FOG-LAMPS INSTALL KIT DODGE RAM (BR, BE) Installation Instructions Read entire instructions thoroughly before starting. For proper removal and installation, follow procedures in the service manual. NOTES: Left and right are determined from the driver s seat (left side). Fog lamps can only be operated with park and low beams. This accessory lamp kit conforms with Federal Safety Standards when installed in accordance with the instructions provided with this kit. State and local regulations may also apply. Please consult local regulatory and law enforcement agencies in your area for specific details. TOOLS REQUIRED: #2 phillips head screwdriver Silicone sealant Trim stick Hooked pick tool Modeler s knife Soldering iron Rosin core solder Electrical tape Complete metric socket set Torque wrench CONTENTS: 9 Item Qty. Description 10 1 1 Left Sight Shield 8 2 1 Right Sight Shield 3 6 Plastic Rivets 4 1 Left Fog Lamp 5 1 Right Fog Lamp 6 4 Carriage Bolts 11 12 13 7 4 Nut and Washer Assy. 8 1 Fog Lamp Wiring Assy. 5 9 1 Self-Tapping Screw 7 10 10 Tie Straps 11 1 2-way Headlamp Connector 6 12 1 Locking Wedge 13 1 Headlamp Switch 14 1 Instruction Sheet 2 3 1 4 3 14 K 6 8 5 8 2 6 1 06/07/98 Page 1 of 9
1) Drill out two rivets (one each side) from the upper front bumper fascia. 2) Starting from the LH side and working to the RH side, push in on ten clip tabs to remove the upper fascia. Front Bumper Upper Fascia 3) Support the front bumper on a suitable lifting device. 4) Unscrew two bolts (one each side) holding the bumper braces to the frame rails. 5) Unscrew six nuts (three each side) from two stud plates and flag bolts (one each side) that hold the bumper brackets to the frame rails. LH Bumper Bracket LH Bumper Brace 6) Unscrew four nuts from four bolts (two each side) that hold the LH and RH brackets to the bumper. 7) Remove four rivets (two each side) from the existing LH and RH sight shields. Discard the rivets and the shields. 8) Install new LH and RH sight shields (Items 1 & 2) with rivets (Item 3) supplied in kit. Existing LH Sight Shield K 6 8 5 8 2 6 1 06/07/98 Page 2 of 9
Carriage Bolts Flanged Nuts 9) Install the LH and RH fog lamps (Items 4 & 5) with carriage bolts (Items 6) and nut/washer assys. (Item 7). Center the lamp s lenses thru the holes in the sight shields. New LH Sight Shield LH Fog Lamp Upper Fascia 10) Re-attach the LH and RH bumper brackets, then re-install the bumper. 11) Re-attach the bumper braces to the frame rails. 12) Re-attach the upper front bumper fascia and secure the ends with two rivets (Item 3) supplied in kit. New Rivet Relay Fog Lamp Wiring Assy. 13) Disconnect negative battery cable and isolate. 14) Install relay from the fog lamp wiring assy. (Item 8) to existing hole in the LH inner fender just rear of the power distribution center with supplied screw (Item 9). Make sure that the relay points down. K 6 8 5 8 2 6 1 06/07/98 Page 3 of 9
Existing PDC Nut Power Lead Eyelet 15) Remove cover from the power distribution center. 16) Route power lead eyelet to the PDC and attach to the positive fused side using existing nut. Tighten the nut to 90 in.-lbs. (10 N m). 17) Using one tie strap (Item 10), secure fuse holder to a convenient mounting point. 18) Route fog lamp wiring assy. forward in-between the battery and the inner fender. Radiator Side Air Deflector 19) Continue routing wiring assy. thru gap inbetween the upper radiator support and the radiator side air deflector. LH Fog Lamp Harness 20) Route LH fog lamp connector harness (the shorter of the two) down and plug it into the LH fog lamp. Upper Radiator Support 21) Route RH fog lamp connector harness across and in-between the A/C condenser mounting bracket and the upper radiator support. 22) Continue routing harness down behind the A/C hoses and plug connector into the RH fog lamp. 23) Using four tie straps, secure the RH fog lamp connector harness to the vehicle as shown. RH Fog Lamp Harness K 6 8 5 8 2 6 1 06/07/98 Page 4 of 9
24) Punch a hole in the top of the main wiring harness bulkhead grommet as shown. Bulkhead Grommet Fog Lamp Wiring Assy. If vehicle is equipped with Daytime Running Lamps (Canada Only) refer to Step A D on page 7 for routing of red wire from the fog lamp wiring assy. 25) Route the remaining wires from the fog lamp wiring assy. thru the grommet and into the driver's compartment. 26) Important: Close hole around the wires with silicone sealant. 27) Remove cluster bezel and knee bolster from the I/P and set them clear of the work area. Cluster Bezel Knee Bolster Headlamp Switch Opening 28) Unscrew three phillips head fasteners to remove the headlamp switch. Disconnect the switch and discard, but save the fasteners for re-use. If there is a 2-way headlamp switch connector present on the vehicle, remove the connector and tape it back to the harness as it will not be used. Black/ Lt. Green Lt. Blue/Black 29) Route the black/lt. green and lt. blue/black wires up into the I/P while reaching into the headlamp switch opening to pull the wires through. K 6 8 5 8 2 6 1 06/07/98 Page 5 of 9
30) Examine the 14-way headlamp switch connector. If there is a blue wire present in terminal #7, you may center splice the lt. blue/black wire to it. 14-Way Headlamp Switch Connector 30a) If there is no wire present in terminal #7, carefully pry out blue locking wedge from the connector. Insert the lt. blue/black wire into terminal #7 and re-install the locking wedge. Lt. Blue/Black Black Ground Wire 31) Insert black/lt. green wire into the 2-way headlamp switch connector (Item 11) supplied in kit, and install locking wedge (Item 12). 32) Plug and lock the 2-way and 14-way connectors into the new headlamp switch (Item 13). Black/Lt. Green Headlamp Switch 2-Way Connector 33) Route black ground wire from the 2-way connector thru the headlamp switch opening and down inside the I/P. 34) Install the new headlamp switch to the I/P. Knee Bolster Support Bracket 35) Remove existing screw from the knee bolster support bracket as shown. 36) Clean area around the hole and attach the black ground wire eyelet. This is the ground for the fog lamps. If vehicle is equipped with Daytime Running Lamps (Canada Only) skip to Step 40 on the next page. Black Ground Wire Existing Screw K 6 8 5 8 2 6 1 06/07/98 Page 6 of 9
1999 RAM Red / Orange Wire Cavity #35 2000/2001 RAM Red / Orange Wire Cavity #5 37) Find the 74-way connector located close to the parking brake. Using a 10mm socket, separate the connector for ease of wire splicing. 38) Locate red/orange wire (high beam ground) and center splice the red wire to it. Refer to the graphic at bottom of page for proper center splicing procedure. 74-Way Connector (Wire Side) DRL Connector (Wire Side) Violet Wire Cavity #9 39) Re-install the 74-way connector. Proceed to Step 40. Red wire installation steps for Canadian vehicles: A) Find the Daytime running lamp module located on the side of the LH (driver side) inner fender. B) Route red wire from the fog lamp wiring assy. to the modules 10-way connector and center splice to the violet wire. C) Tie strap red wire to existing engine harness. D) Return to Step 25 on Page 5 of 9 for the remainder of kit installation instructions. Center Splice Procedure Strip back insulation without cutting wire. Twist and solder wire onto exposed wire. 40) Re-connect negative battery cable and test fog lamps using the test procedure on next page. Cover with a minimum of 4 wraps of tape. 41) Re-install I/P cluster bezel and knee bolster. 42) Refer to the diagram on page 9 of 9 for proper alignment of the fog lamps. K 6 8 5 8 2 6 1 06/07/98 Page 7 of 9
Wiring and components shown with dotted lines are supplied with kit. Fog lamps turn ON with park lamps or LO beam headlamps when they are grounded thru the fog lamp switch (The fog lamp switch and the indicator are part of the headlamp switch). The fog lamps and the indicator are turned OFF if the driver switches the HI beams ON. This happens because the normally closed fog lamp relay is grounded by the HI beam circuit (or DRL module). The fog lamp relay location in the PDC is unused with this kit. TEST PROCEDURE: Fog lamps will only work with the park lamps or headlamps ON and set to LOW-BEAM. The fog lamps will cut off when headlamps are set to HIGH-BEAM. The indicator lamp in the switch will only light up if the park lamps are ON or headlamps are on LOW-BEAM and the switch is ON. K 6 8 5 8 2 6 1 06/07/98 Page 8 of 9
FOG LAMP AIMING INSTRUCTIONS Aim Fog Lamps (Figures 1 & 2). a. Point the vehicle at a target wall twenty-five (25) feet away. b. Measure the vertical distance from the ground surface to the center of the fog lamp. c. Subtract 4 from this measurement and mark it on the target wall directly in front of the vehicle (Fig. #1). d. The fog lamps should be aimed in such a manner so that the top edge of the high intensity zone is located at least 4 under the horizontal centerline of the fog lamps at a distance of 25 feet (Fig. #2). Vertical centerlines ahead of fog lamps Car Axis Horizontal centerline of fog lamps Height of fog lamps Height of fog lamps (-)4 Fog lamp beam Top edge of high intensity zone TARGET WALL Figure 1 T A R G E T Centerlines of fog lamps Fog lamp W A L L Height of fog lamps (-)4 Height of fog lamps Ground surface 25 Ft. Figure 2 The vertical centerlines will vary according to the distance between the fog lamps. During the actual aiming procedure, the fog lamp beams will streak across the entire surface of the target wall and it may be difficult to determine the center of the high intensity zone. Therefore, when aiming your fog lamps, ensure that the front of the vehicle is parked parallel to the target wall and the fog lamp lenses are perpendicular to the longitudinal axis of the vehicle. K 6 8 5 8 2 6 1 06/07/98 Page 9 of 9