Dodge RAM 2000 2500 5.9L Workshop Manual

dodge :: Dodge Truck RAM 2500 Van V8-5.9L
VIN Z LDC (2000)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation

Keyless Entry Module: Description and Operation

(RKE)

(VTSS)

The power lock and Remote Keyless Entry module is used on models that are not equipped with the optional Vehicle Theft Security System . This module is mounted on the inboard side of the left center instrument panel support. The module contains the RKE receiver and the RKEsystem program logic. The relays for the power door locks, the RKE system, and the illuminated entry system are also integral to this module.

The RKE receiver has a memory function to retain the vehicle access code of at least one, but no more than two transmitters. The RKE receiver isdesigned to retain the transmitter codes in memory, even if the battery is disconnected.

(about 35 seconds)

This RKE system includes an illuminated entry feature, which turns on the courtesy lamps for a timed interval , when the power locksare unlocked using the RKE transmitter. This power lock system includes a delay lock feature. With the delay lock feature, if a side or rear door is stillopen when a lock request is received by the power lock module, the module will automatically cycle all of the power lock motors to lock five secondsafter the doors are closed.

The power lock and RKE module receives inputs from the ignition switch, the power door lock switches, and both the side and rear cargo door jambswitches. It also receives the radio signal input from the RKE transmitter. In response to those inputs, it is programmed to control outputs to the powerlock motors and the courtesy lamp circuits.
The power lock and remote keyless entry module cannot be repaired and, if faulty or damaged, it must be replaced.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Page 7

Keyless Entry Module: Testing and Inspection

(RKE)

The power lock and Remote Keyless Entry 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 fuseblock module. If OK, go to Step 2. 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 fuseblock module. If OK, go to Step 3. If not OK, repair the open circuit to the Power

Distribution Center as required.(PDC)

3. Check the fused ignition switch output fuse in the fuseblock module. If OK, go to Step 4. If not OK, repair the shorted circuit or component as
required and replace the faulty fuse.

4. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output fuse in the fuseblock module. If OK, turn
the ignition switch to the OFF position and go to Step 5. 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.

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 7. 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 8. 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 9. If not OK, repair the open circuit to the fuse in the fuseblock module 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 10. If not OK, repair the open circuit from either or bothpower lock switch(es) 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 11. If not OK, repair the open circuit from either or bothpower lock switch(es) 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 sideor rear cargo doors opened. Test each of the side and the rear doors. If OK, go to Step 12. If not OK, repair the open circuit to the door jambswitch(es) or replace the faulty door jamb switch(es) as required.

12. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output circuit cavity in the blue power lock and
RKE module wire harness connector. If OK, turn the ignition switch to the OFF position and go to Step 13. If not OK, repair the open circuit tothe fuse in the fuseblock module 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

30 seconds

power lock and RKE module wire harness connector and check for continuity to a good ground. There should be no continuity. Press and releasethe Unlock button of the RKE transmitter. There should now be continuity for about . If OK, go to Step 14. If not OK, replace thefaulty 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 15. If notOK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch. If not OK using the RKE transmitter, but OK with thepower lock switch, see Remote Keyless Entry Transmitter. If not OK, with the power lock switch or the RKE transmitter, replace the faulty powerlock 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 fiveseconds of the last door closing, there should be battery voltage on the door lock driver circuit. If OK, go to Step 16. If not OK, replace the faultypower lock and RKE module.

16. Back probe the door unlock driver circuit cavity in the black power lock and RKE module wire harness connector and check for battery voltage as

the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter. If OK, see Power LockMotor. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch. If not OK using the RKE transmitter, butOK with the power lock switch, see Remote Keyless Entry Transmitter. If not OK, with the power lock switch or the RKE transmitter, replace thefaulty power lock and RKE module.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Page 8

Keyless Entry Module: Service and Repair

(RKE)

(VTSS)

A power lock and Remote Keyless Entry module is only used on high-line versions of this vehicle that are not equipped with the optional VehicleTheft Security System . Models equipped with the optional VTSS have the power lock and RKE functions controlled by the Central TimerModule . See Power Lock System and Remote Keyless Entry System.(CTM)

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFOREATTEMPTING 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 POSSIBLEPERSONAL INJURY.
REMOVAL AND INSTALLATION

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 Nm (30 in. lbs.)

> Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Service and Repair

Door Module: Service and Repair
DOOR MODULE

REMOVAL

1. Remove door glass.2. Remove inside handle actuator.3. Disconnect power window harness connector, if equipped.

Fig. 14

> Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Service and Repair > Page 13

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

Fig. 15

4. Remove bolts attaching front door module to door inner panel (Fig. 14) and (Fig. 15).5. Separate front door module from door.

INSTALLATION

1. Position front door module on door.2. Install bolts attaching front door module to door inner panel (Fig. 14).3. Connect power window harness connector, if equipped.4. Install door glass.5. Install inside handle actuator.

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation

Keyless Entry Module: Description and Operation

(RKE)

(VTSS)

The power lock and Remote Keyless Entry module is used on models that are not equipped with the optional Vehicle Theft Security System . This module is mounted on the inboard side of the left center instrument panel support. The module contains the RKE receiver and the RKEsystem program logic. The relays for the power door locks, the RKE system, and the illuminated entry system are also integral to this module.

The RKE receiver has a memory function to retain the vehicle access code of at least one, but no more than two transmitters. The RKE receiver isdesigned to retain the transmitter codes in memory, even if the battery is disconnected.

(about 35 seconds)

This RKE system includes an illuminated entry feature, which turns on the courtesy lamps for a timed interval , when the power locksare unlocked using the RKE transmitter. This power lock system includes a delay lock feature. With the delay lock feature, if a side or rear door is stillopen when a lock request is received by the power lock module, the module will automatically cycle all of the power lock motors to lock five secondsafter the doors are closed.

The power lock and RKE module receives inputs from the ignition switch, the power door lock switches, and both the side and rear cargo door jambswitches. It also receives the radio signal input from the RKE transmitter. In response to those inputs, it is programmed to control outputs to the powerlock motors and the courtesy lamp circuits.
The power lock and remote keyless entry module cannot be repaired and, if faulty or damaged, it must be replaced.

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Page 17

Keyless Entry Module: Testing and Inspection

(RKE)

The power lock and Remote Keyless Entry 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 fuseblock module. If OK, go to Step 2. 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 fuseblock module. If OK, go to Step 3. If not OK, repair the open circuit to the Power

Distribution Center as required.(PDC)

3. Check the fused ignition switch output fuse in the fuseblock module. If OK, go to Step 4. If not OK, repair the shorted circuit or component as
required and replace the faulty fuse.

4. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output fuse in the fuseblock module. If OK, turn
the ignition switch to the OFF position and go to Step 5. 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.

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 7. 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 8. 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 9. If not OK, repair the open circuit to the fuse in the fuseblock module 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 10. If not OK, repair the open circuit from either or bothpower lock switch(es) 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 11. If not OK, repair the open circuit from either or bothpower lock switch(es) 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 sideor rear cargo doors opened. Test each of the side and the rear doors. If OK, go to Step 12. If not OK, repair the open circuit to the door jambswitch(es) or replace the faulty door jamb switch(es) as required.

12. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output circuit cavity in the blue power lock and
RKE module wire harness connector. If OK, turn the ignition switch to the OFF position and go to Step 13. If not OK, repair the open circuit tothe fuse in the fuseblock module 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

30 seconds

power lock and RKE module wire harness connector and check for continuity to a good ground. There should be no continuity. Press and releasethe Unlock button of the RKE transmitter. There should now be continuity for about . If OK, go to Step 14. If not OK, replace thefaulty 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 15. If notOK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch. If not OK using the RKE transmitter, but OK with thepower lock switch, see Remote Keyless Entry Transmitter. If not OK, with the power lock switch or the RKE transmitter, replace the faulty powerlock 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 fiveseconds of the last door closing, there should be battery voltage on the door lock driver circuit. If OK, go to Step 16. If not OK, replace the faultypower lock and RKE module.

16. Back probe the door unlock driver circuit cavity in the black power lock and RKE module wire harness connector and check for battery voltage as

the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter. If OK, see Power LockMotor. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch. If not OK using the RKE transmitter, butOK with the power lock switch, see Remote Keyless Entry Transmitter. If not OK, with the power lock switch or the RKE transmitter, replace thefaulty power lock and RKE module.

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Page 18

Keyless Entry Module: Service and Repair

(RKE)

(VTSS)

A power lock and Remote Keyless Entry module is only used on high-line versions of this vehicle that are not equipped with the optional VehicleTheft Security System . Models equipped with the optional VTSS have the power lock and RKE functions controlled by the Central TimerModule . See Power Lock System and Remote Keyless Entry System.(CTM)

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFOREATTEMPTING 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 POSSIBLEPERSONAL INJURY.
REMOVAL AND INSTALLATION

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 Nm (30 in. lbs.)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Recalls: > D20 > Sep >

04 > Recall - ABS Wiring Corrosion

Technical Service Bulletin # D20

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 retaildelivery. 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 abovevehicles. 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.

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Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 28

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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. Claimssubmitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 29

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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 inquiryas 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 sortedby: 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.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 30

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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 ofvarious 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 scheduleappointments 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.

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).

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 31

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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).

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 removethe terminal clamp from the battery post (Figure 3).

4. Loosen the battery positive cable terminal clamp pinch-bolt hex nut.

5.

Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If necessary, use a battery terminal puller to removethe terminal clamp from the battery post (Figure 3).

6. Remove the two nuts with washers that secure the battery hold down strap to the threaded end of the J-bolt and the long stud (Figure 4).

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 32

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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.

: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).

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 33

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

14.

In the area below the battery location, inspect the front (large) wiring harness connector on the ABS control module for acid damage, by sprayingthe 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 withSection E - Battery Tray Installation.

> 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. Thenpush 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 ModuleWiring 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 greencolored corrosion is found in one or more of the connector cavities continue with Section C - ABS Control Module Wiring HarnessConnector 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 ordiscoloration. If a dull finish or discoloration is found, continue with Section C - ABS Control Module Wiring Harness ConnectorReplacement because the original connector housing wire weather seals have been damaged. If no dull or discolored terminals are foundcontinue 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 bythe inspection in Section B, require replacement.

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Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 34

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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 plugssupplied 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 betransferred 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 armwhile 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 mayrequire 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 followingprocess:

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.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 35

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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 insulationfrom the wire.

d. Place a piece of sealant lined heat shrink tubing on one side of the wire.

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 thefuture.

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 sealedand sealant comes out of both ends of the shrink tubing (Figure 11).

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 36

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

5.
After all of the terminals have been transferred or replaced, install the blue secondary terminal lock into the ABS control module wiring harnessconnector (Figure 8).

6.
Using a small mirror (Snap-on GA295 or equivalent), inspect the ABS control module connector pins for green corrosion and the connectorhousing for heat damage (Figure 12).

> ABS control module connectors found with green corroded pins continue with Section D - ABS Control Module Replacement.
> ABS control module connector housings found with heat damage continue with Section D - ABS Control Module Replacement.
> ABS control module connectors found without heat damage or green corroded pins continue with Section E - Battery Tray Installation.

D. ABS Control Module Replacement

:NOTE

Only ABS control modules with a heat damaged (melted) connector or green corroded connector pins, as determined by the inspection in Section Band C, require replacement. Very few vehicles are expected to require ABS control module replacement.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 37

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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.

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 andNeutralizing 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).

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 38

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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 thebattery temperature sensor electrical connector.

8. Install the battery tray mounting bolts. Tighten the bolts to 95 in. lbs. (10.7 N.m).

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 newcontrol module.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins > Recalls: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 39

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Recalls: >

NHTSA04V185000 > Apr > 04 > Recall 04V185000: ABS Control Module Corrosion

Controller Antilock Brake: RecallsRecall 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 ontothe ABS control module connector, which can compromise the sealing integrity of the connector. This may allow development of a short circuit in theconnector, 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 hasnot yet provided an owner notification for this campaign. Owners may contact DaimlerChrysler at 1-800-853-1403.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest: >

18-002-02 > Jan > 02 > Rear Axle - Vehicle Speed Is Inaccurate

Controller Antilock Brake: Customer InterestRear 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 ATLEVEL 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 onthe rear axle has caused the calibration to change. Accurate calibration can be restored by reprogramming the applicable module, (ABS) Antilock BrakeSystem 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 THEREPROGRAMMING.

POLICY:Information Only

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service

Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion

Technical Service Bulletin # D20

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 retaildelivery. 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 abovevehicles. 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.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins> All Technical Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 54

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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. Claimssubmitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins> All Technical Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 55

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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 inquiryas 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 sortedby: 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.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins> All Technical Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 56

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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 ofvarious 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 scheduleappointments 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.

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).

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins> All Technical Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 57

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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).

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 removethe terminal clamp from the battery post (Figure 3).

4. Loosen the battery positive cable terminal clamp pinch-bolt hex nut.

5.

Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If necessary, use a battery terminal puller to removethe terminal clamp from the battery post (Figure 3).

6. Remove the two nuts with washers that secure the battery hold down strap to the threaded end of the J-bolt and the long stud (Figure 4).

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins> All Technical Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 58

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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.

: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).

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins> All Technical Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 59

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

14.

In the area below the battery location, inspect the front (large) wiring harness connector on the ABS control module for acid damage, by sprayingthe 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 withSection E - Battery Tray Installation.

> 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. Thenpush 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 ModuleWiring 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 greencolored corrosion is found in one or more of the connector cavities continue with Section C - ABS Control Module Wiring HarnessConnector 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 ordiscoloration. If a dull finish or discoloration is found, continue with Section C - ABS Control Module Wiring Harness ConnectorReplacement because the original connector housing wire weather seals have been damaged. If no dull or discolored terminals are foundcontinue 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 bythe inspection in Section B, require replacement.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins> All Technical Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 60

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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 plugssupplied 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 betransferred 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 armwhile 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 mayrequire 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 followingprocess:

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.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins> All Technical Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 61

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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 insulationfrom the wire.

d. Place a piece of sealant lined heat shrink tubing on one side of the wire.

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 thefuture.

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 sealedand sealant comes out of both ends of the shrink tubing (Figure 11).

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins> All Technical Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 62

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

5.
After all of the terminals have been transferred or replaced, install the blue secondary terminal lock into the ABS control module wiring harnessconnector (Figure 8).

6.
Using a small mirror (Snap-on GA295 or equivalent), inspect the ABS control module connector pins for green corrosion and the connectorhousing for heat damage (Figure 12).

> ABS control module connectors found with green corroded pins continue with Section D - ABS Control Module Replacement.
> ABS control module connector housings found with heat damage continue with Section D - ABS Control Module Replacement.
> ABS control module connectors found without heat damage or green corroded pins continue with Section E - Battery Tray Installation.

D. ABS Control Module Replacement

:NOTE

Only ABS control modules with a heat damaged (melted) connector or green corroded connector pins, as determined by the inspection in Section Band C, require replacement. Very few vehicles are expected to require ABS control module replacement.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins> All Technical Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 63

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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.

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 andNeutralizing 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).

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins> All Technical Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 64

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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 thebattery temperature sensor electrical connector.

8. Install the battery tray mounting bolts. Tighten the bolts to 95 in. lbs. (10.7 N.m).

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 newcontrol module.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins> All Technical Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 65

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service

Bulletins for Controller Antilock Brake: > NHTSA04V185000 > Apr > 04 > Recall 04V185000: ABS Control Module Corrosion

Controller Antilock Brake: All Technical Service BulletinsRecall 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 ontothe ABS control module connector, which can compromise the sealing integrity of the connector. This may allow development of a short circuit in theconnector, 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 hasnot yet provided an owner notification for this campaign. Owners may contact DaimlerChrysler at 1-800-853-1403.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service

Bulletins for Controller Antilock Brake: > 18-002-02 > Jan > 02 > Rear Axle - Vehicle Speed Is Inaccurate

Controller Antilock Brake: All Technical Service BulletinsRear 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 ATLEVEL 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 onthe rear axle has caused the calibration to change. Accurate calibration can be restored by reprogramming the applicable module, (ABS) Antilock BrakeSystem 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 THEREPROGRAMMING.

POLICY:Information Only

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Other Service

Bulletins for Controller Antilock Brake: > 18-002-02 > Jan > 02 > Rear Axle - Vehicle Speed Is Inaccurate

Controller Antilock Brake: All Technical Service BulletinsRear 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 ATLEVEL 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 onthe rear axle has caused the calibration to change. Accurate calibration can be restored by reprogramming the applicable module, (ABS) Antilock BrakeSystem 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 THEREPROGRAMMING.

POLICY:Information Only

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Other Service

Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion

Technical Service Bulletin # D20

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 retaildelivery. 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 abovevehicles. 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.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins > All Other Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 84

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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. Claimssubmitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins > All Other Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 85

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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 inquiryas 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 sortedby: 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.

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Technical Service Bulletins > All Other Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 86

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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 ofvarious 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 scheduleappointments 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.

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).

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Technical Service Bulletins > All Other Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 87

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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).

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 removethe terminal clamp from the battery post (Figure 3).

4. Loosen the battery positive cable terminal clamp pinch-bolt hex nut.

5.

Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If necessary, use a battery terminal puller to removethe terminal clamp from the battery post (Figure 3).

6. Remove the two nuts with washers that secure the battery hold down strap to the threaded end of the J-bolt and the long stud (Figure 4).

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins > All Other Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 88

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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.

: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).

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins > All Other Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 89

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

14.

In the area below the battery location, inspect the front (large) wiring harness connector on the ABS control module for acid damage, by sprayingthe 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 withSection E - Battery Tray Installation.

> 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. Thenpush 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 ModuleWiring 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 greencolored corrosion is found in one or more of the connector cavities continue with Section C - ABS Control Module Wiring HarnessConnector 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 ordiscoloration. If a dull finish or discoloration is found, continue with Section C - ABS Control Module Wiring Harness ConnectorReplacement because the original connector housing wire weather seals have been damaged. If no dull or discolored terminals are foundcontinue 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 bythe inspection in Section B, require replacement.

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Technical Service Bulletins > All Other Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 90

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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 plugssupplied 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 betransferred 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 armwhile 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 mayrequire 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 followingprocess:

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.

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Technical Service Bulletins > All Other Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 91

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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 insulationfrom the wire.

d. Place a piece of sealant lined heat shrink tubing on one side of the wire.

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 thefuture.

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 sealedand sealant comes out of both ends of the shrink tubing (Figure 11).

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins > All Other Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 92

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

5.
After all of the terminals have been transferred or replaced, install the blue secondary terminal lock into the ABS control module wiring harnessconnector (Figure 8).

6.
Using a small mirror (Snap-on GA295 or equivalent), inspect the ABS control module connector pins for green corrosion and the connectorhousing for heat damage (Figure 12).

> ABS control module connectors found with green corroded pins continue with Section D - ABS Control Module Replacement.
> ABS control module connector housings found with heat damage continue with Section D - ABS Control Module Replacement.
> ABS control module connectors found without heat damage or green corroded pins continue with Section E - Battery Tray Installation.

D. ABS Control Module Replacement

:NOTE

Only ABS control modules with a heat damaged (melted) connector or green corroded connector pins, as determined by the inspection in Section Band C, require replacement. Very few vehicles are expected to require ABS control module replacement.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information >

Technical Service Bulletins > All Other Service Bulletins for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 93

RAM 2500 Van V8-5.9L VIN Z LDC (2000)

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.

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 andNeutralizing 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).