Dodge RAM 2001 1500 VAN V8 5.9L, RAM 2001 1500 Van 5.9L Workshop Manual

dodge :: Dodge Truck RAM 1500 Van V8-5.9L
VIN Z LDC (2001)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service Precautions

Keyless Entry Module: Service Precautions

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERINGWHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAGSYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SUREWAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTALAIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service Precautions > Page 7

Keyless Entry Module: Description and Operation

Fig. 9 Power Lock & RKE Module

POWER LOCK & REMOTE KEYLESS ENTRY MODULE

(RKE)

(VTSS)

(RF)

The power lock and Remote Keyless Entry module is used on models that are not equipped with the optional Vehicle Theft SecuritySystem . This module is secured with two screws to the inboard side of the left center instrument panel support above the engine housing.The module contains a Radio Frequency receiver and integrated circuitry to control all of the power lock and RKE system features. The RKEreceiver has a memory function to retain the vehicle access code of at least one, but no more than two transmitters. The RKE receiver is designedto retain the transmitter codes in memory, even if the battery is disconnected.

thirty-fiveseconds

The power lock and RKE module provides an illuminated entry feature, which turns ON the courtesy lamps for a timed interval (about ), when the power locks are unlocked using the RKE transmitter. The module also provides a delay lock feature which, if a side or reardoor is still open when a lock request is received by the module, will automatically cycle all of the power lock motors to the lock position after all of the doors are closed.fiveseconds

The power lock and RKE module cannot be adjusted or repaired and, if faulty or damaged, it must be replaced.

The power lock and Remote Keyless Entry module is connected to the vehicle electrical system through two take outs and connectors of theinstrument panel wire harness. The module operates on battery current received through a non-switched fused B(+) circuit so the power lock andRKE systems remain functional at all times. The module receives inputs from the ignition switch, the power door lock switches, and both the sideand rear door ajar switches. It also receives the Radio Frequency (RF) signal inputs from the RKE transmitter. In response to those inputs, it isprogrammed to control outputs to the power lock motors and the courtesy lamp circuits.

Because of the active electronic elements within the power lock and RKE module, it cannot be tested with conventional automotive electrical testequipment. If the module is believed to be faulty, test the hard wired power lock system inputs to and outputs from the module. Then replace themodule with a known good unit to confirm system operation.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service Precautions > Page 8

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)

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERINGWHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAGSYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SUREWAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTALAIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

1. Check the fused B(+) fuse (Fuse ) in the fuse block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as15 - 20 ampere

required and replace the faulty fuse.

2. Check for battery voltage at the fused B(+) fuse (Fuse ) in the fuse block. If OK, go to Step 3. If not OK, repair the open fused15 - 20 ampere

B(+) circuit between the fuse block and the Power Distribution Center as required.(PDC)

3. Check the fused ignition switch output (run-start) fuse (Fuse ) in the fuse block. If OK, go to Step 4. If not OK, repair the shorted7 - 10 ampere

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 (run-start) fuse (Fuse ) in7 - 10 ampere

the fuse block. If OK, turn the ignition switch to the OFF position and go to Step 5. If not OK, repair the open fused ignition switch output(run-start) circuit between the fuse block and the ignition switch as required.

5. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connectors for the power lock and RKE module
from the module connector receptacles. Inspect the wire harness connectors and the receptacles for loose, corroded, or damaged terminals andpins. If OK, go to Step 6. If not OK, repair the connections as required.

6. Check for continuity between the ground circuit cavity in the instrument panel wire harness connector (Connector C2) for the power lock and RKE
module and a good ground. There should be continuity. If OK, go to Step 7. If not OK, repair the open ground circuit to ground (G203) asrequired.

7. Reconnect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity in the instrument panel wire harness connector
(Connector C2) for the power lock and RKE module wire harness connector. If OK, go to Step 8. If not OK, repair the open fused B(+) circuitbetween the power lock and RKE module and the fuse block as required.

8. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run-start) circuit cavity of the instrument
panel wire harness connector (Connector C1) for the power lock and RKE module. If OK, go to Step 9. If not OK, repair the open fused ignitionswitch output (run-start) circuit between the power lock and RKE module and the fuse block as required.

9. Turn the ignition switch to the OFF position. Check for battery voltage at the door lock switch output (lock) circuit cavity in the instrument panel

wire harness connector (Connector C2) for the power lock and RKE module as you actuate each power lock switch to the Lock position. If OK, goto Step 10. If not OK, repair the open door lock switch output (lock) circuit between the power lock and RKE module and either or both powerlock switch(es) as required.

10. Check for battery voltage at the door lock switch output (unlock) circuit cavity of the instrument panel wire harness connector (Connector C2) for
the power lock and RKE module as you actuate each power lock switch to the Unlock position. If OK, go to Step 11. If not OK, repair the opendoor lock switch output (unlock) circuit between the power lock and RKE module and either or both power lock switch(es) as required.

11. Check for continuity between the auxiliary door switch sense circuit cavity of the instrument panel wire harness connector (Connector C2) for the

power lock and RKE module wire harness connector and a good ground. There should be no continuity with both the side and the rear doorsclosed, and continuity with any of the side or rear doors opened. Test each of the side and the rear doors. If OK, go to Step 12. If not OK, repairthe open auxiliary door switch sense circuit(s) between the power lock and RKE module and the door ajar switch(es) as required.

12. Disconnect and isolate the battery negative cable. Reconnect the instrument panel wire harness connectors for the power lock and RKE module to

thirty seconds

the module connector receptacles. Reconnect the battery negative cable. Back probe the courtesy lamp driver circuit cavity of the instrument panelwire harness connector (Connector C2) for the power lock and RKE module and check for battery voltage. Press and release the Unlock button ofthe RKE transmitter. There should be battery voltage on this circuit for about , then none. If OK, go to Step 13. If not OK, replacethe faulty power lock and RKE module.

13. Back probe the door lock driver circuit cavity in the instrument panel wire harness connector (Connector C2) for the power lock and RKE module

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service Precautions > Page 9

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

and check for battery voltage as the power lock switch is moved to the Lock position. Repeat the test while pressing the Lock button of the RKEtransmitter. If OK, go to Step 14. If not OK using the power lock switch, but OK with the RKE transmitter, proceed to diagnosis of the power lockswitches. (Refer to POWER LOCKS/POWER LOCK SWITCH - DIAGNOSIS AND TESTING). If not OK using the RKE transmitter, but OKwith the power lock switch, proceed to diagnosis of the RKE transmitter. (Refer to POWER LOCKS/REMOTE KEYLESS ENTRYTRANSMITTER - DIAGNOSIS AND TESTING). If not OK, with the power lock switch or the RKE transmitter, replace the faulty power lockand RKE module.

14. Still back probing the door lock driver circuit cavity in the instrument panel wire harness connector (Connector C2) for the power lock and RKE

five seconds

module, open a side or rear door. Move the power lock switch to the Lock position, or press the Lock button of the RKE transmitter. Now close allof the doors. Within of the last door closing, there should be battery voltage on the door lock driver circuit. If OK, go to Step 15. Ifnot OK, replace the faulty power lock and RKE module.

15. Back probe the door unlock driver circuit cavity in the instrument panel wire harness connector (Connector C2) for the power lock and RKE

module and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test while pressing the Unlock buttonof the RKE transmitter. If OK, proceed to diagnosis of the power lock motors. (Refer to POWER LOCKS/POWER LOCK MOTOR -DIAGNOSIS AND TESTING). If not OK using the power lock switch, but OK with the RKE transmitter, proceed to diagnosis of the power lockswitches. (Refer to POWER LOCKS/POWER LOCK SWITCH - DIAGNOSIS AND TESTING). If not OK using the RKE transmitter, but OKwith the power lock switch, proceed to diagnosis of the RKE transmitter. (Refer to POWER LOCKS/REMOTE KEY- LESS ENTRY

TRANSMITTER - DIAGNOSIS AND TESTING). If not OK, with the power lock switch or the RKE transmitter, replace the faulty power lockand RKE module.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service Precautions > Page 10

Keyless Entry Module: Service and Repair
REMOVAL

(RKE)

A power lock and Remote Keyless Entry module is only used on vehicles that are not equipped with the optional Vehicle Theft SecuritySystem . Models equipped with the optional VTSS have the power lock and RKE functions controlled by the Central Timer Module .(VTSS) (CTM)

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THEAIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THEONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT INACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

1. Disconnect and isolate the battery negative cable.2. Remove the engine cover from the passenger compartment.

Fig. 10 Power Lock & RKE 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 disconnect the two instrument panel wire harness
connectors for the module from the module connector receptacles.

5. Remove the power lock and RKE module from the instrument panel.

INSTALLATION

A power lock and Remote Keyless Entry (RKE) module is only used on vehicles that are not equipped with the optional Vehicle Theft SecuritySystem (VTSS). Models equipped with the optional VTSS have the power lock and RKE functions controlled by the Central Timer Module (CTM).

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THEAIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THEONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT INACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

1. Position the power lock and RKE module to the instrument panel.2. Reconnect the two instrument panel wire harness connectors for the power lock and RKE module to the module connector receptacles.3. Position the power lock and RKE module to its mounting location on the inboard side of the left center instrument panel support.4. Install and tighten the two screws that secure the power lock and RKE module to the inboard side of the left center instrument panel support.

Tighten the screws to .3 Nm (30 in. lbs.)

5. Reinstall the engine cover into the passenger compartment. 6. Reconnect the battery negative cable.

> 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 15

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 > Service Precautions

Keyless Entry Module: Service Precautions

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERINGWHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAGSYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SUREWAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTALAIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service Precautions > Page 19

Keyless Entry Module: Description and Operation

Fig. 9 Power Lock & RKE Module

POWER LOCK & REMOTE KEYLESS ENTRY MODULE

(RKE)

(VTSS)

(RF)

The power lock and Remote Keyless Entry module is used on models that are not equipped with the optional Vehicle Theft SecuritySystem . This module is secured with two screws to the inboard side of the left center instrument panel support above the engine housing.The module contains a Radio Frequency receiver and integrated circuitry to control all of the power lock and RKE system features. The RKEreceiver has a memory function to retain the vehicle access code of at least one, but no more than two transmitters. The RKE receiver is designedto retain the transmitter codes in memory, even if the battery is disconnected.

thirty-fiveseconds

The power lock and RKE module provides an illuminated entry feature, which turns ON the courtesy lamps for a timed interval (about ), when the power locks are unlocked using the RKE transmitter. The module also provides a delay lock feature which, if a side or reardoor is still open when a lock request is received by the module, will automatically cycle all of the power lock motors to the lock position after all of the doors are closed.fiveseconds

The power lock and RKE module cannot be adjusted or repaired and, if faulty or damaged, it must be replaced.

The power lock and Remote Keyless Entry module is connected to the vehicle electrical system through two take outs and connectors of theinstrument panel wire harness. The module operates on battery current received through a non-switched fused B(+) circuit so the power lock andRKE systems remain functional at all times. The module receives inputs from the ignition switch, the power door lock switches, and both the sideand rear door ajar switches. It also receives the Radio Frequency (RF) signal inputs from the RKE transmitter. In response to those inputs, it isprogrammed to control outputs to the power lock motors and the courtesy lamp circuits.

Because of the active electronic elements within the power lock and RKE module, it cannot be tested with conventional automotive electrical testequipment. If the module is believed to be faulty, test the hard wired power lock system inputs to and outputs from the module. Then replace themodule with a known good unit to confirm system operation.

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service Precautions > Page 20

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)

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERINGWHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAGSYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SUREWAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTALAIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

1. Check the fused B(+) fuse (Fuse ) in the fuse block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as15 - 20 ampere

required and replace the faulty fuse.

2. Check for battery voltage at the fused B(+) fuse (Fuse ) in the fuse block. If OK, go to Step 3. If not OK, repair the open fused15 - 20 ampere

B(+) circuit between the fuse block and the Power Distribution Center as required.(PDC)

3. Check the fused ignition switch output (run-start) fuse (Fuse ) in the fuse block. If OK, go to Step 4. If not OK, repair the shorted7 - 10 ampere

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 (run-start) fuse (Fuse ) in7 - 10 ampere

the fuse block. If OK, turn the ignition switch to the OFF position and go to Step 5. If not OK, repair the open fused ignition switch output(run-start) circuit between the fuse block and the ignition switch as required.

5. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connectors for the power lock and RKE module
from the module connector receptacles. Inspect the wire harness connectors and the receptacles for loose, corroded, or damaged terminals andpins. If OK, go to Step 6. If not OK, repair the connections as required.

6. Check for continuity between the ground circuit cavity in the instrument panel wire harness connector (Connector C2) for the power lock and RKE
module and a good ground. There should be continuity. If OK, go to Step 7. If not OK, repair the open ground circuit to ground (G203) asrequired.

7. Reconnect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity in the instrument panel wire harness connector
(Connector C2) for the power lock and RKE module wire harness connector. If OK, go to Step 8. If not OK, repair the open fused B(+) circuitbetween the power lock and RKE module and the fuse block as required.

8. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run-start) circuit cavity of the instrument
panel wire harness connector (Connector C1) for the power lock and RKE module. If OK, go to Step 9. If not OK, repair the open fused ignitionswitch output (run-start) circuit between the power lock and RKE module and the fuse block as required.

9. Turn the ignition switch to the OFF position. Check for battery voltage at the door lock switch output (lock) circuit cavity in the instrument panel

wire harness connector (Connector C2) for the power lock and RKE module as you actuate each power lock switch to the Lock position. If OK, goto Step 10. If not OK, repair the open door lock switch output (lock) circuit between the power lock and RKE module and either or both powerlock switch(es) as required.

10. Check for battery voltage at the door lock switch output (unlock) circuit cavity of the instrument panel wire harness connector (Connector C2) for
the power lock and RKE module as you actuate each power lock switch to the Unlock position. If OK, go to Step 11. If not OK, repair the opendoor lock switch output (unlock) circuit between the power lock and RKE module and either or both power lock switch(es) as required.

11. Check for continuity between the auxiliary door switch sense circuit cavity of the instrument panel wire harness connector (Connector C2) for the

power lock and RKE module wire harness connector and a good ground. There should be no continuity with both the side and the rear doorsclosed, and continuity with any of the side or rear doors opened. Test each of the side and the rear doors. If OK, go to Step 12. If not OK, repairthe open auxiliary door switch sense circuit(s) between the power lock and RKE module and the door ajar switch(es) as required.

12. Disconnect and isolate the battery negative cable. Reconnect the instrument panel wire harness connectors for the power lock and RKE module to

thirty seconds

the module connector receptacles. Reconnect the battery negative cable. Back probe the courtesy lamp driver circuit cavity of the instrument panelwire harness connector (Connector C2) for the power lock and RKE module and check for battery voltage. Press and release the Unlock button ofthe RKE transmitter. There should be battery voltage on this circuit for about , then none. If OK, go to Step 13. If not OK, replacethe faulty power lock and RKE module.

13. Back probe the door lock driver circuit cavity in the instrument panel wire harness connector (Connector C2) for the power lock and RKE module

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service Precautions > Page 21

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

and check for battery voltage as the power lock switch is moved to the Lock position. Repeat the test while pressing the Lock button of the RKEtransmitter. If OK, go to Step 14. If not OK using the power lock switch, but OK with the RKE transmitter, proceed to diagnosis of the power lockswitches. (Refer to POWER LOCKS/POWER LOCK SWITCH - DIAGNOSIS AND TESTING). If not OK using the RKE transmitter, but OKwith the power lock switch, proceed to diagnosis of the RKE transmitter. (Refer to POWER LOCKS/REMOTE KEYLESS ENTRYTRANSMITTER - DIAGNOSIS AND TESTING). If not OK, with the power lock switch or the RKE transmitter, replace the faulty power lockand RKE module.

14. Still back probing the door lock driver circuit cavity in the instrument panel wire harness connector (Connector C2) for the power lock and RKE

five seconds

module, open a side or rear door. Move the power lock switch to the Lock position, or press the Lock button of the RKE transmitter. Now close allof the doors. Within of the last door closing, there should be battery voltage on the door lock driver circuit. If OK, go to Step 15. Ifnot OK, replace the faulty power lock and RKE module.

15. Back probe the door unlock driver circuit cavity in the instrument panel wire harness connector (Connector C2) for the power lock and RKE

module and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test while pressing the Unlock buttonof the RKE transmitter. If OK, proceed to diagnosis of the power lock motors. (Refer to POWER LOCKS/POWER LOCK MOTOR -DIAGNOSIS AND TESTING). If not OK using the power lock switch, but OK with the RKE transmitter, proceed to diagnosis of the power lockswitches. (Refer to POWER LOCKS/POWER LOCK SWITCH - DIAGNOSIS AND TESTING). If not OK using the RKE transmitter, but OKwith the power lock switch, proceed to diagnosis of the RKE transmitter. (Refer to POWER LOCKS/REMOTE KEY- LESS ENTRY

TRANSMITTER - DIAGNOSIS AND TESTING). If not OK, with the power lock switch or the RKE transmitter, replace the faulty power lockand RKE module.

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service Precautions > Page 22

Keyless Entry Module: Service and Repair
REMOVAL

(RKE)

A power lock and Remote Keyless Entry module is only used on vehicles that are not equipped with the optional Vehicle Theft SecuritySystem . Models equipped with the optional VTSS have the power lock and RKE functions controlled by the Central Timer Module .(VTSS) (CTM)

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THEAIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THEONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT INACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

1. Disconnect and isolate the battery negative cable.2. Remove the engine cover from the passenger compartment.

Fig. 10 Power Lock & RKE 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 disconnect the two instrument panel wire harness
connectors for the module from the module connector receptacles.

5. Remove the power lock and RKE module from the instrument panel.

INSTALLATION

A power lock and Remote Keyless Entry (RKE) module is only used on vehicles that are not equipped with the optional Vehicle Theft SecuritySystem (VTSS). Models equipped with the optional VTSS have the power lock and RKE functions controlled by the Central Timer Module (CTM).

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THEAIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THEONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT INACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

1. Position the power lock and RKE module to the instrument panel.2. Reconnect the two instrument panel wire harness connectors for the power lock and RKE module to the module connector receptacles.3. Position the power lock and RKE module to its mounting location on the inboard side of the left center instrument panel support.4. Install and tighten the two screws that secure the power lock and RKE module to the inboard side of the left center instrument panel support.

Tighten the screws to .3 Nm (30 in. lbs.)

5. Reinstall the engine cover into the passenger compartment. 6. Reconnect the battery negative cable.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Recalls 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 > Recalls for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 32

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 33

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 > Recalls for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 34

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 > Recalls for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 35

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 >

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RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 37

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 >

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RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 39

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 40

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 41

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 >

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RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 for Controller Antilock Brake: > D20 > Sep > 04 > Recall - ABS Wiring Corrosion > Page 43

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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

Antilock Brake: > 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 > 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.

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RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 >

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RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 55

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 56

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 >

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RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 58

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 59

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 >

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RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 61

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 >

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RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 63

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

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 64

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

> 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 > Page 69

Controller Antilock Brake: Specifications

Mounting Screws 3 ft.lb

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 325

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 325 > Page 72

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Controller Antilock Brake: Diagrams

Controller Antilock Brake C1

Controller Antilock Brake C2

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Controller Antilock Brake: Description and Operation
CONTROLLER ANTILOCK BRAKE

Fig. 8 RWAL Cab

(CAB)

The Controller Antilock Brakes is a micro-processor which handles testing, monitoring and controlling the ABS brake system operation.The CAB functions are:-

Perform self-test diagnostics.

- Monitor the RWAL brake system for proper operation.

- Control the RWAL valve solenoids.

If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB.NOTE:

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Locations > Page 75

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

Fig. 9 CAB/HCU

The CAB is mounted on the top of the hydraulic control unit. The CAB operates the ABS system and is separate from other vehicle electricalcircuits. CAB voltage source is through the ignition switch in the RUN position.

System Self-test

When the ignition switch is turned-ON the microprocessor RAM and ROM are tested. If an error occurs during the test, a DTC will be set into theRAM memory. However it is possible the DTC will not be stored in memory if the error has occurred in the RAM module were the DTC's arestored. Also it is possible a DTC may not be stored if the error has occurred in the ROM which signals the RAM to store the DTC.

Cab Inputs

The CAB continuously monitors the speed of the differential ring gear by monitoring signals generated by the rear wheel speed sensor. The CABdetermines a wheel locking tendency when it recognizes the ring gear is decelerating too rapidly. The CAB monitors the following inputs todetermine when a wheel locking tendency may exists:-

Rear Wheel Speed Sensor

- Brake Lamp Switch

- Brake Warning Lamp Switch

- Reset Switch

- 4WD Switch (If equipped)

Cab Outputs

The CAB controls the following outputs for antilock braking and brake warning information:-

RWAL Valve

- ABS Warning Lamp

- Brake Warning Lamp

The CAB contains dual microprocessors. A logic block in each microprocessor receives identical sensor signals. These signals are processed andcompared simultaneously.

The CAB contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnosticprogram memory and are accessible with the DRB scan tool.

ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery isdisconnected.

If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB.NOTE:

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 76

Controller Antilock Brake: Service and Repair
REMOVAL

If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. NOTE:

1. Disconnect battery cables and remove the battery.2. Remove the power distribution center.3. Remove the battery and power distribution center mount.4. Remove the washer reservoir mounting screws.5. Lift up the reservoir and disconnect the pump motor connector and pump hose.6. Remove the reservoir from the engine compartment.

Fig. 10 Harness Connector Locks

7. Push the harness connector locks to release the locks, then remove the connectors from the CAB.

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Locations > Page 77

RAM 1500 Van V8-5.9L VIN Z LDC (2001)

Fig. 11 Pump Motor Connector

8. Disconnect the pump motor connector.

Fig. 12 Controller Mounting Screws

9. Remove screws attaching CAB to the HCU.

10. Remove the CAB.

INSTALLATION

If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB.NOTE:

1. Place the CAB onto the HCU.

Insure the CAB seal is in position before installation.NOTE:

4.4 Nm (39 in. lbs.)

2. Install the mounting screws and tighten to .3. Connect the pump motor harness.4. Connect the harnesses to the CAB and lock the connectors.5. Install the reservoir in the engine compartment. Connect the pump motor connector and pump hose.6. Install the washer reservoir mounting screws.7. Install the battery and power distribution center mount.8. Install the power distribution center.9. Install the battery and battery cables.

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations

Blower Motor Relay: Locations

The blower motor relay control circuit is protected by a fuse located in the junction block.
The front blower motor relay is located in the PDC in the engine compartment.

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 82

Blower Motor Relay: Diagrams