Speed control DODGE RAM 1500 1998 2.G Workshop Manual

TRANSFER CASE - NV273
TABLE OF CONTENTS
page page
TRANSFER CASE - NV273
DESCRIPTION........................542
OPERATION..........................543
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV273.......................543
REMOVAL............................544
DISASSEMBLY........................544
CLEANING...........................554
INSPECTION.........................554
ASSEMBLY...........................556
INSTALLATION........................568
SPECIFICATIONS
TRANSFER CASE - NV273.............568
SPECIAL TOOLS
TRANSFER CASE NV271/NV273.........569
EXTENSION HOUSING SEAL AND DUST BOOT
REMOVAL............................571
INSTALLATION........................571FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL............................571
FRONT OUTPUT SHAFT SEAL
REMOVAL............................572
INSTALLATION........................572
MODE SENSOR
DESCRIPTION........................573
OPERATION..........................573
SELECTOR SWITCH
DESCRIPTION........................574
OPERATION..........................574
SHIFT MOTOR
DESCRIPTION........................575
OPERATION..........................575
REMOVAL............................575
INSTALLATION........................575
TRANSFER CASE - NV273
DESCRIPTION
The NV273 is an electronically controlled part-time
transfer case with a low range gear reduction system.
The NV273 has three operating ranges plus a NEU-
TRAL position. The low range system provides a gear
reduction ratio for increased low speed torque capa-
bility.
The geartrain is mounted in two aluminum case
halves attached with bolts. The mainshaft front and
rear bearings are mounted in aluminum case halves.
OPERATING RANGES
Transfer case operating ranges are:
²2WD (2-wheel drive)
²4HI (4-wheel drive)
²4LO (4-wheel drive low range)
²NEUTRAL
The 2WD range is for use on any road surface at
any time.The 4HI and 4LO ranges are for off road use only.
They are not for use on hard surface roads. The only
exception being when the road surface is wet or slip-
pery or covered by ice and snow.
The low range reduction gear system is operative
in 4LO range only. This range is for extra pulling
power in off road situations. Low range reduction
ratio is 2.72:1.
SHIFT MECHANISM
Operating ranges are selected with a dash
mounted shift selector switch. The shift selector
switch provides a input to the Transfer Case Control
Module (TCCM) to indicate the driver's desire to
change operating ranges. The TCCM uses this input,
along with input from the transfer case mounted
mode sensor and information from the vehicle's bus,
to determine if a shift is permitted. If the TCCM
decides the shift is permitted, the TCCM controls the
shift motor, mounted to the exterior of the transfer
case, to perform the shift.
21 - 542 TRANSFER CASE - NV273DR

have not been met. This is in an attempt to notify
the driver that the transmission needs to be put into
NEUTRAL, the vehicle speed is too great, or some
other condition outlined (other than a diagnostic fail-
ure that would prevent this shift) elsewhere (Refer to
8 - ELECTRICAL/ELECTRONIC CONTROL MOD-
ULES/TRANSFER CASE CONTROL MODULE -
OPERATION) is not met. Note that this flashing will
continue indefinitely until the conditions are eventu-
ally met, or the selector switch position is changed,
or if diagnostic routines no longer allow the
requested shift.
²
If the driver attempts to make a shift into transfer
case NEUTRAL, and any of the driver controllable con-
ditions are not met, the request will be ignored until all
of the conditions are met or until the NEUTRAL select
button is released. Additionally the neutral lamp will
flash, or begin to flash while the button is depressed
and operator controllable conditions are not being met.
All of the LED's except the Neutral will flash if any of
the operator controllable conditions for shifting are not
met while the Neutral button is depressed. This9toggle9
type of feature is necessary because the TCCM would
interpret another request immediately after the shift
into transfer case NEUTRAL has completed.
²No LED's illuminated indicate a fault in the
transfer case control system.
SHIFT MOTOR
DESCRIPTION
The shift motor (Fig. 96) consists of a permanent
magnet D.C. motor with gear reduction to convert a
high speed-low torque device into a low speed-high
torque device. The output of the device is coupled to
a shaft which internally moves the mode and range
forks that change the transfer case operating ranges.
The motor is rated at 25 amps maximum at 72É F
with 10 volts at the motor leads.
OPERATION
The transfer case shift motor responds to the
Transfer Case Control Module (TCCM) commands to
move the transfer case shift sector bi-directionally, as
required, to obtain the transfer case operating mode
indicated by the instrument panel mounted selector
switch.
REMOVAL
NOTE: New shift motor assemblies are shipped in
the 2WD/AWD position. If a new shift motor assem-
bly will be installed, it will be necessary to shift the
transfer case to the 2WD/AWD position prior to
motor removal.(1) Raise the vehicle on a suitable hoist.
(2) Disengage the wiring connectors from the shift
motor and mode sensor.
(3) Remove the bolts holding the shift motor and
mode sensor assembly onto the transfer case.
(4) Separate the shift motor and mode sensor
assembly from the transfer case.
INSTALLATION
(1) Verify that the shift sector o-ring is clean and
properly positioned over the shift sector and against
the transfer case.
NOTE: Verify that the shift motor position and sec-
tor shaft orientation are aligned. It may be neces-
sary to manually shift the transfer case if the shift
motor and sector shaft are not aligned.
(2) Position the shift motor and mode sensor
assembly onto the transfer case.
(3) Install the bolts to hold the assembly onto the
transfer case. Tighten the bolts to 16-24 N´m (12-18
ft.lbs.).
CAUTION: If the original shift motor and mode sen-
sor assembly bolts are reused, be sure to use
MoparTLock & Seal or LoctiteŸ 242 to replenish
the lock patch material originally found on the bolts
(4) Engage the wiring connectors to the shift motor
and mode sensor.
(5) Refill the transfer case as necessary.
(6) Lower vehicle and verify transfer case
operation.
Fig. 96 Shift Motor - Shown Inverted - Typical
1 - SHIFT MOTOR
DRTRANSFER CASE - NV273 21 - 575
SELECTOR SWITCH (Continued)

DESCRIPTION - TIRE PRESSURE FOR HIGH
SPEEDS
For proper tire pressure specification refer to the
Owners Manual.
DESCRIPTION - REPLACEMENT TIRES
The original equipment tires provide a proper bal-
ance of many characteristics such as:
²Ride
²Noise
²Handling
²Durability
²Tread life
²Traction
²Rolling resistance
²Speed capability
It is recommended that tires equivalent to the orig-
inal equipment tires be used when replacement is
needed.
Failure to use equivalent replacement tires may
adversely affect the safety and handling of the vehi-
cle.
The use of oversize tires may cause interference
with vehicle components. Under extremes of suspen-
sion and steering travel, interference with vehicle
components may cause tire damage.
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
DESCRIPTION - TIRE INFLATION PRESSURES
Under inflation will cause rapid shoulder wear, tire
flexing, and possible tire failure (Fig. 12).Over inflation will cause rapid center wear and
loss of the tire's ability to cushion shocks (Fig. 13).
Improper inflation can cause:
²Uneven wear patterns
²Reduced tread life
²Reduced fuel economy
²Unsatisfactory ride
²Vehicle drift
For proper tire pressure specification refer to the
vehicles Owners Manual.
WARNING: OVER OR UNDER INFLATED TIRES CAN
AFFECT VEHICLE HANDLING AND TREAD WEAR.
THIS MAY CAUSE THE TIRE TO FAIL SUDDENLY,
RESULTING IN LOSS OF VEHICLE CONTROL.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - PRESSURE
GAUGES
A quality air pressure gauge is recommended to
check tire pressure. After checking the air pressure,
replace valve cap finger tight.
DIAGNOSIS AND TESTING - TIRE NOISE OR
VIBRATION
Radial-ply tires are sensitive to force impulses
caused by improper mounting, vibration, wheel
defects, or possibly tire imbalance.
To find out if tires are causing the noise or vibra-
tion, drive the vehicle over a smooth road at varying
speeds. Note the noise level during acceleration and
deceleration. The engine, differential and exhaust
noises will change as speed varies, while the tire
noise will usually remain constant.
Fig. 12 Under Inflation Wear
1 - THIN TIRE THREAD AREAS
Fig. 13 Over Inflation Wear
1 - THIN TIRE THREAD AREA
DRTIRES/WHEELS 22 - 7
TIRES (Continued)

VISUAL INSPECTION BEFORE WATER LEAK TESTS
Verify that floor and body plugs are in place, body
drains are clear, and body components are properly
aligned and sealed. If component alignment or seal-
ing is necessary, refer to the appropriate section of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the conditions causing a water leak have
been determined, simulate the conditions as closely
as possible.
²If a leak occurs with the vehicle parked in a
steady light rain, flood the leak area with an open-
ended garden hose.
²If a leak occurs while driving at highway speeds
in a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water. Direct the
spray in a direction comparable to actual conditions.
²If a leak occurs when the vehicle is parked on an
incline, hoist the end or side of the vehicle to simu-
late this condition. This method can be used when
the leak occurs when the vehicle accelerates, stops or
turns. If the leak occurs on acceleration, hoist the
front of the vehicle. If the leak occurs when braking,
hoist the back of the vehicle. If the leak occurs on left
turns, hoist the left side of the vehicle. If the leak
occurs on right turns, hoist the right side of the vehi-
cle. For hoisting recommendations (Refer to LUBRI-
CATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE).
WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water
test and watch for water tracks or droplets forming
on the inside of the vehicle. If necessary, remove inte-
rior trim covers or panels to gain visual access to the
leak area. If the hose cannot be positioned without
being held, have someone help do the water test.
Some water leaks must be tested for a considerable
length of time to become apparent. When a leak
appears, find the highest point of the water track or
drop. The highest point usually will show the point of
entry. After leak point has been found, repair the
leak and water test to verify that the leak has
stopped.
Locating the entry point of water that is leaking
into a cavity between panels can be difficult. The
trapped water may splash or run from the cavity,
often at a distance from the entry point. Most water
leaks of this type become apparent after accelerating,
stopping, turning, or when on an incline.MIRROR INSPECTION METHOD
When a leak point area is visually obstructed, use
a suitable mirror to gain visual access. A mirror can
also be used to deflect light to a limited-access area
to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can
be detected without water testing. Position the vehi-
cle in a brightly lit area. From inside the darkened
luggage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage
compartment. If light is visible through a normally
sealed location, water could enter through the open-
ing.
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compart-
ment cannot be detected by water testing, pressurize
the passenger compartment and soap test exterior of
the vehicle. To pressurize the passenger compart-
ment, close all doors and windows, start engine, and
set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to ensure adequate voltage to the blower.
With interior pressurized, apply dish detergent solu-
tion to suspected leak area on the exterior of the
vehicle. Apply detergent solution with spray device or
soft bristle brush. If soap bubbles occur at a body
seam, joint, seal or gasket, the leak entry point could
be at that location.
DIAGNOSIS AND TESTING - WIND NOISE
Wind noise is the result of most air leaks. Air leaks
can be caused by poor sealing, improper body compo-
nent alignment, body seam porosity, or missing plugs
in the engine compartment or door hinge pillar areas.
All body sealing points should be airtight in normal
driving conditions. Moving sealing surfaces will not
always seal airtight under all conditions. At times,
side glass or door seals will allow wind noise to be
noticed in the passenger compartment during high
cross winds. Over compensating on door or glass
adjustments to stop wind noise that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After a repair pro-
cedure has been performed, test vehicle to verify
noise has stopped before returning vehicle to use.
VISUAL INSPECTION BEFORE TESTS
Verify that floor and body plugs are in place and
body components are aligned and sealed. If compo-
nent alignment or sealing is necessary, refer to the
appropriate section of this group for proper proce-
dures.
23 - 2 BODYDR
BODY (Continued)

ber above the heating, ventilation and air condition-
ing (HVAC) housing. On models equipped with air
conditioning, the air passes through the evaporator
coil. Air flow can be directed either through or
around the heater core. This is done by adjusting the
blend door with the temperature control knob on the
A/C-heater control located the instrument panel. The
air flow can then be directed from the panel, floor
and defrost outlets in various combinations using the
mode control knob located on the A/C-heater control.
Air flow velocity can be adjusted with the blower
speed selector located on the A/C-heater control.
NOTE: It is important to keep the air intake opening
clear of debris. Leaf particles and other debris that
is small enough to pass through the cowl opening
screen can accumulate within the HVAC housing.
The closed, warm, damp and dark environment cre-
ated within the housing is ideal for the growth of
certain molds, mildews and other fungi. Any accu-mulation of decaying plant matter provides an addi-
tional food source for fungal spores, which enter
the housing with the fresh intake-air. Excess debris,
as well as objectionable odors created by decaying
plant matter and growing fungi can be discharged
into the passenger compartment during heater-A/C
operation if the air intake opening is not kept clear
of debris.
The heater and air conditioning systems are blend-
air type systems. In a blend-air system, a blend door
controls the amount of unconditioned air (or cooled
air from the evaporator on models with air condition-
ing) that is allowed to flow through, or around, the
heater core. A temperature control knob determines
the discharge air temperature by actuating an elec-
tric motor, which operates the blend door. This allows
an almost immediate control of the output air tem-
perature of the system.
On all models, the outside air intake can be shut
off by selecting the Recirculation Mode with the
mode control knob. This will operate a electric actu-
ated recirculation air door that closes off the outside
fresh air intake and recirculates the air that is
already inside the vehicle.
The air conditioning compressor can be engaged in
any mode by pressing the snowflake, A/C on/off but-
ton. It can also be engaged by placing the mode con-
trol in the mix to defrost positions. This will remove
heat and humidity from the air before it is directed
through or around the heater core. The mode control
knob on the A/C-heater control is used to also direct
the conditioned air to the selected system outlets.
The mode control switch uses an electric motor to
control the mode doors.
The defroster outlet receives airflow from the
HVAC housing through the molded plastic defroster
duct, which connects to the HVAC housing defroster
outlet. The airflow from the defroster outlets is
directed by fixed vanes in the defroster outlet grilles
and cannot be adjusted. The defroster outlet grilles
are integral to the instrument panel top cover.
The side window demister outlets receive airflow
from the HVAC housing through the molded plastic
defroster duct and two molded plastic demister ducts.
The airflow from the side window demister outlets is
directed by fixed vanes in the demister outlet grilles
and cannot be adjusted. The side window demister
outlet grilles are integral to the instrument panel.
The demisters direct air from the HVAC housing
through the outlets located on the top corners of the
instrument panel. The demisters operate when the
mode control knob is positioned in the floor-defrost
and defrost-only settings. Some air may be noticeable
from the demister outlets when the mode control is
in the bi-level to floor positions.
Fig. 1 HVAC Housing - Dual Zone Shown, Single
Zone Typical
1 - NUT
2 - PASSENGER BLEND DOOR ACTUATOR
3 - NUT
4 - INLET BAFFLE
5 - RECIRCULATION DOOR ACTUATOR
6 - RECIRCULATION DOOR
7 - DRIVER SIDE BLEND DOOR ACTUATOR
8 - HVAC HOUSING
9 - BOLT
10 - DEFROSTER DOOR ACTUATOR
11 - MODE DOOR ACTUATOR
24 - 2 HEATING & AIR CONDITIONINGDR
HEATING & AIR CONDITIONING (Continued)

The panel outlets receive airflow from the HVAC
housing through a molded plastic main panel duct,
center panel duct and two end panel ducts. The two
end panel ducts direct airflow to the left and right
instrument panel outlets, while the center panel duct
directs airflow to the two center panel outlets. Each
of these outlets can be individually adjusted to direct
the flow of air.
The floor outlets receive airflow from the HVAC
housing through the floor distribution duct. The front
floor outlets are integral to the molded plastic floor
distribution duct, which is secured to the bottom of
the housing. The floor outlets cannot be adjusted.
The air conditioner for all models is designed for
the use of non-CFC, R-134a refrigerant. The air con-
ditioning system has an evaporator to cool and dehu-
midify the incoming air prior to blending it with the
heated air. This air conditioning system uses a fixed
orifice tube in the liquid line near the condenser out-
let tube to meter refrigerant flow to the evaporator
coil. To maintain minimum evaporator temperature
and prevent evaporator freezing, a evaporator tem-
perature sensor is used. The JTEC control module is
programmed to respond to the evaporator tempera-
ture sensor input by cycling the air conditioning com-
pressor clutch as necessary to optimize air
conditioning system performance and to protect the
system from evaporator freezing.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C
PERFORMANCE
The air conditioning system is designed to remove
heat and humidity from the air entering the passen-
ger compartment. The evaporator, located in the
HVAC housing, is cooled to temperatures near the
freezing point. As warm damp air passes over the
fins in the evaporator, moisture in the air condenses
to water, dehumidifying the air. Condensation on the
evaporator fins reduces the evaporators ability to
absorb heat. During periods of high heat and humid-
ity, an air conditioning system will be less effective.
With the instrument control set to Recirculation
mode, only air from the passenger compartment
passes through the evaporator. As the passenger com-
partment air dehumidifies, A/C performance levels
rise.
Humidity has an important bearing on the temper-
ature of the air delivered to the interior of the vehi-
cle. It is important to understand the effect that
humidity has on the performance of the air condition-
ing system. When humidity is high, the evaporator
has to perform a double duty. It must lower the air
temperature, and it must lower the temperature ofthe moisture in the air that condenses on the evapo-
rator fins. Condensing the moisture in the air trans-
fers heat energy into the evaporator fins and tubing.
This reduces the amount of heat the evaporator can
absorb from the air. High humidity greatly reduces
the ability of the evaporator to lower the temperature
of the air.
However, evaporator capacity used to reduce the
amount of moisture in the air is not wasted. Wring-
ing some of the moisture out of the air entering the
vehicle adds to the comfort of the passengers.
Although, an owner may expect too much from their
air conditioning system on humid days. A perfor-
mance test is the best way to determine whether the
system is performing up to standard. This test also
provides valuable clues as to the possible cause of
trouble with the air conditioning system.
PERFORMANCE TEST PROCEDURE
Review Safety Warnings and Cautions before per-
forming this procedure (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING) and
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - CAUTION). Air temperature in test
room and on vehicle must be 21É C (70É F) minimum
for this test.
NOTE: When connecting the service equipment
coupling to the line fitting, verify that the valve of
the coupling is fully closed. This will reduce the
amount of effort required to make the connection.
(1) Connect a tachometer and a manifold gauge set
or A/C recycling/charging station.
(2) Set the A/C-heater mode control in the Recircu-
lation Mode position, the temperature control knob in
the full cool position, and the blower motor switch to
the highest speed position.
(3) Start the engine and hold at 1,000 rpm with
the A/C compressor clutch engaged.
(4) The engine should be warmed up to operating
temperature with the doors closed and windows
open.
(5) Insert a thermometer in the driver side center
panel A/C-heater outlet and operate the engine for
five minutes.
(6) The compressor clutch may cycle, depending
upon the ambient temperature and humidity.
(7) With the compressor clutch engaged, record the
discharge air temperature and the compressor dis-
charge pressure.
(8) If the discharge air temperature fails to meet
the specifications in the A/C Performance Tempera-
ture chart, refer to the Pressure Diagnosis chart.
DRHEATING & AIR CONDITIONING 24 - 3
HEATING & AIR CONDITIONING (Continued)

Condition Possible Causes Correction
The low side pressure is too
low, and the high side
pressure is too high.1. Restricted refrigerant flow
through the refrigerant lines.1. See Liquid, Suction, and Discharge Line in this
group. Inspect the refrigerant lines for kinks, tight
bends or improper routing. Correct the routing or
replace the refrigerant line, if required.
2. Restricted refrigerant flow
through the fixed orifice tube.2. See A/C Orifice Tube in this group. Replace
the liquid line, if required.
3. Restricted refrigerant flow
through the condenser.3. See A/C Condenser in this group. Replace the
restricted condenser, if required.
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE TEST
Review Safety Warnings and Cautions before per-
forming this procedure (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING) and
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - CAUTION).
Check the coolant level, drive belt tension, vacuum
line connections, radiator air flow and fan operation.
Start engine and allow to warm up to normal tem-
perature.
WARNING: DO NOT REMOVE RADIATOR CAP
WHEN ENGINE IS HOT, PERSONAL INJURY CAN
RESULT.
If vehicle has been run recently, wait 15 minutes
before removing cap. Place a rag over the cap andturn it to the first safety stop. Allow pressure to
escape through the overflow tube. When the system
stabilizes, remove the cap completely.
MAXIMUM HEATER OUTPUT: TEST AND ACTION
Engine coolant is provided to the heater system by
two heater hoses. With the engine idling at normal
operating temperature, set the temperature control
to maximum heat, the mode control to the floor posi-
tion, and the blower in the highest speed position.
Using a test thermometer, check the temperature of
the air being discharged from the floor outlets. Com-
pare the test thermometer reading to the Tempera-
ture Reference chart.
TEMPERATURE REFERENCE CHART
Ambient Air Temperature15.5É C
(60É F)21.1É C
(70É F)26.6É C
(80É F)32.2É C
(90É F)
Minimum Air Temperature at
Floor Outlet62.2É C
(144É F)63.8É C
(147É F)65.5É C
(150É F)67.2É C
(153É F)
Both of the heater hoses should be HOT to the
touch (coolant return hose should be slightly cooler
than the supply hose). If the coolant return hose is
much cooler than the supply hose, locate and repair
the engine coolant flow obstruction in the heater sys-
tem. If both heater hoses are cool to the touch,
inspect the engine cooling system (Refer to 7 -
COOLING - DIAGNOSIS AND TESTING).
OBSTRUCTED COOLANT FLOW Possible loca-
tions or causes of obstructed coolant flow are as fol-
lows:
²Pinched or kinked heater hoses.
²Improper heater hose routing.
²Plugged heater hoses or supply and return ports
at the cooling system connections.
²Plugged heater core.If proper coolant flow through the cooling system is
verified, and heater outlet air temperature is insuffi-
cient, a mechanical problem may exist.
MECHANICAL PROBLEMS Possible causes of
insufficient heat due to mechanical problems are as
follows:
²Obstructed cowl air intake.
²Obstructed heater system outlets.
²Blend door not functioning properly.
TEMPERATURE CONTROL
If the heater outlet air temperature cannot be
adjusted with the temperature control knob on the
A/C-heater control, the following could require ser-
vice:
²Blend door binding.
²Faulty blend door motor.
24 - 6 HEATING & AIR CONDITIONINGDR
HEATING & AIR CONDITIONING (Continued)

and coil are the only serviced parts on the compres-
sor.
A/C compressor clutch engagement is controlled by
several components: the A/C-heater control, A/C pres-
sure transducer, A/C compressor clutch relay, evapo-
rator temperature sensor and the powertrain control
module (PCM). The PCM may delay compressor
clutch engagement for up to thirty seconds (Refer to
8 - ELECTRICAL/ELECTRONIC CONTROL MOD-
ULES/POWERTRAIN CONTROL MODULE -
DESCRIPTION).
DIAGNOSIS AND TESTING - A/C COMPRESSOR
CLUTCH COIL
For circuit descriptions and diagrams, (Refer to
Appropriate Wiring Information). The battery must
be fully-charged before performing the following
tests. Refer to Battery for more information.
(1) Connect an ammeter (0 to 10 ampere scale) in
series with the clutch coil terminal. Use a voltmeter
(0 to 20 volt scale) with clip-type leads for measuring
the voltage across the battery and the compressor
clutch coil.
(2) With the A/C-heater controls in any A/C mode,
and the blower motor switch in the lowest speed
position, start the engine and run it at normal idle.
(3) The compressor clutch coil voltage should read
within 0.2 volts of the battery voltage. If there is
voltage at the clutch coil, but the reading is not
within 0.2 volts of the battery voltage, test the clutch
coil feed circuit for excessive voltage drop and repair
as required. If there is no voltage reading at the
clutch coil, use a DRB IIItscan tool and (Refer to
Appropriate Diagnostic Information) for testing of thecompressor clutch circuit and PCM control. The fol-
lowing components must be checked and repaired as
required before you can complete testing of the clutch
coil:
²Fuses in the junction block and the power distri-
bution center (PDC)
²A/C-heater control
²A/C compressor clutch relay
²A/C pressure transducer
²Evaporator temperature sensor
²Powertrain control module (PCM)
(4) The compressor clutch coil is acceptable if the
current draw measured at the clutch coil is within
specifications with the electrical system voltage at
11.5 to 12.5 volts (Refer to 24 - HEATING & AIR
CONDITIONING - SPECIFICATIONS). This should
only be checked with the work area temperature at
21É C (70É F). If system voltage is more than 12.5
volts, add electrical loads by turning on electrical
accessories until the system voltage drops below 12.5
volts.
(a) If the clutch coil current reading is above
specifications, the coil is shorted and should be
replaced.
(b) If the clutch coil current reading is zero, the
coil is open and should be replaced.
STANDARD PROCEDURE - A/C COMPRESSOR
CLUTCH BREAK-IN
After a new compressor clutch has been installed,
cycle the compressor clutch approximately twenty
times (five seconds on, then five seconds off). During
this procedure, set the A/C-heater control to the
Recirculation Mode, the blower motor switch in the
highest speed position, and the engine speed at 1500
to 2000 rpm. This procedure (burnishing) will seat
the opposing friction surfaces and provide a higher
compressor clutch torque capability.
REMOVAL
The refrigerant system can remain fully-charged
during compressor clutch, rotor, or coil replacement.
The compressor clutch can be serviced in the vehicle.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Disconnect the compressor clutch coil wire har-
ness connector.
(4) Remove the bolts that secure the compressor to
the mounting bracket.
(5) Remove the compressor from the mounting
bracket. Support the compressor in the engine com-
partment while servicing the clutch.
Fig. 1 Compressor Clutch - Typical
1 - CLUTCH PLATE
2 - SHAFT KEY (not used on KJ)
3 - ROTOR
4 - COIL
5 - CLUTCH SHIMS
6 - SNAP RING
7 - SNAP RING
24 - 10 CONTROLSDR
A/C COMPRESSOR CLUTCH/COIL (Continued)

spikes and electromagnetic interference that can be
generated as the electromagnetic field of the relay
coil collapses.
The A/C compressor clutch relay terminals are con-
nected to the vehicle electrical system through a
receptacle in the integrated power module (IPM). The
inputs and outputs of the A/C compressor clutch
relay include:
²The common feed terminal (30) receives a bat-
tery current input from a fuse in the IPM through a
fused B(+) circuit at all times.
²The coil ground terminal (86) receives a ground
input from the PCM/ECM through the A/C compres-
sor clutch relay control circuit only when the PCM/
ECM electronically pulls the control circuit to
ground.
²The coil battery terminal (85) receives a battery
current input from PTC 1 in the IPM through a
fused ignition switch output (run) circuit only when
the ignition switch is in the On position.
²The normally open terminal (87) provides a bat-
tery current output to the compressor clutch coil
through the A/C compressor clutch relay output cir-
cuit only when the A/C compressor clutch relay coil is
energized.
²The normally closed terminal (87A) is not con-
nected to any circuit in this application, but provides
a battery current output only when the A/C compres-
sor clutch relay coil is de-energized.
Refer to the appropriate wiring information for
diagnosis and testing of the micro-relay and for com-
plete HVAC wiring diagrams.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the integrated power
module (IPM) (Fig. 11).
(3) Refer to the fuse and relay layout label on the
IPM cover for compressor clutch relay identification
and location.
(4) Remove the A/C compressor clutch relay from
the IPM.
INSTALLATION
(1) See the fuse and relay layout label affixed to
the underside of the IPM cover for A/C compressor
clutch relay location.
(2) Position the A/C compressor clutch relay in the
proper receptacle in the IPM.
(3) Align the A/C compressor clutch relay termi-
nals with the terminal cavities in the IPM receptacle.
(4) Push down firmly on the A/C compressor clutch
relay until the terminals are fully seated in the ter-
minal cavities in the IPM receptacle.
(5) Install the cover onto the IPM.(6) Reconnect the negative battery cable.
A/C HEATER CONTROL
DESCRIPTION
The heater and air conditioning systems use elec-
trical controls. These controls provide the vehicle
operator with a number of setting options to help
control the climate and comfort within the vehicle.
The A/C-heater control for the Single Zone system
(Fig. 12) or Dual Zone system (Fig. 13) is located to
the right of the instrument cluster on the instrument
panel.
The Single Zone control panel contains a rotary-
type temperature control switch, a rotary-type mode
control switch and a rotary-type blower motor speed
switch. The A/C-heater control also has a push but-
ton to activate the optional heated side view mirror
defroster elements and to turn the A/C on.
The Dual Zone control panel contains a pair of slid-
er-type temperature control switches, a rotary-type
mode control switch and a rotary-type blower motor
speed switch. The control also has buttons to activate
the optional heated sideview mirror defroster ele-
ments, turn the A/C on and set the system to Max
A/C.
The A/C-heater control panel cannot be repaired. If
faulty or damaged, the entire unit must be replaced.
Fig. 11 Integrated Power Module (IPM)
1 - BATTERY
2 - INTEGRATED POWER MODULE (IPM)
24 - 14 CONTROLSDR
A/C COMPRESSOR CLUTCH RELAY (Continued)

NOTE: The single zone heating and air conditioning
system is equipped with a single blend door actua-
tor. The dual zone system has two blend door
actuators, one for the driver side blend air door and
one for the passenger side blend air door. The
same service procedures can be used for each of
these actuators.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel from the vehicle
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Disconnect the wire harness connector from the
blend door actuator(s) (Fig. 16).
(4) Remove the screws that secure the blend door
actuator(s) to the HVAC housing.
(5) Remove the blend door actuator(s) from the
HVAC housing.INSTALLATION
(1) Position the blend door actuator(s) into the
HVAC housing. If necessary, rotate the actuator(s)
slightly to align the splines on the actuator output
sleeve(s) with those on the blend door linkage.
(2) Install and tighten the screws that secure the
blend door actuator(s) to the HVAC housing. Tighten
the screws to 2 N´m (17 in. lbs.).
(3) Connect the HVAC wire harness connector to
the blend door actuator(s).
(4) Install the instrument panel (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION).
(5) Reconnect the battery negative cable.
BLOWER MOTOR RESISTOR
BLOCK
DESCRIPTION
The blower motor resistor is mounted to the bot-
tom side of the HVAC housing near the blower motor.
It can be accessed for service from underneath the
instrument panel.
OPERATION
The resistor has multiple resistor wires, each of
which will reduce the current flow to the blower
motor to change the blower motor speed by changing
the resistance in the blower motor ground path. The
blower motor switch directs the ground path through
the correct resistor wire to obtain the selected speed.
With the blower motor switch in the lowest speed
position, the ground path for the motor is applied
through all of the resistor wires. Each higher speed
selected with the blower motor switch applies the
blower motor ground path through fewer of the resis-
tor wires, increasing the blower motor speed. When
the blower motor switch is in the highest speed posi-
tion, the blower motor resistor is bypassed and the
blower motor receives a direct path to ground.
The blower motor resistor cannot be repaired and,
if faulty or damaged, it must be replaced.
Fig. 16 HVAC Housing - Dual Zone Shown, Single
Zone Typical
1 - NUT
2 - PASSENGER BLEND DOOR ACTUATOR
3 - NUT
4 - INLET BAFFLE
5 - RECIRCULATION DOOR ACTUATOR
6 - RECIRCULATION DOOR
7 - DRIVER SIDE BLEND DOOR ACTUATOR
8 - HVAC HOUSING
9 - BOLT
10 - DEFROSTER DOOR ACTUATOR
11 - MODE DOOR ACTUATOR
24 - 18 CONTROLSDR
BLEND DOOR ACTUATOR (Continued)