1999 Dodge or Ram Truck RAM 1500 Truck 2WD V8-5.9L VIN Z LDC

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Doreen Griffith
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1 ALLDATA Repair Dodge or Ram Truck RAM 1500 Truck 2WD V8-5.9L VIN Z... Page 1 of Dodge or Ram Truck RAM 1500 Truck 2WD V8-5.9L VIN Z LDC Vehicle» Instrument Panel, Gauges and Warning Indicators» Technical Service Bulletins» All Technical Service Bulletins» Instrument Cluster - Erratic Operation NUMBER: GROUP: Electrical EFFECTIVE DATE: April21, 2000 SUBJECT: Intermittent Operation Of The Instrument Cluster OVERVIEW: This bulletin involves replacing the instrument cluster wire harness connector and associated wire terminals. MODELS: 1999 (AB) Ram Van/Wagon 1999 (AN) Dakota 1999 (BR/BE) Ram Truck 1999 (DN) Durango SYMPTOM/CONDITION: The needle of the instrument cluster gauges may intermittently drop to zero and/or the telltale lamps, such as the AIRBAG warning lamp, may intermittently come on. DIAGNOSIS: Connect the DRB III to the 16-way Data Link Connector (DLC). Read and record all active and stored Airbag Control Module (ACM) Diagnostic Trouble Codes (DTC). If active and/or stored "No Cluster CCD Bus" DTC is present, perform the Repair Procedure. PARTS REQUIRED: AA Kit, Instrument Cluster Harness Connector Wiring Repair Kit Includes: (1) Cluster Connector With Terminated Wires (1) Pink Wire With Terminal (1) Yellow Wire With Terminal (1) Black Wire With Terminal (1) Black/Orange Wire With Terminal (10) Heat Shrink Tubing (12) Splice Bands EQUIPMENT REQUIRED: Soldering Gun Rosin Core Solder Heat Gun

2 ALLDATA Repair Dodge or Ram Truck RAM 1500 Truck 2WD V8-5.9L VIN Z... Page 2 of 10 REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1.Disconnect and isolate the battery negative cable. On vehicles equipped with the 5.9L Cummins diesel engine, disconnect and isolate both battery negative cables. 2.Remove the instrument cluster bezel. Refer to the appropriate Service Manual, Group 8E, for information regarding Instrument Cluster Bezel removal. Fig Remove the four screws that secure the instrument cluster to the instrument panel (Figure 1). 4.If the vehicle is equipped with an automatic transmission, place the automatic transmission gear selector into the PARK position and perform Steps 5 and 6. If the vehicle is equipped with a manual transmission, set the parking brake and proceed to Step Remove the steering column opening cover. Fig. 2

3 ALLDATA Repair Dodge or Ram Truck RAM 1500 Truck 2WD V8-5.9L VIN Z... Page 3 of 10 a.on Dakota/Durango/Ram Truck Models, remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement (Figure 2). Using a trim stick or other suitable wide flatbladed tool, gently pry the upper edge of the opening cover just below the cluster bezel on each side of the steering column away from the instrument panel far enough to disengage the snap clip retainers from the receptacles in the instrument panel. Then, remove the steering column opening cover from the instrument panel. b.on Ram Van/Wagons, move tilt steering column to the fully raised position, (if equipped). Remove the end cap from the left end of the instrument panel. Remove the three screws that secure the lower edge of the steering column opening cover to the knee blocker. Remove the two screws that secure the outboard end of the steering column opening cover to the left side of the instrument panel end bracket. Using a trim stick or other suitable wide flatbladed tool, gently pry the upper edge of the opening cover just below the cluster bezel to disengage the four snap clip retainers that secure the cover to the instrument panel. Then, remove the steering column opening cover from the instrument panel. Fig. 3

4 ALLDATA Repair Dodge or Ram Truck RAM 1500 Truck 2WD V8-5.9L VIN Z... Page 4 of Disconnect the shift indicator from the steering column (Figure 3). 7. Pull the instrument cluster rearward far enough to disengage the two self-docking instrument panel wire harness connectors from the connector receptacles on the back of the cluster housing. 8. Remove the instrument cluster from the instrument panel. 9. Separate the right side (passenger side) wire harness connector from the self-docking receptacle on the instrument panel. 10.From the back of the right side instrument cluster wire harness connector, remove approximately three inches of the electrical wire wrapping tape.

5 ALLDATA Repair Dodge or Ram Truck RAM 1500 Truck 2WD V8-5.9L VIN Z... Page 5 of Assemble the new instrument panel wire harness connector p/n AA by inserting the appropriate color-coded terminal/wire into the appropriate wire terminal cavity. The charts on the following page identify proper wire color code connector cavity locations. 12.Push in the wire connector primary lock. The red primary lock is in its proper position when the lock is flush with the back of the housing. 13.Use one of the two following methods to splice the wires from the new connector to the wires from the original connector. It is recommended to cut and splice one wire at a time to help prevent accidentally splicing the wrong wires together. The previous charts should be used to ensure that the proper wires are spliced together. Splice joints should be staggered about 1/2 in. apart to help limit the size of the wire bundle. CAUTION: SOME VEHICLES HAVE MORE THAN ONE WIRE WITH THE SAME COLOR COMBINATION. IT IS NOT ADVISED TO CUT ALL OF THE CONNECTOR WIRES AT ONCE. WIRE SPLICING METHOD 1 1.Remove one (1) inch of insulation from each wire that needs to be spliced. 2.Place a piece of heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area.

6 ALLDATA Repair Dodge or Ram Truck RAM 1500 Truck 2WD V8-5.9L VIN Z... Page 6 of 10 Fig. 4 3.Spread the strands of wire apart on each exposed portion of the wire that needs to be spliced (Figure 4 - Example 1). 4.Push the two ends of the wires together until the strands of wire are close to the insulation (Figure 4 - Example 2). 5.Twist the wires together (Figure 4 - Example 3). 6. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Fig. 5

7 ALLDATA Repair Dodge or Ram Truck RAM 1500 Truck 2WD V8-5.9L VIN Z... Page 7 of 10 7.Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Figure 5). WIRE SPLICING METHOD 2 1.Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2.Place a piece of heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Fig. 6 3.Place the strands of wire overlapping each other inside of the splice clip (Figure 6). Fig. 7

8 ALLDATA Repair Dodge or Ram Truck RAM 1500 Truck 2WD V8-5.9L VIN Z... Page 8 of Using crimping tool 8272 or equivalent, crimp the splice clip and wires together (Figure 7). Fig Solder the connection together using rosin core type solder only (Figure 8). CAUTION: DO NOT USE ACID CORE SOLDER. Fig. 5

9 ALLDATA Repair Dodge or Ram Truck RAM 1500 Truck 2WD V8-5.9L VIN Z... Page 9 of 10 6.Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Figure 5). INSTALLATION 1. Secure the bundle of wires together using electrical tape. 2. Install the instrument cluster wire harness connector into the self-docking receptacle. 3. Position the instrument cluster to the instrument panel. 4. If the vehicle is equipped with a manual transmission, proceed to Step 6. If the vehicle is equipped with an automatic transmission, install the PRNDL cable onto the steering column PRNDL lever. 5. Install the steering column opening cover. a.on Dakota/Durango/Ram Truck, position the steering column opening cover to the instrument panel. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel. Press firmly on the steering column opening cover over the snap clip locations until each snap clip is fully engaged in its receptacle. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Tighten the screws to 2.2 Nm (20 in. lbs.). b.on Ram Van/Wagon, position the steering column opening cover to the instrument panel. Align the four snap clip retainers on the steering column opening cover with the receptacles in the instrument panel. Press firmly on the steering column opening cover over the snap clip locations until each snap clip is fully engaged in its receptacle. Install and tighten the two screws that secure the outboard end of the steering column opening cover to the left instrument panel end bracket. Tighten the screws to 2.2 Nm (20 in. lbs.). Install and tighten the three screws that secure the lower edge of the steering column opening cover to the knee blocker. Tighten the screws to 2.2 Nm (20 in. lbs.). Install the end cap onto the left end of the instrument panel. 6. Align the instrument cluster with the cluster opening in the instrument panel and push the cluster firmly and evenly into place. The instrument panel has two self-docking wire harness connectors that will be

10 ALLDATA Repair Dodge or Ram Truck RAM 1500 Truck 2WD V8-5.9L VIN... Page 10 of 10 automatically aligned with, and connected to the instrument cluster connector receptacles when the cluster is installed in the instrument panel. 7. Install and tighten the four screws that secure the instrument cluster to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 8. Install the cluster bezel onto the instrument panel. Refer to the appropriate Service Manual, Group 8E, for information regarding Instrument Cluster Bezel installation. 9. Connect the battery negative cable(s). 10.Reset the clock in the radio and verify proper operation of the cluster. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: PB - New Part

SYMPTOM/CONDITION: The Service 4WD lamp is illuminated even though the truck is not a 4X4 vehicle.

SYMPTOM/CONDITION: The Service 4WD lamp is illuminated even though the truck is not a 4X4 vehicle. NUMBER: GROUP: 08-032-00 REV. A Electrical DATE: Dec. 29, 2000 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced,