relay DODGE RAM 1999 Service Owners Manual

Fig. 2: Identifying Starter Relay Terminals (Concorde, Dakota,
Durango, Intrepid, LHS, Ram Van, Ram Wagon &
300M)
Courtesy of Chrysler Corp.

STARTER RELAY CIRCUIT TEST
NOTE: Perform STARTER RELAY TEST before testing starter relay
circuit.
1) Ensure battery is fully charged. Remove starter relay from
Power Distribution Center (PDC). Refer to PDC cover for proper relay
location. PDC is located in engine compartment.
2) Connect a jumper wire between starter relay socket
terminal No. 30 and terminal No. 87. See Fig. 1 or 2. If engine does
not crank, go to SOLENOID TEST under BENCH TESTING. If engine cranks,
go to next step.
3) Turn ignition on. Check voltage between ground and starter
relay socket terminal No. 30. If battery voltage is not present,
repair open in circuit between starter relay socket and battery. If
battery voltage is present, go to next step.
4) Check voltage between ground and starter relay socket
terminal No. 86 with ignition switch in START position and clutch
pedal depressed (if equipped with M/T). If battery voltage is present,\
circuit is okay. Go to step 6) if equipped with M/T or step 7) if
equipped with A/T. If battery voltage is not present, repair open in
circuit between ignition switch and starter relay socket (A/T) or go
to next step (M/T).
5) Unplug wiring connector from clutch position switch
mounted on clutch pedal bracket. Connect jumper wire between clutch
position switch connector terminals. Recheck for voltage at starter
relay socket terminal No. 86 with ignition switch in START position.
If battery voltage is present, check clutch position switch adjustment
(if applicable). Adjust switch as necessary. If switch adjustment is
okay, check clutch position switch. See CLUTCH POSITION SWITCH TEST.
If battery voltage is not present, repair wiring between ignition
switch and starter relay socket as necessary.
6) On M/T models, connect voltmeter negative lead to starter
relay socket terminal No. 85 and positive lead to terminal No. 86.
Turn ignition switch to START position and depress clutch pedal. If
battery voltage is present, starter relay socket ground circuit is
good. Replace faulty starter relay. If battery voltage is not present,
repair ground wire circuit.
7) On A/T models, connect voltmeter negative lead to starter
relay socket terminal No. 85 and positive lead to terminal No. 86.
Ensure transmission gear selector is in Park or Neutral position.
Ground circuit runs through Park/Neutral Position (PNP) switch or
Transmission Range (TR) sensor on transmission. Turn ignition switch
to START position. If battery voltage is present, starter relay socket
ground circuit is good. Replace faulty starter relay.
8) If battery voltage is not present, check PNP switch or TR
sensor for loose or damaged connections. Also, check ground to PNP
switch or TR sensor. Repair as necessary. If connections and ground
are okay, check PNP switch or TR sensor. See PARK/NEUTRAL POSITION
(PNP) SWITCH & TRANSMISSION RANGE (TR) SENSOR TEST.
PARK/NEUTRAL POSITION (PNP) SWITCH & TRANSMISSION RANGE (TR)
SENSOR TEST
NOTE: Transmission Range (TR) sensor may be also known as
Park/Neutral Position (PNP) switch or Park/Neutral switch.
NOTE: The following test is for Caravan, Ram Van, Ram Wagon and
Voyager with 3-speed transmission. All other models are
equipped with a Transmission Range (TR) sensor. If TR sensor
or sensor circuit is defective, see appropriate NTC test in
appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE
section.

STE ER IN G C O LU M N S W IT C HES
1999 D odge P ic ku p R 1500
1999 ACCESSORIES & EQUIPMENT
CHRY - Steering Column Switches
Dakota, Durango & Ram Pickup
WARNING: Deactivate air bag system before performing any service
operation involving steering column components. See
appropriate AIR BAG RESTRAINT SYSTEMS article. DO NOT apply
electrical power to any component on steering column without
first disconnecting air bag module. Air bag may deploy. Wait
at least 2 minutes after disconnecting negative battery cable
before servicing air bag system. System reserve capacitor,
integral to ACM, maintains air bag system voltage for about 2
minutes after battery is disconnected. Servicing air bag
system before 2-minute period may cause accidental air bag
deployment and possible personal injury.
DESCRIPTION
Turn signal, hazard flasher, headlight beam selector,
headlight flash-to-pass, windshield wipe, pulse wipe and windshield
wash systems use a common switch assembly (multifunction switch)
mounted within upper steering column housing.
Ignition switch and lock cylinder are incorporated into an
assembly attached to side of steering column. Ignition switch assembly
can be serviced as a separate unit, but requires removal of lock
cylinder.
COMPONENT LOCATIONS
COMPONENT LOCATIONS








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Component Location
Combination Flasher Relay ........................... Junction Block
Horn ............................... In Right Front Corner Of Engine
Compartment
Horn Relay ............................ In Power Distribution Center
Junction Block ................. Under Left Side Of Instrument Panel
Power Distribution Center ...... In Left Side Of Engine Compartment,
On Left Inner Panel
Relay/Flasher Module ........ Under Right Side Of Instrument Panel,
Behind Glove Box









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TROUBLE SHOOTING
TURN SIGNAL AND HAZARD FLASHER SYSTEM
Bulbs Burn Out Rapidly
Check charging system. See appropriate GENERATORS &
REGULATORS article in STARTING & CHARGING SYSTEMS.
Hazard Flashers Inoperative
Blown fuse. Faulty hazard flasher. Open circuit in feed wire
to hazard switch. Faulty turn signal/hazard switch. Open or grounded
circuit in wiring to external lights.

Hazard Warning Lights Okay To Front Lights Only
Faulty external bulbs. Faulty contact in turn signal/hazard
switch. Open circuit between hazard switch and turn signal switch.
Open or grounded circuit in wiring to rear lights.
Hazard Warning Lights Okay To Rear Lights Only
Faulty external bulbs. Faulty contact in turn signal/hazard
switch. Open or grounded circuit in wiring to front lights.
Indicator Light Inoperative, External Lights Okay
Burned-out indicator bulb in instrument cluster. Faulty
contact. Open circuit.
Indicator Light Okay, External Lights Inoperative
Open circuit in wiring to external light(s).
Indicator Light Okay, External Lights Glow Dimly Or Do Not
Flash
Loose or corroded external light connections. Poor ground
circuit at external light(s).
Turn Signals Do Not Cancel After Turn
Broken canceling pawl on turn signal switch. Improperly
aligned canceling cam. Broken or loose canceling cam.
Turn Signals Inoperative (Both Sides)
Blown fuse. Faulty turn signal flasher. Loose bulkhead
connector. Loose or faulty rear wiring harness or terminals. Open
circuit to turn signal flasher. Open circuit in feed wire to turn
signal switch. Faulty switch connections. Open or grounded circuit in
wiring to external lights.
Turn Signal Inoperative (One Side)
Faulty external bulb. Poor ground at external light. Open
circuit in wiring to external light(s). Faulty turn signal/hazard
switch.
COMPONENT TESTS
CAUTION: When battery is disconnected, vehicle computer and memory
systems may lose memory data. Driveability problems may exist
until computer systems have completed a relearn cycle. See
COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION
before disconnecting battery.
NOTE: For additional testing procedures, see appropriate CRUISE
CONTROL SYSTEMS and WIPER/WASHER SYSTEMS articles.
NOTE: For component locations, see COMPONENT LOCATIONS.
HORN RELAY
1) Remove horn relay from Power Distribution Center (PDC).
Use label on PDC cover to identify and locate relay. Check continuity
between relay terminals No. 87A and 30. See Fig. 1. If continuity does
not exist, replace relay. If continuity exists, go to next step.
2) Check continuity between relay terminals No. 30 and 87. If
continuity exists, replace relay. If continuity does not exist, check
resistance between relay terminals No. 85 and 86. If resistance is not
70-80 ohms, replace relay. If resistance is 70-80 ohms, go to next
step.
3) Using jumper wires, connect positive battery voltage to

relay terminal No. 86 and ground to relay terminal No. 85. Continuity
should exist between terminals No. 30 and 87. Continuity should not
exist between relay terminals No. 87A and 30. If continuity is not as
specified, replace relay. If continuity is as specified, relay is
okay. Go to HORN RELAY CIRCUIT test under SYSTEM TESTS.
Fig. 1: Identifying Horn Relay Terminals
Courtesy of Chrysler Corp.
IGNITION SWITCH
NOTE: For ignition switch circuit identification, see IGNITION
SWITCH CIRCUIT FUNCTIONS table.
Remove ignition switch. See IGNITION SWITCH under REMOVAL &
INSTALLATION. Check continuity between appropriate ignition switch
terminals with switch in specified position. See IGNITION SWITCH
CONTINUITY table. See Fig. 2.
IGNITION SWITCH CONTINUITY









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Switch Position Continuity Between Terminals
ACC .......................................................... 6 & 7
OFF ............................................................ ( 1)
RUN ............................................ 2 & 7; 4 & 5; 6 & 7
START ............................................. ( 2) 1 & 7; 2 & 7
( 1) - Continuity should not exist between any terminals with key
removed.
( 2) - Continuity should also exist between terminal No. 3 and case

Fig. 3: Identifying Multifunction Switch Terminals
Courtesy of Chrysler Corp.
SYSTEM TESTS
HORN
1) Check resistance between horn mounting bracket and ground.
If resistance is zero ohms, go to next step. If resistance is not zero
ohms, repair horn ground connection.
2) Check for battery voltage at horn harness connector when
horn switch is pressed. If battery voltage exists, replace horn. If
battery voltage does not exist, go to next step.
3) Test horn relay. See HORN RELAY under COMPONENT TESTS. If
relay is okay, check horn circuit. See HORN RELAY CIRCUIT. If relay is
not okay, replace horn relay.
HORN RELAY CIRCUIT
1) Remove horn relay from Power Distribution Center (PDC).
Measure voltage between ground and horn relay terminals No. 30 and 86
in PDC. See Fig. 4. If battery voltage exists at both terminals, go to
next step. If battery voltage does not exist at one or both terminals,
repair open circuit to PDC.
2) Disconnect both horn connectors. Check continuity between
horn relay terminal No. 87 in PDC and Dark Green/Red wire at each horn
harness connector. If continuity exists, go to next step. If
continuity does not exist, repair open in Dark Green/Red wire.
3) Check continuity between ground and relay terminal No. 85
in PDC. With horn switch depressed, continuity should exist. With horn
switch released, continuity should not exist. If continuity is not as
specified, go to HORN SWITCH. If continuity is as specified, no fault
is indicated in relay circuits.

Fig. 4: Identifying Horn Relay Terminals In PDC
Courtesy of Chrysler Corp.
HORN SWITCH
1) Disconnect negative battery cable. Remove steering column
opening cover from instrument panel. Check continuity between ground
and metal steering column jacket. If continuity exists, go to next
step. If continuity does not exist, check for proper installation of
steering column mounting nuts.
2) Disable air bag system and remove driver's air bag module.
See appropriate AIR BAG RESTRAINT SYSTEMS article. Remove horn relay
from Power Distribution Center (PDC). Use label on PDC cover to
identify and locate relay. Check continuity between horn relay
terminal No. 85 in PDC and Black/Red wire at steering column horn

switch connector. See Fig. 4. If continuity does not exist, repair
open Black/Red wire. If continuity exists, go to next step.
3) Check continuity between ground and Black/Red wire at
steering column horn switch connector. If continuity does not exist,
go to next step. If continuity exists, repair short to ground in
Black/Red wire.
4) Continuity between horn switch terminal and ground.
Continuity should exist with horn switch depressed. Continuity should
not exist without horn switch depressed. If continuity is not as
specified, replace horn switch. If continuity is as specified, install
horn relay and go to HORN under COMPONENT TESTS.
TURN SIGNAL & HAZARD WARNING SYSTEMS
1) If bulbs burn out rapidly, check charging system for
overcharging condition. See appropriate GENERATORS & REGULATORS
article in STARTING & CHARGING SYSTEMS. If charging system is okay, go
to next step. If charging system is not okay, repair as necessary.
2) If problem is turn signals failing to cancel after a turn,
inspect multifunction switch or cancelling cam lobes on clockspring
for damage or improper installation. If problem exists, repair as
necessary. If problem does not exist, go to next step.
3) Turn ignition on. Actuate turn signal switch or hazard
warning switch. Observe turn signal indicator light(s) in instrument
cluster. If flash rate is very high, check for a bulb that is not lit
or is dimly lit. Repair circuit or replace bulb as necessary. If turn
signals fail to light, go to next step.
4) Turn ignition off. Check turn signal fuse in junction
block and/or hazard warning fuse in PDC. If fuses are okay, go to next
step. If either fuse is blown, repair short circuit and replace fuse.
5) Check for battery voltage at hazard warning fuse in PDC.
Turn ignition on. Check for battery voltage at turn signal fuse in
junction block. If battery voltage exists, go to next step. If battery
voltage does not exist, repair open circuit to battery or ignition
switch as necessary.
6) Turn ignition off. Disconnect negative battery cable.
Remove combination flasher from junction block and replace with a
known good unit. Connect battery cable and test operation of turn
signal and hazard warning systems. If operation is okay, discard
faulty flasher. If operation is not okay, go to next step.
7) Turn ignition on. Check for battery voltage at combination
flasher terminals No. 51 and 48 in junction block. If battery voltage
exists, go to next step. If battery voltage does not exist, repair
open circuit to fuse in junction block or PDC as necessary.
8) Disconnect negative battery cable. Check continuity
between combination flasher terminal No. 50 and ground. If continuity
exists, go to next step. If continuity does not exist, repair open
ground circuit.
9) Disconnect multifunction switch harness connector. Check
continuity between junction block terminal No. 4 and multifunction
switch terminal No. 13 (Pink wire). If continuity exists, go to next
step. If continuity does not exist, repair open in Pink wire between
multifunction switch and junction block.
10) Check continuity between junction block terminal No. 13
and multifunction switch terminal No. 17 (Red/White wire). If
continuity exists, test multifunction switch. See MULTIFUNCTION SWITCH
under COMPONENT TESTS. If continuity does not exist, repair open in
Red/White wire between junction block and multifunction switch.
REMOVAL & INSTALLATION
WARNING: Deactivate air bag system before performing any service


* S TE ER IN G U NIF O RM IN SPEC TIO N G UID ELIN ES *

1 999 D odge P ic ku p R 1500
GENERAL INFORMATION
Steering, Suspension, Wheel Alignment, Wheels and Tires
Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Steering and Suspension
AIR RIDE SUSPENSION
AIR RIDE SUSPENSION - AIR SHOCKS AND AIR STRUTS
AIR RIDE SUSPENSION - AIR SPRING VALVES
AIR RIDE SUSPENSION - AIR SPRINGS
AIR RIDE SUSPENSION - COMPRESSORS
AIR RIDE SUSPENSION - HEIGHT SENSORS
AIR RIDE SUSPENSION - MODULES
AIR RIDE SUSPENSION - RELAYS (COMPRESSOR)
AIR RIDE SUSPENSION - SWITCHES (ON/OFF)
AIR RIDE SUSPENSION - TORSION SPRINGS (COUNTER BALANCING)
AIR RIDE SUSPENSION - TUBING
AIR RIDE SUSPENSION - WARNING LAMPS
AIR RIDE SUSPENSION - WIRING HARNESSES
BALL JOINTS
BUSHINGS
CENTER LINKS
CONTROL ARM SHAFTS
CONTROL ARMS
DRAG LINKS
ELECTRONIC RIDE CONTROL SHOCKS AND STRUTS
IDLER ARMS
KING PINS
PITMAN ARMS
POWER STEERING HOSES
POWER STEERING (HYDRAULIC) PUMPS
RADIUS ARMS
RELAY RODS
SHOCK ABSORBERS, STRUT CARTRIDGES AND STRUT ASSEMBLIES
SPINDLES
SPRINGS - COIL, LEAF AND TORSION BAR
STEEL POWER STEERING LINES
STEERING ARMS
STEERING DAMPERS
STEERING GEARS (EXCEPT RACK AND PINION)
STEERING GEARS - RACK AND PINION
STEERING KNUCKLES
STRIKE OUT BUMPERS
STRUT RODS
STRUT UPPER BEARING PLATE ASSEMBLIES
SWAY BAR LINKS
SWAY BARS

threads damaged ........ A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Dust boot missing ....... 2 ........ (1) Suggest replacement.
Dust boot split ......... 2 ........ ( 1) Suggest replacement.
Dust boot torn .......... 2 ........ ( 1) Suggest replacement.
Housing cracked ......... A ............ Require replacement.
Lead routing incorrect .. B .. Require rerouting according to
vehicle manufacturer's
specifications.
Loose ................... B ... Require adjustment to vehicle
manufacturer's specifications.
Missing ................. C ............ Require replacement.
Output signal incorrect . A .. Require repair or replacement.
Wire lead damaged ....... A .. Require repair or replacement.
( 1) - This condition can lead to damage of the sliding magnet,
which, in turn, causes premature sensor failure.









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AIR RIDE SUSPENSION - MODULES
AIR RIDE SUSPENSION - MODULE INSPECTION








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Condition Code Procedure
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part.
Attaching hardware
missing ................ C .. Require replacement of missing
part.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Housing cracked ......... 2 .. Suggest repair or replacement.
Inoperative ............. A ............ Require replacement.
Missing ................. C ............ Require replacement.









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AIR RIDE SUSPENSION - RELAYS (COMPRESSOR)
AIR RIDE SUSPENSION - RELAY (COMPRESSOR) INSPECTION








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Condition Code Procedure
Housing cracked ......... 2 ........ ( 1) Suggest replacement.
Intermittent ............ A ............ Require replacement.
Missing ................. C ............ Require replacement.
Output signal incorrect . A ............ Require replacement.
( 1) - If moisture enters the relay, it can reduce life
expectancy or impair function.









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AIR RIDE SUSPENSION - SWITCHES (ON/OFF)