5. Reinstall the
heater-A/C housing in the engine compartment.
NOTE: If the front evaporator coil is replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to
the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the
vehicle.
Rear
The evaporator coil for the optional rear heater-A/C unit is integral with the rear heating system
heater core. This unit is referred to as the combination coil.
Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and
Operation
Expansion Valve: Description and Operation
SYSTEM OPERATION
Front
The front "H" valve-type thermal expansion valve (TXV) is located at the front of the heater-A/C
housing between the liquid and suction lines and the evaporator coil. High-pressure, high
temperature liquid refrigerant from the liquid line passes through the expansion valve orifice,
converting it into a low- pressure, low-temperature mixture of liquid and gas before it enters the
evaporator coil.
A temperature sensor in the expansion valve control head monitors the temperature of the
refrigerant leaving the evaporator coil through the suction line and adjusts the orifice size at the
liquid line to let the proper amount of refrigerant into the evaporator coil to meet the vehicle cooling
requirements. Controlling the refrigerant flow through the evaporator ensures that none of the
refrigerant leaving the evaporator is still in a liquid state, which could damage the compressor.
The expansion valve is a factory calibrated unit and cannot be adjusted or repaired. If faulty or
damaged, the expansion valve must be replaced.
Rear
Models equipped with the optional rear heater-A/C unit have a second "H" valve-type thermal
expansion valve (TXV) installed between the rear unit liquid and suction lines, and the combination
coil. High pressure, high temperature liquid refrigerant from the liquid line passes through the
expansion valve orifice, converting it into a low-pressure, low-temperature mixture of liquid and gas
before it enters the combination coil.
A temperature sensor in the expansion valve control head monitors the temperature of the
refrigerant leaving the combination coil through the suction line, and adjusts the orifice size at the
liquid line to let the proper amount of refrigerant into the combination coil to meet the vehicle
cooling requirements. Controlling the refrigerant flow through the combination coil ensures that
none of the refrigerant leaving the combination coil is still in a liquid state, which could damage the
compressor
The rear expansion valve is a factory calibrated unit and cannot be adjusted or repaired. If faulty or
damaged, the expansion valve must be replaced.
Expansion Valve: Testing and Inspection
These tests must be made at an ambient temperature of 21 to 290 C (70 to 850 F).
Front (ONLY) 1. Attach a manifold gauge set. Close the vehicle doors and windows, start the
engine, and hold the engine speed at 1,000 rpm. Set the heater-A/C
mode control switch knob in the recirculation mode (Max A/C) position, the temperature control
knob in the full hot position, and the blower motor switch in the highest speed position. Disconnect
and plug the vacuum harness connector at the water valve in the engine compartment. Unplug the
fin sensing cycling clutch switch wire harness connector.
2. Operate the air conditioning system for at least five minutes to stabilize the system, and to
provide sufficient reheat to load the evaporator. The
discharge pressure (high side) at the service port should reach 966 to 1656 kPa (140 to 240 psi). If
this discharge pressure cannot be obtained, check the refrigerant system charge. See Refrigerant
System Charge in the Service Procedures.
WARNING: EXTREME CARE MUST BE USED WHEN HANDLING LIQUID CARBON DIOXIDE
(CO2), AS SKIN INJURY CAN OCCUR. PROTECTIVE GLOVES SHOULD BE WORN.
3. Apply liquid carbon dioxide (CO2) to the expansion valve control head (completely cover the
head) for a minimum of thirty seconds. Observe the
manifold gauge set. The suction pressure (low side) must drop to below 50 kPa (7.25 psi). If this
reading is not obtained, the expansion valve is faulty and must be replaced.
4. Remove the liquid carbon dioxide (CO2) from the control head. Observe the manifold gauge set.
The suction pressure (low side) must increase to
a minimum of 262 kPa (38 psi), and then stabilize to a pressure of 172 to 240 kPa (25 to 35 psi). If
these readings are not obtained, the expansion valve is faulty and must be replaced.
5. Set the engine idle speed at 1,000 rpm and the blower motor switch in the highest speed
position. The suction pressure (low side) should be 138 to
207 kPa (20 to 30 psi). If the discharge pressure (highside) is higher than 1656 kPa (240 psi),
check for a restricted discharge line. Also check the engine cooling system for overheating, air
trapped in the system, or a faulty fan drive. If the discharge pressure (high side) is less than 966
kPa (140 psi), deck for a faulty compressor.
Front And Rear AC 1. Attach a manifold gauge set. Close the vehicle doors and windows, start the
engine, and hold the engine speed at 1,000 rpm. Set the heater-A/C
mode control switch knob in the recirculation mode (Max A/C) position, the temperature control
knob in the full hot position, and both the front and rear blower motor switches in their highest
speed positions. Disconnect and plug the vacuum harness connector at the water valve in the
engine compartment. Unplug the fin sensing cycling clutch switch wire harness connector.
2. Operate the air conditioning system for at least five minutes to stabilize the system, and to
provide sufficient reheat to load the front evaporator
and the rear combination coil. The discharge pressure (high side) at the service port should reach
966 to 1656 kPa (140 to 240 psi). If this discharge pressure cannot be obtained, check the
refrigerant system charge. See Refrigerant System Charge.
WARNING: EXTREME CARE MUST BE USED WHEN HANDLING LIQUID CARBON DIOXIDE
(CO2) AS SKIN INJURY CAN OCCUR. PROTECTIVE GLOVES SHOULD BE WORN.
3. Both the front and rear expansion valves should be checked for correct operation. Apply liquid
carbon dioxide (CO2) to the front expansion valve
control head (completely cover the head) for a minimum of thirty seconds. Remove the rear
heater-A/C trim cover and apply liquid carbon dioxide (CO2) to the rear expansion valve control
head (completely cover the head) for a minimum of thirty seconds. Grasp the suction line (large
line) off the combination coil with a bare hand and hold it for at least two minutes. Use the same
procedure with the front expansion valve. Grasp the suction line jumper below the expansion valve
(before the rear suction line tee) with a bare hand and hold for at least two minutes. When testing
the front expansion valve, place the rear blower motor switch in the Off position.
4. With a correctly operating expansion valve, the suction line will feel warm with the closing of the
valve (cold applied). Then the line will cool
sharply within two minutes as the valve opens. If this temperature change does not occur, the
expansion valve is faulty and must be replaced.
Expansion Valve: Service and Repair
Front

refrigerant system. 3. Remove the screw that secures the filter-drier to its mounting bracket.
Front Expansion Valve Remove/Install
5. Move the suction line jumper and filter-drier as a unit away from the expansion valve far enough
to access the mounting screws. 6. Remove the two screws that secure the expansion valve to the
evaporator coil block fitting, and separate the expansion valve from the fitting.
INSTALLATION 1. Remove the tape or plugs from the evaporator coil block fitting and the
evaporator side of the expansion valve. Position the expansion valve to the
evaporator coil block fitting and secure the connection with two screws. Tighten the mounting
2. Remove the tape or plugs from the block fitting on the suction line jumper and the expansion
valve. Position the suction line jumper block fitting
N.m (200 in. lbs.).
screw to 8.5 N.m (75 in. lbs.). 4. Connect the battery negative cable. 5. Evacuate the refrigerant
Rear
The rear expansion valve is used only on models with the optional rear heater-A/C unit. The
expansion valve can be removed without removing the rear heater-A/C unit from the vehicle.
refrigerant system. 3. Remove the cover from the rear heater-A/C unit.
Rear Expansion Valve Remove/Install
4. Remove the screw from the adapter plate that secures the rear heater-A/C unit liquid and suction
lines to the expansion valve. 5. Separate the rear heater-A/C unit liquid and suction lines from the
expansion valve. Install plugs in, or tape over all of the opened refrigerant line
fittings.
6. Remove the two screws that secure the expansion valve to the rear heater-A/C unit combination
coil evaporator tube bracket. Install plugs in, or
tape over all of the opened refrigerant line fittings.
7. Remove the expansion valve from the rear heater-A/C unit.
INSTALLATION 1. Remove the tape or plugs from the combination coil evaporator tube bracket
and the evaporator side of the expansion valve. Position the
expansion valve to the tube bracket and secure the connection with two screws. Tighten the
2. Remove the tape or plugs from the rear heater- A/C unit suction and liquid lines and from the
expansion valve. Position the suction and liquid lines
to the expansion valve and secure the connection with the adapter plate and mounting screw.
Tighten the mounting screw to 22 N.m (200 in. lbs.).
3. Reinstall the cover to the rear heater-A/C unit. See Rear Heater-A/C Cover. 4. Connect the
battery negative cable. 5. Evacuate the refrigerant system. 6. Charge the refrigerant system.
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Heater Control Valve Cable >
Heater Control Valve Cable: Service and Repair
The rear water valve control cable is used only on models with the optional rear heater-A/C unit.
The rear water valve control cable can be removed without removing the rear heater-A/C unit from
the vehicle.
REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Disconnect the control cable
from the rear water valve. 3. Remove the rear mode control motor from the rear heater-A/C unit.
Rear Water Valve Control Cable Remove/Install
4. Remove the screw that secures the rear water valve control cable flag retainer to the rear
heater-A/C unit upper housing. 5. Remove the water valve control cable adaptor from the rear
heat-A/C mode door pivot shaft. 6. Remove the rear water valve control cable and adaptor from the
rear heater-A/C unit upper housing. 7. Separate the rear water valve control cable end from the
hole on the end of the adaptor lever.
INSTALLATION 1. Install the rear water valve control cable end into the hole on the end of the
adaptor lever. 2. Position the rear water valve control cable and adaptor to the rear heater-A/C unit
upper housing. 3. Install the rear water valve control cable adaptor into the rear heat-A/C mode
door pivot shaft. Be certain to index the alignment splines on the
adaptor to the spline in the pivot shaft.
4. Install the screw that secures the rear water valve control cable flag retainer to the rear
heater-A/C unit upper housing. Tighten the mounting screw
to 2.2 N.m (20 in. lbs.).
5. Reinstall the rear mode control motor onto the rear heater-A/C unit. 6. Connect the control cable
to the rear water valve. 7. Connect the battery negative cable.
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and
Operation
Heater Core: Description and Operation
SYSTEM OPERATION
Front
The heater core is located in the heater-A/C housing, on the right side of the engine compartment.
It is a heat exchanger made of rows of tubes and fins. Engine coolant is circulated through heater
hoses to the heater core whenever the front water valve is open. As the coolant flows through the
heater core, heat removed from the engine is transferred to the heater core fins and tubes.
Air directed through the heater core picks up the heat from the heater core fins. The blend air door
allows control of the heater output air temperature by controlling how much of the air flowing
through the heater-A/C housing is directed through or around the heater core. The blower motor
speed controls the volume of air flowing through the heater-A/C system.
The heater core cannot be repaired and, if faulty or damaged, it must be replaced.
Rear
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and
Heater Core: Service and Repair
Front
Assembly HVAC : Service and Repair" See: Housing
Assembly HVAC/Service and Repair
2. Remove the top cover from the heater-A/C housing.
Heater Core Remove/Install
3. Remove the screw that secures the heater core tube support bracket to the mounting boss on
the top of the heater-A/C housing. 4. Lift the heater core out of the heater-A/C housing
INSTALLATION 1. Insert the heater core into the bottom of the heater-A/C housing. 2. Install the
screw that secures the heater core tube support bracket to the mounting boss on the top of the
heater-A/C housing. Tighten the mounting
3. Reinstall the top cover to the heater-A/C housing. 4. Reinstall the heater-A/C housing in the
engine compartment.
Rear
The heater core for the optional rear heater-A/C unit is integral with the air conditioning evaporator
coil. This unit is referred to as the combination coil.
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Rear Heater-A/C Unit Plumbing

lines.
Rear Heater-A/C Unit Plumbing > Page 5522
free.

REMOVAL

Rear Heater-A/C Unit Plumbing > Page 5523
INSTALLATION
Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
High Pressure Safety Valve HVAC: Description and Operation
SYSTEM OPERATION
High Pressure Relief Valve
The high pressure relief valve is located on the rear surface of the compressor housing. This
mechanical valve is designed to vent refrigerant from the system to protect against damage to the
compressor and other system components, caused by condenser air flow restriction or an
overcharge of refrigerant.
The high pressure relief valve vents the system when a discharge pressure of 3445 to 4135 kPa
(500 to 600 psi) or above is reached. The valve closes with a minimum discharge pressure of 2756
kPa (400 psi) is reached.
The high pressure relief valve vents only enough refrigerant to reduce the system pressure, and
then re-seats itself. The majority of the refrigerant is conserved in the system. If the valve vents
refrigerant, it does not mean the valve is faulty.
On new compressor assemblies, a mylar disc is applied to the venting port of the valve. The disc is
primarily intended for protection of the valve during the painting operation. A missing or damaged
disc does not indicate failure. If the mylar disc has loosened or come off, apply a drop or two of
refrigerant oil into the valve mechanism through the venting holes. This will prevent salt, dirt, or
moisture from affecting the operation of the valve.
The high pressure relief valve is only serviced as part of the compressor assembly, and must not
be removed or otherwise disturbed.
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and
Operation
Hose/Line HVAC: Description and Operation
SYSTEM OPERATION
Refrigerant Line The refrigerant lines and hoses are used to carry the refrigerant between the
various air conditioning system components. A barrier hose design with a nylon tube inner hose
liner is used for the R-134a air conditioning system on this vehicle. This nylon liner helps to further
contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The
ends of the refrigerant hoses are made from lightweight aluminum, and use brazeless fittings.
The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be
replaced.
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > A/C Discharge Hose/Line Replacement
Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement

fittings.
Repair > A/C Discharge Hose/Line Replacement > Page 5532
Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement

refrigerant system.
Liquid Line Remove/Install
3. Remove the screw that secures the block fitting of the liquid line to the inlet of the filter-drier, and
separate the fitting from the filter-drier. Install
plugs in, or tape over all of the opened refrigerant line fittings.
4. Remove the radiator grille from the vehicle. 5. Remove the screw that secures the block fitting on
the liquid line to the block fitting on the outlet of the condenser, and separate the fitting from
6. Remove the liquid line from the engine compartment.
INSTALLATION 1. Remove the tape or plugs from the liquid line block fitting and the outlet of the
condenser. Connect the liquid line to the condenser outlet and
2. Reinstall the radiator grille to the vehicle. 3. Remove the tape or plugs from the liquid line block
fitting and the inlet of the filter-drier. Connect the liquid line to the filter-drier inlet and secure
the connection with a screw. Tighten the mounting screw to 13.5 N.m (120 in. lbs.).
4. Connect the battery negative cable. 5. Evacuate the refrigerant system. 6. Charge the refrigerant
system.
Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement
Suction and Discharge Line

fittings.
Suction Line Jumper
conditioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. High pressures are produced in the refrigerant system when the
air conditioning compressor is operating. Extreme care must be exercised to make sure that each
of the refrigerant system connections is pressure-tight and leak free.

REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the low pressure
cut-off switch from the fitting on the suction line jumper. See Low Pressure Cut-Off Switch
Replacement for the
procedures.
3. Recover the refrigerant from the refrigerant system.
Suction Line Jumper Remove/Install
5. If the vehicle is equipped with the optional rear heater-A/C unit, go to Step 7. If not, go to Step 9.
6. Disconnect the flare nut on the underbody plumbing suction line from the threaded fitting on the
suction line jumper. Install plugs in, or tape over

7. Disconnect the flare nut on the underbody plumbing liquid line from the threaded fitting on the
liquid line extension. Install plugs in, or tape over
secures the block fitting of the suction line jumper to the outlet of the filter-drier, and separate the
fitting from the
fitter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings.
11. Remove the suction line jumper from the engine compartment.
INSTALLATION 1. Remove the tape or plugs from the block fitting on the suction line jumper and
the expansion valve. Position the suction line jumper block fitting
N.m (200 in. lbs.).
2. Remove the tape or plugs from the block fitting on the suction line jumper and the outlet of the
fitter-drier. Position the outlet of the filter-drier to
the suction line jumper block fitting and secure the connection with a screw. Tighten the mounting
screw to 8.5 N.m (75 in. lbs.). 4. If the vehicle is equipped with the optional rear heater-A/C unit, go
to Step 6. If not, go to Step 8. 5. Remove the tape or plugs from the refrigerant tine fittings on the
underbody plumbing liquid line and the liquid line extension. Connect the flare
nut on the underbody plumbing liquid line to the threaded fitting on the liquid line extension. Tighten
the fitting to 27 N.m (244 in. lbs.).
6. Remove the tape or plugs from the refrigerant line fittings on the underbody plumbing suction
line and the suction line jumper. Connect the flare
nut on the underbody plumbing suction line to the threaded fitting on the suction line jumper.
Tighten the fitting to 47 N.m (420 in. lbs.).
jumper Connect the flare nut on the suction line
8. Install the low pressure cut-off switch to the fitting on the suction line jumper. See Low Pressure
Cut-Off Switch. 9. Connect the battery negative cable.
10. Evacuate the refrigerant system. 11. Charge the refrigerant system.
Hose/Line HVAC: Service and Repair Rear Heater-A/C Unit Plumbing

unit liquid and suction lines from the expansion valve. 3. Disconnect the rear heater-A/C unit heater
hoses from the heater inlet and outlet lines.
Hose/Line HVAC: Service and Repair Underbody Plumbing
free.

REMOVAL
jumper. See Suction Line Jumper in the Replacement. Install plugs in, or tape over all of the
opened refrigerant line fittings.
INSTALLATION
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Heater-A/C Housing Removal and Installation
Housing Assembly HVAC: Service and Repair Heater-A/C Housing Removal and Installation
WARNING:
- REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT PERFORMING THE FOLLOWING
OPERATION.
- ON VEHICLES EQUIPPED WITH AIRBAGS, FAILURE TO TAKE THE PROPER

PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
REMOVAL 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is not equipped
with air conditioning, go to Step 6. If the vehicle is equipped with air conditioning, disconnect the
suction line
jumper at the expansion valve.
3. Remove the screws that secure the filter-drier and its mounting bracket to the heater-A/C
housing and the cowl side panel. Swing the filter-drier,
mounting bracket and refrigerant plumbing as a unit out of the way towards the center of the
vehicle.
4. Unplug the wire harness connector from the fin sensing cycling clutch switch. 5. Unplug the wire
harness connectors from the blower motor resistor, and the high speed blower motor relay 6. Place
waterproof material over the generator, to protect it from spilled engine coolant. 7. Drain the engine
cooling system. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair"
See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair
8. Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened
heater core tubes.
Heater-A/C Housing Remove/Install
9. Remove the right headlamp assembly, the grille panel, the right cowl grille support panel, and
the right radiator core support assembly.
10. Remove the two screws that secure the lower heater-A/C housing flange to the blower housing.
11. Disconnect the link from the blend-air door motor on the top of the distribution duct in the
passenger compartment. 12. From the passenger compartment, reach through the instrument
panel glove box opening to access and remove the two stamped nuts and one screw
that secure the heater-A/C housing to the dash panel below the distribution duct.
13. From the passenger compartment, reach through the instrument panel glove box opening to
access and remove the two stamped nuts that secure
the heater-A/C housing to the dash panel above the distribution duct.
14. From the engine compartment, remove the one stamped nut that secures the heater-A/C
housing to the stud on the dash panel. 15. Carefully separate the lower heater-A/C housing flange
from the blower housing. 16. Pull the heater-A/C housing away from the dash panel until the
blend-air door link is clear of the hole in the dash panel. 17. Remove the heater-A/C housing from
the engine compartment.
Disassembly
and Repair > Heater-A/C Housing Removal and Installation > Page 5542
1. Place the heater-A/C housing on a work bench, with the heater-A/C housing top cover facing up.
Blend-Air Door Linkage
2. Remove the nut that secures the lever to the blend-air door pivot shaft. 3. Disengage the boot for
the blend-air door link from the rear mounting flange of the heater-A/C housing. 4. Remove the
blend-air door link, boot and lever from the heater-A/C housing as a unit.
Heater-A/C Housing Top Cover Remove/Install
5. Remove the screw that secures the high speed blower motor relay mounting bracket to the
heater-A/C housing and remove the relay and
bracket.
6. Remove the screws that secure the top cover to the heater-A/C housing. 7. Remove the top
cover from the heater-A/C unit.
Inspection Examine all of the heater-A/C housing seals for damage. Replace all damaged or
deformed seals. Clean all of the heater-A/C mounting flanges and apply new sealant prior to
reassembly.
Inspect the evaporator coil and heater core for bent fins or other damage. Remove any foreign
material or other restrictions to air flow. Repair or replace any faulty or damaged components as
required.
Assembly 1. Position the top cover onto the heater-A/C unit. Be certain that the blend-air door
pivots, all seals, and the grommet for the fin sensing cycling
clutch switch wire harness are properly positioned.
2. Secure the top cover to the heater-A/C housing with screws. Tighten the mounting screws to 2.2
N.m (20 in. lbs.). 3. Rotate the blend-air door pivot shaft back and forth to confirm that the door
moves freely throughout its travel. If there is any binding or
interference, remove the top cover from the heater-A/C housing and repair as required.
4. Reinstall the blend-air door lever, link, and boot unit to the heater-A/C housing. Be certain that
the boot flange is properly seated in the hole on
the rear mounting flange of the housing.

5. Reinstall the lever to the blend-air door pivot shaft and secure it to the shaft with a nut. 6.
Position the high speed blower motor relay and mounting bracket to the heater-A/C housing and
secure it with a screw. Tighten the mounting
INSTALLATION
1. Position the heater-A/C housing to the dash panel. Be certain that the blend-air door link and the
housing studs are inserted through the proper
holes in the dash panel.
2. Secure the lower heater-A/C housing flange to the blower housing with two screws. Tighten the
mounting screws to 2.7 N.m (24 in. lbs.). 3. Secure the heater-A/C unit to the stud on the engine
compartment side of the dash panel with a nut. Tighten the mounting nut to 4.5 N.m (40 in.
lbs.).
install the two nuts that secure the heater-A/C housing
studs on the dash panel above the distribution duct. Tighten the mounting nuts to 4.5 N.m (40 in.
lbs.).
install the two nuts and the screw that secure the
heater-A/C housing to the dash panel below the distribution duct. Tighten the mounting nuts to 4.5
N.m (40 in. lbs.). Tighten the mounting screw to 2.7 N.m (24 in. lbs.).
6. Connect the link to the blend-air door motor. See Blend-Air Door Motor Replacement for the
procedures. 7. Reinstall the right radiator core support assembly, the right cowl grille support panel,
the grille panel, and the right headlamp assembly. 8. Unplug or remove the tape from the heater
core tubes. Connect the heater hoses to the heater core tubes and fill the engine cooling system. 9.
Plug in the wire harness connectors to the blower motor resistor and the high speed blower motor
relay.
10. If the vehicle is not equipped with air conditioning, go to Step 14. If the vehicle is equipped with
air conditioning, plug in the wire harness
connector to the fin sensing cycling clutch switch.
11. Reconnect the suction line jumper to the expansion valve. 12. Reinstall the screws that secure
the filter-drier and its mounting bracket to the cowl side panel and the heater-A/C housing. 13.
Connect the battery negative cable. 14. Start the engine and check for proper operation of the
heating and air conditioning systems.
Housing Assembly HVAC: Service and Repair Rear Heater-A/C Unit Replacement and Service
REMOVAL
1. Remove the rear bench seat from the passenger compartment, if the vehicle is so equipped.
Rear Heater-A/C Cover Remove/Install
2. Remove the three screws that secure the cover to the rear heater-A/C unit. 3. Remove the cover
from the rear heater-A/C unit.
INSTALLATION
1. Position the cover over the rear heater-A/C unit. 2. Install the three screws that secure the cover
to the rear heater-A/C unit. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). 3. Reinstall the
rear bench seat to the passenger compartment, if the vehicle is so equipped.
WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT BEFORE

PERFORMING THE FOLLOWING OPERATION.
REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Disconnect the underbody
plumbing at the rear heater-A/C unit plumbing connections. See Underbody Plumbing
Replacement procedures. Install
plugs in, or tape over all of the opened plumbing fittings.
Rear Heater-A/C Unit Plumbing Plate Remove/Install
3. Remove the three nuts that secure the rear heater-A/C unit plumbing plate studs to the
underbody panel.
Rear Heater-A/C Unit Remove/Install
4. Remove the one screw that secures the rear heater-A/C unit to the underbody panel from
underneath. 5. Lower the vehicle and remove the cover from the rear heater-A/C unit. See Rear
Heater-A/C Cover Replacement Procedures. 6. Remove the vertical duct from the rear heater-A/C
unit. See Ducts and Outlets - Vertical Duct Replacement procedures. 7. Remove the horizontal
duct from the rear heater-A/C unit. See Ducts and Outlets - Horizontal Duct Replacement
procedures. 8. Remove the screw that secures the rear heater-A/C unit ground wire eyelet to the
left side panel strainer behind the unit. 9. Remove the two screws that secure the bottom of the
rear heater-A/C unit to the underbody panel.
10. Lift the rear heater-A/C unit upwards far enough for the plumbing to clear the hole in the
underbody panel, then pull the unit away from the side
panel far enough to access and unplug the wire harness connector from the body wire harness
near the front of the unit.
11. Remove the rear heater-A/C unit from the passenger compartment.
Disassembly
1. Lift the two relay wire harness connectors upward to disengage them from the mounting tabs on
the rear of the rear heater-A/C unit housing. 2. Unplug the wire harness connectors from the rear
heater-A/C unit blower motor and the rear mode control motor. 3. Disengage the blower motor
cooling tube from the nipple on the lower housing of the rear heater- A/C unit. 4. Remove the
control cable from the rear heater-A/C unit water valve. See Water Valve Replacement.
Rear Heater-A/C Unit Housing Clip
5. Remove the clip on the rear inboard corner of the rear heater-A/C unit that secures the upper
housing to the lower housing. 6. Remove the six screws that secure the upper housing of the rear
heater-A/C unit to the lower housing. 7. Remove the upper housing from the rear heater-A/C unit.
Inspection Inspect the combination coil for bent fins or other damage. Remove any foreign material
or other restrictions to air flow. Repair or replace any faulty or damaged components as required.
Clean any foreign material from all of the mating edges of the upper and lower rear heater-A/C unit
housing halves prior to reassembly.
Assembly
1. Position the upper housing over the lower housing of the rear heater-A/C unit. Be certain that the
mating edges of the upper housing are engaged in
the channel on the edges of the lower housing.
2. Secure the upper housing to the lower housing of the rear heater-A/C unit with six screws.
Tighten the mounting screws to 2.2 N.m (20 in. lbs.). 3. Reinstall the clip on the rear inboard corner
of the rear heater-A/C unit that secures the upper housing to the lower housing. 4. Reinstall the
control cable to the rear heater-A/C unit water valve. See Water Valve - Rear Replacement for the
procedures. 5. Reinstall the blower motor cooling tube over the nipple on the lower housing of the
rear heater- A/C unit. 6. Plug in the wire harness connectors for the rear heater-A/C unit blower
motor and the rear mode control motor. 7. Slide the two relay wire harness connectors downward
over the mounting tabs on the rear of the rear heater-A/C unit housing. Be certain that the
two connectors are interlocked with each other before trying to reinstall them to the mounting tabs
on the housing.
INSTALLATION 1. Position the rear heater-A/C unit in the passenger compartment. Be certain that
the stud on the plumbing plate are inserted through the proper
holes in the underbody panel.
2. Plug in the rear heater-A/C unit wire harness connector to the body wire harness. 3. Secure the
rear heater-A/C unit to the underbody panel with two screws. Tighten the mounting screws to 1.9
N.m (17 in. lbs.). 4. Secure the rear heater-A/C unit ground wire eyelet to the left side panel strainer
behind the unit. Tighten the mounting screw to 1.9 N.m (17 in.
lbs.).
5. Reinstall the horizontal duct to the rear heater-A/C unit. See Ducts and Outlets - Horizontal Duct
Replacement for the procedures. 6. Reinstall the vertical duct to the rear heater-A/C unit. See
Ducts and Outlets - Vertical Duct Replacement for the procedures. 7. Reinstall the cover to the rear
heater-A/C unit. See Rear Heater-A/C Cover replacement procedures. 8. Raise and support the
vehicle. 9. From underneath the vehicle, reinstall the one screw that secures the rear heater-A/C
unit to the underbody panel. Tighten the mounting screw to
1.9 N.m (17 in. lbs.).
10. Reinstall the three nuts that secure the rear heater-A/C unit plumbing plate to the underbody
panel. Tighten the mounting nuts to 11.2 N.m (100 in.
lbs.).
11. Remove the tape or plugs from all of the plumbing connections. Connect the underbody
plumbing to the rear heater-A/C unit plumbing. See
Underbody Plumbing Replacement for the procedures.

Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and
Operation
Receiver Dryer: Description and Operation
SYSTEM OPERATION
evaporator inlet. Refrigerant enters the filter-drier as a high- pressure, high-temperature liquid.
Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and
Receiver Dryer: Service and Repair

refrigerant system.
N.m (120 in. lbs.).
vehicle.
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications >
Refrigerant: Capacity Specifications
R134a Single Capacity

...........................................................................................................................................................
0.96 kg (33.86 oz. or 2.12 lbs)
R134a Dual Capacity

.............................................................................................................................................................
1.30 kg (45.85 oz. or 2.87 lbs)
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications >
Refrigerant: Fluid Type Specifications
Hydrofluorocarbon (HFC), ...................................................................................................................

............................................... R-134a liquefied gas
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page
5556
Refrigerant: Description and Operation
SYSTEM OPERATION
The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a.
Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain
ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless
liquefied gas.
Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like
CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global
warming.
R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a
small amount of R-12 added to an R-134a refrigerant system will cause compressor failure,
refrigerant oil sludge or poor air conditioning system performance. In addition, the PolyAlkylene
Glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible
with the mineral-based refrigerant oils used in an R-12 refrigerant system.
R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles
have all been designed with unique fittings to ensure that an R-134a system is not accidentally
contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine
compartment of the vehicle and on the compressor identifying to service technicians that the air
conditioning system is equipped with R-134a.
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Description and
Operation
Refrigerant Filter: Description and Operation
SYSTEM OPERATION
evaporator inlet. Refrigerant enters the filter-drier as a high-pressure, high-temperature liquid.
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Description and
Refrigerant Filter: Service and Repair

refrigerant system.
N.m (120 in. lbs.).
vehicle.
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Refrigerant Oil: Capacity Specifications
Total System ........................................................................................................................................

........................................ (Front only) 236 ml 8.0 oz.
Total System ........................................................................................................................................

.................................. (Front & Rear) 295 ml 10.0 oz.
Condenser ...........................................................................................................................................
................................................................ 30 ml 1.0 oz.
Evaporator ...........................................................................................................................................
............................................................... 60 ml 2.0 oz. Filter-Drier ......................................................
................................................................................................................................................... 30 ml
1.0 oz.
Compressor
............................................................................................................................................. Drain and
measure the oil from the old compressor
Refrigerant Oil: Fluid Type Specifications
Synthetic-based, Polyalkylene Glycol ..................................................................................................

......................................................................... SP-10
Page 5566
Refrigerant Oil: Service and Repair
Refrigerant Oil Level
Refrigerant Oil Capacities
When an air conditioning system is assembled at the factory, all components except the
compressor and the combination coil, if the vehicle is so equipped, are refrigerant oil free. After the
refrigerant system has been charged and operated, the refrigerant oil in the compressor and the
combination coil is dispersed throughout the refrigerant system. The combination coil, evaporator,
filter-drier, condenser, and compressor will each retain a significant amount of the needed
refrigerant oil.
It is important to have the correct amount of oil in the refrigerant system. This ensures proper
lubrication of the compressor. Too little oil will result in damage to the compressor. Too much oil
will reduce the cooling capacity of the air conditioning system.
It will not be necessary to check the oil level in the compressor or to add oil, unless there has been
an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting,
a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant
oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at
the leak point by the presence of a wet, shiny surface around the leak.
Refrigerant oil must be added when a filter-drier, evaporator coil, combination coil, or condenser
are replaced. See the Refrigerant Oil Capacities chart. When a compressor is replaced, the
refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant
oil from the new compressor, then fill the new compressor with the same amount of refrigerant oil
that was drained out of the old compressor.
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure
Sensor / Switch, HVAC > Component Information > Description and Operation
SYSTEM OPERATION
Sensor / Switch, HVAC > Component Information > Description and Operation > Page 5571
repair the A/C
Sensor / Switch, HVAC > Component Information > Description and Operation > Page 5572
REMOVAL
and discard.
INSTALLATION
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure
Sensor / Switch, HVAC > Component Information > Diagrams
8w-80-4
Sensor / Switch, HVAC > Component Information > Diagrams > Page 5576
SYSTEM OPERATION
on.
must be replaced.
Sensor / Switch, HVAC > Component Information > Testing and Inspection > Fin Sensing Cycling Clutch Switch
required.
Sensor / Switch, HVAC > Component Information > Testing and Inspection > Fin Sensing Cycling Clutch Switch > Page
5579
Ports.
Sensor / Switch, HVAC > Component Information > Service and Repair > Fin Sensing Cycling Clutch Switch Replacement
Replacement
REMOVAL
INSTALLATION
Sensor / Switch, HVAC > Component Information > Service and Repair > Fin Sensing Cycling Clutch Switch Replacement >
Page 5582
REMOVAL
INSTALLATION
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay >
8w-10-2
Component Information > Description and Operation > Blower Motor Relay
SYSTEM OPERATION
Front
Rear
Component Information > Description and Operation > Blower Motor Relay > Page 5589
SYSTEM OPERATION
Front
replaced.
Rear
location.
replaced.
Component Information > Testing and Inspection > Blower Motor Relay
Blower Motor Relay
Relay Test

relay.
Relay Circuit Test
Component Information > Testing and Inspection > Blower Motor Relay > Page 5592
Blower Motor Relay
Relay Test

relay.
Relay Circuit Test
Front
Rear
unit.
place.
relay operation.

firmly into place.
relay operation.
Rear
heater-A/C unit.
firmly into place.
relay operation.
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Component Locations
8w-10-2


SYSTEM OPERATION
Relay Test

Relay Circuit Test
relay operation.
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
SYSTEM OPERATION
Front
Rear
an Off position.
blower motor speed.

INJURY.
as required.
ground as required.
switch.
Instrument Panel,

Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Description and Operation
SYSTEM OPERATION
repair the A/C
REMOVAL
and discard.
INSTALLATION
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams
8w-80-4
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 5619
SYSTEM OPERATION
on.
must be replaced.
Cycling Clutch Switch
required.
Cycling Clutch Switch > Page 5622
Ports.
Cycling Clutch Switch Replacement
Replacement
REMOVAL
INSTALLATION
Cycling Clutch Switch Replacement > Page 5625
REMOVAL
INSTALLATION
Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description
and Operation
Service Port HVAC: Description and Operation
SYSTEM OPERATION
The two refrigerant system service ports are used to charge, recover/recycle, evacuate, and test
the air conditioning refrigerant system. Unique service port coupler sizes are used on the R-134a
system, to ensure that the refrigerant system is not accidentally contaminated by the use of the
wrong refrigerant (R-12), or refrigerant system service equipment.
The high pressure service port is located on the discharge line between the compressor and the
condenser, near the front of the engine compartment. The low pressure service port is located on
the suction line jumper, near the filter-drier at the front of the engine compartment. Each of the
service ports has a threaded plastic protective cap installed over it from the factory. After servicing
the refrigerant system, always reinstall both of the service port caps.
Dodge Workshop Manuals > Heating and Air Conditioning > Thermal Limiter Switch <--> [Thermal Limiting Fuse] >
Thermal Limiter Switch: Description and Operation
SYSTEM OPERATION
Thermal Limiter Switch The thermal limiter switch is used to measure the compressor surface
temperature. If the compressor surface temperature is excessive, the switch will cut the battery
feed voltage to the compressor clutch coil. The switch will reset itself, once the compressor surface
temperature returns to normal.
The thermal limiter switch will interrupt the battery feed to the compressor clutch coil at a
temperature of about 122 to 128° C (250 to 260° F). The switch will reset and restore the clutch coil
operation at a temperature of about 104 to 116° C (220 to 240° F).
Thermal Limiter Switch: Testing and Inspection
The thermal limiter switch is calibrated to open and close as follows:
_ Open circuit (no continuity) at 125° C ± 3° C (255° F ± 5° F)
_ Closed circuit (continuity) at 110° C ± 6° C (230° F ± 10° F).
1. Unplug the wire harness connectors from the thermal limiter switch. 2. Use an ohmmeter to
check for correct continuity, as indicated above, between the two thermal limiter switch terminals. if
the continuity is
incorrect, replace the faulty switch.

Thermal Limiter Switch: Service and Repair
After removing the thermal limiter switch, always replace it with a new unit. The refrigerant system
can remain fully-charged during thermal limiter switch replacement.
REMOVAL 1. Unplug the two wire harness connectors between the compressor clutch wire
harness and the thermal limiter switch.
Thermal Limiter Switch Remove/Install
2. Remove the single screw that secures the thermal limiter switch clamp to the top of the
compressor housing. 3. Using a straight-bladed screwdriver, pry the thermal switch from the socket
in the top of the compressor housing. 4. Remove the thermal limiter switch from the compressor.
Cleaning 1. Remove the old silicone sealant filler from the thermal limiter switch socket on the top
of the compressor housing. 2. Thoroughly clean the thermal limiter switch socket with paint thinner
or another suitable solvent that leaves no residue.
INSTALLATION 1. Place the new thermal limiter switch on a suitable work bench with the flat
copper surface of the switch facing upward. 2. Apply an even coating of RTV silicone sealant to the
flat copper surface of the thermal limiter switch. Dispense and apply the silicone sealant to
the switch directly from the tube, and do not try to spread the material with your fingers.
3. Install the thermal limiter switch with the flat copper surface facing downward into the socket of
the compressor housing. 4. Position the clamp over the thermal limiter switch and secure the clamp
to the compressor housing with the mounting screw. Tighten the mounting
5. Plug in the thermal limiter switch wire harness connectors to the compressor clutch wire
harness.
Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information >
Vacuum Check Valve HVAC: Description and Operation
SYSTEM OPERATION
A vacuum check valve is installed in the vacuum supply line in the vacuum harness. The check
valve
is located near the left end of the distribution duct under the instrument panel in the passenger
compartment. The vacuum check valve is designed to allow vacuum to flow in only one direction
through the vacuum supply circuits.
The use of a vacuum check valve helps to maintain the system vacuum needed to retain the
selected heater-A/C mode settings. The check valve will prevent the engine from bleeding down
system vacuum through the intake manifold during extended heavy engine load (low engine
vacuum) operation.
The vacuum check valve cannot be repaired and, if faulty or damaged, it must be replaced.
Vacuum Check Valve HVAC: Testing and Inspection
Adjust Vacuum Test Bleed Valve
Vacuum control is used to operate the mode doors in the heater-only and the heater-A/C systems.
Testing of the heater-A/C mode control switch operation will determine if the vacuum and electrical
controls are functioning. However, it is possible that a vacuum control system that operates
perfectly at engine idle (high engine vacuum) may not function properly at high engine speeds or
loads (low engine vacuum). This can be caused by leaks in the vacuum system, or by a faulty or
improperly installed vacuum check valve.
A vacuum system test will help to identify the source of poor vacuum system performance or
vacuum system leaks. Before starting this test, stop the engine and make certain that the problem
is not a disconnected vacuum supply tube at the engine vacuum source or at the vacuum reservoir.
Use an adjustable vacuum test set (Special Tool C-3707) and a suitable vacuum pump to test the
heater-A/C vacuum control system. With a finger placed over the end of the vacuum test hose
probe, adjust the bleed valve on the test set gauge to obtain a vacuum of exactly 27 kPa (8 in.
Hg.). Release and block the end of the probe several times to verify that the vacuum reading
returns to the exact 27 kPa (8 in. Hg.) setting. Otherwise, a false reading will be obtained during
testing.
Vacuum Check Valve 1. Remove the vacuum check valve. The valve is located in the vacuum
supply tube (black) within the vacuum harness on the left end of the
distribution duct under the instrument panel in the passenger compartment. The vacuum check
valve must be removed in order to perform the following tests. See Vacuum Check Valve in the
Removal and Installation procedures.
2. Connect the test set vacuum supply hose to the heater-A/C control side of the valve. When
connected to this side of the check valve, no vacuum
should pass and the test set gauge should return to the 27 kPa (8 in. Hg.) setting. If OK, go to step
Step 4. If not OK, replace the faulty valve.
3. Connect the test set vacuum supply hose to the engine vacuum side of the valve. When
connected to this side of the check valve, vacuum should
flow through the valve without restriction. If not OK, replace the faulty valve.
Heater-A/C Controls 1. Connect the test set vacuum probe to the heater-A/C vacuum supply
(black) tube in the engine compartment. Position the test set gauge so that it
can be viewed from the passenger compartment.
2. Place the heater-A/C mode control switch knob in each mode position, one position at a time,
and pause after each selection. The test set gauge
should return to the 27 kPa (8 in. Hg.) setting shortly after each selection is made. If not OK, a
component or vacuum line in the vacuum circuit of the selected mode has a leak. See Locating
Vacuum Leaks.
CAUTION: Do not use lubricant on the switch ports or in the holes in the plug, as lubricant will ruin
the vacuum valve in the switch. A drop of clean water in the connector plug holes will help the
connector slide onto the switch ports.
Vacuum Circuit Test

Vacuum Circuits
Locating Vacuum Leaks

INJURY.
1. Disconnect the vacuum harness connector on the back of the heater-A/C mode control switch on
the instrument panel. 2. Connect the test set vacuum hose probe to each p0rt in the vacuum
harness connector, one port at a time, and pause after each connection. The test
set gauge should return to the 27 kPa (8 in. Hg.) setting shortly after each connection is made. if
OK, replace the faulty heater-A/C control. if not OK, go to Step 4.
3. Determine the vacuum line color of the vacuum circuit that is leaking. To determine the vacuum
line colors, see the Vacuum Circuits chart. 4. Disconnect and plug the vacuum line from the
component (fitting, actuator, valve, switch, or reservoir) on the other end of the leaking circuit.
instrument panel disassembly or removal may be necessary to gain access to some components.
5. Connect the test set hose or probe to the open end of the leaking circuit. The test set gauge
should return to the 27 kPa (8 in. Hg.) setting shortly
after each connection is made. If OK, replace the faulty disconnected component. If not OK, go to
Step 7.
6. To locate a leak in a vacuum line, leave one end of the line plugged and connect the test set
hose or probe to the other end of the line. Run your
fingers slowly along the line while watching the test set gauge. The vacuum reading will fluctuate
when your fingers contact the source of the leak. To repair the vacuum line, cut out the leaking
section of the line. Then, insert the loose ends of the line into a suitable length of 3 millimeter
(0.125 inch) inside diameter rubber hose.
Vacuum Check Valve HVAC: Service and Repair

INJURY.
REMOVAL 1. Remove the engine cover from the passenger compartment.
Vacuum Check Valve
2. Look between the upper dash panel engine housing extension and the bottom of the instrument
panel to locate the vacuum check valve, which is
installed in the housing half of the vacuum harness which is secured near the left defroster outlet
on the distribution duct.
3. Note the orientation of the check valve in the vacuum supply line for correct reinstallation. 4.
Unplug the vacuum check valve from the connectors in the vacuum harness. 5. Reverse the
removal procedures to install.
Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information >
Vacuum Reservoir HVAC: Description and Operation
SYSTEM OPERATION
The vacuum reservoir is mounted in the engine compartment on the right cowl side panel near the
speed control servo and below the right headlamp. The right front fender extension panel must be
removed from the vehicle to access the vacuum reservoir for service.
Engine vacuum is stored in the vacuum reservoir. The stored vacuum is used to operate the
vacuum-controlled vehicle accessories during periods of low engine vacuum such as when the
vehicle is climbing a steep grade, or under other high engine load operating conditions. The
vacuum reservoir cannot be repaired and, if faulty or damaged, it must be replaced.
Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information >
Vacuum Reservoir HVAC: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Remove the right front fender extension
from the fender.
Vacuum Reservoir Remove/Install
3. Unplug the vacuum harness connector from the vacuum reservoir. 4. Remove the two screws
that secure the vacuum reservoir to the right cowl side panel. 5. Remove the vacuum reservoir
from the right cowl side panel. 6. Reverse the removal procedures to install. Tighten the mounting
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System
Information > Service Precautions
.
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > Airbag/Clock Spring - Service
Air Bag: Technical Service Bulletins Airbag/Clock Spring - Service
NUMBER: 08-010-01
GROUP: Electrical
DATE: May 25, 2001
SUBJECT: Airbag/Clock Spring Service
MODELS:
1988 - 1993 (AG) Daytona
1990 (AL) Horizon/Omni
1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1994 - 2002 (AN) Dakota
1990 - 1991 (AQ) Chrysler Maserati
1995 - 1996 (B7) Stealth
1998 - 2002 (DN) Durango
2002 (DR) Ram Pickup
2002 (KJ) Liberty
1995 - 2002 (PL) Neon
1997 - 2002 (PR) Prowler

1996 - 2002 (SR) Viper
DISCUSSION:
Airbag
When servicing any airbag system, it is essential to follow the proper Service Manual and/or
Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When
diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the
Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in
conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only
replace the component or wiring that has failed. This will reduce unnecessary cost to the customer
or DaimlerChrysler.
NOTE:
AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN

ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL
WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED.
NOTE:
Bulletins > Airbag/Clock Spring - Service > Page 5656
TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT
CODES ON THE REPAIR ORDER.
Clock Springs
Recent analysis of returned clock springs have indicated that prior service may have contributed to
the clock spring's failure.
^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often
used in the clock spring area of the steering column to eliminate noise. Lubricants may have an
adverse effect on the clock spring.
^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the
front wheels will require that the clock spring be centered. This includes clock spring replacement,
steering column service, HVAC service, steering gear service, and front suspension crossmember
service. Refer to the appropriate Service Manual for the clock spring centering procedure.

Air Bag: Diagrams
Driver Squib Connector
Passenger Squib Connector
Passenger Squib Connector

Air Bag: Description and Operation
SYSTEM OPERATION
Airbag Module
Driver Side The airbag module protective trim cover is the most visible part of the driver side airbag
system. The module is mounted directly to the steering wheel. Located under the airbag module
trim cover are the horn switch, the airbag cushion, and the air-bag cushion supporting components.
The airbag module includes a housing to which the cushion and inflator are attached and sealed.
The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged.
The inflator assembly is mounted to the back of the airbag module. The inflator seals the hole in
the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied
with the proper electrical signal. The protective trim cover is fitted to the front of the airbag module
and forms a decorative cover in the center of the steering wheel. Upon airbag deployment, this
cover will split at a predetermined breakout line.
Passenger Side The airbag door on the instrument panel above the glove box is the most visible
part of the passenger side airbag system. Located under the airbag door are the airbag cushion
and its supporting components. The airbag module includes a housing to which the cushion and
inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if
deployed or in any way damaged.
The inflator assembly is mounted to the back of the airbag module. The inflator includes a small
canister of highly compressed argon gas. The inflator seals the hole in the airbag cushion so it can
discharge the compressed gas it contains directly into the cushion when supplied with the proper
electrical signal. The airbag door is secured to the airbag module and the instrument panel base
trim, and has predetermined breakout lines concealed beneath its decorative cover. Upon airbag
deployment, the airbag door will split at the breakout lines and the door will pivot out of the way.
The airbag module is secured with screws at the rear to the instrument panel glove box opening
reinforcement, and at the front it is secured to a bracket on the instrument panel armature. The
airbag module and airbag door are available as separate service items. Following an airbag
deployment, the airbag module and airbag door must be replaced.
Storage An airbag module must be stored in its original, special container until used for service.
Also, it must be stored in a clean, dry environment; away from sources of extreme heat, sparks,
and high electrical energy. Always place or store an airbag module on a surface with its trim cover
or airbag side facing up, to minimize movement in case of an accidental deployment.
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and
Repair > Air Bag Replacement
Air Bag: Service and Repair Air Bag Replacement
WARNING:

WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST
PERSONAL INJURY.
- WHEN REMOVING A DEPLOYED AIRBAG MODULE, RUBBER GLOVES, EYE PROTECTION,

AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE
AIRBAG MODULE AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS
MAY CAUSE IRRITATION TO THE SKIN AND EYES.
Driver Side 1. Disconnect and isolate the battery negative cable. If the airbag has not been
deployed, wait two minutes for the system capacitor to discharge
Driver Side Airbag Module Remove/Install
2. From the underside of the steering wheel, remove the two screws that secure the driver side
airbag module to the steering wheel. 3. Pull the airbag module away from the steering wheel far
enough to access the wire harness connectors on the back of the airbag module. 4. Unplug the
airbag module and horn switch wire harness connectors from the back of the airbag module. 5.
Remove the driver side airbag module from the steering wheel. 6. If the airbag has been deployed,
the clockspring must be replaced and the steering column must be inspected. See Clockspring
service procedures. 7. When installing the airbag module, connect the clockspring wire harness
connector to the module by pressing straight in on the connector. Be
certain that the connector is fully engaged by observing the latch arms on each side of the
connector. When these arms move outward from the connector, the connector is latched.
8. Connect the horn switch wire harness connector. 9. Position the airbag module in the steering
wheel. Be certain that the airbag and horn wiring is not pinched between the airbag module and the
steering wheel armature.
10. Install the airbag module mounting screws. Tighten the mounting screws to 10.2 N.m (90 in.
lbs.). 11. Do not connect the battery negative cable at this time. See Airbag System in the
Diagnosis and Testing procedures.
Passenger Side 1. Disconnect and isolate the battery negative cable. If the airbag has not been
deployed, wait two minutes for the system capacitor to discharge
2. Roll down the glove box from the instrument panel. Refer to Instrument Panel, Gauges and
Warning Indicators/Instrument Panel/Glove Box -Roll
Down Replacement.
Repair > Air Bag Replacement > Page 5661
Passenger Side Airbag Remove/Install
3. Remove the three small screws and Three small screws that secure the passenger side airbag
module rear bracket and airbag door lower flange to
the glove box opening upper reinforcement.
4. Reach through and above the glove box opening to access and unplug the passenger side
airbag module wire harness connector located on the
instrument panel armature.
5. Reach through and above the glove box opening to remove the two screws that secure the
passenger side airbag module front bracket to the
instrument panel armature.
6. Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper edge of the
passenger side airbag door away from the instrument
panel to release the five snap retainers.
7. Remove the passenger side airbag module and door from the instrument panel as a unit. 8.
Reverse the removal procedures to install. When reinstalling the airbag door to the instrument
panel top cover, be certain that the snap retainers on
the upper edge of the airbag door are fully engaged in the five instrument panel receptacles.
Tighten the three small screws for the passenger side airbag door lower flange on the glove box
opening upper reinforcement to 1.9 N.m (17 in. lbs.). Tighten the four passenger side airbag
module front and rear bracket mounting screws to 8.4 N.m (75 in. lbs.).
9. Before reinstalling the glove box, be certain that the airbag module wire harness connector
latches are fully engaged.
10. Do not connect the battery negative cable at this time. See Airbag System in the Diagnosis and
Testing procedures.
Air Bag: Service and Repair Driver Side Airbag Module Trim Cover Replacement
REMOVAL
WARNING:

PERSONAL INJURY.
PERSONAL INJURY.
2. Remove the driver side airbag module from the steering wheel. See Airbag Module -Driver Side
in the Replacement.
airbag housing.
DEPLOYMENT.
cover.

Air Bag: Service and Repair Passenger Side Airbag Door Replacement
WARNING:
- THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT BEFORE

WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST
PERSONAL INJURY.
- WHEN REMOVING A DEPLOYED AIRBAG MODULE, RUBBER GLOVES, EYE PROTECTION,

AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE
AIRBAG MODULE AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS
MAY CAUSE IRRITATION TO THE SKIN AND EYES.
2. Remove the passenger side airbag module from the instrument panel. See Air Bag
System/Airbag Module -Passenger Side Replacement.
Passenger Side Airbag Door Remove/Install
3. With the airbag module on a bench, remove the two screws that secure one of the end brackets
to the passenger side airbag module and remove the
bracket.
4. Slide the passenger side airbag door sideways towards the end of the airbag module from which
the bracket was removed until the upper and lower
airbag door flanges clear the slots on the top and the bottom of the airbag housing.
5. Remove the passenger side airbag door from the airbag module.
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Recalls for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag Electronic Control
Module
February 1999
Models
NOTE:
IMPORTANT:
Repair
1 AECM
1 AECM Cover
payments.
Number Allowance

NOTE:
Parts Return
Not required.

Module > Page 5673
mail to:
48326-2757
Service Office.
Service Procedure
Note:
service procedure.
Module > Page 5674
Discard the screws.
Module > Page 5675
cover.
Note:
ft-lbs (75 N.m).
and then go out.
NOTE:
Owner Letter
Vehicle Safety Act.
The problem is...
Module > Page 5676
If you need help...
toll free, at 1-800-992-1997.
816
Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 816 > Feb > 99 > Recall - Airbag
Electronic Control Module
February 1999
Models
NOTE:
IMPORTANT:
Repair
1 AECM
1 AECM Cover
payments.
Number Allowance

NOTE:
Parts Return
Not required.

Electronic Control Module > Page 5682
mail to:
48326-2757
Service Office.
Service Procedure
Note:
service procedure.
Discard the screws.
cover.
Note:
ft-lbs (75 N.m).
and then go out.
NOTE:
Owner Letter
Vehicle Safety Act.
The problem is...
If you need help...
toll free, at 1-800-992-1997.
816

Module Locations


ACM Connector
ACM Connector
SYSTEM OPERATION
indicator lamp.
with the ACM.
WARNING:
PROTECTIVE COVER.

Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches
NUMBER: 08-025-01
GROUP: Electrical
DATE: Nov. 23, 2001

NOTE:
MODELS:
1995 - **2001** (AB) Ram Van/Wagon
1990 - 1993 (AG) Daytona
1994 - **2001** (AN) Dakota
1994 - **2001** (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - **2001** (DN) Durango
1995 - **2001** (PL) Neon
1997 (PR) Prowler


> Technical Service Bulletins > Air Bag - On/Off Switches > Page 5694
1996 - 1997 (SR) Viper
1997 - 2001** (TJ) Wrangler
1997 - **2001** (XJ) Cherokee
NOTE:

PART WARRANTY.
NOTE:

DISCUSSION:
NOTE:
AIRBAG KIT.

PARTS REQUIRED:
NOTE:
NOTE:

Availibility
NO: 08-17-98 Rev. C
GROUP: Electrical
DATE: Dec. 30, 1998

EQUIPMENT.

MODELS:
1995 - **1999** (AB) Ram Van/Wagon
1990 - 1993 (AG) Daytona
1994 -**1999** (AN) Dakota
1994 - **1999** (BR) Ram Pickup
**1995 - 1996 (B7) Stealth**
1998 - **1999** (DN) Durango
1995 - **1999** (PL) Neon
1996 - 1997 (SR) Viper
1997 - **1999** (TJ) Wrangler

1997 - **1999** (XJ) Cherokee
NOTE:

PART WARRANTY.
DISCUSSION:
Hotline at 1-800-424-9393.
PARTS REQUIRED:
NOTE:
NOTE:
> Locations > Component Locations

> Locations > Component Locations > Page 5709

> Locations > Page 5710

> Locations > Page 5711
REMOVAL


and Testing.
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service
Clockspring Assembly / Spiral Cable: Technical Service Bulletins Airbag/Clock Spring - Service
NUMBER: 08-010-01
GROUP: Electrical
DATE: May 25, 2001
SUBJECT: Airbag/Clock Spring Service
MODELS:
1988 - 1993 (AG) Daytona
1990 (AL) Horizon/Omni
1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1994 - 2002 (AN) Dakota
1990 - 1991 (AQ) Chrysler Maserati
1995 - 1996 (B7) Stealth
1998 - 2002 (DN) Durango
2002 (DR) Ram Pickup
2002 (KJ) Liberty
1995 - 2002 (PL) Neon
1997 - 2002 (PR) Prowler

1996 - 2002 (SR) Viper
DISCUSSION:
Airbag
When servicing any airbag system, it is essential to follow the proper Service Manual and/or
Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When
diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the
Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in
conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only
replace the component or wiring that has failed. This will reduce unnecessary cost to the customer
or DaimlerChrysler.
NOTE:
AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN

ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL
WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED.
NOTE:
Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 5716
TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT
CODES ON THE REPAIR ORDER.
Clock Springs
Recent analysis of returned clock springs have indicated that prior service may have contributed to
the clock spring's failure.
^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often
used in the clock spring area of the steering column to eliminate noise. Lubricants may have an
adverse effect on the clock spring.
^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the
front wheels will require that the clock spring be centered. This includes clock spring replacement,
steering column service, HVAC service, steering gear service, and front suspension crossmember
service. Refer to the appropriate Service Manual for the clock spring centering procedure.

Clockspring Connector
Clockspring Assembly / Spiral Cable: Description and Operation
SYSTEM OPERATION
The clockspring is used to maintain a continuous electrical circuit between the instrument panel
wire harness, the driver side airbag module, and the vehicle speed control switches on vehicles
that are so equipped. The clockspring is mounted on the steering column behind the steering
wheel. This assembly consists of a plastic housing which contains a flat, ribbon-like, electrically
conductive tape that winds and unwinds with the steering wheel rotation.
The clockspring must be properly centered when it is installed on the steering column following any
service removal, or it will be damaged. See Clockspring Centering in the Adjustments for the
procedures.
The clockspring cannot be repaired. If the clock-spring is faulty, damaged, or if the airbag has been
deployed, the clockspring must be replaced.
Clockspring Assembly / Spiral Cable: Adjustments
The clockspring is designed to wind and unwind when the steering wheel is rotated, but is only
designed to rotate the same number of turns (about five complete rotations) as the steering wheel
can be turned from stop to stop. If the rotating tape within the clockspring is not indexed properly to
the steering wheel and the front wheels, the clockspring may become wound too tight and fail
during use. The clockspring must be centered if it is not known to be properly indexed, or if the
front wheels were moved from the straight-ahead position with the clockspring removed during any
service procedure.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT.

1. Turn the steering wheel until the front wheels are in the straight-ahead position before starting
the centering procedure. 2. Disconnect and isolate the battery negative cable. If the airbag has not
been deployed, wait two minutes for the system capacitor to discharge
3. Remove the clockspring from the steering column. See Clockspring Replacement.
Clockspring Centering
4. Hold the clockspring with the bottom side facing up and depress the spring lock. 5. Keeping the
spring lock depressed, rotate the clockspring hub counterclockwise to the end of its travel. Do not
apply excessive torque. 6. From the end of the counterclockwise travel, rotate the clockspring hub
about two and one-half turns clockwise, then release the spring lock
between the locking tabs.
7. The front wheels should still be in the straight ahead position. Reinstall the clockspring on the
steering column. See Clockspring Replacement.
Clockspring Assembly / Spiral Cable: Service and Repair
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT

REMOVAL 1. Turn the steering wheel until the front wheels are in the straight-ahead position
before starting the procedure. 2. Disconnect and isolate the battery negative cable. If the airbag
has not been deployed, wait two minutes for the system capacitor to discharge
3. Remove the driver side airbag module from the steering wheel. See Airbag Module Replacement
for the procedures. 4. If the vehicle is equipped with the optional vehicle speed control, unplug the
wire harness connectors from the speed control switches in the
steering wheel.
blocker from the instrument panel. Refer Instrument Panel, Gauges and Warning
Indicators/Instrument Panel to Knee Blocker 8. If the vehicle is so equipped, remove the tilt steering
column lever by grasping the lever firmly and pulling it sharply away from the column.
upper shroud.
10. Unsnap the front and both sides of the lower shroud from the upper shroud.
upper shroud.
14. Remove the two upper wire harness tie wraps, but not the clockspring wire harness tie wrap or
the overdrive switch wire harness tie wrap. 15. Unplug the wire harness connector between the
clockspring and the instrument panel wire harness, located on the left side of the steering column
wire harness connector mounting bracket.

Clockspring Remove/Install
16. Using snap ring pliers, remove the snap ring that secures the clockspring to the upper steering
column shaft. 17. To remove the clockspring, carefully lift the locating fingers of the clockspring
assembly from the steering column as necessary. The clockspring
cannot be repaired. It must be replaced if faulty or damaged, or if the airbag has been deployed.
INSTALLATION
1. Before reinstalling the clockspring on the steering column, be certain that the wave washer is in
place on the upper steering column shaft.
CAUTION: Before reinstalling the clockspring, be certain that the front wheels are still in the
straight-ahead position, the alignment spline on the upper steering column shaft is in the 12 o'clock
position, and that the clockspring is centered. See Clockspring Centering in the Adjustments for the
centering procedure. Failure to follow these procedures may result in damage to the clockspring.
2. Align the hole in the clockspring hub with the horn tower and slide the clockspring onto the upper
steering column shaft. 3. Reinstall the snap ring onto the upper steering column shaft. Be certain
that the snap ring is fully seated in the groove on the shaft.
NOTE: The clockspring wire harness tie-wrap must be positioned above the upper steering column
wire harness tie-wrap.
4. Route the clockspring wire harness along the steering column wire harness and secure the
harnesses with two new tie-wraps. Be certain that the
new tie-wraps are installed in the same positions as those that were removed and that the steering
column wire harnesses are routed so that they will not be pinched or stretched.
5. Plug the clockspring wire harness connector into the instrument panel wire harness connector.
Be certain that the connector latches are fully
engaged.
NOTE: Before reinstalling the upper shroud on the steering column, be certain that the upper
shroud spacer mounting stud is fully seated to the mounting boss on the inside surface of the
shroud.
6. Reinstall the steering column shrouds. Be certain that the upper shroud spacer mounting stud is
fully seated to the mounting boss on the inside of
the shroud. Tighten the upper shroud mounting screws to 1.4 N.m (12 in. lbs.). Tighten the lower
shroud mounting screws to 3.4 N.m (30 in. lbs.).
7. Reinstall the steering column opening cover and the knee blocker to the instrument panel. Refer
to Steering and Suspension/Steering/Steering
Column Opening Cover and to Knee Blocker.
8. Install the steering wheel being certain to index the alignment splines in the hub of the steering
wheel with the splines on the upper steering column shaft. Pull the wire harnesses from the
clockspring between the steering wheel back trim cover and the steering wheel armature. Tighten
the steering wheel nut to 61 N.m (45 ft. lbs.). Be certain not to pinch the wiring between the
steering wheel and the nut.
9. If the vehicle is so equipped, plug in the wire harness connectors to the vehicle speed control
switches.
10. Install the driver side airbag module onto the steering wheel. See Airbag Module Replacement.
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component
Malfunction Lamp / Indicator: Description and Operation
SYSTEM OPERATION
The airbag indicator lamp gives an indication when the airbag system is faulty or inoperative. The
lamp is controlled by the instrument cluster circuitry based upon messages received from the
Airbag Control Module (ACM) on the Chrysler Collision Detection (CCD) data bus. The lamp is
turned on by the ACM for about seven seconds when the ignition switch is turned to the On
The ACM continually monitors the airbag system circuits and sensors to decide whether the system
is in good operating condition. The ACM then sends the proper messages to the instrument cluster
on the CCD data bus to turn the lamp on or off. If the ACM turns the lamp on after the bulb test, it
indicates the ACM has detected a system malfunction and/or that the airbag system has become
inoperative. The instrument cluster circuitry will also send a chime request to the Central Timer
Module (CTM) when a lamp-on message is received from the ACM. A lamp-on message does not
mean that either or both airbags will not deploy upon an impact, only that they might not deploy,
depending upon the nature of the detected malfunction. Each time that the instrument cluster
circuitry receives a lamp-on message from the ACM, it will light the lamp for three seconds or the
duration of the airbag system malfunction, whichever is longer.
The airbag indicator lamp also has a lamp backup feature. About ten seconds after the ignition
switch is turned to the On position, if an inoperative airbag warning lamp circuit was detected
during the bulb test sequence, the instrument cluster circuitry will flash the seat belt reminder lamp
on and off for about thirty seconds. If the seat belt reminder lamp stays on after flashing for thirty
seconds, or comes on at any time other than about ten seconds after the initial ignition-on
sequence, it may indicate that an airbag system fault has been detected and that the airbag
indicator lamp is inoperative. See Seat Belt Reminder Lamp in the Description and Operation for
more information on the airbag lamp backup feature. Refer to Air Bag Systems for more
information on airbags.
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component
Malfunction Lamp / Indicator: Testing and Inspection
The diagnosis found here addresses an inoperative airbag indicator lamp condition. If the airbag
indicator lamp stays on with the ignition switch in the On position, or comes on and stays on while
driving, refer to Air Bag Systems for diagnosis.

INJURY.
The airbag indicator lamp has a lamp backup feature. Ten seconds after the ignition switch is
turned to the On position, if the instrument cluster circuitry has detected an inoperative airbag
warning lamp circuit it will flash the seat belt reminder lamp on and off for thirty seconds. Once the
instrument cluster circuitry has detected an inoperative airbag warning lamp circuit, if a lamp-on
message is received from the Airbag Control Module (ACM) on the Chrysler Collision Detection
(CCD) data bus, the seat belt reminder lamp will remain on for the duration of the airbag system
malfunction.
If the airbag indicator lamp fails to light when the ignition switch is turned to the On position, and
the seat belt reminder lamp flashes following its normal display function (about six seconds after
the ignition switch is turned to the On position), diagnosis of the airbag system and/or the CCD
data bus should be performed with a DRB scan tool as described in the proper Diagnostic
Procedures. For further diagnosis of the airbag indicator lamp and the instrument cluster circuitry,
see Instrument Cluster in the Diagnosis and Testing.
Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child
Seat - Tether Anchor Part Numbers & Labor Time
Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time
NUMBER: 23-008-00 Rev. B
GROUP: Body
DATE: Nov. 24, 2000
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED

JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS.
SUBJECT: Child Seat Tether Anchors
MODELS: 1989 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1994 (AG) Daytona
1989 - 1993 (AJ) Lebaron Coupe
1989 - 2000 (AN) Dakota
1988 - 1992 (BB) Monaco/Premier
1990 - 1994 (BD) Laser/Talon
1989 - 1992 (B2) Colt/Summit
1992 - 1995 (B3) Colt Vista
1989 (B5) Conquest
1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada)
1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon
1993 - 1994 (B9) Colt/Summit
1998 - 2000 (DN) Durango

1995 - 1999 JA Cirrus/Stratus/Breeze
1995 - 2000 (PL) Neon
1997 - 1999 (PR) Prowler
1996 - 1999 (SR) Viper/Viper GTS
**2000 (TJ) Wrangler**
1989 - **2000** (XJ) Cherokee/Wagoneer
1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION

NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER
WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING
DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY
ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS.
DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in
the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the
performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit
for a Kid" Program, owners of earlier products are expected to approach dealers for the free
provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat
tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit
containing all necessary parts and a detailed instruction sheet.
Seat - Tether Anchor Part Numbers & Labor Time > Page 5731
PARTS REQUIRED:
POLICY: Customer Satisfaction

TIME ALLOWANCE:
FAILURE CODE:
Dodge Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair
Knee Diverter: Service and Repair
Knee Blocker
REMOVAL
INJURY.
1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening
cover. See Steering Column Opening Cover Replacement. 3. Remove the two screws that secure
the park brake release handle to the lower edge of the knee blocker and lower the handle to the
floor. 4. Remove the two screws that secure the 16-way data link connector to the lower edge of
the knee blocker and lower the connector to the floor. 5. Remove the two screws that secure the
inside hood release handle to the lower edge of the knee blocker and lower the handle to the floor.
Steering Column Support Bracket
6. Reach under the instrument panel to loosen the two screws that secure the slotted holes of the
knee blocker to the steering column support bracket.
Knee Blocker Remove/Install
7. Remove the four screws that secure the knee blocker to the instrument panel on each side of the
steering column opening. 8. Pull the knee blocker rearward far enough for the slotted holes to clear
the loosened screws on the steering column support bracket. 9. Remove the knee blocker from the
instrument panel.
10. Reverse the removal procedures to install. Tighten the mounting hardware as follows:
- Knee blocker to instrument panel screws - 1.9 N.m (17 in. lbs.)
- Knee blocker to steering column support bracket screws - 28 N.m (250 in. lbs.).
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
February 1999
Models
NOTE:
IMPORTANT:
Repair
1 AECM
1 AECM Cover
payments.
Number Allowance

NOTE:
Parts Return
Not required.

mail to:
48326-2757
Service Office.
Service Procedure
Note:
service procedure.
Discard the screws.
cover.
Note:
ft-lbs (75 N.m).
and then go out.
NOTE:
Owner Letter
Vehicle Safety Act.
The problem is...
If you need help...
toll free, at 1-800-992-1997.
816
Feb > 99 > Recall - Airbag Electronic Control Module
February 1999
Models
NOTE:
IMPORTANT:
Repair
1 AECM
1 AECM Cover
payments.
Number Allowance

NOTE:
Parts Return
Not required.

mail to:
48326-2757
Service Office.
Service Procedure
Note:
service procedure.
Discard the screws.
cover.
Note:
ft-lbs (75 N.m).
and then go out.
NOTE:
Owner Letter
Vehicle Safety Act.
The problem is...
If you need help...
toll free, at 1-800-992-1997.
816

Module Locations


ACM Connector
ACM Connector
SYSTEM OPERATION
indicator lamp.
with the ACM.
WARNING:
PROTECTIVE COVER.

Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service Precautions
.
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation
Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Tether
Installation
NUMBER: 23-029-08
GROUP: Body
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. B, DATED

NOVEMBER 24, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A
COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
DEALERS PLEASE NOTE, THIS IS REIMBURSABLE REGARDLESS OF VEHICLE AGE OR
MILEAGE.
SUBJECT: Child Seat Tether Anchor Installation
OVERVIEW: This bulletin describes procedures to install Child Seat Tether Anchors based on
Customer Request.
NOTE:
Dealers are encouraged to honor any customers request for the installation of the Child Seat
Tether Anchors and Dealer reimbursement will be made by Chrysler regardless of vehicle age or
mileage. See the Warranty Policy and Procedure Manual and or Warranty Bulletin D-08-33 for
reimbursement detail.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1994 (AG) Daytona
1989 - 2000 (AN) Dakota
1989 - 1994 (AP) Shawdow/Sundance

1989 - 1992 (B2) Colt/Summit
1992 - 1995 (B3) Colt Vista
1989 (B5) Conquest

Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5775
1993 - 1994 (B9) Colt/Summit
1998 - 2000 (DN) Durango
1995 - 2000 (PL) Neon
1997 - 1999 (PR) Prowler
2000 (TJ) Wrangler
1989 - 2000 (XJ) Cherokee/Wagoneer
the 2000 Model Year, and in light trucks in the 2001 Model Year and later. Tether straps improve
the performance of child restraints in collisions. Because of the publicity that has accompanied the
"Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free
provision and installation of the anchor hardware.
Chrysler is offering child seat tether anchors for the selected vehicles listed above. Each tether
anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet.
NOTE:
This bulletin is provided to identify the parts and labor operation numbers necessary to install a
Child Seat Tether Anchor. Each dealer is encouraged to install these kits based on customer
request and Chrysler will reimburse any Chrysler / Dodge / or Jeep dealer installing these kits
regardless of vehicle age or mileage.
PARTS REQUIRED:
POLICY: Customer Satisfaction, Reimbursable regardless of mileage or age.

TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Child Seat Tether Attachment: Technical Service Bulletins Child Seat Tether Anchor - Labor/Parts
Identification
GROUP: Body
DATE: Oct. 1, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-35-99 DATED

SEPTEMBER 3, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES IN SOME TIME
ALLOWANCES.
NOTE:
THIS BULLETIN DOES NOT APPLY TO DAIMLERCHRYSLER CANADA DEALERS.
MODELS: 1989 - 1995
1989 - 1994 (AG) Daytona
1989 - 1993 (AJ) LeBaron Coupe
1989 - 2000 (AN) Dakota
1989 - 1992 (B2) Colt/Summit
1992 - 1995 (B3) Colt Vista
1989 (B5) Conquest

1993 - 1994 (B9) Colt/Summit
1998 - 2000 (DN) Durango
1995 - 2000 (PL) Neon
1997 - 1999 (PR) Prowler
1989 - 2000 (XJ) Cherokee/Wagoneer
NOTE:

DISCUSSION
User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model
Year, and in light truck in the 2001 Model Year. Tether straps improve the performance of child
restraints in collisions. Because of the publicity that has accompanied the "Fit for a kid" Program,
owners of earlier products are expected to approach dealers for the free provision and installation
of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the
selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary
parts and a
detailed instruction sheet.

PARTS REQUIRED:

TIME ALLOWANCE:
Failure Code: CG - Customer Satisfaction

Child Seat Tether Attachment: Technical Service Bulletins Child Seat - Tether Anchor Part
Numbers & Labor Time
GROUP: Body
DATE: Nov. 24, 2000

MODELS: 1989 - 1995
1989 - 1994 (AG) Daytona
1989 - 2000 (AN) Dakota
1989 - 1992 (B2) Colt/Summit
1992 - 1995 (B3) Colt Vista
1989 (B5) Conquest
1993 - 1994 (B9) Colt/Summit

1998 - 2000 (DN) Durango
1995 - 2000 (PL) Neon
1997 - 1999 (PR) Prowler
NOTE:

PARTS REQUIRED:

TIME ALLOWANCE:
FAILURE CODE:
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information
> Description and Operation
Seat Belt Reminder Lamp: Description and Operation
SYSTEM OPERATION
The seat belt reminder lamp gives a visual reminder to the vehicle occupants to fasten their seat
belts. The lamp is turned on by the instrument cluster circuitry for about seven seconds when the
ignition switch is turned to the On position.
The instrument cluster also receives a hard wired input from the driver seat belt switch. However,
this input only affects the chime function and has no effect on the seat belt reminder lamp
operation. If the driver seat belt switch is closed (seat belt is not buckled), the instrument cluster will
send a chime request to the Central Timer Module (CTM) lasting the duration of the seat belt
reminder lamp illumination. The chime warning will stop when the driver seat belt switch is open
(seat belt is buckled).
The seat belt reminder lamp also serves as a backup for the airbag indicator lamp. About twenty
seconds after the ignition switch is turned to the On position, if an inoperative airbag indicator lamp
circuit was detected during the bulb test sequence, the instrument cluster circuitry will flash the seat
belt reminder lamp on and off for about thirty seconds. If the seat belt reminder lamp stays on after
flashing for thirty seconds, or comes on at any time other than about twenty seconds after the initial
ignition-on sequence, it indicates an airbag system fault has been detected and that the airbag
indicator lamp is inoperative.
Refer to Air Bags and Seat Belts/Air Bags for more information on the airbag system.
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information
> Description and Operation > Page 5795
Seat Belt Reminder Lamp: Testing and Inspection
The diagnosis found here addresses an inoperative seat belt reminder lamp condition. If the lamp
comes on and flashes following its display function (about ten seconds after the ignition switch is
turned to the On position), it indicates an inoperative airbag indicator lamp. Refer to Restraint
Systems/Air Bag Systems/Testing and Inspection for additional testing procedures. See: Air Bag
Systems/Testing and Inspection

INJURY.
If the seat belt reminder lamp fails to light during its normal display function (about six seconds
after the ignition switch is turned to the On position), see Instrument Cluster in the Diagnosis and
Testing for further diagnosis. This lamp is completely controlled by the instrument cluster circuitry.
On models equipped with a Central Timer Module, the hard wired seat belt switch input to the
instrument cluster has no control over the seat belt reminder lamp function and is only used by the
instrument cluster circuitry as a reference for its chime request function.
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches
NUMBER: 08-025-01
GROUP: Electrical
DATE: Nov. 23, 2001

NOTE:
MODELS:
1995 - **2001** (AB) Ram Van/Wagon
1990 - 1993 (AG) Daytona
1994 - **2001** (AN) Dakota
1994 - **2001** (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - **2001** (DN) Durango
1995 - **2001** (PL) Neon
1997 (PR) Prowler


> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5801
1996 - 1997 (SR) Viper
1997 - 2001** (TJ) Wrangler
1997 - **2001** (XJ) Cherokee
NOTE:

PART WARRANTY.
NOTE:

DISCUSSION:
NOTE:
AIRBAG KIT.

PARTS REQUIRED:
NOTE:
NOTE:

Availibility
NO: 08-17-98 Rev. C
GROUP: Electrical
DATE: Dec. 30, 1998

EQUIPMENT.

MODELS:
1995 - **1999** (AB) Ram Van/Wagon
1990 - 1993 (AG) Daytona
1994 -**1999** (AN) Dakota
1994 - **1999** (BR) Ram Pickup
**1995 - 1996 (B7) Stealth**
1998 - **1999** (DN) Durango
1995 - **1999** (PL) Neon
1996 - 1997 (SR) Viper
1997 - **1999** (TJ) Wrangler

1997 - **1999** (XJ) Cherokee
NOTE:

PART WARRANTY.
DISCUSSION:
Hotline at 1-800-424-9393.
PARTS REQUIRED:
NOTE:
NOTE:
> Component Information > Locations > Component Locations

> Component Information > Locations > Component Locations > Page 5816


REMOVAL


and Testing.
Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Description and
Operation
Antenna: Description and Operation
SYSTEM OPERATION
All models use a fixed-length stainless steel rod- type antenna mast, installed at the right front
fender of the vehicle. The antenna mast has a spiral groove cut down its length to reduce wind
noise.
The antenna mast is connected to the center wire of the coaxial antenna cable, and is not
grounded to any part of the vehicle. To eliminate static, the antenna base must have a good
ground. The coaxial antenna cable shield (the outer wire mesh of the cable) is grounded to the
antenna base and the radio chassis.
The antenna coaxial cable has an additional disconnect, located on the outboard side of the right
instrument panel end bracket and hidden beneath the passenger side instrument panel end cap.
This additional disconnect allows the instrument panel assembly to be removed and installed
without removing the radio.
The factory-installed Electronically Tuned Radios (ETRs) automatically compensate for radio
antenna trim. Therefore, no antenna trimmer adjustment is required or possible when replacing the
receiver or the antenna.
Antenna: Testing and Inspection

INJURY.
The following four tests are used to diagnose the antenna with an ohmmeter:
- Test 1 - Mast to ground test
- Test 2 - Tip-of-mast to tip-of-conductor test
- Test 3 - Body ground to battery ground test
- Test 4 - Body ground to coaxial shield test.
Antenna Tests
The ohmmeter test lead connections for each test are shown in Antenna Tests.
NOTE: This model has a two-piece antenna coaxial cable. Tests 2 and 4 must be conducted in two
steps to isolate a coaxial cable problem; from the coaxial cable connection on the right end bracket
of the instrument panel near the right cowl side inner panel to the antenna base, and then from the
coaxial cable connection to the radio chassis connection.
Test 1 Test 1 determines if the antenna mast is insulated from the base. Proceed as follows: 1.
Unplug the antenna coaxial cable connector from the radio chassis and isolate. 2. Connect one
ohmmeter test lead to the tip of the antenna mast. Connect the other test lead to the antenna base.
Check for continuity. 3. There should be no continuity If continuity is found, replace the faulty or
damaged antenna base and cable assembly
Test 2 Test 2 checks the antenna for an open circuit as follows: 1. Unplug the antenna coaxial
cable connector from the radio chassis. 2. Connect one ohmmeter test lead to the tip of the
antenna mast. Connect the other test lead to the center pin of the antenna coaxial cable connector.
3. Continuity should exist (the ohmmeter should only register a fraction of an ohm). High or infinite
resistance indicates damage to the base and cable
assembly Replace the faulty base and cable, if required.
Test 3 Test 3 checks the condition of the vehicle body ground connection. This test should be
performed with the battery positive cable removed from the battery Disconnect both battery cables,
the negative cable first. Reconnect the battery negative cable and perform the test as follows: 1.
Connect one ohmmeter test lead to the vehicle fender. Connect the other test lead to the battery
negative post. 2. The resistance should be less than one ohm. 3. If the resistance is more than one
ohm, check the braided ground strap connected to the engine and the vehicle body for being loose,
corroded, or
damaged. Repair the ground strap connection, if required.
Test 4 Test 4 checks the condition of the ground between the antenna base and the vehicle body
as follows: 1. Connect one ohmmeter test lead to the vehicle fender. Connect the other test lead to
the outer crimp on the antenna coaxial cable connector. 2. The resistance should be less then one
ohm. 3. If the resistance is more then one ohm, clean and/or tighten the antenna base to fender
mounting hardware.
Antenna: Service and Repair
The instrument panel half of the antenna coaxial cable is routed from the right instrument panel end
bracket to the radio in a plastic trough with the instrument panel wire harness. The instrument
panel wire harness trough is secured to the instrument panel armature. In order to remove the
instrument panel half of the antenna coaxial cable from the trough, the instrument panel assembly
must be removed from the vehicle. The procedure that follows covers the removal of only the body
half of the antenna coaxial cable.

INJURY.
1. Disconnect and isolate the battery negative cable. 2. Remove the end cap from the passenger
side end of the instrument panel. Refer to Instrument Panel End Cap in the Removal and
Installation
Instrument Panel, Gauges and Warning Indicators/Instrument Panel for the procedures.
3. Roll down the glove box from the instrument panel. Refer to Instrument Panel, Gauges and
Warning Indicators/Instrument Panel/Glove Box - Roll
Down in the Replacement for the procedures.
Antenna Coaxial Cable Connector
4. Unplug the coaxial cable connector. Unplug the connector by pulling it apart while twisting the
metal connector halves. Do not pull on the cable. 5. Disengage the retainer for the body half of the
coaxial cable from the right instrument panel end bracket. 6. Reach through the glove box opening
to access the body half of the coaxial cable and pull it through the space between the right
instrument panel
end bracket and the dash panel.
7. Reach through the glove box opening to push the coaxial cable grommet through the hole in the
dash panel and into the cowl plenum area. 8. Remove the cowl plenum cover/grille panel at the
base of the windshield from the cowl top. Refer to Wiper Linkage and Pivot in the Removal and
Installation in Wiper and Washer Systems for the procedures.
Antenna Mast Remove/Install - Typical
9. Unscrew the antenna mast from the antenna body.

Antenna Cap Nut Remove/Install - Typical
10. Remove the antenna cap nut and adapter using an antenna nut wrench (Special Tool C-4816).
Antenna Mounting
11. Lower the antenna body and cable assembly through the top of the fender far enough to
access the antenna body by reaching through the opening
in the right end of the cowl plenum.
12. Remove the antenna body and cable from the cowl plenum. 13. Reverse the removal
procedures to install. Tighten the antenna cap nut to 7.3 N.m (65 in. lbs.). Tighten the antenna
mast to 3.3 N.m (30 in. lbs.).
Antenna Nut Wrench C-4816

Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch
(For Alarm) > Component Information > Diagrams

(For Alarm) > Component Information > Diagrams > Page 5831
SYSTEM OPERATION
(For Alarm) > Component Information > Diagrams > Page 5832
REMOVAL
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Module > Component Information > Service and Repair

INJURY.
Keyless Entry Programming Connector > Component Information > Locations
16-Way Data Link Connector - Typical

Keyless Entry Receiver > Component Information > Description and Operation
Keyless Entry Receiver: Description and Operation
SYSTEM OPERATION
The Remote Keyless Entry (RKE) receiver is a radio frequency unit that is integral to the power
lock and RKE module or to the Central Timer Module (CTM). The RKE receiver has a memory
function to retain the vehicle access codes of the RKE transmitters, even if the battery is
disconnected. The power lock and RKE module can store two transmitter vehicle access codes,
the CTM can store up to four.
The RKE receiver is energized by one of two radio frequency inputs from the RKE transmitter,
Unlock or Lock. The programming of the power lock and RKE module or the CTM responds to
these RKE inputs, as well as many other inputs, by sending the proper control outputs to the power
lock motors, the courtesy lamp circuit, and (with the CTM-based RKE system only) the horn relay.
The RKE receiver is only serviced as a unit with the power lock and RKE module or the CTM and,
if faulty or damaged, the module unit must be replaced.
Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins >
Customer Interest for Keyless Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery
Failure
Keyless Entry Transmitter Battery: Customer Interest RKE Transmitter - Premature Battery Failure
NO: 08-39-97
GROUP: Electrical
DATE: Nov. 28, 1997
SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely
MODELS:
1997 - 1998 (AN) Dakota/Dakota Cab & Chassis
1998 (BRIBE)Ram Truck
1998 (DN) Durango
1997 (LH) Concorde/Intrepid/LHS/Vision
1997 - 1998 (PL) Neon
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX).
SYMPTOM/CONDITION:
Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks.
DIAGNOSIS:
If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH
0815XX, perform the Repair Procedure.
PARTS REQUIRED:
AR 04686366 Transmitter, RKE- NS, PL & PR
AR 04759136AB Transmitter, RKE- LH
AR 56007049 Transmitter, RKE- AB & 1997 AN
AR 56008761 Transmitter 1, RKE- ZJ & DN
AR 56008762 Transmitter 2, RKE- ZJ
AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN
REPAIR PROCEDURE:
This bulletin involves replacing the RKE transmitter(s).
1. Replace RKE transmitter(s) that have discharged batteries.
2. Program the RKE transmitter(s) to the vehicle.

TIME ALLOWANCE:

Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Keyless Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature
Battery Failure
Keyless Entry Transmitter Battery: All Technical Service Bulletins RKE Transmitter - Premature
Battery Failure
NO: 08-39-97
GROUP: Electrical
DATE: Nov. 28, 1997
MODELS:
1998 (DN) Durango
1997 - 1998 (PL) Neon
1997 (PR) Prowler
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
REPAIR PROCEDURE:

TIME ALLOWANCE:

Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins >
Page 5857
Keyless Entry Transmitter Battery: Service and Repair
The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To
replace the RKE transmitter batteries:
1. Using a trim stick or another suitable wide flat-bladed tool, gently pry at the center seam of the
transmitter case halves near the key ring until the
two halves unsnap.
2. Lift the back half of the transmitter case off of the transmitter. 3. Remove the two batteries from
the transmitter. 4. Replace the two batteries with new Duracell DL2016, or their equivalent. Be
certain that the batteries are installed with their polarity correctly
oriented.
5. Align the two transmitter case halves with each other, and squeeze them firmly together until
they snap back into place.
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch >
SYSTEM OPERATION
replaced.
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch >
REMOVAL
the front door.
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator
Security Lamp/Indicator: Description and Operation
SYSTEM OPERATION
The security lamp gives an indication of the status of the optional Vehicle Theft Security System
(VTSS). The lamp is controlled by a hard wired input to the instrument cluster from the high-line
Central Timer Module (CTM). The lamp is turned on by the CTM for about two seconds when the
ignition switch is turned to the On position as a bulb test.
After the bulb test, the CTM turns the lamp on or off based upon the arming status of the VTSS. If
the security lamp stays on for about thirty seconds after the ignition switch is turned to the On
position, it indicates that Chrysler Collision Detection (CCD) data bus communication with the
Powertrain Control Module (PCM) is inoperative, and that the next attempt to arm the VTSS may
not be successful.
Refer to Accessories and Optional Equipment/Antitheft and Alarm/Vehicle Theft/Security Systems

for more information on the VTSS and the security lamp.
The security lamp is an amber lamp located within the instrument cluster on the instrument panel.
The security lamp receives fused battery feed at all times and is grounded by the high line Central
Timer Module (CTM) to give a visible indication of the Vehicle Theft Security System (VTSS)
arming status.
The security lamp incandescent bulb and bulb holder can be serviced. Refer to Instrument Panel,
Gauges and Warning Indicators/Cluster Bulbs Service Procedures.
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator
Security Lamp/Indicator: Testing and Inspection
The diagnosis found here addresses an inoperative security lamp condition. If the problem being
diagnosed is an inaccurate security lamp, refer to Accessories and Optional Equipment/Antitheft
and Alarm System/Vehicle Theft/Security Systems for diagnosis of the Vehicle Theft Security
System ( VTSS).

INJURY.
circuit to the battery as required. 3. Disconnect and isolate the battery negative cable. Remove the
Central Timer Module (CTM). Unplug the CTM wire harness connectors. Connect
the battery negative cable. Install a jumper wire between the security indicator control circuit cavity
of the 18-way CTM wire harness connector and a good ground. The security lamp should light. If
OK, use a DRB scan tool and the proper Diagnostic Procedures to diagnose the Vehicle Theft
Security System (VTSS) and the CTM. If not OK, go to Step 5.
4. Disconnect and isolate the battery negative cable. Remove the instrument cluster. Check for
continuity between the fused B(+) circuit cavity of the
instrument cluster wire h ness connector (connector A) and the fuse in the PDC. There should be
continuity If OK, go to Step 6. If not OK, repair the open circuit to the PDC as required.
5. Check for continuity between the security indicator control circuit cavities of the instrument
18-way CTM wire harness connector. There should be continuity. If OK, see Instrument Cluster in
the Diagnosis and Testing for further diagnosis of the security lamp and the instrument cluster
circuitry. If not OK, repair the open circuit as required.
Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical
Service Bulletins > Radio Communication Equipment - Recommendations
Radio Communication Equipment - Recommendations
NUMBER: 08-23-99
GROUP: Electrical
DATE: Jul. 9, 1999
1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998
TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000
MODEL YEAR VEHICLES.
SUBJECT: Installation of Radio Transmitting Equipment
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram
Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth
Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000**
(DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ)
Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 -
**2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New
Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 -
**2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 -
**2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ)
Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand
Cherokee/Grand Wagoneer
DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment

Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in
properly installing communication equipment in DaimlerChrysler vehicles. This information should
be given to any owner inquiring about installing radio-transmitting equipment.
Installation Recommendations
DaimlerChrysler
Radio Communication Equipment Installation Recommendations

Service Bulletins > Radio Communication Equipment - Recommendations > Page 5870
The following is excerpted from the owners manual of new DaimlerChrysler products:
"INSTALLATION OF RADIO TRANSMITTING EQUIPMENT
Special design considerations are incorporated into this vehicle's electronic system to provide
immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be
installed properly by trained personnel. The following must be observed during installation.
The positive power connection should be made directly to the battery and fused as close to the
battery as possible. The negative power connection should be made to body sheet metal adjacent
to the negative battery connection. This connection should not be fused.
Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care
should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or
operation of the compass on vehicles so equipped.
The antenna cable should be as short as practical and routed away from the vehicle wiring when
possible. Use only fully shielded coaxial cable.
Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR).
Mobile radio equipment with output power greater than normal may require special precautions.
All installations should be checked for possible interference between the communications
equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for
detailed assistance."
The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied
with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the
problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles,
the following information is provided. Always use good construction practices (see The ARRL
Handbook or other standard reference works).
The information contained in this guide has been prepared for use by persons installing two-way
radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with
current engineering principles and generally accepted practices, using the best information
available at the time of publication. It is not possible to cover all of the possible installations of
two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held
responsible for incidental or consequent damages arising out of the use of the information
contained herein. The responsibility for installations and modifications is the sole responsibility of
the customer.
The installation recommendations presented here are intended to supplement the radio
manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and
brake control before extensive driving.
1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan,
put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are
available at most body shops for this purpose.) This will keep moisture out of the carpet and
insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and
behind instrument panel.
If you mount the radio under the instrument panel, be sure that there is no interference with proper
operation of the foot controls. Mount the control head or front panel (especially the microphone
cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit
is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and
energy absorbing materials in the knee blocker (the lower part of the Instrument Panel).
For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power
relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed.
Try the installation out before you start drilling holes.
2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery
NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.:
radio presets) after a protracted time without battery power.
For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or
cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat
shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +)
lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle
has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder
and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard
corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and
the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola
Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG
cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi
Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with
cover 12033731 for standard SAE plastic fuses.
Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher
underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas.
Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest
location.
DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply
current would be conducted by an alternate current return path, which could cause the feedline to
overheat, with possible resulting damage.
For low or medium power installations, connect the ground (battery -) to body sheet near the power
feed point. If you use a screw through the floor, put body sealer over the underbody projection.
(Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high
power installations, connect the ground (battery -) lead at the battery connection to the body. This
is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse
or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so
diameter area of body panel where the ground lead is to be connected (usually the case with
commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or
5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size
for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the
terminal and the screw head. As above, some grease or protectant should be used if the
connection is in an unprotected area.
If the power cable must pass through the dash panel, try to find an existing hole with a grommet
that is unused. If none is available, pull the carpet back from under the dash panel in the passenger
footwell in the cabin. Locate a place where there are no other components on either side, as high
up as possible. An awl is the best tool to use to punch a small hole through to the engine
compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is
not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will
leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or
commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the
underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold,
steering shaft, throttle linkage, fans, etc. Tie wrap as required.
3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets
the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats
or carpet and padding. For most left hand drive vehicles, use the right side for best separation to
the main body harness (usually on the left side).
Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible.
4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to
remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is
usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the
front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear
compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping
points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which
must be pierced to pass the cable.
Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie
wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back
and cushion, taking care that the cable is not pinched by the seat cushion when there is someone
sitting in the seat. On some vehicles, there may be a channel for wiring at this location.
For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a
good method to mount the transceiver to the shelf. It provides a good mounting surface, some
shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of
the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be
mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic
modules located in the rear of the vehicle.
In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22
watts (@70% efficiency). Do not pile things on top of the unit.
5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way
as the control and power cables. Route flat along body sheet metal wherever possible to avoid
sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some
cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is
important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is
not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at
UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits.
Do not rely on the obsolete military "RG" designations as an indicator of quality.
Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the
correct connector.
The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A
small amount of silicone dielectric grease (not the white heat sink compound) in the connector
(after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize
losses.
6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile
installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the
center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas
should be mounted at the very top edge of the clear portion of the glass away from the heater grid.
Vehicles with printed-on-glass antennas may be damaged by through-glass installations.
For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are
an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel
for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for
corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A
small grinder with a coarse stone will break through the anodized coating for electrical connection.
7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass
or body-lip mounts for anything other than for low power or temporary installations. Most of these
alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from
the feedline inside the passenger compartment, and may be picked up by the vehicle wiring.
For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short,
wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and
even some FM installations, the hood must be bonded to the body. In some cases the doors may
need to be bonded, as well.
Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass
(Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper)
require a half-wavelength antenna or a ground plane with radius approximately equal to the length
of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used.
Install on the inside of the body panel with a good adhesive or tape and provide a good RF
connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used.
Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay
one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof
mechanism for interference to the base and to the feedline.
For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center
conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in
antenna selection and is the best choice for electrical and mechanical considerations. Use the
proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with
power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the
antenna base.
To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where
the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or
plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through,
leaving 6 in., which can be taped, to the transmission line (easier without the connector, but
possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the
hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps
maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small
amount of silicone grease to the contact and insulator surface of the base. This will help exclude
water, but must be renewed periodically. Tip: if you remove your antenna to go through the car
wash, there are caps available to exclude water during the process.
In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If
necessary, the technique used on the roof can also be used to snake the cable down the inside the
pillar.
Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a
clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are
a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely
important.
Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler

Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757
Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information >
Technical Service Bulletins > Radio Communication Equipment - Recommendations
Radio Communication Equipment - Recommendations
NUMBER: 08-23-99
GROUP: Electrical
DATE: Jul. 9, 1999
1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998
TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000
MODEL YEAR VEHICLES.
SUBJECT: Installation of Radio Transmitting Equipment
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram
Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth
Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000**
(DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ)
Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 -
**2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New
Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 -
**2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 -
**2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ)
Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand
Cherokee/Grand Wagoneer
DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment

Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in
properly installing communication equipment in DaimlerChrysler vehicles. This information should
be given to any owner inquiring about installing radio-transmitting equipment.
Installation Recommendations
DaimlerChrysler
Radio Communication Equipment Installation Recommendations

Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5877
The following is excerpted from the owners manual of new DaimlerChrysler products:
"INSTALLATION OF RADIO TRANSMITTING EQUIPMENT
Special design considerations are incorporated into this vehicle's electronic system to provide
immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be
installed properly by trained personnel. The following must be observed during installation.
The positive power connection should be made directly to the battery and fused as close to the
battery as possible. The negative power connection should be made to body sheet metal adjacent
to the negative battery connection. This connection should not be fused.
Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care
should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or
operation of the compass on vehicles so equipped.
The antenna cable should be as short as practical and routed away from the vehicle wiring when
possible. Use only fully shielded coaxial cable.
Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR).
Mobile radio equipment with output power greater than normal may require special precautions.
All installations should be checked for possible interference between the communications
equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for
detailed assistance."
The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied
with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the
problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles,
the following information is provided. Always use good construction practices (see The ARRL
Handbook or other standard reference works).
The information contained in this guide has been prepared for use by persons installing two-way
radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with
current engineering principles and generally accepted practices, using the best information
available at the time of publication. It is not possible to cover all of the possible installations of
two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held
responsible for incidental or consequent damages arising out of the use of the information
contained herein. The responsibility for installations and modifications is the sole responsibility of
the customer.
The installation recommendations presented here are intended to supplement the radio
manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and
brake control before extensive driving.
1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan,
put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are
available at most body shops for this purpose.) This will keep moisture out of the carpet and
insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and
behind instrument panel.
If you mount the radio under the instrument panel, be sure that there is no interference with proper
operation of the foot controls. Mount the control head or front panel (especially the microphone
cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit
is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and
energy absorbing materials in the knee blocker (the lower part of the Instrument Panel).
For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power
relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed.
Try the installation out before you start drilling holes.
2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery
NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.:
radio presets) after a protracted time without battery power.
For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or
cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat
shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +)
lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle
has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder
and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard
corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and
the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola
Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG
cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi
Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with
cover 12033731 for standard SAE plastic fuses.
Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher
underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas.
Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest
location.
DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply
current would be conducted by an alternate current return path, which could cause the feedline to
overheat, with possible resulting damage.
For low or medium power installations, connect the ground (battery -) to body sheet near the power
feed point. If you use a screw through the floor, put body sealer over the underbody projection.
(Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high
power installations, connect the ground (battery -) lead at the battery connection to the body. This
is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse
or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so
diameter area of body panel where the ground lead is to be connected (usually the case with
commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or
5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size
for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the
terminal and the screw head. As above, some grease or protectant should be used if the
connection is in an unprotected area.
If the power cable must pass through the dash panel, try to find an existing hole with a grommet
that is unused. If none is available, pull the carpet back from under the dash panel in the passenger
footwell in the cabin. Locate a place where there are no other components on either side, as high
up as possible. An awl is the best tool to use to punch a small hole through to the engine
compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is
not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will
leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or
commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the
underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold,
steering shaft, throttle linkage, fans, etc. Tie wrap as required.
3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets
the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats
or carpet and padding. For most left hand drive vehicles, use the right side for best separation to
the main body harness (usually on the left side).
Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible.
4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to
remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is
usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the
front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear
compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping
points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which
must be pierced to pass the cable.
Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie
wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back
and cushion, taking care that the cable is not pinched by the seat cushion when there is someone
sitting in the seat. On some vehicles, there may be a channel for wiring at this location.
For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a
good method to mount the transceiver to the shelf. It provides a good mounting surface, some
shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of
the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be
mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic
modules located in the rear of the vehicle.
In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22
watts (@70% efficiency). Do not pile things on top of the unit.
5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way
as the control and power cables. Route flat along body sheet metal wherever possible to avoid
sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some
cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is
important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is
not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at
UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits.
Do not rely on the obsolete military "RG" designations as an indicator of quality.
Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the
correct connector.
The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A
small amount of silicone dielectric grease (not the white heat sink compound) in the connector
(after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize
losses.
6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile
installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the
center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas
should be mounted at the very top edge of the clear portion of the glass away from the heater grid.
Vehicles with printed-on-glass antennas may be damaged by through-glass installations.
For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are
an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel
for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for
corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A
small grinder with a coarse stone will break through the anodized coating for electrical connection.
7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass
or body-lip mounts for anything other than for low power or temporary installations. Most of these
alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from
the feedline inside the passenger compartment, and may be picked up by the vehicle wiring.
For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short,
wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and
even some FM installations, the hood must be bonded to the body. In some cases the doors may
need to be bonded, as well.
Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass
(Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper)
require a half-wavelength antenna or a ground plane with radius approximately equal to the length
of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used.
Install on the inside of the body panel with a good adhesive or tape and provide a good RF
connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used.
Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay
one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof
mechanism for interference to the base and to the feedline.
For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center
conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in
antenna selection and is the best choice for electrical and mechanical considerations. Use the
proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with
power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the
antenna base.
To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where
the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or
plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through,
leaving 6 in., which can be taped, to the transmission line (easier without the connector, but
possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the
hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps
maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small
amount of silicone grease to the contact and insulator surface of the base. This will help exclude
water, but must be renewed periodically. Tip: if you remove your antenna to go through the car
wash, there are caps available to exclude water during the process.
In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If
necessary, the technique used on the roof can also be used to snake the cable down the inside the
pillar.
Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a
clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are
a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely
important.
Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler

Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Service and Repair
Amplifier: Service and Repair
REMOVAL

INJURY.
1. Disconnect and isolate the battery negative cable. 2. Remove the end cap from the passenger
side end of the instrument panel. Refer to Instrument Panel End Cap in the Removal and
Installation
Instrument Panel, Gauges and Warning Indicators/Instrument Panel for the procedures.
3. Roll down the glove box from the instrument panel. Refer to Glove Box - Roll Down in the
Removal and Installation Instrument Panel, Gauges
and Warning Indicators/Instrument Panel for the procedures.
4. Reach through the outboard side of the glove box opening to access and unplug the two wire
harness connectors from the lower end of the
amplifier.
Amplifier Remove/Install
5. Reach through the outboard side of the glove box opening to support the amplifier while
removing the two screws that secure the amplifier from
the outboard side of the right instrument panel end bracket.

6. Lift the amplifier upwards far enough to disengage the mounting tab from the slot in the lower
rear corner of the right instrument panel end
bracket.
7. Remove the amplifier through the instrument panel glove box opening. 8. Reverse the removal
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc
Player (CD) > Component Information > Technical Service Bulletins > CD Player - CD Compatibility
Compact Disc Player (CD): Technical Service Bulletins CD Player - CD Compatibility
BULLETIN NUMBER: 08-11-00
GROUP: Electrical
DATE: March 24, 2000
SUBJECT: Recordable Compact Discs Used in Automotive CD players
MODELS: 1989 - 2000 (AB) Ram Van/Wagon 1989 - 2000 (AN) Dakota 1994 - 2000 (BR/BE) Ram
Truck 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 -
2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler
1996 - 1999 (SR) Viper/Viper GT 1997 - 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee
1997 - 2000 (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee
DISCUSSION: Some recordable compact disc media, such as CD-R and CD-RW, may not comply
with the standard CD format used in automotive CD players. When these CD's are used,
customers may encounter error messages, skipping, or delaminating of the labels, which can
cause an eject failure. It is important to question whether these kinds of CD media are being used.
When customers encounter these symptoms, check the system with a known playable CD. Explain
that the media may not be compatible with some automotive CD players. Replacing or exchanging
the CD player will not address these issues.

Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo: Diagram Information and Instructions
Introduction
8w-01-002
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

Radio/Stereo: Diagnostic Aids
position
problem

Testing For Voltage
Testing For Voltage


Probing Tool
Radio/Stereo: Electrical Diagrams
Base
8w-47-2
8w-47-3
Premium
8w-47-2
8w-47-4
8w-47-5
Radio/Stereo: Testing and Inspection

INJURY.
CAUTION: The speaker output of the radio is a "floating ground" system. Do not allow any speaker
lead to short to ground, as damage to the radio may result.
1. Check the fuse(s) in the junction block and the Power Distribution Center (PDC). If OK, go to
Step 3. If not OK, repair the shorted circuit or
component as required and replace the faulty fuse(s).
circuit to the battery as required. 3. Turn the ignition switch to the On position. Check for battery
voltage at the fuse in the junction block. If OK, go to Step 5. If not OK, repair the
Remove the radio, but do not unplug the radio wire
harness connectors. Check for continuity between the radio chassis and a good ground. There
should be continuity. If OK, go to Step 6. If not OK, repair the open radio chassis ground circuit as
required.
voltage at the fused ignition switch output
(accessory/run) circuit cavity of the left (gray) radio wire harness connector. If OK, go to Step 7. If
not OK, repair the open circuit as required.
6. Turn the ignition switch to the Off position. Check for battery voltage at the fused B(+) circuit
cavity of the left (gray) radio wire harness
connector. If OK, replace the faulty radio. If not OK, repair the open circuit to the Ignition-Off Draw
(IOD) fuse as required.
Radio/Stereo: Service and Repair
REMOVAL

INJURY.
instrument panel. Refer to Cluster Bezel in the Removal and Installation Instrument Panel, Gauges
and Warning
Indicators/Instrument Panel for the procedures.
Radio Remove/Install
3. Remove the two screws that secure the radio to the instrument panel.
CAUTION: Care must be used when removing or installing the radio so as not to damage the
accessory switch plate, which is located just to the right of the radio and the heater-air conditioner
controls in the instrument panel.
Radio Connections - Typical
4. Pull the radio out from the instrument panel far enough to access the wire harness connectors
and the antenna coaxial cable connector. 5. Unplug the wire harness connectors and the antenna
coaxial cable connector from the rear of the radio. 6. Remove the radio from the instrument panel.
7. Reverse the removal procedures to install. Thghten the radio mounting screws to 3.3 N.m (30 in.
lbs.).
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Speaker: Description and Operation
SYSTEM OPERATION
The standard equipment speaker system includes speakers in four locations. One full-range 8.9
centimeter (3.50 inch) diameter speaker is located in each end of the instrument panel top cover,
and one full-range 15.2 by 22.9 centimeter (6.00 by 9.00 inch) speaker is located in each front
door. An optional six speaker stereo system adds one full-range 15.2 by 22.9 centimeter (6.00 by
9.00 inch) speaker to each side panel of the vehicle, near the rear wheel housings.
The optional premium speaker system replaces the speakers used in the six speaker stereo
system with six Infinity model speakers in the same six locations, and includes a 120 watt amplifier.
The Infinity amplifier is mounted to the inboard side of the right instrument panel end bracket,
outboard of the glove box opening. The amplifier is accessed for service by rolling the glove box
down from the instrument panel.
Speaker: Testing and Inspection

INJURY.
CAUTION: The speaker output of the radio is a "floating ground" system. Do not allow any speaker
lead to short to ground, as damage to the radio may result.
1. Turn the ignition switch to the On position. Turn the radio on. Adjust the balance and fader
controls to check the performance of each individual
speaker. Note the speaker locations that are not performing correctly. Go to Step 3.
2. Turn the radio off. Turn the ignition switch to the Off position. Disconnect and isolate the battery
negative cable. Remove the radio from the
instrument panel. If the vehicle is equipped with the Infinity speaker package, also unplug the wire
harness connectors at the amplifier. Check both the speaker feed (+) circuit and return (-) circuit
cavities for the inoperative speaker location(s) at the radio wire harness connectors for continuity to
ground. In each case, there should be no continuity. If OK, go to Step 4. If not OK, repair the
shorted speaker circuit(s) as required.
3. If the vehicle is equipped with the Infinity speaker package, go to Step 7. If the vehicle is
equipped with the standard speaker system, check the
resistance between the speaker feed (+) circuit and return (-) circuit cavities of the radio wire
harness connectors for the inoperative speaker location(s). The meter should read between 2 and
12 ohms (speaker resistance). If OK, go to Step 5. If not OK, go to Step 6.
4. Install a known good radio. Connect the battery negative cable. Turn the ignition switch to the On
position. Turn on the radio and test the speaker
operation. If OK, replace the faulty radio. If not OK, turn the radio on turn the ignition switch to the
Off position, disconnect and isolate the battery negative cable, remove the test radio, and go to
Step 6.
5. Unplug the speaker wire harness connector at the inoperative speaker. Check for continuity
between the speaker feed (+) circuit cavities of the
radio wire harness connector and the speaker wire harness connector. Repeat the check between
the speaker return (-) circuit cavities of the radio wire harness connector and the speaker wire
harness connector. In each case, there should be continuity If OK, replace the faulty speaker. If not
OK, repair the open circuit(s) as required.
6. For each inoperative speaker location, check for continuity between the speaker feed (+) circuit
cavities of the radio wire harness connectors and
the amplifier wire harness connectors. Repeat the check for each inoperative speaker location
between the speaker return (-) circuit cavities of the radio wire harness connectors and the
amplifier wire harness connectors. In each case, there should be continuity. If OK, go to Step 8. If
not OK, repair the open circuit as required.
7. Check for continuity between the two ground circuit cavities of the amplifier wire harness
connector and a good ground. There should be
continuity. If OK, go to Step 9. If not OK, repair the open circuit(s) as required.
8. Check the amplifier fuse in the junction block. If OK, go to Step 10. If not OK, repair the shorted
faulty fuse.
9. Install the radio. Connect the battery negative cable. Check for battery voltage at the amplifier
fuse in the junction block. If OK, go to Step 11. If
not OK, repair the open circuit to the PDC as required.
10. Check for battery voltage at the two fused B(+) circuit cavities of the amplifier wire harness
connector. If OK, go to Step 12. If not OK, repair the
11. Turn the ignition switch to the On position. Turn the radio on. Check for battery voltage at the
radio 12 volt output circuit cavity of the amplifier
wire harness connector. If OK, go to Step 3. If not OK, repair the open circuit to the radio as
required.
12. Turn the radio off. Turn the ignition switch to the Off position. Disconnect and isolate the battery
negative cable. For each inoperative speaker
location, check both the amplified feed (+) circuit and the amplified return (-) circuit cavities of the
amplifier wire harness connectors for continuity to ground. In each case there should be no
continuity If OK, go to Step 14. If not OK, repair the short circuit as required.
13. For each inoperative speaker location, check the resistance between the amplified feed (+)
circuit and the amplified return (-) circuit cavities of the
amplifier wire harness connectors. The meter should read between 2 and 12 ohms (speaker
resistance). If OK, replace the faulty amplifier. If not OK, go to Step 15.
14. Unplug the speaker wire harness connector at the inoperative speaker. Check for continuity
between the amplified feed (+) circuit cavities of the
speaker wire harness connector and the amplifier wire harness connector. Repeat the check
between the amplified return (-) circuit cavities of the speaker wire harness connector and the
amplifier wire harness connector. In each case there should be continuity If OK, replace the faulty
speaker. If not OK, repair the open circuit as required.
Speaker: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Remove the top cover from the instrument
panel. Refer to Instrument Panel Top Cover in the Removal and Installation Instrument Panel,
Gauges
and Warning Indicators/Instrument Panel for the procedures.
Instrument Panel Speaker Remove/Install
3. Remove the two screws that secure the speaker to the top of the instrument panel. 4. Pull the
speaker away from the top of the instrument panel far enough to access and unplug the speaker
wire harness connector. 5. Remove the speaker from the instrument panel. 6. Reverse the removal
procedures to install. Tighten the mounting screws to 2 N.m (17 in. lbs.).
Front Door 1. Disconnect and isolate the battery negative cable. 2. Remove the inside trim panel
from the front door.
Front Door Speaker Remove/Install
3. Remove the three screws that secure the speaker to the front door inner panel. 4. Pull the
speaker away from the front door inner panel far enough to access and unplug the speaker wire
harness connector. 5. Remove the speaker from the front door. 6. Reverse the removal procedures
to install. Tighten the mounting screws to 4 N.m (35 in. lbs.).
Rear Panel
Without Cargo Compartment Trim 1. Disconnect and isolate the battery negative cable.
Rear Panel Speaker Remove/Install - Without Cargo Compartment Trim
2. Remove the four screws that secure the speaker mounting bracket to the rear panel
reinforcements. 3. Pull the speaker mounting bracket away from the rear panel reinforcements far
enough to access and unplug the speaker wire harness
connector.
4. Remove the four nuts that secure the grille from the rear of the speaker mounting bracket. 5.
Remove the grille from the front of the speaker mounting bracket. 6. Remove the four screws that
secure the speaker from the front of the speaker mounting bracket. 7. Remove the speaker from
the rear of the speaker mounting bracket. 8. Reverse the removal procedures to install. Tighten all
of the mounting hardware to 2.2 N.m (20 in. lbs.).
With Cargo Compartment Trim 1. Disconnect and isolate the battery negative cable. 2. Remove the
inside trim panel from the rear panel.
Rear Panel Speaker Remove/Install - With Cargo Compartment Trim
3. Remove the four nuts that secure the grille from the rear of the trim panel. 4. Remove the grille
from the front of the trim panel. 5. Remove the four screws that secure the speaker from the front of
the trim panel. 6. Remove the speaker from the rear of the trim panel. 7. Reverse the removal
procedures to install. Tighten all of the mounting hardware to 2.2 N.m (20 in. lbs.).
Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Service and Repair

INJURY.
Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams

Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Page 5931
SYSTEM OPERATION
Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Page 5932
REMOVAL
Equipment > Lock Cylinder Switch > Component Information > Description and Operation
SYSTEM OPERATION
replaced.
Equipment > Lock Cylinder Switch > Component Information > Description and Operation > Page 5936
REMOVAL
the front door.
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Trailer Connector: Diagram Information and Instructions
Introduction
8w-01-002
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

Trailer Connector: Diagnostic Aids
position
problem

Testing For Voltage
Testing For Voltage


Probing Tool
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Trailer Connector: Diagram Information and Instructions
Introduction
8w-01-002
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

Trailer Connector: Diagnostic Aids
position
problem

Testing For Voltage
Testing For Voltage


Probing Tool
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Module Locations

Introduction
8w-01-002
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

position
problem

Testing For Voltage
Testing For Voltage


Probing Tool

CTM Connector
CTM Connector

Description and Operation > Central Timer Module Description
would perform.
- Chime
Description and Operation > Central Timer Module Description > Page 6014
harnesses.
Testing and Inspection > Component Tests and General Diagnostics
- symptom analysis
- problem isolation

Dodge Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair
Access Cover: Service and Repair
NOTE: The engine cover is attached with screws at the rear and with latches at the dash
extension.
REMOVAL
1. Remove screws attaching holddown brackets to floor pan. 2. Disengage latches from dash
extension.
3. Remove engine cover from vehicle.
INSTALLATION
1. Position engine cover on floor pan. 2. Ensure seal is seated correctly. 3. Position holddown
brackets on cover and install screws in floor pan finger tight. 4. Engage latches with dash panel
extension. 5. Tighten screws attaching cover to floor pan.
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front
Door Exterior Handle > System Information > Service and Repair
Front Door Exterior Handle: Service and Repair
EXTERIOR HANDLE
REMOVAL
1. Raise window glass to closed position. 2. Remove the waterdam. Refer to Front Door Panel.
Fig. 7
3. Remove nuts attaching outside handle to door (Fig. 7). 4. Disconnect handle latch rod from latch.
5. Separate handle from door.
INSTALLATION
1. Position handle on door. 2. Install nuts attaching door handle to door. 3. Connect handle latch
rod to latch. 4. Install the waterdam.
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor
Front Door Window Motor: Service and Repair
the front door.
Power Window Motor Remove/Install
3. Disengage the power window motor wire harness connector retainer from the mounting hole on
the front door module and unplug the connector. 4. Remove the three screws that secure the
power window motor and mechanism to the front door module. 5. Remove the power window motor
and mechanism from the front door module. 6. Reverse the removal procedures to install. Tighten
the mounting screws to 11 N.m (98 in. lbs.).
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Exterior Handle
> System Information > Service and Repair > Rear Cargo Doors
Rear Door Exterior Handle: Service and Repair Rear Cargo Doors
EXTERIOR HANDLE
REMOVAL
1. Open the rear cargo door. 2. Remove the trim panel from the door inner panel.
Fig. 4
Fig. 5
3. Disconnect the outside door handle rod from the latch lever (Fig. 4) and (Fig. 5). 4. Remove the
nuts that attach the handle to the door outer panel. Remove the handle from the door.
> System Information > Service and Repair > Rear Cargo Doors > Page 6035
INSTALLATION
1. Position the handle on the door outer panel with the handle rod inserted in the opening. Insert
the handle studs into the panel holes. 2. Attach the handle rod to the latch. 3. Install the nuts that
attach the handle to the door outer panel. 4. Install the door trim panel.
REAR CARGO DOOR OUTSIDE HANDLE/LATCH LEVER
1. Insert a 4 mm (5/32 in.) hex-wrench through the adjustment slot and into the latch release lever
adjustment screw. Loosen the adjustment screw. 2. Depress and release the door outside handle
latch release button several times. 3. Tighten the adjustment screw to 3 N.m (30 in. lbs.) torque. 4.
Test the door handle for correct operation.
Rear Door Exterior Handle: Service and Repair Dual Cargo Doors
EXTERIOR HANDLE
REMOVAL
1. Open the cargo doors. 2. Remove the trim panel from the right door.
Fig. 4
Fig. 5
3. Disconnect the outside handle latch rod from the latch lever (Fig. 4) and (Fig. 5). 4. Remove the
nuts that attach the handle to the door panel. Remove the handle from the door.
INSTALLATION
1. Position the handle on the door panel with the handle latch rod inserted in the opening. Insert the
handle studs into the panel holes. 2. Attach the handle latch rod to the latch lever. 3. Install the nuts
that attach the handle to the door panel. 4. Install the door trim panel.
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle >
Component Information > Technical Service Bulletins > Customer Interest for Sliding Door Handle: > 23-40-98 > Sep > 98 >
Side/Rear Cargo Door - Outside Handle(s) Loose
Sliding Door Handle: Customer Interest Side/Rear Cargo Door - Outside Handle(s) Loose
NO: 23-40-98
GROUP: Body
DATE: Sep. 4, 1998
SUBJECT: Side And/Or Rear Cargo Door Outside Handle(s) Loose
MODELS: 1998 (AB) Ram Van/Wagon
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE MAY 16, 1998 (MDH 0516XX).
SYMPTOM/CONDITION:
Side and/or rear cargo door outside handle(s) are loose.
DIAGNOSIS:
Inspect the side and rear cargo door handles to verify handle looseness. If either the side and/or
rear cargo door handle(s) is/are loose, perform the Repair Procedure.
PARTS REQUIRED:
AR (1) 04318031 Adhesive, Lock & Seal
AR (1) 55075654 Handle, Dual Cargo Door
AR (1) 55359037AA Handle, Single Rear Cargo Door
AR (1) J4200306 Nut, Door Handle Retaining
REPAIR PROCEDURE:
This bulletin involves adding Mopar Lock & Seal Adhesive to the threads of the door handle stud
and nut.
1. Open the cargo door(s).
2. Remove the inside door handle retaining screw and separate the handle from the vehicle.
3. Remove the inside door handle trim bezel. This can be accomplished by inserting trim sticks in
the upper half of the trim bezel. Then, gently tapping on the upper bezel half with a plastic mallet
until it is released from the trim bezel. Remove the upper bezel from the trim and then tap the lower
trim bezel upward.
4. Use a trim removal tool to pry the trim panel away from the door inner panel.
5. Separate the trim panel away from the door.
6. Remove the nuts that attach the outside door handle to the door panel.
7. Apply a small amount of Mopar Lock & Seal p/n 04318031 to the threads of the nuts. Then,
install the nuts onto the outside door handle. Tighten the nuts to 2.8 Nm (25 in.lbs.).
NOTE:
IF THE STUDS ON THE OUTSIDE DOOR HANDLE ARE BROKEN, REPLACE THE DOOR
HANDLE AND ATTACHING NUTS (SEE PARTS REQUIRED SECTION). USE MOPAR LOCK &
SEAL PIN 04318031 ON THE THREADS OF THE NUTS WHEN INSTALLING THE HANDLE.
REFER TO THE 1998 RAM VAN SERVICE MANUAL (PUBLICATION NO.81-370-8107), PAGE
23-44 FOR DUAL CARGO DOOR OUTSIDE HANDLE REMOVAL AND INSTALLATION
PROCEDURES OR PAGES 23-49 AND 23-50 FOR A SINGLE REAR CARGO DOOR OUTSIDE
HANDLE REMOVAL AND INSTALLATION PROCEDURES.
8. Position the trim panel onto the inner door panel.
9. Push inward and force the clip retainers into the door panel holes.
Component Information > Technical Service Bulletins > Customer Interest for Sliding Door Handle: > 23-40-98 > Sep > 98 >
Side/Rear Cargo Door - Outside Handle(s) Loose > Page 6047
10. Insert the lower trim bezel half into the door handle opening and seat it in place.
11. Insert the upper bezel half into the door handle opening and seat it in place.
12. Install the inside door handle. Tighten the screw to 11 Nm (95 in.lbs.).
TIME ALLOWANCE:
Labor Operation No:
23-42-15-97 Apply Adhesive To The Outside Cargo Door Handle Nut Threads - One
0.2 Hrs.
23-42-15-98 Remove And Install Outside Cargo Door Handle And Apply Adhesive To The Outside
Cargo Door Handle Nut Threads One
0.3 Hrs.

Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Handle: > 23-40-98
> Sep > 98 > Side/Rear Cargo Door - Outside Handle(s) Loose
Sliding Door Handle: All Technical Service Bulletins Side/Rear Cargo Door - Outside Handle(s)
Loose
NO: 23-40-98
GROUP: Body
DATE: Sep. 4, 1998
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
REPAIR PROCEDURE:
and nut.
trim bezel upward.
NOTE:
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Handle: > 23-40-98
> Sep > 98 > Side/Rear Cargo Door - Outside Handle(s) Loose > Page 6053
TIME ALLOWANCE:
Labor Operation No:
0.2 Hrs.
0.3 Hrs.

Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch >
System Information > Technical Service Bulletins > Customer Interest for Sliding Door Latch: > 23-15-00 > Apr > 00 >
Sliding Door - Will Not Open And/Or Close/Latch
Sliding Door Latch: Customer Interest Sliding Door - Will Not Open And/Or Close/Latch
NUMBER: 23-15-00
GROUP: Body
SUBJECT: Sliding Door Will Not Open And/Or Close/Latch
MODELS: 1998 - 2000 (AB) Ram Van/Wagon
OVERVIEW: This bulletin involves installing revised sliding door rear latch assembly and latch rods
and modifying the rear latch opening.
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE SLIDING SIDE DOOR
(SALES CODE GKF) BUILT BEFORE FEBRUARY 26,2000 (MDH 0226XX).
SYMPTOM/CONDITION: The sliding door will not open and/or will not close/latch.
DIAGNOSIS: DOOR WILL NOT OPEN
1. Remove the sliding door trim panel attaching screws.
2. Remove the door pull handle (Figure 1).
3. Using a trim removal tool, carefully pry the trim panel away from the door inner panel.
4. Separate the trim panel from the sliding door.

Sliding Door - Will Not Open And/Or Close/Latch > Page 6062
5. Remove the sliding door inside handle attaching screw (Figure 2).
6. Remove the inside sliding door handle and spacers.
7. Remove the lock knob from the knob latch rod.
8. Remove the latch cover screws from the door panel.
9. Remove the cover from the door panel.
10. Inspect the front latch-to-rear latch control rod. If the rod is positioned as shown in Figure 3, the
rear latch has over-traveled and jammed. Use a screwdriver to pry the latch rod rearward to
dislodge the latch rod. A dislodged rod can be identified by the rod being free to move fore and aft
by grasping the rod with your hand. If the rod is not positioned as shown in Figure 3, this bulletin
will not correct a door that will not open complaint. Further diagnosis is required.
11. Remove the rear door latch attaching screws (Figure 4).
12. With the rear latch loose, push open the rear of the door enough to disconnect the rear latch
rods (Figure 5).
13. Remove the rear latch.

14. Inspect the rear latch reinforcement on the rear latch opening of the inner door panel for a high
trim condition as shown in Figure 6. If the reinforcement sticks up higher than the opening, perform
the Repair Procedure. If the rod is not positioned as shown in Figure 3 and/or the latch
reinforcement does not stick up higher than the opening, this bulletin will not correct a door that will
not open complaint. Further diagnosis is required.
DOOR WILL NOT CLOSE/LATCH
5. Inspect the front latch-to-rear latch control rod to ensure that the rod clips are attached. Perform
the Repair Procedure if the rod clips are not attached.
6. Disconnect both front latch-to-rear latch control rods.
7. Remove the rear latch attaching screws.
8. Separate the rear latch from the inner door panel.

9. Inspect the rear latch torsional spring to ensure that it is properly positioned. If the rear latch
torsional spring is NOT positioned as shown in Figure 7, perform the Repair Procedure. If the
spring is properly positioned and the latch rod clips were attached (Step 5), this bulletin will not
correct a door that will not close/latch complaint. Further diagnosis is required.
PARTS REQUIRED:
REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH IDAIMLERCHRYSLER'S MOBILE

SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE
FACILITY SPECIAL EQUIPMENT.
1. Remove the rear latch assembly (if not already performed). Refer to the 2000 Ram Van/Wagon
Service Manual (Publication No.81-370-0007), page 23-42 "Sliding Cargo Door Rear latch
Removal."
2. Remove the sliding door inside handle attaching screw (Figure 2) (if not already performed).
3. Remove the inside sliding door handle and spacers (if not already performed).
4. Remove the lock knob from the knob latch rod (if not already performed).
5. Remove the latch cover screws from the door panel (if not already performed).
6. Remove the cover from the door panel (if not already performed).
7. Remove the front latch-to-rear latch control rods from the front latch assembly.
8. Remove the latch rods from the inner door panel.
9. Using a grinder, grind down the rear latch reinforcement trim edge so that the reinforcement is
flush with the inner door panel rear latch opening.
10. To prevent corrosion, apply a brushable primer to the exposed bare metal.
11. Connect the latch rods p/n 55076381AB and p/n 55346503AB to the front latch.
12. Position the rear latch p/n 55347099AC near the rear latch opening.
13. Attach the latch rods to the rear latch.
14. Install the latch screws in the door inner panel. Tighten the screws to 11 N.m (95 in. lbs).
15. Position the front latch cover onto the inner door panel with the knob latch rod and the outside
handle shaft inserted in the cover holes.
16. Install the cover screws in the door panel.
17. Position the inside door handle spacers and the inside handle onto the outside handle shaft.
Verify both spacers are installed.
18. Attach the inside handle with the screw.
19. Install lock knob.
20. Position the door trim panel on the door inner panel and press inward around the edge of the
panel.
21. Position the door pull handle onto the trim panel with the screw holes aligned.
22. Install the pull handle screws.
TIME ALLOWANCE:

System Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Latch: > 23-15-00 > Apr
> 00 > Sliding Door - Will Not Open And/Or Close/Latch
Sliding Door Latch: All Technical Service Bulletins Sliding Door - Will Not Open And/Or Close/Latch
NUMBER: 23-15-00
GROUP: Body

> 00 > Sliding Door - Will Not Open And/Or Close/Latch > Page 6072
rods (Figure 5).


PARTS REQUIRED:

Removal."
panel.
TIME ALLOWANCE:

System Information > Technical Service Bulletins > All Technical Service Bulletins for Sliding Door Latch: > Page 6077
Sliding Door Latch: By Symptom
NUMBER: 23-15-00
GROUP: Body

rods (Figure 5).



PARTS REQUIRED:

Removal."
panel.
TIME ALLOWANCE:
NUMBER: 23-15-00
GROUP: Body


rods (Figure 5).


PARTS REQUIRED:

Removal."
panel.
TIME ALLOWANCE:

Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Handle: > 23-40-98 > Sep >
98 > Side/Rear Cargo Door - Outside Handle(s) Loose
Trunk / Liftgate Handle: Customer Interest Side/Rear Cargo Door - Outside Handle(s) Loose
NO: 23-40-98
GROUP: Body
DATE: Sep. 4, 1998
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
REPAIR PROCEDURE:
and nut.
trim bezel upward.
NOTE:
Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Handle: > 23-40-98 > Sep >
98 > Side/Rear Cargo Door - Outside Handle(s) Loose > Page 6097
TIME ALLOWANCE:
Labor Operation No:
0.2 Hrs.
0.3 Hrs.

Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Handle: >
23-40-98 > Sep > 98 > Side/Rear Cargo Door - Outside Handle(s) Loose
Trunk / Liftgate Handle: All Technical Service Bulletins Side/Rear Cargo Door - Outside Handle(s)
Loose
NO: 23-40-98
GROUP: Body
DATE: Sep. 4, 1998
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
REPAIR PROCEDURE:
and nut.
trim bezel upward.
NOTE:
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Handle: >
23-40-98 > Sep > 98 > Side/Rear Cargo Door - Outside Handle(s) Loose > Page 6103
TIME ALLOWANCE:
Labor Operation No:
0.2 Hrs.
0.3 Hrs.

Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service Precautions
.
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service Precautions > Page 6109
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information >
Service and Repair > Glove Box Replacement/Rolldown
Glove Compartment: Service and Repair Glove Box Replacement/Rolldown
The glove box on this model can be rolled down beyond the integral stops in order to access many
components for service, without complete glove box removal. See Roll Down for the procedure.
The glove box can also be removed from the instrument panel completely See Removal for the
procedure.

INJURY.
Roll Down 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. 3. Locate
the two rubber stop bumpers on the sides of the instrument panel glove box opening.
Glove Box Roll Down
4. Depress both sides of the glove box bin inwards far enough so that the glove box stops that are
integral to each side of the bin can be moved past
the rubber stop bumpers.
5. Holding the sides of the glove box bin depressed, roll the glove box downward until the stops
molded into the sides of the glove box bin are
beyond the rubber stop bumpers, then release the sides of the glove box bin.
6. Reverse the roll down procedure to roll the glove box back up.
REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Roll down the glove box. See
Glove Box - Roll Down Procedures.
Service and Repair > Glove Box Replacement/Rolldown > Page 6114
Glove Box Remove/Install
3. Remove the three screws that secure the glove box hinge to the instrument panel lower glove
box opening reinforcement. 4. Remove the glove box from the instrument panel. 5. Reverse the
Service and Repair > Glove Box Replacement/Rolldown > Page 6115
Glove Compartment: Service and Repair Glove Box Component Replacement
The glove box bin and inner door unit and the glove box handle and latch unit are available for
service. The glove box outer door and the glove box hinge are serviced only in the complete glove
box assembly.

INJURY.
Handle And Latch 1. Disconnect and isolate the battery negative cable. 2. Roll down the glove box
from the instrument panel. See Glove Box - Roll Down replacement.
Glove Box Latch And Handle Remove/Install
3. Remove the four screws that secure the handle and latch unit to the glove box inner door. 4.
Remove the handle and latch unit from the glove box inner door. 5. Reverse the removal
Inner Door And Bin 1. Disconnect and isolate the battery negative cable. 2. Remove the handle
and latch from the glove box. See Glove Box Components - Handle and Latch Replacement for the
procedures. 3. Remove the glove box from the instrument panel. See Glove Box - Removal
Replacement.
Glove Box Inner Door And Bin Remove/Install
4. Remove the two screws that secure the bottom of the glove box outer door to the bottom of the
glove box bin. 5. Remove the eight screws that secure the inner door and bin unit to the glove box
outer door. 6. Separate the inner door and bin unit from the glove box outer door. 7. Reverse the
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair
Trim Panel: Service and Repair
WINDSHIELD HEADER, A-PILLAR AND FRONT DOOR HEADER TRIM PANELS
REMOVAL
1. Remove the sunvisor and retaining clip screws from the windshield header. Remove the visors
and clips from the windshield header.
2. Remove the trim panel screws from the body interior panels.
3. Remove the trim panels from the body interior panels.
INSTALLATION
1. Position the trim panels at the body interior panels.
2. Install the trim panel screws in the body interior panels. Tighten the screws to 2 Nm (17 in. lbs.)
torque.
3. Position the sunvisors and retaining clips on the windshield header with the screw holes aligned.
4. Install the screws in the windshield header. Tighten the screws to 2 Nm (17 in. lbs.) torque.
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Service and Repair

INJURY.
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Programming Connector >
16-Way Data Link Connector - Typical

Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information
Keyless Entry Receiver: Description and Operation
SYSTEM OPERATION
The Remote Keyless Entry (RKE) receiver is a radio frequency unit that is integral to the power
lock and RKE module or to the Central Timer Module (CTM). The RKE receiver has a memory
function to retain the vehicle access codes of the RKE transmitters, even if the battery is
disconnected. The power lock and RKE module can store two transmitter vehicle access codes,
the CTM can store up to four.
The RKE receiver is energized by one of two radio frequency inputs from the RKE transmitter,
Unlock or Lock. The programming of the power lock and RKE module or the CTM responds to
these RKE inputs, as well as many other inputs, by sending the proper control outputs to the power
lock motors, the courtesy lamp circuit, and (with the CTM-based RKE system only) the horn relay.
The RKE receiver is only serviced as a unit with the power lock and RKE module or the CTM and,
if faulty or damaged, the module unit must be replaced.
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry
Transmitter Battery > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry
Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure
Keyless Entry Transmitter Battery: Customer Interest RKE Transmitter - Premature Battery Failure
NO: 08-39-97
GROUP: Electrical
DATE: Nov. 28, 1997
MODELS:
1998 (DN) Durango
1997 - 1998 (PL) Neon
1997 (PR) Prowler
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
REPAIR PROCEDURE:

TIME ALLOWANCE:

Transmitter Battery > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless
Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure
Keyless Entry Transmitter Battery: All Technical Service Bulletins RKE Transmitter - Premature
Battery Failure
NO: 08-39-97
GROUP: Electrical
DATE: Nov. 28, 1997
MODELS:
1998 (DN) Durango
1997 - 1998 (PL) Neon
1997 (PR) Prowler
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
REPAIR PROCEDURE:

TIME ALLOWANCE:

Transmitter Battery > Component Information > Technical Service Bulletins > Page 6144
Keyless Entry Transmitter Battery: Service and Repair
The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To
replace the RKE transmitter batteries:
1. Using a trim stick or another suitable wide flat-bladed tool, gently pry at the center seam of the
transmitter case halves near the key ring until the
two halves unsnap.
2. Lift the back half of the transmitter case off of the transmitter. 3. Remove the two batteries from
the transmitter. 4. Replace the two batteries with new Duracell DL2016, or their equivalent. Be
certain that the batteries are installed with their polarity correctly
oriented.
5. Align the two transmitter case halves with each other, and squeeze them firmly together until
they snap back into place.
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Door Lock Motor Connectors

Power Door Lock Actuator: Description and Operation
SYSTEM OPERATION
In the power lock and Remote Keyless Entry (RKE) systems, the door latch lock mechanisms can
be actuated by a reversible electric motor. A power lock motor module is secured to the bottom of
the door latch mounted within each front door. A power lock motor is integral to the latches used on
dual side or rear doors. A separate power lock motor with a connecting link is used to actuate the
latch in the sliding side or single rear door.
The power lock motor direction is controlled by the battery and ground feeds from the power lock
and unlock relays. The power lock and unlock relays are integral to the power lock and Remote
Keyless Entry (RKE) module, or the Central Timer Module (CTM).
The power door lock motors cannot be repaired and, if faulty or damaged, they must be replaced.
On dual side or rear doors the entire door latch unit must be replaced. The front door, sliding side
door, and single rear door power lock motors are serviced separately.
Power Door Lock Actuator: Testing and Inspection
Before you proceed with this diagnosis, confirm proper power lock switch, power lock and Remote
Keyless Entry (RKE) module or Central Timer Module (CTM), and power lock switch output circuit
operation. See Power Lock Switch, and Power Lock and Remote Keyless Entry Module or Central
Timer Module in the Diagnosis. Remember, the module circuitry controls the output to each of the
power lock motors.
1. Check each power lock motor for correct operation while moving the power lock switch to both
the Lock and Unlock positions. If all of the power
lock motors are inoperative, go to Step 3. If one power lock motor is inoperative, go to Step 4.
2. If all of the power lock motors are inoperative, the problem may be caused by one shorted motor.
Unplugging a shorted power lock motor from the
power lock circuit will allow the good power lock motors to operate. Unplug each power lock motor
wire harness connector, one at a time, and recheck both the lock and unlock functions by operating
the power lock switch. If all of the power lock motors are still inoperative after the above test, check
for a short or open circuit between the power lock motors and the power lock and RKE module or
the CTM. If unplugging one power lock motor causes the other motor to become functional, go to
Step 4 to test the unplugged motor.
3. Once it is determined which power lock motor is inoperative, that motor can be tested as follows.
Unplug the wire harness connector at the
inoperative power lock motor. Apply 12 volts to the motor terminals to check its operation in one
direction. Reverse the polarity to check the operation in the other direction. If OK, repair the short
or open circuits between the power lock motor and the power lock and RKE module or the CTM as
required. If not OK, replace the faulty power lock motor.
Power Door Lock Actuator: Service and Repair
REMOVAL
Front Door 1. Disconnect and isolate the battery negative cable. 2. Remove the door latch
assembly from the front door.
Front Door Power Lock Motor Remove/Install
3. Remove the screw that secures the power lock motor to the front door latch. 4. Pivot the side of
the power lock motor from which the screw was removed downwards to remove it from the bottom
of the front door latch. 5. Reverse the removal procedures to install. Tighten the mounting screw to
2.2 N.m (20 in. lbs.).
Dual Side/Rear Door On models equipped with dual side or rear doors the power lock motor is
integral to the door latch unit. If the power lock motor is faulty or damaged, the entire door latch unit
must be replaced.
Sliding Side Or Single Rear Door 1. Disconnect and isolate the battery negative cable. 2. Remove
the trim panel from the inside of the door.
Sliding Side Door Power Lock Motor Remove/Install
Single Rear Door Lock Motor Remove/Install
3. Reach through the access hole in the inner door panel to disengage the connecting link from the
power lock motor. 4. Disengage the power lock motor wire harness connector retainer from its
mounting hole and unplug the connector. 5. Remove the screws that secure the power lock motor
mounting bracket to the inner door panel. 6. Remove the power lock motor from the door. 7.
Reverse the removal procedures to install. Tighten the mounting screws to 10 N.m (90 in. lbs.).
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
faulty fuse.
switch as required.
block as required.
as required.
module as required.
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component

INJURY.
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information
> Diagrams

> Diagrams > Page 6160
SYSTEM OPERATION
replaced.
Center
(PDC) as required.
REMOVAL
mirror flag bezel.
Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Description and
Operation
SYSTEM OPERATION
REMOVAL
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >

INJURY.
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module
> Component Information > Testing and Inspection
faulty fuse.
switch as required.
block as required.
as required.
module as required.
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module
> Component Information > Testing and Inspection > Page 6176

INJURY.
Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins
> Child Seat - Tether Anchor Part Numbers & Labor Time
Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time
GROUP: Body
DATE: Nov. 24, 2000

MODELS: 1989 - 1995
1989 - 1994 (AG) Daytona
1989 - 2000 (AN) Dakota
1989 - 1992 (B2) Colt/Summit
1992 - 1995 (B3) Colt Vista
1989 (B5) Conquest
1993 - 1994 (B9) Colt/Summit
1998 - 2000 (DN) Durango

1995 - 2000 (PL) Neon
1997 - 1999 (PR) Prowler
NOTE:

> Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6182
PARTS REQUIRED:

TIME ALLOWANCE:
FAILURE CODE:
Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Description and
Operation
Power Seat Motor: Description and Operation
SYSTEM OPERATION
Power Seat Adjuster And Motors There are three reversible motors that operate the power seat
adjuster. The motors are connected to worm-drive gearboxes that move the seat adjuster through a
combination of screw-type drive units.
The front and rear of a seat are operated by different motors. They can be raised or lowered
independently of each other. When the center seat switch is pushed to the Up or Down position,
both the front and rear motors operate in unison, moving the entire seat up or down. The
forward-rearward motor is operated by pushing the center seat switch to the Forward or Rearward
position.
When a switch is actuated, a battery feed and a ground path are applied through the switch
contacts to the motor(s). The motor(s) and drives operate to move the seat in the selected direction
until the switch is released, or until the travel limit of the power seat adjuster is reached. When the
switch is moved in the opposite direction, the battery feed and ground path to the motor(s) are
reversed through the switch contacts. This causes the motor to run in the opposite direction.
Each motor contains a self-resetting circuit breaker to protect it from overload. Consecutive or
frequent resetting of the circuit breakers must not be allowed to continue, or the motors may be
damaged. Make the necessary repairs.
The power seat adjuster and motors cannot be repaired, and are serviced only as a complete unit.
If any component in this unit is faulty or damaged, the entire power seat adjuster and motors
assembly must be replaced.
Power Seat Motor: Testing and Inspection
Operate the power seat switch to move all three seat motors in each direction. The seat should
move in each of the selected directions. If the power seat adjuster fails to operate in only one
direction, move the adjuster a short distance in the opposite direction and test again to be certain
that the adjuster is not at its travel limit. If the power seat adjuster still fails to operate in only one
direction, see Power Seat Switch in the Diagnosis and Testing. If the power seat adjuster fails to
operate in more than one direction, proceed as follows:
1. Test the circuit breaker in the junction block as described. If OK, Step 3. If not OK, replace the
faulty circuit breaker. 2. Remove the power seat switch from the seat. Check for battery voltage at
the fused B(+) circuit cavity of the power seat switch wire harness
connector. If OK, go to Step 4. If not OK, repair the open circuit to the junction block as required.
3. Check for continuity between the ground circuit cavity of the power seat switch wire harness
connector and a good ground. There should be
continuity If OK, go to Step 5. If not OK, repair the open circuit to ground as required.
4. Test the power seat switch as described. If the switch tests OK, check the wire harness for the
inoperative power seat motor(s) between the power
seat switch and the motor for shorts or opens. If the circuits check OK, replace the faulty power
seat adjuster and motors assembly. If the circuits are not OK, repair the wire harness as required.
Power Seat Motor: Service and Repair
REMOVAL
If the driver side front power seat is in the raised position, it is possible to access and remove the
seat and/or the power seat adjuster and motors assembly without removing the seat riser, go to
Step 7. If the driver side front power seat is not in the raised position, the seat assembly must be
removed from the passenger compartment for service of the power seat adjuster and motors. The
seat assembly includes the seat, the seat adjuster and the seat riser. Proceed as follows:
Seat Riser Rear Shield Remove/Install
2. Remove the four fasteners that secure the lower portion of the rear shield to the seat riser.
Power Seat Adjuster And Motors Remove/Install
3. Unplug the power seat adjuster and seat belt switch wire harness connectors. 4. Remove the
four nuts that secure the seat riser to the studs on the floor panel. The rear nuts are accessed by
lifting up the seat riser rear shield. 5. Remove the seat assembly from the passenger compartment
and place it on a suitable work surface for further service. 6. Remove the four screws that secure
the power seat adjuster and motors assembly to the bottom of the seat cushion frame. 7. Unplug
the wire harness connector between the power seat switch and the power seat adjuster and motors
wire harnesses. 8. Remove the seat cushion frame from the power seat adjuster and motors unit.
9. Remove the four nuts that secure the power seat adjuster and motors unit to the seat riser.
10. Remove the power seat adjuster and motors unit from the seat riser. 11. Reverse the removal
procedures to install. Tighten the seat mounting hardware as follows:
- Seat adjuster to seat cushion frame screws - 22.6 N.m (200 in.lbs.)
- Seat adjuster to seat riser nuts - 22.6 N.m (200 in.lbs.)

Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Description and
Operation
SYSTEM OPERATION
REMOVAL
Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins
> Recalls for Seat Track: > 781 > May > 98 > Recall - Power Seat Riser
Recall - Power Seat Riser
No. 781
May, 1998
To: All Dodge Truck Dealers
Subject: Safety Recall # 781 -- Power Seat Riser
Models: 1998 Model Year Dodge Ram (AB) Vans and Wagons Equipped With a Power Driver's
Seat (Sales Code CDG or JPS) Built Through March 2, 1998 (MDH 030213)
The power driver's seat riser on about 3,600 of the above listed vehicles, may have inadequate
front crossmember spot welds. A seat riser with inadequate welds may allow the front
crossmember to separate from the riser under certain accident conditions. To correct this condition,
the power driver's seat riser must be replaced.
IMPORTANT:
All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer
to whom involved vehicles were invoiced (or the current dealer at the same street address) will
receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification
Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer
reference in arranging for service of involved vehicles.
Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The
customer name, address and phone number is listed if known. Parts information is also provided.
Completed vehicles are removed from Function 53 within several days of repair claim submission.
To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD781".
Parts
IMPORTANT:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will
cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support
customer demand.
Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the
same street address), will receive enough Seat Risers to service about 50% of those vehicles.
Dealers should determine which part is required for each vehicle at the time appointments are
scheduled to assure that the correct part is available when the customer arrives. The appropriate
seat riser for the vehicle to be serviced may be determined by:
^ Using the part code in the third column of the VIN list along with the table shown (involved
dealers):
^ Using the VIN and part number list electronically transmitted to DIAL System Function 53
(involved dealers) or
^ Entering the VIN to the DIAL VIP System (sales code information) along with the table shown (all
dealers).

> Recalls for Seat Track: > 781 > May > 98 > Recall - Power Seat Riser > Page 6205
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule appointments for this service with their dealers. A copy
of the owner notification letter is included.
submitted will be used by Chrysler to record recall service completions and provide dealer
payments.
Labor Operation Time Allowance
Number
Replace power driver's seat riser 23781182 0.4 hours
Note:
Parts Return
Not required.
pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the
reason on a postcard and mail to:
Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757
Following the above procedures will expedite the processing of your claim.
Service Office.
Service Procedure
IMPORTANT:
The battery must be disconnected as the airbag electronic control module (AECM) is located under
the driver's seat.
Note:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
2. Remove the seat belt buckle assembly from the driver's seat riser.
shield to the rear of the driver's seat riser (Figure 1). Set the trim shield aside.
disconnect the connector (Figure 2).
5. Remove the nuts that attach the seat riser to the floor pan (Figure 2).
6. Remove the driver's seat from the vehicle.
7. Remove the nuts that attach the seat riser to the power seat track adjuster (Figure 2). Discard
the seat riser.
8. Install the new seat riser on the power seat track adjuster (Figure 2). Tighten the nuts to 16 ft-lbs
(22 N.m).
9. Install the seat assembly back into the vehicle.
10. Install the nuts that attach the seat riser to the floorpan (Figure 2). Tighten the nuts to 55 ft-lbs
(75 N.m).
11. Connect the power seat wiring harness connector and attach it to the front riser crossmember.
12. Install the seat riser trim shield (Figure 1).
13. Install the seat belt buckle assembly on to the seat riser. Tighten the bolt to 29 ft-lbs (40 N.m).
14. Reconnect the negative battery cable.
Dealer Service Instructions
IMPORTANT
DEALER SERVICE INSTRUCTIONS Safety Recall # 781 -- Power Seat Riser
^ This service requirement applies only to 1998 model year Dodge Ram (AB) vans and wagons
equipped with a power driver's seat (Sales Code -- CDG or JPS) built through March 2, 1998 (MDH
030213).
^ The power driver's seat riser on the above listed vehicles, may have inadequate front
crossmember spot welds. To correct this condition, the power driver's seat riser must be replaced.
^ Dealers are encouraged to consider alternative scheduling and servicing approaches for this
recall. This repair does not require hoists or other full service facility special equipment and is a
CHRYSLER MOBILE SERVICE approved repair.
Parts Packages:
^ Two (2) unique parts are required for this recall depending upon the interior color of the vehicle.
Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough Seat Risers
to service about 50% of those vehicles.
scheduled to assure that the correct part is available when the customer arrives. Refer to the Parts
section for details.
Owner Letter
SAFETY RECALL TO REPLACE YOUR VEHICLE'S POWER DRIVER'S SEAT RISER
Dear Dodge Ram Van or Wagon Owner:
Vehicle Safety Act.
Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in
some 1998 Dodge Ram Vans and Wagons equipped with a power driver's seat.
The problem is...
The power driver's seat riser (seat base) on your Ram van or wagon (identified on the enclosed
form), may have been improperly manufactured and could have inadequate strength. The seat riser
front crossmember may separate from the seat riser. This will cause increased injury to the driver
of the vehicle under certain accident conditions.
What Chrysler and your dealer will do...
Chrysler will repair your Ram van or wagon free of charge (parts and labor). To do this, your dealer
will replace the power driver's seat riser. The work will take about 1/2 hour to complete. However,
additional time may be necessary depending on how dealer appointments are scheduled and
processed.
^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required
If you need help...
If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll
free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If your
dealer fails or is unable to remedy this defect without charge and within a reasonable time, you
may submit a written complaint to the Administrator, National Highway Traffic Safety
Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto
Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 1-202-366-0123.)
> All Technical Service Bulletins for Seat Track: > 781 > May > 98 > Recall - Power Seat Riser
Recall - Power Seat Riser
No. 781
May, 1998
To: All Dodge Truck Dealers
Subject: Safety Recall # 781 -- Power Seat Riser
Models: 1998 Model Year Dodge Ram (AB) Vans and Wagons Equipped With a Power Driver's
Seat (Sales Code CDG or JPS) Built Through March 2, 1998 (MDH 030213)
The power driver's seat riser on about 3,600 of the above listed vehicles, may have inadequate
front crossmember spot welds. A seat riser with inadequate welds may allow the front
crossmember to separate from the riser under certain accident conditions. To correct this condition,
the power driver's seat riser must be replaced.
IMPORTANT:
All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer
to whom involved vehicles were invoiced (or the current dealer at the same street address) will
receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification
Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer
reference in arranging for service of involved vehicles.
Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The
customer name, address and phone number is listed if known. Parts information is also provided.
Completed vehicles are removed from Function 53 within several days of repair claim submission.
To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD781".
Parts
IMPORTANT:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will
cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support
customer demand.
Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the
same street address), will receive enough Seat Risers to service about 50% of those vehicles.
scheduled to assure that the correct part is available when the customer arrives. The appropriate
seat riser for the vehicle to be serviced may be determined by:
^ Using the part code in the third column of the VIN list along with the table shown (involved
dealers):
^ Using the VIN and part number list electronically transmitted to DIAL System Function 53
(involved dealers) or
^ Entering the VIN to the DIAL VIP System (sales code information) along with the table shown (all
dealers).

> All Technical Service Bulletins for Seat Track: > 781 > May > 98 > Recall - Power Seat Riser > Page 6213
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule appointments for this service with their dealers. A copy
of the owner notification letter is included.
submitted will be used by Chrysler to record recall service completions and provide dealer
payments.
Labor Operation Time Allowance
Number
Replace power driver's seat riser 23781182 0.4 hours
Note:
Parts Return
Not required.
pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the
reason on a postcard and mail to:
Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757
Following the above procedures will expedite the processing of your claim.
Service Office.
Service Procedure
IMPORTANT:
The battery must be disconnected as the airbag electronic control module (AECM) is located under
the driver's seat.
Note:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
2. Remove the seat belt buckle assembly from the driver's seat riser.
shield to the rear of the driver's seat riser (Figure 1). Set the trim shield aside.
disconnect the connector (Figure 2).
5. Remove the nuts that attach the seat riser to the floor pan (Figure 2).
6. Remove the driver's seat from the vehicle.
7. Remove the nuts that attach the seat riser to the power seat track adjuster (Figure 2). Discard
the seat riser.
8. Install the new seat riser on the power seat track adjuster (Figure 2). Tighten the nuts to 16 ft-lbs
(22 N.m).
9. Install the seat assembly back into the vehicle.
10. Install the nuts that attach the seat riser to the floorpan (Figure 2). Tighten the nuts to 55 ft-lbs
(75 N.m).
11. Connect the power seat wiring harness connector and attach it to the front riser crossmember.
12. Install the seat riser trim shield (Figure 1).
13. Install the seat belt buckle assembly on to the seat riser. Tighten the bolt to 29 ft-lbs (40 N.m).
14. Reconnect the negative battery cable.
Dealer Service Instructions
IMPORTANT
DEALER SERVICE INSTRUCTIONS Safety Recall # 781 -- Power Seat Riser
^ This service requirement applies only to 1998 model year Dodge Ram (AB) vans and wagons
equipped with a power driver's seat (Sales Code -- CDG or JPS) built through March 2, 1998 (MDH
030213).
^ The power driver's seat riser on the above listed vehicles, may have inadequate front
crossmember spot welds. To correct this condition, the power driver's seat riser must be replaced.
^ Dealers are encouraged to consider alternative scheduling and servicing approaches for this
recall. This repair does not require hoists or other full service facility special equipment and is a
CHRYSLER MOBILE SERVICE approved repair.
Parts Packages:
^ Two (2) unique parts are required for this recall depending upon the interior color of the vehicle.
Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough Seat Risers
to service about 50% of those vehicles.
scheduled to assure that the correct part is available when the customer arrives. Refer to the Parts
section for details.
Owner Letter
SAFETY RECALL TO REPLACE YOUR VEHICLE'S POWER DRIVER'S SEAT RISER
Dear Dodge Ram Van or Wagon Owner:
Vehicle Safety Act.
Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in
some 1998 Dodge Ram Vans and Wagons equipped with a power driver's seat.
The problem is...
The power driver's seat riser (seat base) on your Ram van or wagon (identified on the enclosed
form), may have been improperly manufactured and could have inadequate strength. The seat riser
front crossmember may separate from the seat riser. This will cause increased injury to the driver
of the vehicle under certain accident conditions.
What Chrysler and your dealer will do...
Chrysler will repair your Ram van or wagon free of charge (parts and labor). To do this, your dealer
will replace the power driver's seat riser. The work will take about 1/2 hour to complete. However,
additional time may be necessary depending on how dealer appointments are scheduled and
processed.
^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required
If you need help...
If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll
free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If your
dealer fails or is unable to remedy this defect without charge and within a reasonable time, you
may submit a written complaint to the Administrator, National Highway Traffic Safety
Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto
Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 1-202-366-0123.)
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >

SYSTEM OPERATION
replaced.
Center
(PDC) as required.
REMOVAL
mirror flag bezel.
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
SYSTEM OPERATION
REMOVAL
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
SYSTEM OPERATION
REMOVAL
Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins >
Customer Interest for Weatherstrip: > 23-43-98 > Sep > 98 > Dual Cargo Door - Water Leak Diagnostic/Repair Procedure
Dual Cargo Door - Water Leak Diagnostic/Repair Procedure
NO: 23-43-98
GROUP: Body
DATE: Sep. 18, 1998
SUBJECT:
Dual Cargo Door Water Leak Diagnostic/Repair Procedure
MODELS:
DISCUSSION:
This bulletin is intended to assist in identifying water leak entry points past the dual cargo door
seals by highlighting areas where leaks are likely to occur based on the experience gained during
the development of the vehicle. A thorough water test is required and the test will often readily
show entry points which require repair.
The bulletin is broken down by specific areas and provides illustrations as to where to look in these
areas. The repair methods may vary depending on the situation you encounter but
recommendations are provided for sealing the effected areas.
PARTS REQUIRED:
AR (1) 04773774 Adhesive, Weatherstrip
AR (1) 04318025 Sealant, Silicone Rubber Adhesive
AR (1) 03759944 Retainers
AR (1) 55134553AC Weatherstrip, Side Cargo Door, First Closing Door
AR (1) 55135270AB Weatherstrip, Side Cargo Door, Second Closing Door
AR (1) 55134555AB Weatherstrip, Rear Cargo Door, First Closing Door
AR (1) 55135271AB Weatherstrip, Rear Cargo Door, Second Closing Door
AR (1) NPN Tape, High/Medium Density Closed Cell Foam (3M 06375 Or Equivalent)
AR (1) NPN Tape, Open Cell Foam (3M p/n 62385 Or Equivalent)
Repair Procedure
This bulletin involves locating points of water entry around the cargo doors and sealing the areas
around the weatherstrips or replacing the weatherstrips on the side and/or rear dual cargo doors.
FIRST CLOSING CARGO DOOR (LEFT DOOR - SIDE AND/OR REAR)

Customer Interest for Weatherstrip: > 23-43-98 > Sep > 98 > Dual Cargo Door - Water Leak Diagnostic/Repair Procedure >
Page 6241
1. Inspect the cavity (Figure 1) on the upper inboard corner of the molded detail and top caliper
latch for a small gap. This condition can leak water into the door and/or past the weatherstrip into
the vehicle interior. If a gap is found, clean the area in and around the cavity then, seal the gap with
Mopar Silicone Rubber Adhesive Sealant p/n 04318025.
NOTE:
ALLOW THE SEALANT TO CURE FOR AT LEAST 30 MINUTES BEFORE PERFORMING A

VERIFICATION WATER TEST.
2. Inspect the front lower corner of the weatherstrip seal (Figure 1) to verify seal retention. The seal
is held in place by a retainer. If the retainer is missing, replace it with a new retainer p/n 03759944
or the weatherstrip seal can be secured to the door inner panel with Mopar Weatherstrip Adhesive
p/n 04773774.
3. Any water that may leak into the door will exit out the door through a drain located in the lower
front corner of the door. The weatherstrip seal has a small hole in the seal to allow the water exiting
out of the door drain to pass through the weatherstrip seal. Inspect the drain hole of the
weatherstrip seal for a clear path from the door drain to the bottom of the seal. If the drain hole in
the seal is restricted, open the hole up using a sharp object.
SECOND CLOSING CARGO DOOR (RIGHT SIDE DOOR - SIDE AND/OR REAR)
1. Inspect the weatherstrip seal in the area where the seal passes over the middle and upper
inboard character lines for a gap (Figure 2). A gap at the character lines may allow water to enter
behind the seal and travel down the interior side of the seal and into the interior of the vehicle at the
bottom of the door. If a gap is found, clean the area around the gap then, seal the gap with Mopar
Silicone Rubber Adhesive Sealant p/n 04318025.
NOTE:

Customer Interest for Weatherstrip: > 23-43-98 > Sep > 98 > Dual Cargo Door - Water Leak Diagnostic/Repair Procedure >
Page 6242
2. Inspect the upper portion of the weatherstrip for a seal lip that may be bent over upon door
closing (Figure 2). If the upper portion of the weatherstrip seal is bent over, replace the
weatherstrip seal with p/n 55135270AB if the condition occurs on the side cargo door or p/n
55135271AB if the condition occurs on the rear cargo door. Refer to the appropriate Ram Van
Service Manual Group 23 for information regarding cargo door weatherstrip seal service.
NOTE:
VERIFY THAT THE LIP OF THE NEW WEATHERSTRIP SEAL DOES NOT BEND OVER WHEN
THE DOOR CLOSES. TRIM ANY EXCESS MATERIAL OFF THE LIP OF THE SEAL TO ENSURE
THAT IT WILL NOT BEND OVER WHEN THE DOOR CLOSES.
3. Inspect the weatherstrip seal at the rear lower corner (Figure 2) of the door for a seal that
squeezes out when the door closes. Use a foam stuffer glued to the hollow cavity behind the seal
to repair the condition. The foam stuffer will allow the seal to retain its form. The foam stuffer
should be made from a piece of 1/2 in. thick loose density foam such as 3M p/n 62385 Open Cell
Foam Tape and glued with Mopar Weatherstrip Adhesive p/n 04773774.
ALL CARGO DOORS
1. Inspect the weatherstrip seal at joints between the extruded bulb of the weatherstrip and the
molded detail for wrinkles or other surface irregularities. Replace any weatherstrip seal if wrinkles
or irregularities are found. Refer to the appropriate Ram Van Service Manual Group 23 for
information regarding cargo door weatherstrip seal service. Once the seal has been replaced,
verify that the sealing area of the new seal is smooth.
2. Inspect the backside of the weatherstrip seal at the header of the door (Figures 1 and 2) for a
water leakpath. Either seal the backside of the weatherstrip with Mopar Silicone Rubber Adhesive
Sealant p/n 04318025 or high/medium density foam tape 2-3 mm thick (such as 3M p/n 06375 or
equivalent), cut to 12 mm wide X 630 mm long. If foam tape is used, make sure the ends of the
foam are tapered so that there is no gaps created from the application of the foam tape.
NOTE:

Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Weatherstrip: > 23-43-98 > Sep > 98 > Dual Cargo Door - Water Leak Diagnostic/Repair
Procedure
Dual Cargo Door - Water Leak Diagnostic/Repair Procedure
NO: 23-43-98
GROUP: Body
DATE: Sep. 18, 1998
SUBJECT:
Dual Cargo Door Water Leak Diagnostic/Repair Procedure
MODELS:
DISCUSSION:
This bulletin is intended to assist in identifying water leak entry points past the dual cargo door
seals by highlighting areas where leaks are likely to occur based on the experience gained during
the development of the vehicle. A thorough water test is required and the test will often readily
show entry points which require repair.
The bulletin is broken down by specific areas and provides illustrations as to where to look in these
areas. The repair methods may vary depending on the situation you encounter but
recommendations are provided for sealing the effected areas.
PARTS REQUIRED:
AR (1) 04773774 Adhesive, Weatherstrip
AR (1) 04318025 Sealant, Silicone Rubber Adhesive
AR (1) 03759944 Retainers
AR (1) 55134553AC Weatherstrip, Side Cargo Door, First Closing Door
AR (1) 55135270AB Weatherstrip, Side Cargo Door, Second Closing Door
AR (1) 55134555AB Weatherstrip, Rear Cargo Door, First Closing Door
AR (1) 55135271AB Weatherstrip, Rear Cargo Door, Second Closing Door
AR (1) NPN Tape, High/Medium Density Closed Cell Foam (3M 06375 Or Equivalent)
AR (1) NPN Tape, Open Cell Foam (3M p/n 62385 Or Equivalent)
Repair Procedure
This bulletin involves locating points of water entry around the cargo doors and sealing the areas
around the weatherstrips or replacing the weatherstrips on the side and/or rear dual cargo doors.
FIRST CLOSING CARGO DOOR (LEFT DOOR - SIDE AND/OR REAR)

Procedure > Page 6248
1. Inspect the cavity (Figure 1) on the upper inboard corner of the molded detail and top caliper
latch for a small gap. This condition can leak water into the door and/or past the weatherstrip into
the vehicle interior. If a gap is found, clean the area in and around the cavity then, seal the gap with
Mopar Silicone Rubber Adhesive Sealant p/n 04318025.
NOTE:

2. Inspect the front lower corner of the weatherstrip seal (Figure 1) to verify seal retention. The seal
is held in place by a retainer. If the retainer is missing, replace it with a new retainer p/n 03759944
or the weatherstrip seal can be secured to the door inner panel with Mopar Weatherstrip Adhesive
p/n 04773774.
3. Any water that may leak into the door will exit out the door through a drain located in the lower
front corner of the door. The weatherstrip seal has a small hole in the seal to allow the water exiting
out of the door drain to pass through the weatherstrip seal. Inspect the drain hole of the
weatherstrip seal for a clear path from the door drain to the bottom of the seal. If the drain hole in
the seal is restricted, open the hole up using a sharp object.
SECOND CLOSING CARGO DOOR (RIGHT SIDE DOOR - SIDE AND/OR REAR)
1. Inspect the weatherstrip seal in the area where the seal passes over the middle and upper
inboard character lines for a gap (Figure 2). A gap at the character lines may allow water to enter
behind the seal and travel down the interior side of the seal and into the interior of the vehicle at the
bottom of the door. If a gap is found, clean the area around the gap then, seal the gap with Mopar
Silicone Rubber Adhesive Sealant p/n 04318025.
NOTE:

Procedure > Page 6249
2. Inspect the upper portion of the weatherstrip for a seal lip that may be bent over upon door
closing (Figure 2). If the upper portion of the weatherstrip seal is bent over, replace the
weatherstrip seal with p/n 55135270AB if the condition occurs on the side cargo door or p/n
55135271AB if the condition occurs on the rear cargo door. Refer to the appropriate Ram Van
Service Manual Group 23 for information regarding cargo door weatherstrip seal service.
NOTE:
VERIFY THAT THE LIP OF THE NEW WEATHERSTRIP SEAL DOES NOT BEND OVER WHEN
THE DOOR CLOSES. TRIM ANY EXCESS MATERIAL OFF THE LIP OF THE SEAL TO ENSURE
THAT IT WILL NOT BEND OVER WHEN THE DOOR CLOSES.
3. Inspect the weatherstrip seal at the rear lower corner (Figure 2) of the door for a seal that
squeezes out when the door closes. Use a foam stuffer glued to the hollow cavity behind the seal
to repair the condition. The foam stuffer will allow the seal to retain its form. The foam stuffer
should be made from a piece of 1/2 in. thick loose density foam such as 3M p/n 62385 Open Cell
Foam Tape and glued with Mopar Weatherstrip Adhesive p/n 04773774.
ALL CARGO DOORS
1. Inspect the weatherstrip seal at joints between the extruded bulb of the weatherstrip and the
molded detail for wrinkles or other surface irregularities. Replace any weatherstrip seal if wrinkles
or irregularities are found. Refer to the appropriate Ram Van Service Manual Group 23 for
information regarding cargo door weatherstrip seal service. Once the seal has been replaced,
verify that the sealing area of the new seal is smooth.
2. Inspect the backside of the weatherstrip seal at the header of the door (Figures 1 and 2) for a
water leakpath. Either seal the backside of the weatherstrip with Mopar Silicone Rubber Adhesive
Sealant p/n 04318025 or high/medium density foam tape 2-3 mm thick (such as 3M p/n 06375 or
equivalent), cut to 12 mm wide X 630 mm long. If foam tape is used, make sure the ends of the
foam are tapered so that there is no gaps created from the application of the foam tape.
NOTE:

Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations
Speed Control Servo

Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6254
Speed Control Servo CONN

Cruise Control Servo: Description and Operation
SYSTEM OPERATION
The servo unit consists of a solenoid valve body, a vacuum servo and the mounting bracket. The
Powertrain Control Module (PCM) controls the solenoid valve body. The solenoid valve body
controls the application and release of vacuum to the diaphragm of the vacuum servo. A cable
connects the servo with the throttle linkage. The servo unit cannot be repaired and is serviced only
as a complete assembly
Cruise Control Servo: Testing and Inspection
Speed Control Servo
Procedures. To test the speed control servo only, refer to the following:
The engine must be started and running for the following voltage tests.
1. Start engine. 2. Disconnect 4-way electrical connector at servo. 3. Turn speed control switch to
ON position.
Fig. 4 Servo Harness Connector
4. Check for battery voltage at pin-3 of wiring harness 4-way connector. This is the 12 volt feed
from the stoplamp switch. When the brake pedal is
depressed, voltage should not be present at pin-3. If voltage is not present with brake pedal not
depressed, check for continuity between servo and stop lamp switch. Also check stop lamp switch
adjustment.
5. Connect a small gauge jumper wire between the disconnected servo harness 4-way connector
pin-3, and pin-3 on the servo. Check for battery
voltage at pins-1, 2 and 4 of the servo. If battery voltage is not at these pins, replace the servo.
6. Turn ignition switch to OFF position. Check for continuity between disconnected servo harness
4way connector pin4 and a good ground. There
should be continuity. If not OK, repair open circuit to ground as required.
Cruise Control Servo: Service and Repair
The speed control servo is bolted to the radiator/ grille support under the right headlamp.
REMOVAL 1. Disconnect negative battery cable at battery. 2. Remove engine cover. 4. Disconnect
servo cable at throttle body Refer to Servo Cable Replacement. 5. Remove right headlamp
assembly. Refer to Lighting and Horns/ Headlamp Bulb Replacement Lamps for procedures.
Speed Control Servo Location
6. Disconnect vacuum hose (line) at servo. 7. Disconnect electrical connector at servo. 8. Remove
2 servo mounting bracket bolts.
Servo Cable Clip Remove/Install - Typical
9. Remove 2 mounting nuts holding servo cable sleeve to bracket.
10. Pull speed control cable sleeve and servo away from servo mounting bracket to expose cable
retaining clip and remove clip. Note: The servo
mounting bracket displayed in is a typical bracket and may/may not be applicable to this model
vehicle.
11. Remove servo from mounting bracket.
INSTALLATION 1. Position servo to mounting bracket. 2. Align hole in cable connector with hole in
servo pin. Install cable-to-servo retaining clip. 3. Insert servo mounting studs through holes in servo
mounting bracket. 4. Install servo-to-servo bracket mounting nuts and tighten to 8.5 N.m (75 in.
lbs.) torque.
5. Position servo assembly to body and install 2 bolts. Tighten bolts to 8.5 N.m (75 in. lbs.) torque.
6. Connect vacuum line at servo. 7. Connect electrical connector at servo. 8. Connect servo cable
to throttle body. Refer to Servo Cable Replacement. 9. Before starting engine, operate accelerator
pedal to check for any binding.
10. Install engine cover. 11. Install air cleaner housing. 12. Connect negative battery cable to
battery.
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and
Operation
Cruise Control Servo Cable: Description and Operation
SYSTEM OPERATION
The speed control servo cable is connected between the speed control vacuum servo diaphragm
and the throttle body control linkage. This cable causes the throttle control linkage to open or close
the throttle valve in response to movement of the vacuum servo diaphragm.
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and
Cruise Control Servo Cable: Service and Repair
REMOVAL
1. Disconnect negative battery cable at battery. 2. Remove engine cover. 3. Remove air cleaner
assembly.
Servo Cable Remove/Install
4. Using finger pressure only, remove speed control cable connector at throttle body bellcrank by
pushing connector rearward off the bellcrank pin.
DO NOT try to pull connector off perpendicular to the bellcrank pin. Connector will be broken.
5. Squeeze 2 tabs on sides of speed control cable at throttle body mounting bracket (locking plate)
and push out of bracket. 6. Disconnect servo cable at speed control servo. Refer to Speed Control
Servo Replacement.
INSTALLATION
1. Install end of cable to speed control servo. Refer to Speed Control Servo Replacement. 2. Install
cable into throttle body mounting bracket (snaps in). 3. Install speed control cable connector at
throttle body bell crank pin (snaps on). 4. Before starting engine, operate accelerator pedal to
check for any binding. 5. Install air cleaner assembly Refer to Air Cleaner. 6. Install engine cover.
7. Connect negative battery cable at battery.
Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations

Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6266

SYSTEM OPERATION
is running.

assembly.
REMOVAL


INSTALLATION
Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Description
and Operation
Cruise Control Vacuum Reservoir: Description and Operation
SYSTEM OPERATION
A vacuum reservoir is used to supply the vacuum needed to maintain proper speed control
operation when engine vacuum drops, such as in climbing a grade while driving. A one-way check
valve is used in the vacuum line between the reservoir and the vacuum source. This check valve is
used to trap engine vacuum in the reservoir. On certain vehicle applications, this reservoir is
shared with the heating/air-conditioning system. The vacuum reservoir cannot be repaired and
must be replaced if faulty.
Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Description
Cruise Control Vacuum Reservoir: Service and Repair
Vacuum Reservoir Location
The vacuum reservoir is attached to the right-inner fender located below the right headlamp.
REMOVAL 1. Remove right headlamp assembly. Refer to Lighting and Horn/Headlamp Bulb
Replacement. 2. Disconnect vacuum line at reservoir. 3. The reservoir is attached with one bolt
(upper). The lower ear at bottom of reservoir fits into an access slot on fender support. Remove
mounting
bolt and remove reservoir from vehicle.
INSTALLATION 1. Fit lower reservoir mounting ear into access slot on fender support. 2. Install
upper bolt and tighten to 4 N.m (35 in. lbs.) torque. 3. Install vacuum line at reservoir. 4. Install right
headlamp assembly Refer to Lighting and Horn/Headlamp Bulb Replacement.
Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Solenoid > Component Information > Description and
Operation
Cruise Control Vacuum Solenoid: Description and Operation
SYSTEM OPERATION
When all of the speed control parameters are met, and the SET button is pressed, the PCM
actuates the vent solenoid and "duty-cycles" the vacuum solenoid to open the throttle and bring the
vehicle up to target speed. When the vehicle is at target speed, it will actuate the vent solenoid with
the vacuum solenoid de-activated to maintain the vehicle at target speed. When the vehicle is
above target speed, the PCM will "duty-cycle" the vent solenoid with the vacuum solenoid still
de-activated to close the throttle to return to target speed.
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component


SYSTEM OPERATION
is running.

assembly.
REMOVAL


INSTALLATION
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer -
Cruise Control > Component Information > Description and Operation
Cruise Control > Component Information > Service and Repair > With Four Wheel Antilock Brakes
Brakes
REMOVAL
INSTALLATION
Cruise Control > Component Information > Service and Repair > With Four Wheel Antilock Brakes > Page 6290
Brakes
REMOVAL
sensor stud.
INSTALLATION
Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information
> Service and Repair > With Four Wheel Antilock Brakes
Brakes
REMOVAL
INSTALLATION
> Service and Repair > With Four Wheel Antilock Brakes > Page 6296
Brakes
REMOVAL
sensor stud.
INSTALLATION
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information >
Description and Operation > General Information
ABS Light: Description and Operation General Information
SYSTEM OPERATION
The Anti-Lock Brake System (ABS)lamp gives an indication when the ABS system is faulty or
inoperative. The lamp is controlled by the instrument cluster circuitry based upon messages
received from the Controller Anti-lock Brake (CAB) on the Chrysler Collision Detection (CCD) data
bus. The lamp is turned on by the CAB for about two seconds when the ignition switch is turned to
the On position as a bulb test.
After the bulb test, the CAB turns the lamp on or off based upon the results of the ABS self-tests.
The CAB continually monitors the ABS circuits and sensors to decide whether the system is in
good operating condition. The CAB then sends the proper messages to the instrument cluster on
the CCD data bus to turn the lamp on or off. If the CAB turns the lamp on after the bulb test, it
indicates that the CAB has detected a system malfunction and/or that the ABS system has become
inoperative. If only the amber ABS lamp is illuminated, and the red brake warning lamp remains off,
the base brake system will operate normally.
Each time the instrument cluster circuitry receives a lamp-on message from the CAB, it will light the
lamp for the duration of the ABS malfunction. The CAB will also flash this lamp during the
diagnostic mode, unless a hard fault is present. If a hard fault is present, the ABS lamp will
illuminate without flashing.
ABS Light: Description and Operation Rear Wheel Antilock Brakes
The amber ABS warning lamp is used to alert the driver of an RWAL problem and identify
Diagnostic Trouble Codes (DTCs) stored in the Controller Antilock Brake (CAB's) memory.
ABS Light: Description and Operation Four Wheel Antilock Brakes
The amber ABS warning lamp is located in the instrument cluster. The lamp illuminates at start-up
to perform a self check. The lamp goes out when the self check program determines the system is
operating normal. If an ABS component exhibits a fault the Controller Antilock Brake (CAB) will
illuminate the lamp and register a trouble code in the microprocessor. The lamp is controlled by the
CAB. The CAB controls the lamp sending a message to the instrument cluster.
Testing and Inspection > Pinpoint Tests
ABS Light: Pinpoint Tests
Testing and Inspection > Pinpoint Tests > Page 6306
Testing and Inspection > Pinpoint Tests > Page 6307
ABS Light: Component Tests and General Diagnostics
The diagnosis found here addresses an inoperative Anti-lock Brake System (ABS) lamp condition.
If the ABS lamp stays on with the ignition switch in the On position, or comes on and stays on while
driving.

INJURY.
If the ABS lamp fails to light when the ignition switch is turned to the On position, replace the ABS
lamp bulb with a known good unit. If the ABS lamp still fails to operate, diagnosis of the ABS
system and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan
tool as described in the proper Diagnostic Procedures. For further diagnosis of the ABS lamp and
the instrument cluster circuitry, see Instrument Cluster in the Diagnosis and Testing.
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Steering Column Connector

Audible Warning Device: Diagram Information and Instructions
Introduction
8w-01-002
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

Audible Warning Device: Diagnostic Aids
position
problem

Testing For Voltage
Testing For Voltage


Probing Tool
Chime
Information > Description and Operation > System Operation
Audible Warning Device: Description and Operation System Operation
SYSTEM OPERATION
Central Timer Module A Central Timer Module (CTM) is used on this vehicle when it is equipped
with the optional Vehicle Theft Security System (VTSS). In addition to serving as the security
system module, the CTM combines the functions of a chime/buzzer module, an intermittent wipe
module, an illuminated entry module, and a Remote Keyless Entry (RKE) module in a single unit.
network.
harness complexity, reduce internal controller hardware, and reduce component sensor current
loads. At the same time, this system provides increased reliability, enhanced diagnostics, and
allows the addition of many new feature capabilities.
Intermittent wipe, wipe-after-wash, and speed sensitive intermittent wipe are some of the features
that the CTM supports. The intermittent wipe relay is one of the outputs that the CTM can control.
The CTM is programmed to energize or de-energize the intermittent wipe relay in response to
certain inputs from the windshield wiper and washer switches and from the windshield wiper motor
park switch.
For the speed sensitive intermittent wipe feature, the CTM also uses vehicle speed messages,
which are received on the CCD data bus from the Powertrain Control Module (PCM).
Panel/Central Timer Module Replacement.
procedures manual are recommended. The CTM cannot be repaired and, if faulty or damaged, it
must be replaced.
Information > Description and Operation > System Operation > Page 6334
Audible Warning Device: Description and Operation Chime System Operation
The chime system is built into the CTM. The system also supports an external chime request from
the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM
for gauge problems and tell tale warnings. The CTM chime functions will have priority over the MIC
chime requests. There are two chime rates, Low; 50 chimes per minute for reminders and High;
180 chimes per minute for serious conditions that require immediate attention. The high rate chime
sounds when the key is left in the ignition and the driver door is open or the headlights are left on.
The low rate chime sounds for any of the other conditions. There is a variable rate feature that
allows the chime to sound continuously for the key-in, and headlamp warning; as long as the
driver's door is open. The seat belt warning chime is activated for 4 to 6 seconds, and all other
chime conditions will activate the chime once at the same time the warning light on the cluster is
illuminated.
The chime will sound for the following conditions:
High Rate
- Key in Warning-ignition off, key in ignition, driver's door open
- Ignition off, headlamps on, driver's door open
Low Rate
- Seat belt warning-6 seconds after key on (6 to 8 chimes) or until seatbelt is buckled
- Airbag lamp illuminated (3 times after prove-out)
- ABS lamp illuminated (2 chimes after prove-out if equipped)
- Check engine lamp illuminated (2 chimes after prove-out)
- Check gauges lamp illuminated (2 chimes)
- Engine Temp-High-when gauge enters red zone (2 chimes)
- Low fuel - when fuel level reaches 1/8 tank (2 chimes)
- Low washer fluid (2 chimes)
- Transmission Temperature High (2 chimes)
If the ignition switch is turned to the run/start position and the driver's door is closed, then opened,
the warning chime is defeated. This allows the doors to be open without the warning chime
constantly sounding. The CTM stays in this mode until the ignition switch is turned to the "off"
position, then normal function will be restored.
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Introduction
8w-01-002
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

position
problem

Testing For Voltage
Testing For Voltage


Probing Tool
8w-45-2
8w-45-3
8w-45-4
8w-45-5
8w-45-6
SYSTEM OPERATION
the VTSS.
replaced.
impact.
network.
capabilities.
VTSS.
Control Module/
DRB scan tool.
(VTSS).
faulty fuse.
switch as required.
as required.
information.

INJURY.
REMOVAL
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions
Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark 20 ABS System Test
Revisions
NUMBER: 26-12-97I
Models: 1998 Teves Mark 20 ABS Diagnostic Manual - Publication Number - 81-699-97013
Revisions to the ABS warning lamp test

Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 6370
94
95
Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark IV/Teves Mark 20 ABS
Revisions
NUMBER: 26-12-97F
Models: 1997-1998 Teves Mark IV, Teves Mark 20 ABS Diagnostic Manual - Publication Number -
81-699-97012
Revisions to the ABS warning light procedure

244
245
Information > Description and Operation > General Information
Brake Warning Indicator: Description and Operation General Information
SYSTEM OPERATION
The brake warning lamp gives an indication when the parking brake is applied, when the pressures
in the two halves of the split brake hydraulic system are unequal, if the Anti-lock Brake System
(ABS) lamp has failed and an ABS fault occurs, and during ABS diagnostics. The lamp is turned on
by the instrument cluster circuitry for about two seconds when the ignition switch is moved to the
Start position as a bulb test. After the bulb test, the lamp is controlled by a hard wired input from
the parking brake switch and/or by the instrument cluster circuitry based upon messages received
from the Controller Anti-lock Brake (CAB) on the Chrysler Collision Detection (CCD) data bus.
The CAB turns the lamp on or off based upon the results of the ABS self-tests. The CAB
continually monitors the ABS circuits and sensors, including the brake warning switch and the ABS
lamp, to decide whether the system is in good operating condition. The CAB then sends the proper
messages to the instrument cluster on the CCD data bus to turn the lamp on or off. If the CAB turns
the lamp on after the bulb test, it indicates that the CAB has detected a system malfunction.
The parking brake switch is hard wired to the instrument cluster and closes to ground when the
parking brake is applied. The brake warning switch is hard wired to the CAB and closes to ground
when it senses unequal hydraulic pressures in the two halves of the split brake hydraulic system,
possibly due to low brake fluid level or brake fluid leakage.
After the bulb test, if the red brake warning lamp remains illuminated with the parking brake
released, the base brake system may not be operational. The vehicle should never be operated
while the red brake warning lamp is illuminated.
Information > Description and Operation > General Information > Page 6377
Brake Warning Indicator: Description and Operation Brake Warning Lamp Description
The red brake warning lamp is used to alert the driver of a hydraulic fault or that the parking brake
is applied. For the RWAL system, the red brake warning lamp also is used to alerts the driver of a
problem with the RWAL system.
The brake warning lamp illuminates when a message is sent over the bus to the cluster to
illuminate the bulb. A ground for the bulb is provided when:
- The brakes are applied and the park brake switch is actuated.
- A hydraulic fault has occurred and the pressure differential switch is actuated.
- A RWAL fault has occurred.

Brake Warning Indicator: Testing and Inspection
The diagnosis found here addresses an inoperative brake warning lamp condition. If the brake
warning lamp stays on with the ignition switch in the On position and the parking brake released, or
comes on while driving,

INJURY.
component and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for
battery voltage at the fuse in the junction block. If OK, go to Step 4. If not OK, repair the
Unplug the wire harness connector at the park brake
switch. With the park brake released, check for continuity between the park brake switch terminal
and a good ground. There should be no continuity If OK, go to Step 5. If not OK, adjust or replace
the faulty park brake switch.
4. Remove the instrument cluster. With the park brake switch wire harness connector still
unplugged, check for continuity between the park brake
switch wire harness connector cavity and a good ground. There should be no continuity. If OK, go
to Step 6. If not OK, repair the short circuit as required.
5. Check for continuity between the park brake switch sense circuit cavities of the instrument
park brake switch wire harness connector, There should be continuity. If OK, see Instrument
Cluster in the Diagnosis and Testing for further testing of the brake warning lamp and the
instrument cluster circuitry. If not OK, repair the open circuit as required.
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component
Check Gauges Lamp: Description and Operation
SYSTEM OPERATION
The check gauges lamp gives an indication when certain gauges reflect a condition requiring
immediate attention. The lamp is turned on by the instrument cluster circuitry for about three
seconds after the ignition switch is turned to the On position as a bulb test. After the bulb test, the
lamp is controlled by the instrument cluster circuitry based upon gauge data messages received
from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus.
The PCM uses several inputs to decide what gauge data messages are required. The PCM then
sends the proper message to the instrument cluster on the CCD data bus. When the instrument
cluster circuitry receives a gauge data message that requires the check gauges lamp to be turned
on, it also sends a chime tone request to the Central Timer Module (CTM).
The gauge data messages for which the instrument cluster is programmed to turn on the check
gauges lamp are: -
Engine coolant temperature is high
- Engine oil pressure is low
- System voltage is high or low.

Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component
Check Gauges Lamp: Testing and Inspection
The diagnosis found here addresses an inoperative check gauges lamp condition. If the check
gauges lamp stays on with the ignition switch in the On position, or comes on while driving with no
unusual gauge readings evident, diagnosis of the Powertrain Control Module (PCM) and the
Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool.

INJURY.
If the coolant temperature gauge, oil pressure gauge, or voltmeter are giving an indication that
should trigger the check gauges lamp, but the check gauges lamp still fails to operate, refer to
Instrument Panel/Testing and Inspection for further diagnosis of the check gauges lamp and the
instrument cluster circuitry. See: Instrument Cluster / Carrier/Testing and Inspection
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Cigarette Lighter: Diagram Information and Instructions
Introduction
8w-01-002
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

Cigarette Lighter: Diagnostic Aids
position
problem

Testing For Voltage
Testing For Voltage


Probing Tool
Cigarette Lighter: Description and Operation
SYSTEM OPERATION
A cigar lighter is available equipment on this model. The cigar lighter is installed in the instrument
panel accessory switch plate, which is located near the center of the instrument panel, inboard of
the radio. The cigar lighter base is secured by a clamp on the back of the instrument panel
accessory switch plate.
The cigar lighter consists of two major components: a knob and heating element unit, and the cigar
lighter base or receptacle shell. The receptacle shell is connected to ground, and an insulated
contact in the bottom of the shell is connected to battery current. The cigar lighter receives battery
voltage from a fuse in the junction block only when the ignition switch is in the Accessory or On
positions.
The knob and heating element are encased within a spring-loaded housing, which also features a
sliding protective heat shield. When the knob and heating dement are inserted in the receptacle
shell, the heating element resistor coil is grounded through its housing to the receptacle shell. If the
cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating
dement, and the heating element extends from the housing toward the insulated contact in the
bottom of the receptacle shell.
Two small spring-clip retainers are located on either side of the insulated contact inside the bottom
of the receptacle shell. These clips engage and hold the heating element against the insulated
contact long enough for the resistor coil to heat up. When the heating element is engaged with the
contact, battery current can flow through the resistor coil to ground, causing the resistor coil to
heat.
When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element
causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating
element, the spring-loaded housing forces the knob and heating element to pop back outward to
their relaxed position. When the cigar lighter knob and element are pulled out of the receptacle
shell, the protective heat shield slides downward on the housing so that the heating element is
recessed and shielded around its circumference for safety.
The cigar lighter knob and heating element unit, and the cigar lighter receptacle unit are available
for service. These components cannot be repaired and, if faulty or damaged, they must be
replaced.
Cigarette Lighter: Testing and Inspection

INJURY.
3. Turn the ignition switch to the Off position. Remove the cigar lighter knob and element from the
cigar lighter receptacle. Check for continuity
between the inside circumference of the cigar lighter receptacle and a good ground. There should
be continuity If OK, go to Step 5. If not OK, go to Step 6.
4. Turn the ignition switch to the On position. Check for battery voltage at the insulated contact
located at the back of the cigar lighter receptacle. If
OK, replace the faulty cigar lighter knob and element. If not OK, go to Step 6.
Remove the instrument panel accessory switch plate.
Check for continuity between the ground circuit cavity of the cigar lighter wire harness connector
and a good ground. There should be continuity If OK, go to Step 7. If not OK, repair the open circuit
to ground as required.
voltage at the fused ignition switch output
(run/accessory) circuit cavity of the cigar lighter wire harness connector. If OK, replace the faulty
cigar lighter receptacle. If not OK, repair the open circuit to the junction block fuse as required.
Cigarette Lighter: Service and Repair
REMOVAL

INJURY.
1. Disconnect and isolate the battery negative cable. 2. Remove the accessory switch plate from
the instrument panel. See Accessory Switch Plate Replacement.
3. Pull the cigar lighter knob and element out of the cigar lighter receptacle base. 4. Unscrew the
shell clamp that secures the cigar lighter receptacle base to the back of the accessory switch plate.
5. Pull the cigar lighter receptacle base out from the front of the accessory switch plate. 6. Reverse
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp >
Cruise Control Indicator Lamp: Description and Operation
SYSTEM OPERATION
The cruise-on indicator lamp gives an indication when the vehicle speed control system is turned
on even when the system is not currently engaged. The lamp is turned on by the instrument cluster
circuitry for about two seconds when the ignition switch is turned to the On position as a bulb test.
After the bulb test, the lamp is controlled by the instrument cluster circuitry based upon messages
data bus.
The PCM uses an input from the analog resistor-multiplexed vehicle speed control switches in the
steering wheel to decide whether to turn the lamp on or off. The PCM then sends the proper
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp >
Cruise Control Indicator Lamp: Testing and Inspection
The diagnosis found here addresses an inoperative cruise-on indicator lamp condition. If the
problem being diagnosed is an inaccurate cruise-on indicator lamp, refer to Cruise Control/Vehicle
Speed Control for diagnosis of the vehicle speed control system.

INJURY.
If the cruise-on indicator lamp fails to light during the bulb test (about two seconds after the ignition
switch is turned to the On position), replace the cruise-on indicator lamp bulb with a known good
unit. If the cruise-on lamp still fails to operate, diagnosis of the Powertrain Control Module (PCM)
and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool.
For further diagnosis of the cruise-on indicator lamp and the instrument cluster circuitry, refer to
Instrument Panel/Testing and Inspection. See: Instrument Cluster / Carrier/Testing and Inspection
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air
Bag(s) Arming and Disarming > System Information > Service Precautions
.
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air
Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6416
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams

Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >

Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Fuel Gauge: Description and Operation
SYSTEM OPERATION
The fuel gauge gives an indication of the level of fuel in the fuel tank. The instrument cluster
gauge pointer position based upon fuel level messages received from the Powertrain Control
Module (PCM) on the Chrysler Collision Detection (CCD) data bus.
The PCM uses an input from the fuel gauge sending unit and internal programming to decide what
fuel level messages are required. The PCM then sends the proper messages to the instrument
cluster on the CCD data bus. If the PCM messages indicate that the fuel level is below one-eighth
of a full tank for more than ten seconds (60 seconds if the vehicle speed input is greater than zero
miles-per-hour), the instrument cluster circuitry turns on the low fuel warning lamp and sends a
chime tone request to the Central Timer Module (CTM).
The fuel gauge sending unit is mounted to the electric fuel pump module located inside the fuel
tank. The sending unit has a float attached to the end of a swing-arm. The float moves up or down
within the fuel tank as the fuel level changes. As the float moves, an electrical contact on the pivot
end of the swing-arm wipes across a resistor coil, which changes the internal electrical resistance
of the sending unit.
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Fuel Gauge: Testing and Inspection
If the problem being diagnosed is related to fuel gauge accuracy, be certain to confirm that the
problem is with the gauge or sending unit and not with the fuel tank. Inspect the fuel tank for signs
of damage or distortion that could affect the sending unit performance before you proceed with fuel
gauge diagnosis.

INJURY.
Diagnosis of the fuel gauge sending unit and circuit, the Chrysler Collision Detection (CCD) data
bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For
further diagnosis of the fuel gauge and the instrument cluster circuitry, refer to Instrument
Panel/Testing and Inspection. See: Instrument Cluster / Carrier/Testing and Inspection
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions
Revisions
NUMBER: 26-12-97H
81-699-97027

Information > Technical Service Bulletins > Engine Controls/Fuel System - Service Manual Revisions > Page 6429
29
56
58

412
DESCRIPTION
OPERATION
for procedures.

REMOVAL
plastic fuel
line within module.
INSTALLATION
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service Precautions
.
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service Precautions > Page 6440
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Bulb > Component Information > Description and Operation
Instrument Panel Bulb: Description and Operation
SYSTEM OPERATION
Cluster Illumination Lamp The cluster illumination lamps are hard wired in the instrument cluster.
When the park or head lamps are turned on, the cluster illumination lamps light. Illumination
brightness is adjusted by rotating the headlamp switch knob (clockwise to dim, counterclockwise to
brighten). The instrument cluster illumination lamps receive battery feed from the panel dimmer
rheostat in the headlamp switch through a fuse in the junction block.
Each of the cluster illumination lamps is located on the instrument cluster circuit board. Each lamp
has a replaceable bulb and bulb holder. Refer to Lighting and Horns/Lamps for more information.
Panel Bulb > Component Information > Description and Operation > Page 6444
Instrument Panel Bulb: Testing and Inspection
The diagnosis found here addresses an inoperative instrument cluster illumination lamp condition.
If the problem being diagnosed includes inoperative exterior lighting controlled by the headlamp
switch, that system needs to be repaired first. 1f the exterior lamps controlled by the headlamp
switch are inoperative, refer to Lighting and Horns/Lamps for diagnosis. If no exterior lighting
system problems are found, the following procedure will help locate a short or open in the cluster
illumination lamp circuit.

INJURY.
component as required and replace the faulty fuse. 2. Turn the park lamps on with the headlamp
switch. Rotate the headlamp switch knob counterclockwise to just before the interior lamps detent.
Check for battery voltage at the fuse in the junction block. Rotate the headlamp switch knob
clockwise while observing the test voltmeter. The reading should go from battery voltage to zero
volts. If OK, go to Step 4. If not OK, repair the open circuit to the headlamp switch or refer to
Lighting and Horns/Lamps to diagnose the headlamp switch.
3. Disconnect and isolate the battery negative cable. Remove the instrument cluster. Turn the
headlamp switch off. Remove the fuse from the
junction block. Probe the fused panel lamp dimmer switch signal circuit cavity of the instrument
cluster wire harness connector (connector B). Check for continuity to a good ground. There should
be no continuity If OK, go to Step 5. If not OK, repair the short circuit as required.
4. Reinstall the fuse in the junction block. Connect the battery negative cable. Turn the park lamps
on with the headlamp switch. Rotate the headlamp
switch knob counterclockwise to just before the interior lamps detent. Check for battery voltage at
the fused panel lamp dimmer switch signal circuit cavity of the instrument cluster wire harness
connector (connector B). If OK, replace the faulty bulb(s) and bulb holder(s). If not OK, repair the
open circuit as required.
Panel Bulb > Component Information > Description and Operation > Page 6445
Instrument Panel Bulb: Service and Repair
REMOVAL

INJURY.
1. Remove the instrument cluster from the instrument panel. See Instrument Cluster Replacement.
Cluster Bulb Remove/Install
2. Remove the bulb and bulb holder from the circuit board on the rear of the instrument cluster
housing by turning the holder counterclockwise.
CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or
type may overheat and cause damage to the instrument cluster circuit board and/or the gauges.
3. Reverse the removal procedures to install.

Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component
Low Fuel Lamp/Indicator: Description and Operation
SYSTEM OPERATION
Low Fuel Warning Lamp The low fuel warning lamp gives an indication when the fuel level in the
fuel tank has fallen below about one-eighth of a full tank, as registered on the fuel gauge. The
instrument cluster circuitry lights the lamp for about two seconds when the ignition switch is turned
to the On position as a bulb test. After the bulb test, the instrument cluster circuitry controls the
lamp based upon fuel level and vehicle speed messages received from the Powertrain Control
The PCM uses inputs from the fuel gauge sending unit, the Controller Anti-lock Brake (CAB), and
internal programming to decide what messages are required. The PCM then sends the proper
If the PCM messages indicate that the fuel level is below one-eighth of a full tank for more than ten
seconds, and that the vehicle is not moving, the instrument cluster circuitry turns on the low fuel
warning lamp and sends a chime tone request to the Central Timer Module (CTM). To reduce the
effects of fuel sloshing, if the vehicle speed message indicates that the vehicle is moving, the fuel
level message must remain below one-eighth of a full tank for more than sixty seconds before the
lamp will be illuminated.
The fuel gauge sending unit is mounted to the electric fuel pump module inside the fuel tank. The
sending unit has a float attached to the end of a swing-arm. The float moves up or down within the
fuel tank as the fuel level changes. As the float moves an electrical contact on the pivot end of the
swing-arm wipes across a resistor coil, which changes the resistance of the sending unit.
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component
Low Fuel Lamp/Indicator: Testing and Inspection
The diagnosis found here addresses an inoperative low fuel warning lamp condition. If the problem
being diagnosed is related to lamp accuracy, be certain to confirm the problem is the with the low
fuel warning lamp and not with the fuel gauge circuit. Refer to Instrument Panel, Gauges and
Warning Indicators/Fuel Gauge/Testing and Inspection. If no fuel gauge problem is found, see
Instrument Panel/Testing and Inspection.

INJURY.
If the low fuel warning lamp fails to light during the bulb test (about two seconds after the ignition
switch is turned to the On position), replace the low fuel warning lamp bulb with a known good unit.
If the indicator lamp still fails to operate, diagnosis of the fuel gauge sending unit and circuit, the
Powertrain Control Module (PCM), and the Chrysler Collision Detection (CCD) data bus should be
performed with a DRB scan tool as described in the proper Diagnostic Procedures manual. For
further diagnosis of the low fuel warning lamp and the instrument cluster circuitry, refer to
Instrument Panel/Testing and Inspection. See: Instrument Cluster / Carrier/Testing and Inspection
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component
Data Link Connector
Monitors).
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component
Management/Computers and Control Systems/Testing and Inspection. See: Powertrain
Management/Computers and Control Systems/Testing and Inspection

INJURY.
circuitry, refer to Instrument Panel/Testing and Inspection. See: Instrument Cluster / Carrier/Testing
and Inspection
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Odometer: Description and Operation
SYSTEM OPERATION
The odometer and the trip odometer share the same Liquid Crystal Display (LCD) on the
instrument cluster circuit board. Each gives an indication of the distance the vehicle has travelled.
However, by depressing the reset knob on the face of the instrument cluster, the display mode can
be switched from odometer to trip odometer. Depressing the reset knob for longer than two
seconds while in the trip odometer mode will reset the trip odometer to zero. The odometer and trip
odometer display values are based upon odometer and trip odometer messages received from the
Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus.
The PCM uses a speed pulse input received from the Controller Anti-lock Brake (CAB) and internal
programming to decide what vehicle speed and distance messages are required. The PCM then
sends the proper messages to the instrument cluster circuitry on the CCD data bus. The CAB uses
an input from the rear wheel speed sensor and internal programming, which includes a
programmable pinion factor to compensate for different axle gear ratios and tire sizes, to determine
what speed pulse output is required. The CAB then sends the proper speed pulse to the PCM on a
hard wired circuit.
The instrument cluster stores both the last odometer and last trip odometer distance messages it
receives from the PCM, and displays the proper value based upon ignition key-on and trip
odometer reset knob inputs. If the instrument cluster stops receiving distance messages from the
PCM during its current ignition key-on cycle, the odometer or trip odometer will display the last
distance value that was received. If the instrument cluster has not received any distance messages
from the PCM during its current ignition key-on cycle, the odometer or trip odometer display will
blink.
The rear wheel speed sensor is excited by an exciter ring on the differential case within the rear
axle housing. Incorrect tire size, incorrect axle ratio, an incorrect pinion factor, a faulty or improperly
installed rear wheel speed sensor, a faulty rear axle exciter ring, or a faulty CAB can each result in
inaccurate odometer readings. For diagnosis of the odometer and trip odometer inputs, a DRB
scan tool and the proper Diagnostic Procedures are recommended.
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Odometer: Testing and Inspection
If the problem being diagnosed is related to odometer and/or trip odometer accuracy, be certain to
confirm that the problem is with the display and not with an incorrect pinion factor, axle ratio, or tire
size.

INJURY.
Diagnosis of the rear wheel speed sensor and circuit, the CAB, the Chrysler Collision Detection
(CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB
scan tool. For further diagnosis of the odometer and/or trip odometer and the instrument cluster
circuitry, refer to Instrument Panel/Testing and Inspection. See: Instrument Cluster / Carrier/Testing
and Inspection
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component
SYSTEM OPERATION
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component

INJURY.
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component

Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component
SYSTEM OPERATION
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component

INJURY.
as required.
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions
Introduction
8w-01-002
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 6475
8w-01-003
to function only.
Circuit Function
Page 6476

models.
Circuit Information
Page 6477
IDENTIFICATION

Page 6478
Fasteners
Page 6479
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
Page 6480
wiring.
Symbols
Page 6481
8w-01-006
Take-Outs
Page 6482
Wire Repair
ends of the tubing.
Page 6483
half/component.
Terminal Removal

Page 6484
Diode Replacement
half/component.

Page 6485
Terminal Removal
Wire Repair
Page 6486
ends of the tubing.
affected systems.
Page 6487
connector.
Single Lock Tab
Wiring Repair
Page 6488
Wire Repair
2).
ends of the tubing.
Special Tools

Page 6489
Terminal Pick 6680

Page 6490
position
problem
Testing For Voltage
Testing For Voltage

Page 6491
Page 6492

Probing Tool
Page 6493
8w-45-2
Page 6494
8w-45-3
Page 6495
8w-45-4
Page 6496
8w-45-5
Page 6497
8w-45-6
Audible Warning Device Control Module > Component Information > Diagrams > Page 6498
SYSTEM OPERATION
the VTSS.
replaced.
impact.
network.
capabilities.
VTSS.
Control Module/
DRB scan tool.
(VTSS).
faulty fuse.
switch as required.
as required.
information.

INJURY.
REMOVAL
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component
Seat Belt Reminder Lamp: Description and Operation
SYSTEM OPERATION
The seat belt reminder lamp gives a visual reminder to the vehicle occupants to fasten their seat
belts. The lamp is turned on by the instrument cluster circuitry for about seven seconds when the
ignition switch is turned to the On position.
The instrument cluster also receives a hard wired input from the driver seat belt switch. However,
this input only affects the chime function and has no effect on the seat belt reminder lamp
operation. If the driver seat belt switch is closed (seat belt is not buckled), the instrument cluster will
send a chime request to the Central Timer Module (CTM) lasting the duration of the seat belt
reminder lamp illumination. The chime warning will stop when the driver seat belt switch is open
(seat belt is buckled).
The seat belt reminder lamp also serves as a backup for the airbag indicator lamp. About twenty
seconds after the ignition switch is turned to the On position, if an inoperative airbag indicator lamp
circuit was detected during the bulb test sequence, the instrument cluster circuitry will flash the seat
belt reminder lamp on and off for about thirty seconds. If the seat belt reminder lamp stays on after
flashing for thirty seconds, or comes on at any time other than about twenty seconds after the initial
ignition-on sequence, it indicates an airbag system fault has been detected and that the airbag
indicator lamp is inoperative.
Refer to Air Bags and Seat Belts/Air Bags for more information on the airbag system.
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component
Seat Belt Reminder Lamp: Testing and Inspection
The diagnosis found here addresses an inoperative seat belt reminder lamp condition. If the lamp
comes on and flashes following its display function (about ten seconds after the ignition switch is
turned to the On position), it indicates an inoperative airbag indicator lamp. Refer to Restraint
Systems/Air Bag Systems/Testing and Inspection for additional testing procedures. See: Restraint
Systems/Air Bag Systems/Testing and Inspection

INJURY.
If the seat belt reminder lamp fails to light during its normal display function (about six seconds
after the ignition switch is turned to the On position), see Instrument Cluster in the Diagnosis and
Testing for further diagnosis. This lamp is completely controlled by the instrument cluster circuitry.
On models equipped with a Central Timer Module, the hard wired seat belt switch input to the
instrument cluster has no control over the seat belt reminder lamp function and is only used by the
instrument cluster circuitry as a reference for its chime request function.
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Door Switch > Component Information > Diagrams

> Door Switch > Component Information > Diagrams > Page 6510

> Fuel Gauge Sender > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Service
Manual Revisions
Revisions
NUMBER: 26-12-97H
81-699-97027

Manual Revisions > Page 6515
29
56
58
412
> Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6519
DESCRIPTION
OPERATION
for procedures.

REMOVAL
plastic fuel
line within module.
INSTALLATION
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Speedometer Head: Description and Operation
SYSTEM OPERATION
The speedometer gives an indication of the current vehicle speed. The instrument cluster circuitry
controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge
pointer position based upon vehicle speed messages received from the Powertrain Control Module
(PCM) on the Chrysler Collision Detection (CCD) data bus.
The PCM uses a speed pulse input received from the Controller Anti-lock Brake (CAB) and internal
programming to decide what vehicle speed and distance messages are required. The PCM then
sends the proper messages to the instrument cluster circuitry on the CCD data bus. The CAB uses
an input from the rear wheel speed sensor and internal programming, which includes a
programmable pinion factor to compensate for different axle gear ratios and tire sizes, to determine
what speed pulse output is required. The CAB then sends the proper speed pulse to the PCM on a
hard wired circuit.
The rear wheel speed sensor is excited by an exciter ring on the differential case within the rear
axle housing. Incorrect tire size, incorrect axle ratio, an incorrect pinion factor, a faulty or improperly
installed rear wheel speed sensor, a faulty rear axle exciter ring, or a faulty CAB can each result in
inaccurate speedometer readings. For diagnosis of the speedometer inputs, a DRB scan tool and
the proper Diagnostic Procedures are recommended.
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Speedometer Head: Testing and Inspection
If the problem being diagnosed is related to speedometer accuracy, be certain to confirm that the
problem is with the speedometer gauge and not with an incorrect pinion factor, axle ratio, or tire
size.

INJURY.
Diagnosis of the rear wheel speed sensor and circuit, the CAB, the Chrysler Collision Detection
(CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB
scan tool. For further diagnosis of the speedometer and the instrument cluster circuitry, refer to
Instrument Panel/Testing and Inspection. See: Instrument Cluster / Carrier/Testing and Inspection.
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
SYSTEM OPERATION
data bus.
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
diagnosis.

INJURY.
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) >

Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator,
Engine Cooling > Component Information > Description and Operation
SYSTEM OPERATION
(CTM).
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator,
Engine Cooling > Component Information > Description and Operation > Page 6536
running.

INJURY.
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator
Lamp > Component Information > Description and Operation
Transmission Shift Position Indicator Lamp: Description and Operation
SYSTEM OPERATION
The gear selector indicator gives an indication of the position of the automatic transmission gear
selector lever. The indicator is mounted to the rear of the instrument cluster housing.
The indicator is mechanically actuated by a cable connected to the gear selector indicator driver
lever of the gear selector lever mechanism on the steering column. This covers only the removal
and installation of the gear selector indicator.
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator
Lamp > Component Information > Description and Operation > Page 6540
Transmission Shift Position Indicator Lamp: Service and Repair
REMOVAL

INJURY.
1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster from the
instrument panel. See instrument Cluster Replacement for the procedures.
Gear Selector Indicator Remove/Install
3. Remove the two screws that secure the gear selector indicator mechanism to the rear of the
instrument cluster housing. 4. Remove the gear selector indicator mechanism from the cluster
housing. 5. Place the gear selector lever on the steering column in the Park position. 6. Remove
the knee blocker from the instrument panel. See Knee Blocker Replacement for the procedures.
Gear Selector Indicator Cable Remove/Install
7. Squeeze the latches on the gear selector indicator cable housing retainer and pull the retainer
out of the receptacle on the PRNDL adjuster, located
on the right side of the steering column near the shift lever actuator.
8. Guide the gear selector indicator cable out of the PRNDL adjuster through the slot in the
receptacle. 9. Disengage the loop end of the gear selector indicator cable from the hook on the
shift lever actuator.
10. Remove the gear selector indicator from the instrument panel. 11. Reverse the removal
procedures to install. Tighten the gear selector indicator mounting screws to 2.2 N.m (20 in. lbs.).
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component
Volt Meter Gauge: Description and Operation
SYSTEM OPERATION
The voltmeter gives an indication of the electrical system voltage. The instrument cluster circuitry
controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge
pointer position based upon system voltage messages received from the Powertrain Control
The PCM uses an input from the electrical system and internal programming to decide what system
voltage messages are required. The PCM then sends the proper messages to the instrument
cluster on the CCD data bus. If the PCM messages indicate that the charging system has failed,
the electrical system voltage is less than 11 volts or greater than 16.6 volts, the instrument cluster
circuitry turns on the Check Gauges lamp and sends a chime tone request to the Central Timer
Module (CTM). Refer to Starting and Charging/Charging Systems for more information on the
charging system components and their diagnosis.
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component
Volt Meter Gauge: Testing and Inspection
If the problem being diagnosed is related to voltmeter gauge accuracy, be certain to confirm proper
charging system operation before considering instrument cluster replacement. Refer to Starting
and Charging/Charging System for more information.

INJURY.
Diagnosis of the system voltage input circuit, the Chrysler Collision Detection (CCD) data bus,
further diagnosis of the voltmeter and the instrument cluster circuitry, refer to Instrument
Panel/Testing and Inspection. See: Instrument Cluster / Carrier/Testing and Inspection
Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Service
and Repair
Backup Light Bulb: Service and Repair
REMOVAL
1. Remove the screws attaching the lamp to the vehicle.
Bulb Socket Removal
2. Rotate the bulb socket 1/4 turn counterclockwise to remove it from the housing. 3. Pull the bulb
straight out of the socket to remove it.
INSTALLATION
1. Press bulb into socket and position socket in housing. 2. Rotate the bulb socket 1/4 turn
clock-wise to install in the housing. 3. Position the lamp on the vehicle and install screws.
Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations
Brake Lamp Switch

Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6553
Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and
Operation > General Information
SYSTEM OPERATION
Operation > General Information > Page 6556
GENERAL INFORMATION
switch.
REMOVAL
pedal.
INSTALLATION
mm (0.55 inch).

Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair >
Dome/Cargo Lamp
Cargo Lamp: Service and Repair Dome/Cargo Lamp
REMOVE
1. Using a small flat blade, pry lens from lamp bezel.
Dome/Cargo Lamp
2. Remove screws attaching lamp bezel to roof crossmember mounting brackets. 3. Detach bulb
socket tabs from lamp bezel. 4. Remove lamp bezel.
INSTALLATION
1. Position lamp bezel in headliner opening. 2. Insert bulb socket tabs in lamp bezel. 3. Align lamp
bezel with roof crossmember mounting brackets and install screws. 4. Install the lamp lens.
Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair >
Dome/Cargo Lamp > Page 6564
Cargo Lamp: Service and Repair Dome/Cargo Lamp Bulb
REMOVAL 1. Remove lamp lens. 2. Pull bulb down to remove from socket.
INSTALLATION 1. Push bulb into socket. 2. Install lamp lens.

Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb >
Center Mounted Brake Lamp Bulb: Service and Repair
REMOVAL
1. Remove the two screws holding the lamp assembly to the housing. 2. Pull the lamp straight out
from the roof panel. 3. To remove a bulb socket, turn it counterclockwise and pull out.
CHMSL Bulb Removal
4. Pull the bulb from the socket.
INSTALLATION
1. Position bulb in socket and turn clock-wise. 2. Position lamp on vehicle and install screws.
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information >
Service and Repair
REMOVAL

INJURY.
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information >
Diagrams

Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and
Repair
Dome Lamp Bulb: Service and Repair
Dome Lamp Bulb
REMOVAL 1. Using a small flat blade, pry the left side (driver's side) of the lamp lens downward. 2.
Pull bulb from lamp.
INSTALLATION 1. Install bulb in lamp. 2. Position lens on lamp and snap into place.
Dome/Cargo Lamp Bulb
REMOVAL 1. Remove lamp lens. 2. Pull bulb down to remove from socket.
INSTALLATION 1. Push bulb into socket. 2. Install lamp lens.

Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams

Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 6587

Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Hazard Warning Flasher: Description and Operation
SYSTEM OPERATION
The combination flasher is a smart relay that functions as both the turn signal system and hazard
warning system flasher. The combination flasher contains active electronic Integrated Circuitry (IC)
elements. This flasher is designed to handle the current flow requirements of the factory-installed
lighting. If supplemental lighting is added to the turn signal lamp circuits, such as when towing a
trailer with lights, the combination flasher will automatically try to compensate to keep the flash rate
the same.
While the combination flasher has a International Standards Organization (ISO)-type relay terminal
configuration or footprint, the internal circuitry is much different. The combination flasher does not
use standard 150-relay inputs or provide ISO-relay type outputs or functions. The combination
flasher should never be substituted for an ISO-relay or replaced with an ISO-relay, or else
component and vehicle damage may occur.
Combination Flasher - Typical
The combination flasher has five blade-type terminals intended for the following inputs and outputs:
Battery B+, Ignition B+, Ground, Turn Signal circuit, and Hazard Warning circuit. Constant battery
voltage and ground are supplied to the flasher so that it can perform the hazard warning function,
and ignition switched battery voltage is supplied for the turn signal function.
The IC within the combination flasher contains the logic that controls the flasher operation and the
flash rate. Pin 6 of the IC receives a sense voltage from the hazard warning portion of the
multi-function switch. When the hazard switch is turned on, the "hazard on sense" voltage will
become low due to the circuit being grounded through the turn signal bulbs. This low voltage sense
signals the IC to energize the flash control Positive-Negative-Positive (PNP) transistor at a
pre-calibrated flash rate or frequency Each time the PNP transistor energizes the hazard warning
circuit, the pin 6 "hazard on sense" voltage will become high and the IC signals the PNP transistor
to de-energize the circuit. This cycling will continue until the hazard warning switch is turned off.
Likewise, pin 8 of the IC receives a sense voltage from the turn signal portion of the multi-function
switch. When the left or right turn signal is turned on, the "turn signal on sense" voltage will become
low due to the circuit being grounded through the turn signal bulbs. This low voltage sense signals
the IC to energize the flash control PNP transistor at a precalibrated flash rate or frequency. Each
time the PNP transistor energizes the turn signal circuit, the pin 8 "turn signal on sense" voltage will
become high and the IC signals the PNP transistor to de-energize the circuit. This cycling will
continue until the right or left turn signal is turned off.
A special design feature of the combination flasher allows it to "sense" that a turn signal circuit or
bulb is not operating, and provide the driver an indication of the condition by flashing the remaining
bulbs in the affected circuit at a higher rate (120 flashes-per-minute or higher). Conventional
flashers either continue flashing at their typical rate (heavy-duty type), or discontinue flashing the
affected circuit entirely (standard-duty type). During turn signal operation, the combination flasher
IC compares normal battery voltage input on pin 2 with the shunt resistor voltage input on pin 7. If
the IC "senses" that the voltage difference between pin 2 and pin 7 is different than the
pre-calibrated value of the IC, it will increase the rate at which it signals the PNP transistor to
energize the pin 1 output. Thus, the inoperative half (left or right side) of the turn signal circuit will
flash faster.
Because of the active electronic elements within the combination flasher, it cannot be tested with
conventional automotive electrical test equipment. If the combination flasher is believed to be
faulty; test the turn signal and hazard warning system circuits as described. Then replace the
combination flasher with a known good unit to confirm system operation.
The combination flasher cannot be repaired and, if faulty or damaged, it must be replaced.
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Hazard Warning Flasher: Service and Repair

INJURY.
end of the instrument panel. Refer to Instrument Panel Gauges and Warning Systems/Instrument
Junction Block
3. Unplug the combination flasher from the junction block. 4. Install the combination flasher by
aligning the flasher terminals with the cavities in the junction block and pushing the flasher firmly
into place. 5. Connect the battery negative cable. 6. Test the flasher operation. 7. Reinstall the end
cap on the instrument panel. Refer to Instrument Panel Gauges and Warning Systems/Instrument
Panel/Instrument Panel End Cap
Replacement.
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
SYSTEM OPERATION
- Windshield wipers

INJURY.
connector.
REMOVAL

INJURY.
steering wheel.
upper shroud.
were removed.
stretched.

Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and
Repair
Headlamp Bulb: Service and Repair
REMOVAL
1. Raise the hood and position the support rod.
Headlamp Assembly Removal
2. Press in and pull up on the headlamp release lever to remove the headlight module.
Headlamp Housing And Bulb Removal
3. Pull the headlamp assembly out of headlamp mounting adaptor. 4. Disconnect wire connector
from bulb. 5. Turn the bulb locking ring 1/4 turn counterclockwise and pull back on the ring to
release it. 6
Pull the halogen bulb out of the headlamp housing and remove the retaining ring.
INSTALLATION
CAUTION: Do not touch the bulb glass. Oil from the technicians hands or other sources, such as
oily shop towels, will reduce the operating time of the bulb.
1. Install lock ring over the new Halogen bulb. 2. Connect wire connector.
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and
Repair > Page 6604
Headlamp Bulb Installation
3. Insert the bulb into the headlamp housing 4. turn Lock ring 1/4 turn clock wise to secure bulb 5.
Install headlamp.
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams

Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams >
Page 6608
SYSTEM OPERATION
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams >
Page 6609

INJURY.
Horns/Headlamp
Switch Replacement.

Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams

Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Page 6613
Headlamp Diagnosis
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Page 6614
WARNING:

Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Description and
Operation
Hi-Beam Indicator Lamp: Description and Operation
SYSTEM OPERATION
The headlamp high beam indicator lamp gives an indication when the headlamp high beams are
turned on. The lamp is controlled by a hard wired input from the headlamp dimmer (multi-function)
switch.
One side of the high beam indicator lamp bulb is grounded at all times. The other side of the bulb
receives a battery feed through the contacts of the dimmer switch when the multi-function switch
stalk is actuated to turn on the headlamp high beams. Refer to Lighting and Horns/Lamps for more
information.
Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Description and
Hi-Beam Indicator Lamp: Testing and Inspection
The diagnosis found here addresses an inoperative headlamp high beam indicator lamp condition.
If the problem being diagnosed is related to inoperative headlamp high beams, refer to Lighting and
Horns/Lamps for diagnosis of the headlamp system. If no headlamp system problems are found,
the following procedure will help locate an open in the high beam indicator lamp circuit. For circuit
descriptions and diagrams.

INJURY.
1. Disconnect and isolate the battery negative cable. Remove the instrument cluster. 2. Connect
the battery negative cable.Turn the headlamps on and select the high beams with the multi-function
switch stalk. Check for battery voltage
at the high beam indicator driver circuit cavity of the instrument cluster wire harness connector
(connector B). If OK, replace the faulty bulb. If not OK, repair the open circuit to the splice in the
dimmer switch high beam output circuit of the headlamp and dash wire harness as required.
Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Description and
Operation
SYSTEM OPERATION
information.
ISO relay

INJURY.
Relay Test
Horn Relay
30. if OK,

relay.
Testing.

INJURY.

Junction Block
Panel End
Cap Replacement.
Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations
function.
a unit.
Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 6628
SYSTEM OPERATION
function.
a unit.
Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 6629

INJURY.
Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair >
Driver Side Airbag Trim Cover and Horn Switch
REMOVAL
WARNING:

PERSONAL INJURY.
PERSONAL INJURY.
in the Replacement.
airbag housing.
Driver Side Airbag Trim Cover and Horn Switch > Page 6632
DEPLOYMENT.
cover.

Driver Side Airbag Trim Cover and Horn Switch > Page 6633
.
Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information >
Service and Repair
License Plate Bulb: Service and Repair
REMOVAL - Base And Standard Bumper
1. Remove license plate.
2. Remove lamp.
3. Remove screws attaching lamp lens to housing.
4. Twist out bulb.
INSTALLATION - Base And Standard Bumper
1. Install bulb in socket.
2. Install screws attaching lamp lens to housing.
3. Install lamp.
4. Install license plate.
REMOVAL - Step Bumper
1. Remove lamp.
2. Remove bulb.
INSTALLATION - Step Bumper
1. Install bulb.
2. Position lamp in bumper.
3. Install lamp.
Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and
Repair
Map Light Bulb: Service and Repair
REMOVAL
1. Using a small flatblade, carefully pry middle of lamp lens away from lamp. 2. Pull reflector from
lamp. 3. Push bulb rearward and twist slightly to disengage wire attaching one end of bulb from
terminal. 4. Separate bulb from lamp.
INSTALLATION
1. Position bulb in lamp and engage bulb wire with lamp terminal. 2. Install reflector. 3. Position
lens on bezel and snap into place.
Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service
and Repair
Marker Lamp Bulb: Service and Repair
REMOVAL
1. Raise hood and position support rod. 2. Remove the screws from the sidemarker and turn signal
lamp housing and pull out to disengage the outboard pin clip to remove the housing.
Sidemarker And Turn Signal Bulb Removal
3. To remove the bulb, twist the it 1/4 turn counterclock-wise and remove it from the housing 4. Pull
the bulb straight out of the socket.
INSTALLATION
1. Push the replacement bulb into the socket. 2. Position the bulb in the housing and twist it 1/4
turn clock-wise. 3. Align the outboard pin clip and position the housing on the vehicle. Install the
screws.
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Service and Repair
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay >

SYSTEM OPERATION

INJURY.
Horns/Headlamp
Switch Replacement.

Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
SYSTEM OPERATION
information.
ISO relay

INJURY.
Relay Test
Horn Relay
30. if OK,

relay.
Testing.

INJURY.

Junction Block
Panel End
Cap Replacement.
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Brake Lamp Switch

SYSTEM OPERATION
GENERAL INFORMATION
switch.
REMOVAL
pedal.
INSTALLATION
mm (0.55 inch).

Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component

Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component

Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch >
REMOVAL

INJURY.
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
SYSTEM OPERATION
- Windshield wipers

INJURY.
connector.
REMOVAL

INJURY.
steering wheel.
upper shroud.
were removed.
stretched.

Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >


Headlamp Diagnosis
WARNING:

Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component
function.
a unit.
SYSTEM OPERATION
function.
a unit.

INJURY.
Information > Service and Repair > Driver Side Airbag Trim Cover and Horn Switch
REMOVAL
WARNING:

PERSONAL INJURY.
PERSONAL INJURY.
in the Replacement.
airbag housing.
Information > Service and Repair > Driver Side Airbag Trim Cover and Horn Switch > Page 6697
DEPLOYMENT.
cover.

Information > Service and Repair > Driver Side Airbag Trim Cover and Horn Switch > Page 6698
.
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch >

Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
SYSTEM OPERATION
- Windshield wipers

INJURY.
connector.
REMOVAL

INJURY.
steering wheel.
upper shroud.
were removed.
stretched.

Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and
Repair
Tail Light Bulb: Service and Repair
REMOVAL
Bulb Socket Removal
INSTALLATION
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Turn Signal Flasher: Description and Operation
SYSTEM OPERATION
The combination flasher is a smart relay that functions as both the turn signal system and hazard
warning system flasher. The combination flasher contains active electronic Integrated Circuitry (IC)
elements. This flasher is designed to handle the current flow requirements of the factory-installed
lighting. If supplemental lighting is added to the turn signal lamp circuits, such as when towing a
trailer with lights, the combination flasher will automatically try to compensate to keep the flash rate
the same.
While the combination flasher has a International Standards Organization (ISO)-type relay terminal
configuration or footprint, the internal circuitry is much different. The combination flasher does not
use standard 150-relay inputs or provide ISO-relay type outputs or functions. The combination
flasher should never be substituted for an ISO-relay or replaced with an ISO-relay, or else
component and vehicle damage may occur.
Combination Flasher - Typical
The combination flasher has five blade-type terminals intended for the following inputs and outputs:
Battery B+, Ignition B+, Ground, Turn Signal circuit, and Hazard Warning circuit. Constant battery
voltage and ground are supplied to the flasher so that it can perform the hazard warning function,
and ignition switched battery voltage is supplied for the turn signal function.
The IC within the combination flasher contains the logic that controls the flasher operation and the
flash rate. Pin 6 of the IC receives a sense voltage from the hazard warning portion of the
multi-function switch. When the hazard switch is turned on, the "hazard on sense" voltage will
become low due to the circuit being grounded through the turn signal bulbs. This low voltage sense
signals the IC to energize the flash control Positive-Negative-Positive (PNP) transistor at a
pre-calibrated flash rate or frequency Each time the PNP transistor energizes the hazard warning
circuit, the pin 6 "hazard on sense" voltage will become high and the IC signals the PNP transistor
to de-energize the circuit. This cycling will continue until the hazard warning switch is turned off.
Likewise, pin 8 of the IC receives a sense voltage from the turn signal portion of the multi-function
switch. When the left or right turn signal is turned on, the "turn signal on sense" voltage will become
low due to the circuit being grounded through the turn signal bulbs. This low voltage sense signals
the IC to energize the flash control PNP transistor at a precalibrated flash rate or frequency. Each
time the PNP transistor energizes the turn signal circuit, the pin 8 "turn signal on sense" voltage will
become high and the IC signals the PNP transistor to de-energize the circuit. This cycling will
continue until the right or left turn signal is turned off.
A special design feature of the combination flasher allows it to "sense" that a turn signal circuit or
bulb is not operating, and provide the driver an indication of the condition by flashing the remaining
bulbs in the affected circuit at a higher rate (120 flashes-per-minute or higher). Conventional
flashers either continue flashing at their typical rate (heavy-duty type), or discontinue flashing the
affected circuit entirely (standard-duty type). During turn signal operation, the combination flasher
IC compares normal battery voltage input on pin 2 with the shunt resistor voltage input on pin 7. If
the IC "senses" that the voltage difference between pin 2 and pin 7 is different than the
pre-calibrated value of the IC, it will increase the rate at which it signals the PNP transistor to
energize the pin 1 output. Thus, the inoperative half (left or right side) of the turn signal circuit will
flash faster.
Because of the active electronic elements within the combination flasher, it cannot be tested with
conventional automotive electrical test equipment. If the combination flasher is believed to be
faulty; test the turn signal and hazard warning system circuits as described. Then replace the
combination flasher with a known good unit to confirm system operation.
The combination flasher cannot be repaired and, if faulty or damaged, it must be replaced.
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Turn Signal Flasher: Service and Repair

INJURY.
end of the instrument panel. Refer to Instrument Panel Gauges and Warning Systems/Instrument
Junction Block
3. Unplug the combination flasher from the junction block. 4. Install the combination flasher by
aligning the flasher terminals with the cavities in the junction block and pushing the flasher firmly
into place. 5. Connect the battery negative cable. 6. Test the flasher operation. 7. Reinstall the end
cap on the instrument panel. Refer to Instrument Panel Gauges and Warning Systems/Instrument
Panel/Instrument Panel End Cap
Replacement.
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information >
Turn Signal Indicator: Description and Operation
SYSTEM OPERATION
The left and right turn signal indicator lamps give an indication when the turn signal circuits are
activated. The lamps are hard wired in the instrument cluster, and are completely controlled by the
turn signal and hazard warning (multi-function) switches.
The indicator lamps are grounded at all times and receive battery feed through the contacts of the
multi-function switch when the turn signal lever (multi-function switch stalk) or the hazard warning
button are actuated to their On positions. The instrument cluster circuitry does not perform a bulb
test of these lamps. Refer to Lighting and Horns/Turn Signal and Hazard Warning Systems for
more information.
The turn signal indicator lamps are located in the instrument duster. They flash with the exterior
turn signal lamps to give the driver a visual indication that a turn signal or the hazard warning
system is operating. Refer to Turn Signal Indicator Lamp in Instrument Panel Systems and Lighting
and Horns for diagnosis or service of these lamps.
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information >
Turn Signal Indicator: Testing and Inspection
The diagnosis found here addresses an inoperative turn signal indicator lamp condition. For any
other turn signal problem, refer to Lighting and Horns /Turn Signal and Hazard Warning Systems
for diagnosis.

INJURY.
1. Disconnect and isolate the battery negative cable. Remove the instrument cluster. 2. Connect
the battery negative cable. Activate the hazard warning system by moving the hazard warning
switch button to the On position. Check for
battery voltage at the inoperative (right or left) turn signal circuit cavity of the instrument cluster wire
harness connector (connector B). There should be a switching (on and off) battery voltage signal. If
OK, replace the faulty (right or left) turn signal indicator lamp bulb. if not OK, repair the open circuit
to the turn signal/hazard warning (multi-function) switch as required.
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component
Information > Service and Repair > Tail, Stop, Turn Signal, Back-Up and Side Marker Lamp Bulbs
Turn Signal Bulb: Service and Repair Tail, Stop, Turn Signal, Back-Up and Side Marker Lamp
Bulbs
REMOVAL
Bulb Socket Removal
INSTALLATION
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component
Information > Service and Repair > Tail, Stop, Turn Signal, Back-Up and Side Marker Lamp Bulbs > Page 6727
Turn Signal Bulb: Service and Repair Turn Signal and Side Marker Lamp Bulb
REMOVAL
1. Raise hood and position support rod. 2. Remove the screws from the sidemarker and turn signal
lamp housing and pull out to disengage the outboard pin clip to remove the housing.
Sidemarker And Turn Signal Bulb Removal
3. To remove the bulb, twist the it 1/4 turn counterclock-wise and remove it from the housing 4. Pull
the bulb straight out of the socket.
INSTALLATION
1. Push the replacement bulb into the socket. 2. Position the bulb in the housing and twist it 1/4
turn clock-wise. 3. Align the outboard pin clip and position the housing on the vehicle. Install the
screws.
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information >
SYSTEM OPERATION
- Windshield wipers

INJURY.
connector.
REMOVAL

INJURY.
steering wheel.
upper shroud.
were removed.
stretched.

Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Light Bulb > Component Information >
Service and Repair
Underhood Light Bulb: Service and Repair
REMOVAL
1. Insert a small flat blade in the access slot between the lamp base and lamp lens.
Underhood Lamp Lens
2. Pry the lamp lens upward and remove the lamp lens.
Underhood Lamp Bulb
3. Depress the bulb terminal inward to release the bulb.
INSTALLATION
1. Engage the replacement bulb wire loop to the terminal closest to the lamp base wire connector.
2. Depress the opposite terminal inward and engage the remaining bulb wire loop. 3. Position the
lamp lens on the lamp base and press into place.
Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Service and Repair > Lamp
Replacement
Vanity Lamp: Service and Repair Lamp Replacement
REMOVAL
1. Fold down sunvisor. 2. Starting at the base of the lamp assembly and working right-to-left, use a
small flat blade, carefully pry lamp from visor. 3. Disconnect visor lamp wire connector and remove
from vehicle.
INSTALLATION
1. Position visor lamp at visor and connect visor lamp wire connector. 2. Position visor lamp in visor
and press into place.
Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Service and Repair > Lamp
Replacement > Page 6743
Vanity Lamp: Service and Repair Bulb Replacement
REMOVAL
1. Using a small flat blade, carefully pry each corner of lens outward from lamp. 2. Separate lens
from lamp. 3. Grasp bulb and pull outward.
INSTALLATION
1. Position bulb in socket and push into place. 2. Position lens on lamp and snap into place.
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Heated Glass Element: Diagram Information and Instructions
Introduction
8w-01-002
8w-01-003
to function only.
Circuit Function

models.
Circuit Information
IDENTIFICATION

Fasteners
catalog.
Fuses
the vehicle.
WARNING:

NEUTRAL.
FAN AND BELTS.

CLOTHING.
wiring.
Symbols
8w-01-006
Take-Outs
Wire Repair
ends of the tubing.
half/component.
Terminal Removal

Diode Replacement
half/component.

Terminal Removal
Wire Repair
ends of the tubing.
affected systems.
connector.
Single Lock Tab
Wiring Repair
Wire Repair
2).
ends of the tubing.
Special Tools

Terminal Pick 6680

Heated Glass Element: Diagnostic Aids
position
problem

Testing For Voltage
Testing For Voltage


Probing Tool
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Page
6767
Heated Glass Element: Description and Operation
INTRODUCTION
An electrically heated rear window defogger is optional factory-installed equipment on this model,
when it is equipped with a single rear cargo door.
Rear Window Defogger System The rear window defogger system will only operate when the
ignition switch is in the On position. When the defogger switch is in the On position, an electric
heater grid on the rear window glass is energized. The electric heater grid produces heat to help
clear the rear window glass of ice, snow, or fog.
The defogger system is controlled by a momentary switch that is integral to the heater and air
conditioner control assembly, which is located below the radio in the instrument cluster bezel on
the instrument panel. An amber indicator lamp above the switch will light to indicate when the
defogger system is turned on. The heater and air conditioner control assembly also contains the
defogger system timer and logic circuitry, and an integral defogger relay.
The defogger system will be automatically turned off after a programmed time interval of about ten
minutes. After the initial time interval has expired, if the defogger switch is turned on again during
the same ignition cycle, the defogger system will automatically turn off after about five minutes.
The defogger system will automatically shut off if the ignition switch is turned to the Off position, or
it can be turned off manually by depressing the defogger switch again. Following are general
descriptions of the major components in the rear window defogger system. Refer to the owner's
manual in the vehicle glove box for more information on the features, use and operation of the rear
window defogger system.
SYSTEM OPERATION
Rear Glass Heating Grid The heated rear window glass has two electrically conductive vertical bus
bars and a series of horizontal grid lines made of a silver-ceramic material, which is baked on and
bonded to the inside surface of the glass. The grid lines and bus bars comprise a parallel electrical
circuit.
When the rear window defogger switch is placed in the On position, electrical current is directed to
the rear window grid lines through the bus bars. The grid lines heat the rear window to clear the
surface of fog or snow. Protection for the heating grid circuit is provided by a fuse in the Power
Distribution Center (PDC).
The grid lines and bus bars are highly resistant to abrasion. However, it is possible for an open
circuit to occur in an individual grid line, resulting in no current flow through the line.
The grid lines can be damaged or scraped off with sharp instruments. Care should be taken when
cleaning the glass or removing foreign materials, decals, or stickers from the glass. Normal glass
deaning solvents or hot water used with rags or toweling is recommended. A repair kit is available
to repair the grid lines and bus bars, or to reinstall the heated glass terminals.
Rear Window Defogger System Control The rear window defogger switch, rear window defogger
indicator lamp, rear window defogger mirror electronic timer/control/logic circuitry and rear window
defogger relay are all integral to the heater and air conditioner control assembly, which is located
below the radio in the instrument cluster bezel on the instrument panel. The momentary-type switch
provides a hard wired battery signal to the electronic circuitry each time it is depressed. An amber
rear window defogger indicator lamp above the rear window defogger switch lights to indicate when
the rear window defogger system is turned On.
The rear window defogger electronic timer/control/ logic circuitry responds to the swift input by
energizing or de-energizing the rear window defogger relay. Energizing the rear window defogger
relay provides electrical current to the rear glass heating grid.
The rear window defogger switch, rear window defogger indicator lamp, rear window defogger
electronic timer/control/logic circuitry and rear window defogger relay cannot be repaired. if
damaged or faulty, the entire heater and air conditioner control assembly must be replaced. Refer
to Heater-A/C Control in the Replacement.
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and
Inspection > Detecting Breaks in Rear Window Defogger Grid
Heated Glass Element: Testing and Inspection Detecting Breaks in Rear Window Defogger Grid
To detect breaks in the grid lines, the following procedure is required:
1. Turn the ignition switch to the On position. Set the defogger switch in the On position. The
indicator lamp should light. If OK, go to Step 3. If not
OK, see Rear window Defogger System Control in the Diagnosis and Testing.
2. Using a 12-volt DC voltmeter, contact the vertical bus bar on the right side of the vehicle with the
negative lead. With the positive lead, contact
the vertical bus bar on the left side of the vehicle. The voltmeter should read battery voltage. If OK,
go to Step 4. If not OK, repair the open circuit to the rear window defogger system control as
required.
3. With the negative lead of the voltmeter, contact a good body ground point. The voltage reading
should not change. If OK, go to Step 5. If not OK,
repair the circuit to ground as required.
4. Connect the negative lead of the voltmeter to the right side bus bar and touch each grid line at
midpoint C with the positive lead. A reading of
approximately six volts indicates a line is good. A reading of zero volts indicates a break in the grid
line between midpoint C and the left side bus bar. A reading of ten to fourteen volts indicates a
break between midpoint C and the right side bus bar. Move the positive lead on the grid line
towards the break and the voltage reading will change as soon as the break is crossed.
Inspection > Detecting Breaks in Rear Window Defogger Grid > Page 6770
Heated Glass Element: Testing and Inspection Defogger System Operation Check

INJURY.
The operation of the electrically heated rear window defogger system can be confirmed in one of
the following manners:
1. Turn the ignition switch to the On position. While monitoring the instrument panel voltmeter, set
the defogger switch in the On position. When the
defogger switch is turned On, a distinct voltmeter needle deflection should be noted.
2. Turn the ignition switch to the On position. Set the defogger switch in the On position. The rear
window defogger operation can be checked by
feeling the rear window glass. A distinct difference in temperature between the grid lines and the
adjacent clear glass can be detected within three to four minutes of operation.
Rear Window Glass Grid Test
3. Using a 12-volt DC voltmeter, contact the rear glass heating grid terminal A (right side) with the
negative lead, and terminal B (left side) with the
positive lead. The voltmeter should read battery voltage.
The above checks will confirm system operation. Illumination of the defogger switch indicator lamp
means that there is electrical current available at the output of the rear window defogger logic and
timer circuitry, but does not confirm that the electrical current is reaching the rear glass heating grid
lines.
If the defogger system does not operate, the problem should be isolated in the following manner:
1. Confirm that the ignition switch is in the On position.

Rear Window Defogger System
2. Ensure that the rear glass heating grid feed and ground wires are connected to the glass.
Confirm that the ground wire has continuity to ground, and
that there is continuity between the electrical contacts in the rear door hinge pillar when the rear
door is closed.
3. Check the fuses in the Power Distribution Center (PDC) and in the junction block. The fuses
must be tight in their receptacles and all electrical
connections must be secure.

When the above steps have been completed and the rear glass heating grid is still inoperative, one
or more of the following is faulty:
- Defogger system control
- Rear window grid lines (all grid lines would have to be broken or one of the feed wires
disconnected for the entire system to be inoperative).
If setting the defogger switch to the On position produces a severe voltmeter deflection, check for a
short circuit between the rear window defogger system control output and the rear glass heating
grid.
Heated Glass Element: Testing and Inspection Defogger System Testing

INJURY.
1. Check the fuses in the junction block and the Power Distribution Center (PDC). If OK, go to Step
3. If not OK, repair the shorted circuit or
component as required and replace the faulty fuse.
circuit to the battery as required. 3. Turn the ignition switch to the On position. Check for battery
voltage at the fuse in the junction block. If OK, go to Step 5. If not OK, repair the
4. Disconnect and isolate the battery negative cable. Remove the heater and air conditioner control
from the instrument panel. Refer to Heater-A/C
Control Replacement. Unplug the 4-way rear window defogger switch wire harness connector from
the control. Check for continuity between the ground circuit cavity of the rear window defogger
switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 6.
If not OK, repair the open circuit to ground as required.
the rear window defogger switch wire harness
connector. If OK, go to Step 7. If not OK, repair the open circuit to the fuse in the PDC as required.
output circuit cavity of the rear window defogger
switch wire harness connector. If OK, go to Step 8. If not OK, repair the open circuit to the fuse in
the junction block as required.
Reconnect the 4-way rear window defogger switch
wire harness connector to the heater and air conditioner control. Connect the battery negative
cable. Turn the ignition switch to the On position. Depress and release the rear window defogger
switch. The amber rear window defogger indicator lamp above the switch button should light. If OK,
go to Step 9. If not OK, replace the faulty heater and air conditioner control assembly
8. Back probe the rear defogger relay output circuit cavity of the rear window defogger switch wire
harness connector and check for battery voltage.
If OK, see Rear Glass Heating Grid in the Diagnosis and Testing. If not OK, replace the faulty
heater and air conditioner control assembly.
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Service and Repair
> Rear Glass Heating Grid Repair
Heated Glass Element: Service and Repair Rear Glass Heating Grid Repair
Repair of the rear glass heating grid lines, bus bars, terminals or pigtail wires can be accomplished
using a Mopar Rear Window Defogger Repair Kit (Part Number 4267922) or equivalent.
WARNING: MATERIALS CONTAINED IN THE REPAIR KIT MAY CAUSE SKIN OR EYE
IRRITATION. THE KIT CONTAINS EPOXY RESIN AND AMINE TYPE HARDENER, WHICH ARE
HARMFUL IF SWALLOWED. AVOID CONTACT WITH THE SKIN AND EYES. FOR SKIN
CONTACT, WASH THE AFFECTED AREAS WITH SOAP AND WATER. FOR CONTACT WITH
THE EYES, FLUSH WITH PLENTY OF WATER. DO NOT TAKE INTERNALLY. IF TAKEN
INTERNALLY, INDUCE VOMITING AND CALL A PHYSICIAN IMMEDIATELY. USE WITH
ADEQUATE VENTILATION. DO NOT USE NEAR FIRE OR FLAME. CONTAINS FLAMMABLE
SOLVENTS. KEEP OUT OF THE REACH OF CHILDREN.
1. Mask the repair area so that the conductive epoxy can be applied neatly. Extend the epoxy
application onto the grid line or the bus bar on each side
of the break.
2. Follow the instructions in the repair kit for preparing the damaged area. 3. Remove the package
separator clamp and mix the two conductive epoxy components thoroughly within the packaging.
Fold the package in half
and cut the center corner to dispense the epoxy
4. For grid line repairs, mask the area to be repaired with masking tape or a template. 5. Apply the
epoxy through the slit in the masking tape or template. Overlap both ends of the break by at least
19 millimeters (0.75 inch). 6. For a terminal or pigtail wire replacement, mask the adjacent areas so
the epoxy can be extended onto the adjacent grid line as well as the bus bar.
Apply a thin layer of epoxy to the area where the terminal or pigtail wire was fastened and onto the
adjacent grid line.
7. Apply a thin layer of conductive epoxy to the terminal or bare wire end of the pigtail and place it
in the proper location on the bus bar. To prevent
the terminal or pigtail wire from moving while the epoxy is curing, it must be wedged or damped.
8. Carefully remove the masking tape or template.
CAUTION: Do not allow the glass surface to exceed 204° C (400° F) or the glass may fracture.
9. Allow the epoxy to cure 24 hours at room temperature, or use a heat gun with a 260° to 371° C
(500° to 700° F) range for fifteen minutes. Hold
the heat gun approximately 25.4 centimeters (10 inches) from the repair.
10. After the conductive epoxy is properly cured, remove the wedge or clamp from the terminal or
pigtail wire. Do not attach the wire harness
connectors until the curing process is complete.
11. Check the operation of the rear window defogger glass heating grid.
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Service and Repair
> Rear Glass Heating Grid Repair > Page 6775
Heated Glass Element: Service and Repair Rear Window Defogger
Service procedures for the components used in the rear window defogger system can be found in
the Removal and Installation Procedures, as follows:
- Rear window defogger system control - refer to Heating and Air Conditioning Systems/Heater-A/C
Control Replacement.
- Rear glass heating grid - refer to Stationary Door Glass Replacement.

Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
SYSTEM OPERATION

REMOVAL
mirror flag bezel.
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information >
Power Window Circuit Breaker: Description and Operation
SYSTEM OPERATION

Power Window Circuit Breaker: Testing and Inspection
1. Locate the circuit breaker in the junction block. Pull out the circuit breaker slightly, but be certain
that the circuit breaker terminals still contact the
terminals in the junction block cavities.
required. If the circuit breaker checks OK, but no power windows operate, see Power Window
Power Window Circuit Breaker: Service and Repair
Panel/
Instrument Panel End Cap Replacement.
Junction Block
Panel/ Instrument Panel End
Cap Replacement.
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Front Door Window Motor: Service and Repair
the front door.
Power Window Motor Remove/Install
3. Disengage the power window motor wire harness connector retainer from the mounting hole on
the front door module and unplug the connector. 4. Remove the three screws that secure the
power window motor and mechanism to the front door module. 5. Remove the power window motor
and mechanism from the front door module. 6. Reverse the removal procedures to install. Tighten
the mounting screws to 11 N.m (98 in. lbs.).
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
SYSTEM OPERATION

REMOVAL
mirror flag bezel.
Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Description and Operation
SYSTEM OPERATION
Control Module > Component Information > Description and Operation > Page 6802

INJURY.

Control Module > Component Information > Description and Operation > Page 6803
REMOVAL

INJURY.
Down Replacement.
Relay > Component Information > Diagrams

Relay > Component Information > Diagrams > Page 6807
SYSTEM OPERATION
the Diagnosis.

INJURY.
Relay Test

relay.
required.

INJURY.
Down Replacement.
connector.
place.
Down Replacement.

Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Description and Operation
SYSTEM OPERATION
replaced.
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Description and Operation > Page 6814
REMOVAL
Replacement.
downwards.
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems >
Windshield Washer Switch > Component Information > Description and Operation
SYSTEM OPERATION
Turn signals
- Hazard warning
Switch Replacement.
Windshield Washer Switch > Component Information > Description and Operation > Page 6818

INJURY.
connector.
Windshield Washer Switch > Component Information > Description and Operation > Page 6819
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Description and Operation
SYSTEM OPERATION
Turn signals
- Hazard warning
Switch Replacement.
Switch > Component Information > Description and Operation > Page 6823

INJURY.
connector.
Switch > Component Information > Description and Operation > Page 6824
Wiper Switch: Service and Repair
Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information >
Washer Fluid Level Indicator: Description and Operation
SYSTEM OPERATION
Low Washer Fluid Warning Lamp The low washer fluid warning lamp gives an indication when the
fluid level in the washer fluid reservoir is too low. The instrument cluster circuitry lights the lamp for
about two seconds when the ignition switch is turned to the On position as a bulb test. After the
bulb test, the instrument cluster circuitry controls the lamp based upon a hard wired input from the
washer fluid level sensor.
The washer fluid level sensor uses a float in the washer fluid reservoir to monitor the fluid level.
The up and down action of the float opens or closes the switch within the washer fluid level sensor
that provides a ground signal to the instrument cluster circuitry.
If the instrument cluster circuitry senses a ground input from the washer fluid level sensor for more
than about sixty seconds, it turns on the low washer fluid warning lamp and sends a chime tone
request to the Central Timer Module (CTM). This helps to reduce the effects of fluid sloshing within
the reservoir. This lamp also latches. Once the lamp has been turned on, it will remain on until
washer fluid is added to the reservoir and the ignition switch is cycled.
Refer to Washer Fluid Level Sensor in Wiper and Washer Systems/Wiper and Washer Systems for
more information.
Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information >
SYSTEM OPERATION
replaced.
Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information >
REMOVAL
Replacement.
downwards.
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams
Washer Motor Connector

Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information >
Locations
Washer Reservoir
Windshield Washer Pump: Description and Operation
SYSTEM OPERATION
The washer pump and motor are mounted near the bottom of the washer reservoir. A barbed
nipple on the pump housing passes through a rubber grommet seal installed in a hole near the
bottom of the reservoir. The washer pump is retained by an interference fit between the barbed
pump nipple and the grommet seal, which is a light press fit.
A permanently lubricated and sealed motor is coupled to a rotor-type pump. Washer fluid is
gravity-fed from the reservoir to the pump. When the motor is energized, the pump pressurizes the
washer fluid and forces it through the plumbing to the nozzles.
The washer pump and motor unit cannot be repaired. If faulty, the entire washer pump and motor
unit must be replaced.
Windshield Washer Pump: Service and Repair
REMOVAL
Replacement. 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed
inlet nipple of the washer pump out of the rubber grommet seal
in the reservoir. Care must be taken not to damage the reservoir.
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information >
Locations
Washer Reservoir
Windshield Washer Reservoir: Description and Operation
SYSTEM OPERATION
The windshield washer fluid reservoir is secured to the left radiator closure panel between the
battery and the coolant reserve bottle in the engine compartment. The washer pump and motor unit
has a barbed nipple, which is installed through a rubber grommet seal inserted in a hole near the
bottom of the reservoir. The washer pump is retained by an interference fit between the barbed
nipple and the grommet seal, which is a light press fit.
The washer reservoir has a snap-fit filler cap with a rubber gasket. The cap hinges on and is
secured to a molded-in hook formation on the reservoir body, behind the filler neck. The reservoir
also has a provision for a washer fluid level sensor.
The washer reservoir, grommet seals and filler cap are each available for service.
Windshield Washer Reservoir: Service and Repair
REMOVAL
Washer Reservoir Remove/Install
2. Unplug the wire harness connectors from the washer pump and the washer fluid level sensor.
3. Remove the washer supply hose from the washer pump and drain the washer fluid from the
reservoir into a clean container for reuse.
4. Remove the two screws that secure the top of the washer reservoir to the top of the radiator
closure panel.
5. Lift the washer reservoir upwards far enough to disengage the reservoir mounting tab from the
mounting slot in the lower radiator closure panel.
6. Remove the washer reservoir from the engine compartment.

Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information >
Windshield Washer Spray Nozzle: Description and Operation
SYSTEM OPERATION
Washer Nozzle And Plumbing Pressurized washer fluid is fed through a single hose, attached to a
barbed nipple on the washer pump. The hose is routed to a tee fitting located in the cowl plenum
area, beneath the cowl plenum cover/grille panel.
Hoses from the tee fitting are routed to the lower nipple of an elbow fitting that is snapped onto the
mounting plate of each wiper pivot. The upper nipple of each elbow fitting protrudes above the cowl
plenum cover/grille panel near the wiper pivots.
A hose attached to the upper nipple of each elbow fitting is routed through a spring-like guard to
prevent the hose from kinking. The hose is then routed through a plastic trough like guard snapped
to the underside of each wiper arm to a nipple on the washer nozzle.
The two washer nozzles are snapped onto the wiper arms near the wiper blade and are not
adjustable. Each nozzle emits four streams of washer fluid onto the windshield through the entire
wipe pattern. The nozzles and hose fittings cannot be repaired and, if faulty or damaged, they must
be replaced.
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information >
Windshield Washer Spray Nozzle: Service and Repair
REMOVAL
1. Unsnap the washer nozzle from the wiper arm. 2. Disconnect the washer supply hose from the
barbed washer nozzle nipple. 3. Reverse the removal procedures to install.
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information >
SYSTEM OPERATION
Turn signals
- Hazard warning
Switch Replacement.

INJURY.
connector.
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and
Operation
Wiper Arm: Description and Operation
SYSTEM OPERATION
All Ram van/wagon models have two 47.5-centimeter (19-inch) windshield wiper blades with
non-replaceable rubber elements (squeegees).
These wiper blades include an anti-lift feature. The wiper blades and squeegees must be oriented
correctly when installed on the wiper arms for the anti-lift feature to be effective. See Wiper Blade
in the Removal and Installation for more information.
Caution should be exercised to protect the rubber squeegees from any petroleum-based cleaners
or contaminants, which will rapidly deteriorate the rubber. If the squeegees are damaged, worn, or
contaminated, the entire wiper blade assembly must be replaced.
Wiper squeegees exposed to the elements for a long time tend to lose their wiping effectiveness.
Periodic cleaning of the squeegees is suggested to remove deposits of salt and road film. The
wiper blades, arms, and windshield should be cleaned with a sponge or cloth and windshield
washer fluid, a mild detergent, or a non-abrasive cleaner. If the squeegees continue to streak or
smear, the wiper blades should be replaced.
The blades are mounted to two spring-loaded wiper arms. The spring tension of the wiper arms
controls the pressure applied to the blades on the glass. The windshield wiper arms are secured by
an integral latch to the two wiper pivots on the cowl plenum cover/grille panel at the base of the
windshield.
The wiper arms and blades cannot be adjusted or repaired. If faulty or damaged, they must be
replaced.
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and
Wiper Arm: Service and Repair
CAUTION: The use of a screwdriver or other prying tool to remove a wiper arm may distort it. This
distortion could allow the arm to come off of the pivot shaft, regardless of how carefully it is
installed.
Wiper Arm Remove/Install
1. Lift the wiper arm to permit the latch to be pulled out to its holding position, then release the arm.
The arm will remain off the windshield with the
latch in this position.
2. Slide the spring-like washer hose guard, located near the wiper pivot, up the hose toward the
wiper blade. Then disconnect the washer hose at the
nipple near the wiper pivot.
3. Remove the wiper arm from the pivot using a rocking motion.
Wiper Arm Installation
4. Install the wiper arm and blade with the wiper motor in the Park position. See the Wiper Arm
Installation illustration. 5. Mount the arms on the pivot shafts so that the distance from the lower
edge of the wiper blade tip to the upper edge of the lower windshield
blackout area is: -
65 ± 25 millimeters (2.56 ± 0.98 inches) on the driver side
- 50 ± 25 millimeters (1.97 ± 0.98 inches) on the passenger side.
6. Lift the wiper arm away from the windshield slightly to relieve the spring tension on the latch.
Push the latch into the locked position and slowly
release the arm until the wiper blade rests on the windshield.
7. Reinstall the washer hoses to the nipples near the wiper pivots and slide the hose guards back
into position. 8. Operate the wipers with the windshield glass wet, then turn the wiper switch to the
Off position. Check for the correct wiper arm positioning and
readjust if required.
Dodge 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.
Disclaimer:
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.
Disclaimer:
Wiper Blade: Description and Operation
SYSTEM OPERATION
All Ram van/wagon models have two 47.5-centimeter (19-inch) windshield wiper blades with
non-replaceable rubber elements (squeegees).
These wiper blades include an anti-lift feature. The wiper blades and squeegees must be oriented
correctly when installed on the wiper arms for the anti-lift feature to be effective. See Wiper Blade
in the Removal and Installation for more information.
Caution should be exercised to protect the rubber squeegees from any petroleum-based cleaners
or contaminants, which will rapidly deteriorate the rubber. If the squeegees are damaged, worn, or
contaminated, the entire wiper blade assembly must be replaced.
Wiper squeegees exposed to the elements for a long time tend to lose their wiping effectiveness.
Periodic cleaning of the squeegees is suggested to remove deposits of salt and road film. The
wiper blades, arms, and windshield should be cleaned with a sponge or cloth and windshield
washer fluid, a mild detergent, or a non-abrasive cleaner. If the squeegees continue to streak or
smear, the wiper blades should be replaced.
The blades are mounted to two spring-loaded wiper arms. The spring tension of the wiper arms
controls the pressure applied to the blades on the glass. The windshield wiper arms are secured by
an integral latch to the two wiper pivots on the cowl plenum cover/grille panel at the base of the
windshield.
The wiper arms and blades cannot be adjusted or repaired. If faulty or damaged, they must be
replaced.
Wiper Blade: Service and Repair
NOTE: The notched retainer end of the wiper element should always be oriented towards the end
of the wiper blade that is nearest to the wiper pivot.
1. Turn the windshield wiper switch to the On position. By turning the ignition switch to the On and
Off positions, cycle the wiper blades to a
convenient working location on the windshield.
2. Lift the wiper arm to raise the wiper blade and element off of the windshield glass.
Wiper Blade Remove/Install - Typical
3. To remove the wiper blade from the wiper arm, push the release tab under the arm tip and slide
the blade away from the tip towards the pivot end
of the arm.
4. To install the wiper blade on the wiper arm, slide the blade retainer into the U-shaped formation
on the tip of the wiper arm until the release tab
snaps into its locked position. Be certain that the notched retainer for the wiper element is oriented
towards the end of the wiper blade that is nearest to the wiper pivot.
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Description
and Operation
SYSTEM OPERATION

INJURY.

REMOVAL

INJURY.
Down Replacement.
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Description and
Operation
Wiper Motor: Description and Operation
SYSTEM OPERATION
The two-speed permanent magnet wiper motor has an integral transmission and park switch. The
motor has a rubber-isolated mounting bracket that is secured with screws to a reinforcement with
weld nuts on the engine side of the cowl plenum panel. The wiper motor output shaft and crank
arm passes through a hole in the cowl plenum panel into the cowl plenum area.
Wiper speed is controlled by current flow to the proper set of brushes. The wiper motor completes
its wipe cycle when the windshield wiper switch on the end of the multi-function switch stalk is
turned to the Off position, and parks the blades in the lowest portion of the wipe pattern.
The windshield wiper motor cannot be repaired. If faulty or damaged, the entire wiper motor
assembly must be replaced. The wiper linkage and pivots, and the reinforcement are available for
service.
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Description and
Wiper Motor: Service and Repair
REMOVAL
1. Remove the drive link from the wiper motor crank arm. See Wiper Linkage and Pivot
Replacement for the procedures.
Wiper Motor Remove/Install
3. Unplug the wire harness connector from the wiper motor.
4. Remove the three screws that secure the wiper motor to the cowl plenum panel reinforcement.
5. Remove the wiper motor from the cowl plenum panel.
6. Reverse the removal procedures to install. Tighten the mounting screws to 11.8 N.m (105 in.
lbs.).
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Description
and Operation
Wiper Motor Linkage: Description and Operation
SYSTEM OPERATION
The wiper linkage and pivot module is secured with screws to the cowl top panel beneath the cowl
plenum cover/grille panel. The wiper motor is secured with screws on the engine compartment side
of the cowl plenum panel. The wiper motor output shaft and crank arm are installed through a hole
in the cowl plenum panel into the cowl plenum area, where they are connected to the wiper linkage.
The two wiper pivot crank arms and the wiper motor crank arm each have ball studs on their ends.
The ball stud on the driver side pivot crank arm is longer than the other two ball studs. A
connecting link with a plastic socket-type bushing in the passenger side end, and a plastic
sleeve-type bushing in the driver side end, is fit over the pivot crank arm ball studs to join the two
pivots.
The wiper drive link has a plastic socket-type bushing on each end. One end of the drive link is
snap-fit over the exposed end of the longer driver side pivot ball stud, while the other end is snap-fit
over the ball stud on the wiper motor crank arm.
The wiper linkage, pivots, and bushings are only serviced as a complete unit. If any part of this
assembly is faulty, the entire wiper linkage unit must be replaced. The wiper motor is serviced
separately.
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Description
Wiper Motor Linkage: Service and Repair
1. Remove the wiper arms from the wiper pivots. See Wiper Arm Replacement.
Cowl Plenum Cover/grille Panel Remove/Install
2. Open the hood and remove the screws that secure the cowl plenum cover/grille panel to the
cowl top panel. 3. Using a trim stick or another suitable wide flat-bladed tool, gently pry up on each
end of the cowl plenum cover/grille panel to release the snap clip
retainer that secures it to the cowl top panel.
4. Remove the cowl plenum cover/grille panel from the cowl top.
CAUTION: Do not apply pressure to, or pry on, the plastic drive link bushing. When removing or
installing the drive link to the crank arm, apply pressure to, or pry on, only the metal portions of the
drive link around the bushing. Otherwise, the bushing may be damaged and the linkage rendered
unserviceable.
Wiper Linkage And Remove/Install
5. Remove the wiper linkage drive link from the wiper motor crank arm by prying the drive link
bushing off of the crank arm ball stud. Use two
suitably sized screwdrivers, one on each side of the ball stud, and pry between the crank arm and
the metal portion of the drive link.
6. Gently pry the two washer hose elbow fittings from the pivot mounting flanges. 7. Remove the
four screws that secure the pivot mounting flanges to the cowl top panel. 8. Working through the
cowl top panel access holes, remove the linkage and pivot assembly from the cowl plenum as a
unit.
unserviceable.
9. Reverse the removal procedures to install. Place a short 19 millimeter or 3/4 inch socket over the
capped side of the drive link bushing as a
protective sleeve. Then use channel-lock pliers to reinstall the drive link bushing onto the crank arm
ball stud. Apply pressure with the pliers to the crank arm and the socket. Do not apply pressure
directly to the plastic bushing. Tighten the pivot mounting screws to 11 N.m (95 in. lbs.). Tighten
the cowl plenum cover/ grille panel mounting screws to 2 N.m (17 in. lbs.).
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Description and
Operation
Wiper Pivot: Description and Operation
SYSTEM OPERATION
The wiper linkage and pivot module is secured with screws to the cowl top panel beneath the cowl
plenum cover/grille panel. The wiper motor is secured with screws on the engine compartment side
of the cowl plenum panel. The wiper motor output shaft and crank arm are installed through a hole
in the cowl plenum panel into the cowl plenum area, where they are connected to the wiper linkage.
The two wiper pivot crank arms and the wiper motor crank arm each have ball studs on their ends.
The ball stud on the driver side pivot crank arm is longer than the other two ball studs. A
connecting link with a plastic socket-type bushing in the passenger side end, and a plastic
sleeve-type bushing in the driver side end, is fit over the pivot crank arm ball studs to join the two
pivots.
The wiper drive link has a plastic socket-type bushing on each end. One end of the drive link is
snap-fit over the exposed end of the longer driver side pivot ball stud, while the other end is snap-fit
over the ball stud on the wiper motor crank arm.
The wiper linkage, pivots, and bushings are only serviced as a complete unit. If any part of this
assembly is faulty, the entire wiper linkage unit must be replaced. The wiper motor is serviced
separately.
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Description and
Wiper Pivot: Service and Repair
1. Remove the wiper arms from the wiper pivots. See Wiper Arm Replacement.
Cowl Plenum Cover/grille Panel Remove/Install
2. Open the hood and remove the screws that secure the cowl plenum cover/grille panel to the
cowl top panel. 3. Using a trim stick or another suitable wide flat-bladed tool, gently pry up on each
end of the cowl plenum cover/grille panel to release the snap clip
retainer that secures it to the cowl top panel.
4. Remove the cowl plenum cover/grille panel from the cowl top.
unserviceable.
Wiper Linkage And Remove/Install
5. Remove the wiper linkage drive link from the wiper motor crank arm by prying the drive link
bushing off of the crank arm ball stud. Use two
suitably sized screwdrivers, one on each side of the ball stud, and pry between the crank arm and
the metal portion of the drive link.
6. Gently pry the two washer hose elbow fittings from the pivot mounting flanges. 7. Remove the
four screws that secure the pivot mounting flanges to the cowl top panel. 8. Working through the
cowl top panel access holes, remove the linkage and pivot assembly from the cowl plenum as a
unit.
unserviceable.
9. Reverse the removal procedures to install. Place a short 19 millimeter or 3/4 inch socket over the
capped side of the drive link bushing as a
protective sleeve. Then use channel-lock pliers to reinstall the drive link bushing onto the crank arm
ball stud. Apply pressure with the pliers to the crank arm and the socket. Do not apply pressure
directly to the plastic bushing. Tighten the pivot mounting screws to 11 N.m (95 in. lbs.). Tighten
the cowl plenum cover/ grille panel mounting screws to 2 N.m (17 in. lbs.).
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams

Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 6893
SYSTEM OPERATION
the Diagnosis.

INJURY.
Relay Test

relay.
required.

INJURY.
Down Replacement.
connector.
place.
Down Replacement.

Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and
Operation
SYSTEM OPERATION
Turn signals
- Hazard warning
Switch Replacement.
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and

INJURY.
connector.

Dodge Ram 3500 Van Workshop Manual (V8-360 5.9L VIN 5 Magnum (1998) )

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Keyless Entry Module: Service and Repair

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE

Power Lock And Remote Keyless Entry Module Remove/Install

Keyless Entry Module: Service and Repair

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE

Power Lock And Remote Keyless Entry Module Remove/Install

Distribution Center (PDC) as required.

required and replace the faulty fuse.

OK, go to Step 8. If not OK, repair the connections as required.

Power Door Lock Control Module: Service and Repair

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS BEFORE

Power Lock And Remote Keyless Entry Module Remove/Install

Dealer Service Instructions for:

Safety Recall D20 - ABS Wiring Corrosion

1998-2003 (AB) Dodge Ram Van/Wagon

Completion Reporting and Reimbursement

Dealer Notification and Vehicle list

Vehicle Lists, Global Recall System, VIP and Dealer Follow Up

Owner Notification and Service Scheduling

Customer Services Field Operations DaimlerChrysler Corporation

A. Install Cowl Seal Extension

1. Open the hood.

2. Loosen the battery negative cable clamp pinch-bolt hex nut.

9. Carefully remove the battery from the battery tray.

If no heat damage is found continue with inspection Step b.

C. ABS Control Module Wiring Harness Connector Replacement

D. ABS Control Module Replacement

E. Battery Tray Installation

9. Install the battery onto the new battery tray.

GROUP: Vehicle Performance

DATE: January 21, 2002

SUBJECT: Pinion Factor Recalibration

1998-2002 AB Ram Van

POLICY: Information Only

Dealer Service Instructions for:

Safety Recall D20 - ABS Wiring Corrosion

1998-2003 (AB) Dodge Ram Van/Wagon

Completion Reporting and Reimbursement

Dealer Notification and Vehicle list

Vehicle Lists, Global Recall System, VIP and Dealer Follow Up

Owner Notification and Service Scheduling

Customer Services Field Operations DaimlerChrysler Corporation

A. Install Cowl Seal Extension

1. Open the hood.

2. Loosen the battery negative cable clamp pinch-bolt hex nut.

9. Carefully remove the battery from the battery tray.

If no heat damage is found continue with inspection Step b.

C. ABS Control Module Wiring Harness Connector Replacement

D. ABS Control Module Replacement

E. Battery Tray Installation

9. Install the battery onto the new battery tray.

GROUP: Vehicle Performance

DATE: January 21, 2002

SUBJECT: Pinion Factor Recalibration

1998-2002 AB Ram Van

POLICY: Information Only

GROUP: Vehicle Performance