Dodge Ram (1981) Wiring Diagram

Page 1187

FIGURE 2D - INSTRUMENT PANEL WIRING

4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from
the instrument panel side (Figure 2-C).

Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with
instrument panel overlay harness, PN 4362289.

Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into
the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors
supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch
connectors (Figure 2-C and 2-D).

FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING

5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way
connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main
instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector
(Figure 2-E).

INSTRUMENT PANEL WIRING

Page 473

Power Window Switch Replacement
Disconnect the battery negative terminal. Using a small flat blade screwdriver, carefully pry the

power window switch from the door panel bezel. Remove the wire connector from the power
window switch by carefully prying between the connector and the back of the switch. Install by
pressing the wire connector onto the switch and pressing the switch into the door panel bezel.
Connect the battery negative terminal and test the system for proper operation.

Locations

Cruise Control Module: Locations
Speed Control System Components
LH Side Of Engine Compartment

Page 986

FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER

E. Engine Compartment Fuel Reservoir/Filter Installation

1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill
(from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size
drill).

Wheel Cover - Loose/Falls Off

Wheels: All Technical Service Bulletins Wheel Cover - Loose/Falls Off

Models
1984 D, W & B 250 - 350 Dodge Pick-Up Trucks & Van/Wagons
Subject
Wheel Cover Retention With 16.5 x 6.75 H.D. Wheels
Index
WHEELS & TIRES
Date November 12, 1984
No.
22-01-84
P-4993-C SYMPTOM/CONDITION
A small number of subject vehicles may exhibit a condition of lack of wheel cover/hub cap

retension on one or more of the wheels. The wheel covers/hub caps may not grip the embossment
on the wheel, thus the cover will not stay on. This occurs primarily during installation at new vehicle
pre-delivery. If the above condition occurs, the wheel must be replaced.

PARTS REQUIRED

16.5 x 6.75 H.D. Wheel PN 4284446
NOTE: REPLACED WHEELS MUST BE RETURNED TO THE MATERIAL RETURN CENTER.
POLICY: Reimbursable within the provisions of the warranty
TIME ALLOWANCE: Labor Operation No.

22-40-01-02 . . . . . . . . . . . 0.6 Hrs.

FAILURE CODE: HR - Improper Retention

Page 871

Oil Pressure Gauge: Description and Operation

CONSTANT VOLTAGE REGULATOR (CVR) TYPE
This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil

pressure gauge and a sending unit which are connected in series. The sending unit consists of a
diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm
actuated the contact on the variable resistor, in turn controlling current flow to the gauge. When oil
pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge,
in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor
is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge
reading.

TROUBLESHOOTING
A special tester is required to diagnose this type gauge. Follow instructions included with the tester.

Page 1468

FIGURE 2D - INSTRUMENT PANEL WIRING
FIGURE 2F - INSTRUMENT PANEL WIRING

6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN
4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F).

Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it
clear of any possible interferences.

Only one of the following installation procedures (Step 7) will be used. Take notice of which one
applies to the vehicle being repaired.

7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291
a. Remove instrument panel hood and bezel assembly and remove radio.

Page 1185

4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine
wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B).

FIGURE 1C - ENGINE COMPARTMENT WIRING

5. Route and secure the engine overlay harness, PN 4362295, along the existing
headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring
clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine
overlay harness.

FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE)

6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar
multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead
connector (Figure 1-D).

B.Instrument Panel Harnesses Pn 4362289, All Models

Page 2621

Universal Joint: Service and Repair Cross & Roller Type

Fig. 3 Cross & roller type universal joints
Fig. 4 Cross & roller type universal joints & propeller shaft
Illustrations show typical examples of universal joints of this type. They all operate on the same

principle and similar service and replacement

Page 3826

FIGURE 3-A

Page 3180

Fig. 12 Using driving & adapter to install seal cup into knuckle. 44 FBJ Units w/disc brakes. Models
w/full time 4WD

Fig. 13 Tools in place after seal cup is installed. 44 FBJ Units w/disc brakes. Models w/full time
4WD

Fig. 15 Forming a seal on bearing retainer face. 44 FBJ Units w/disc brakes. Models w/full time
4WD

Fig. 16 Bearing retainer positioned with grease fitting facing forward. 44 FBJ Units w/disc brakes.
Models w/full time 4WD

Page 196

Coolant Temperature Sensor/Switch (For Computer): Locations

Engine Mounted Switches & Sensors.
Upper LH Side Of Engine

Page 1660

FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION
b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the

chassis tube (Figure 4-B), and clamp with PN 6500651 at each end.
c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6".
d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4".

e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and
install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN
6500651 at each end.

CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8"
RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE
KINKING.

NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO
CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F.

f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet
tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end.

4. On 4 x 4 Models
a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis

tube, and clamp with PN 6500650 at each end.

Page 9

Power Door Lock Relay: Testing and Inspection

To test the relay, move either of the front lock knobs to the lock and unlock positions. An audible
clicking sound should be heard from under the dash near the steering column support. If the sound
is heard while operating one knob but not the other, a defective switch or wiring may be at fault. If a
clicking sound is not heard, locate the relay and test as follows:

1. Check for power by back probing the LG wire at the relay.
^ If power is present, go to step 2.
^ If power is not present, check the circuit breaker and the wire between the relay and the circuit

breaker.

2. Back probe the OR wire at the relay and move the lock knob to the lock position. Battery voltage
should be momentarily present, indicating that

the relay operates in the lock position. ^
If power is present go to step 4.
^ If power is not present, go to step 3.

3. Backprobe the VT wire and move the lock knob to the lock position.
^ If power is present, the relay is defective.
^ If power is not present, the door switch or wiring may be defective.

4. Backprobe the LB wire at the relay and move the lock knob to the unlock position. Battery
voltage should be momentarily present, indicating that

the relay operates in the unlock position. ^
If power is present, the relay is operating properly.
^ If power is not present, go to step 5.

5. Backprobe the LG wire and move the lock knob to the unlock position.
^ If power is present, the relay is defective.
^ If power is not present, the door switch or wiring may be defective.

Specifications

Page 3476

Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons

Adjustments

Fig. 2 Transfer case shifter assembly and linkage adjustment. 1984 NP-208

Page 3743

Fig. 37 Oil Lamp With Gauge Cluster Wiring Circuit. 1984

Page 614

FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM

5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall
engine compartment half of bulkhead connector and torque bolt to 40 inch pounds.

NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM

Page 1480

FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER
WINDOWS

Page 2594

yoke and result in propshaft imbalance or knocking of the slip yoke plug.)

9. Install the boot on the driveshaft and the clamp, using Miller Tool #C-4653 as follows:
a. Wrap binding strap around boot twice, plus 63 mm (2-1/2 inches).
b. Pass the strap through the buckle and fold it back about 29 mm (1-1/8 inches) on the inside of

the buckle.
c. Put the strip around the boot with the eye of the buckle toward you. Wrap the strip around the

boot once and pass it through the buckle, then wrap it around a second time also passing it through
the buckle.

d. Fold the strip back slightly to prevent it from slipping backwards.
e. Open the tool all the way and place strip in narrow slot approximately 13 mm (1/2 inch) from

buckle.
f. Hold the binding strip with the left hand and push the tool forward and slightly upward. Then fit

the hook of the tool into the eye of the buckle.
g. Tighten the strip by closing the tool handles. Then rotate the tool (handles) downward while

slowly releasing the pressure on the tool handles. Allow the tool (handles) to open progressively.
Then open the tool entirely and remove them sideways.

h. If the strap is not tight enough, re-engage the tool a second or even a third time, always about 13
mm (112 inch) from the buckle. When tightening always be careful to see that the strap slides in a
straight line and without resistance in the buckle, that is without making a fold. An effective grip will
be obtained only by following the above instructions.

10. Install the slip yoke on the driveshaft. (Make sure universal joints are placed properly.)

11. Install boot and second clamp on the slip yoke with the splined stub extended approximately

1.5" from the fully collapsed position, and the boot vented at this position before installing the
clamp, using the same procedure as in Step 9.

12. Install driveshaft in truck.
Road test vehicle to assure that "clunk" or "snap" is corrected.
Advise the customer that it is no longer necessary to lubricate the slip yoke.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
16-30-10-91 0.8 Hrs.
FAILURE CODE: 07 - Binds, Sticks or Seized

Page 1663

TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule

Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs.

14-70-17-50 - Add with Carter . . . . . 0.4 Hrs.

Thermoquad Carburetor
FAILURE CODE: AM - Authorized Modification
Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks
PARTS LIST
VAPOR LOCK PACKAGE
1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK
PACKAGE PART NO. 4364384
QTY. PART NAME
PART NO.
1 Gauge/Pump Unit Assembly
4075484
1 Engine Compartment Wiring Harness 4362295
1 Instrument Panel Wiring Harness 4362284
1 Body Wiring Harness 4362286
1 Control Module 5226640
20 Tie Wrap 6015756
1 10-Amp Fuse 6101135
1 Fuel Reservoir/Filter & Bracket Assembly 4418012
1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968
5 Hose Clamp 5/16" 6500651
3 Hose Clamp 1/4" 6500650
2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777
1 Template (4 x 4) 4418013
2 Hose - 5/16" x 8" Long 4203576
1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005
2 Convolute Tubing - 6" Long 4279993
1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042
1 Template (4 x 2) 1987 Vehicles Only 4418412
1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967

1 Seal - Fuel Tank Gauge 4185002
1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761*
*It may be necessary to order clamp separately on early released packages. PARTS LIST
VAPOR LOCK PACKAGE
1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK
PACKAGE PART NO. 4364385
QTY. PART NAME PART NO.
1 Gauge/Pump Unit Assembly 4075485
1 Engine Compartment Wiring Harness 4362295
1 Instrument Panel Wiring Harness 4362284
1 Body Wiring Harness 4362286
1 Control Module 5226640
20 Tie Wrap 6015756
1 10-Amp Fuse 6101135
1 Fuel Reservoir/Filter & Bracket Assembly 4418012
1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968

Page 71

FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER
WINDOWS

5. For all vehicles except those which require a 78 amp alternator package:
Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque

bolt to 40 inch pounds.
NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS.
E.Engine Compartment Fuel Reservoir/Filter Lnstallation

Battery: Mechanical Specifications

Page 2945

Optional Battery
Optional Battery
BCI Group Number 24

Cranking Performance 500 A

Standard Battery
Standard Battery
BCI Group Number 25

Cranking Performance 370 A

Locations

Power Window Relay: Locations
Door Lock And Power Window Circuit Breaker And Relays Location
The relay is located behind the dash panel, to the left of the glove box.

Page 3591

FIGURE 1-C - ENGINE COMPARTMENT WIRING

5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar
multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead
connector (Figure 1-C).

FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE)
B. Instrument Panel Harness PN 4362284

1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the
instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below:

a. Grey with black tracer wire into cavity #11.
b. Dark green wire into cavity #12.
FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL

WIRING)

Page 3057

Fuse: Service and Repair
Circuit Breaker/Fuse Replacement
Door Lock And Power Window Circuit Breaker And Relays Location
Disconnect the battery negative terminal. Remove the two wires from the circuit breaker and

remove the circuit breaker from its mounting clip. Install new circuit breaker to the mounting clip
and connect the two wires. Connect the battery negative terminal and test power door lock system
for proper operation.

Specifications

Diagram Information and Instructions

Intake Air Temperature Switch: Diagram Information and Instructions
Symbol Identification
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.

Page 3862

heated rear window defroster.
Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire

and hose routing.

11. Reinstall engine cover.
F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure

Regulator Package Installation (Pn 4397
FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION

1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake
manifold) and discard.

2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2)
self-tapping screws supplied, PN 6033066 (Figure 5).

NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET.

3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure
regulator assembly using the screw and washer, PN 6O22254, (Figure 5).

NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS
LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND
DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE
REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED
SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT.

CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE
AREA.

Page 3657

TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule

Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs.

14-70-17-50 - Add with Carter . . . . . 0.4 Hrs.

Thermoquad Carburetor
FAILURE CODE: AM - Authorized Modification
Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks
PARTS LIST
VAPOR LOCK PACKAGE
1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK
PACKAGE PART NO. 4364384
QTY. PART NAME
PART NO.
1 Gauge/Pump Unit Assembly
4075484
1 Engine Compartment Wiring Harness 4362295
1 Instrument Panel Wiring Harness 4362284
1 Body Wiring Harness 4362286
1 Control Module 5226640
20 Tie Wrap 6015756
1 10-Amp Fuse 6101135
1 Fuel Reservoir/Filter & Bracket Assembly 4418012
1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968
5 Hose Clamp 5/16" 6500651
3 Hose Clamp 1/4" 6500650
2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777
1 Template (4 x 4) 4418013
2 Hose - 5/16" x 8" Long 4203576
1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005
2 Convolute Tubing - 6" Long 4279993
1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042
1 Template (4 x 2) 1987 Vehicles Only 4418412
1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967

1 Seal - Fuel Tank Gauge 4185002
1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761*
*It may be necessary to order clamp separately on early released packages. PARTS LIST
VAPOR LOCK PACKAGE
1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK
PACKAGE PART NO. 4364385
QTY. PART NAME PART NO.
1 Gauge/Pump Unit Assembly 4075485
1 Engine Compartment Wiring Harness 4362295
1 Instrument Panel Wiring Harness 4362284
1 Body Wiring Harness 4362286
1 Control Module 5226640
20 Tie Wrap 6015756
1 10-Amp Fuse 6101135
1 Fuel Reservoir/Filter & Bracket Assembly 4418012
1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968

Upholstery - Cleaning Procedure

Seats: Technical Service Bulletins Upholstery - Cleaning Procedure

Models
All ChryslerPlymouth & Dodge Vehicles
Subject
Cloth Seat Cleaning Procedure
Index
BODY
Date
February 6, 1989
No.
23-03-89
P-367 (C23-02-9) The following is the recommended procedure for the cleaning of soiled cloth seat

upholstery. Use of improper cleaning materials or procedures may result in swelling or deterioration
of foam, discoloration of fabric, or loosening the bond between the seat fabric and foam.

NOTE: USE ONLY THE APPROVED MOPAR CLEANERS OR EQUIVALENT OR A MILD SOAP
SOLUTION.

PARTS REQUIRED
Super Kleen PN 4318015
or
Total Clean PN 4318019
REPAIR PROCEDURE

1. Apply approved cleaner to soiled area with cloth after wringing out excess cleaner.

2. Do not soak upholstery, even with recommended cleaners.

3. Wipe soiled area with a lifting motion.

4. Wipe off immediately with a clean, dry towel or rag.
NOTE: DO NOT USE CARPET TYPE CLEANING APPARATUS THAT BLOWS IN SOLVENT OR

STEAM, NOR ANY HOUSEHOLD CLEANERS NOT SPECIFICALLY RECOMMENDED FOR
CLOTH UPHOLSTERY.

POLICY: Information only

Page 2554

Axle Shaft: Technical Service Bulletins Differential Gear/Axle Shaft - C Lock Revision
Models
1984 Domestic Trucks, Vans & Wagons Equipped With 9-1/4 Rear Axle
Subject

Revised "C" Lock, Differential Gear & Axle Shaft
Index
REAR AXLE
Date
November 5, 1984
No.
03-02-84
P-4912-C
FIGURE 1
FIGURE 2
A revised rear axle assembly with larger axle "C" locks entered production on February 12, 1984

(Figure 1). The corresponding axle shafts and differential side gears were changed to
accommodate the larger "C" locks. Axle assemblies built with the larger "C" locks and components
are identified with the letter "X" stamped as shown in Figure 2.

CAUTION: THE LARGER "C" LOCKS AND CORRESPONDING AXLE SHAFTS AND
DIFFERENTIAL GEARS MUST NOT BE INTERCHANGED WITH

Page 1189

FIGURE 2D - INSTRUMENT PANEL WIRING

b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the
existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D).

c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper
harness, PN 4362291, into the existing 3-way red molded connector from the main instrument
panel wiring harness (Figure 2-D).

d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291,
to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289
(Figure 2-D).

e. Reinstall instrument panel hood and bezel assembly and install radio.
FIGURE 2F - INSTRUMENT PANEL WIRING

7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN
4362292

a. Disconnect from each other, the two existing brown colored 1-way connectors located near the
left instrument panel vent (Figure 2-F).

Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors
from instrument panel jumper harness, PN 4362292 (Figure 2-F).

b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN
4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN
4362289 (Figure 2-F).

Testing and Inspection

Starter Relay: Testing and Inspection

1. Place transmission in Neutral and apply parking brake.

2. Check for battery voltage between starter relay battery terminal and ground.

3. Connect jumper wire on starter relay between battery and ignition terminals.

4. If engine does not crank, connect a second jumper wire to starter relay between ground terminal
and good ground and repeat test.

5. If engine cranks in step 4, transmission linkage is misadjusted or neutral safety switch is
defective.

6. If engine does not crank in step 4, starter relay is defective.

Page 981

INSTRUMENT PANEL WIRING

4. Route the instrument panel overlay harness along the existing instrument panel ignition switch
wiring from the bulkhead connector and behind the fuse block to the existing red mold connector
and instrument panel ground terminal (Figure 2-C).

Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition
switch wiring and one tie wrap, PN 6015756 (Figure 2-C).

5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay
harness onto an instrument panel ground terminal located to the right of the steering column
(Figure 2-C).

6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the
existing 3-way red molded connector, from the main instrument panel wiring harness, (Located
near radio, Figure 2-C).

INSTRUMENT PANEL WIRING

7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored
8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto
the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead
connector (Figure 2-E).

C. In-Tank Fuel Pump Installation

1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and
discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to
protect the float and gauge assembly during installation into the fuel tank.

2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply
hoses. Secure the hoses with the hose clamps provided.

3. Install existing gauge/pump wiring:
^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump

assembly.
^ Tape back existing yellow mold connector white wire (this wire will no longer be used).
^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay

harness, PN 4362286, onto the red stud of gauge/pump assembly.
^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on

gauge/pump assembly.
CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE

UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE.
^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel

tank.

4. Reinstall fuel tank to original position.

Page 1213

2. Screw - Self Tapping - 6022777 (2 Req.)

3. Tube Assy - Fuel Pump to Reservoir - 4306968

4. Return Hose & Sleeve Assy - 4418006

5. Hose Clamps - 6500650 (2 Req.) - 1/4"

6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576

7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576

8. Hose Clamps - 6500651 (4 Req.) - 5/16"
Included but not shown: 2 piece Convolute Tubing - 4279993
FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION

1 SCREW & WASHER - 6022254
2 REGULATOR BRACKET - 4418010
3 REGULATOR - 4418OD9
4 TUBE - REGULATOR TO
CARB - 4418008
5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014
6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066
7 CLAMP (5116) - 6500651

Page 2736

Fig. 16 Bearing retainer positioned with grease fitting facing forward. 44 FBJ Units w/disc brakes.
Models w/full time 4WD

4. Install seal cup using adapter, Tool C-4398-2, and driver, Tool No. C-4398-1. Use a small
amount of wheel bearing grease on adapter face to hold

cup in position, then drive up until bottomed in knuckle. Do not remove tool at this time.

5. Using a suitable tool, install new outer seal in retainer plate, then locate retainer plate over hub
of rotor. 6. Thoroughly pack wheel bearings with Multi-Purpose grease and press outer bearing
onto hub using Tool No. C-4246-A and adapters. Remove tool

and place grease coated outer bearing cup over bearing cone followed by spacer, grease coated
inner bearing cup and inner bearing cone. Again use Tool No. C-4246-A and adapters to press
components into position. Remove tool.

7. Apply a 1/4 inch bead of RTV sealer to retainer face on the chamfer. This replaces O-ring
discarded during disassembly. 8. Carefully remove seal installing tool from knuckle bore so that
outer axle shaft remains centered. If shaft is moved, be sure that lip seal is still

riding inside cup. Correct if necessary.

9. Before assembling hub and rotor to knuckle, position bearing retainer in hub so that grease
fitting is facing forward, if equipped. Using a crossing

method, torque retainer plate bolts to 30 ft-lbs. Bearing retainers that have a grease fitting must be
positioned on knuckle so that fitting is facing directly forward.

10. Install brake adapter and remove pry bar from universal joint. 11. Install axle shaft washer and
nut. Torque nut to 100 ft-lbs, and continue to tighten nut until next slot in nut aligns with hole in axle
shaft. Install

cotter pin.

12. Through the access hole in hub, lubricate fitting in bearing retainer with multipurpose grease
until grease flows through new inner seal. Seal may

be viewed at the universal joint area. Spin hub several times and lubricate fitting again. Grease
must flow from 1/2 of seal diameter.

13. Replace brake caliper assembly and wheel, then lower truck and test operation.
With Part Time 4WD

Differentials

Fluid - Differential: Specifications Differentials

Above 90°F (32°C), 140, 80W-140, 85W-140; above -10°F (-23°C), 90 80W-90, 80W-140,

85W-140; below-10°F (-23°C), 75W, 80W, 75W-90, 80W-140 REAR: Standard................................

..............................................................................................................................................................

...............GL-5

Anti-Spin, Limited-Slip, Powr-Loc, Sure-Grip, Trac-Loc.......................................................................

......................................................................GL-5* FRONT: 4 x 4.......................................................

..........................................................................................................................................................G

L-5 CAPACITY, Refill: Front: 4-wheel drive Spicer 60F.......................................................................

....................................................................................3.1 Liters 6.5 Pints

Others...................................................................................................................................................

...............................................1.7 Liters 3.5 Pints

Rear: Spicer 60, 60 HD........................................................................................................................

................................................2.8 Liters 6.0 Pints

Spicer 70..............................................................................................................................................

................................................3.1 Liters 6.5 Pints

Others...................................................................................................................................................

...............................................2.1 Liters 4.5 Pints ANTI-SPIN, LIMITED-SLIP, POWR-LOC,

SURE-GRIP OR TRAC-LOC IDENTIFICATION:
Lift both rear wheels off the ground, turn one wheel & other will rotate in same direction

Service and Repair

Backup Lamp Switch: Service and Repair

1. Unscrew switch from transmission case, allowing fluid to drain into container. 2. Move shift lever
to Park and then to Neutral positions and inspect to ensure switch operating lever is centered in
switch opening in case. 3. Screw switch into transmission case, then add fluid to the proper level.

4. Check to ensure proper switch operation.

Page 3426

Power Door Lock Relay: Service and Repair
Door Lock And Power Window Circuit Breaker And Relays Location
Disconnect the battery negative terminal. Remove the wire connector from the relay. Remove the

attaching bolt that holds the relay to the instrument panel support bracket. Install by attaching relay
to the instrument panel support bracket and connecting the wires to the relay. Connect the battery
negative terminal and test the system for proper operation.

Page 989

b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576.
c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump

outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B).
d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the

reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure
4-B).

NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO
CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F.

5. Tighten all hose clamps to 10 inch pounds.
FIGURE 7

6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI
label.

7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor:
Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire

and hose routing.

F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure
Regulator Package Installation (PN 4397639)

1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake
manifold) and discard.

Page 2732

Outer Locknut, Lockwasher And Inner Locknut

Fig 1 Disc Brake Assembly (Rear View)

Electronic Control Unit

Engine Control Module: Locations Electronic Control Unit

Electronic Ignition System Components
On Firewall

Map Lamp - Tabs Broken

Map Light: Customer Interest Map Lamp - Tabs Broken
Models
1982-1989 Domestic D/AD & W model Trucks & Sport Utility Vehicles
Subject
Map Lamp Tab Breakage
Index
ELECTRICAL
Date
February 20, 1989
No.
08-05-89 P-617 (C08-04-9)
FIGURE 1
This Technical Service Bulletin is being revised to include
1988 and 1989 model years.