Transmission DODGE RAM 2002 Service Owners Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 2002, Model line: RAM, Model: DODGE RAM 2002Pages: 2255, PDF Size: 62.07 MB
Page 599 of 2255
fault or malfunction. Refer to the appropriate diag-
nostic information to diagnose the problem.
SPECIAL TOOLS - AIRBAG SYSTEM
AIRBAG CONTROL MODULE
DESCRIPTION
The Airbag Control Module (ACM) is concealed
underneath the plastic ACM trim cover (automatic
transmission) or center console (manual transmis-
sion), directly below the instrument panel in the pas-
senger compartment of the vehicle. The ACM is
secured with screws to a stamped steel mounting
bracket located under the instrument panel center
support bracket on the floor panel transmission tun-
nel. The ACM contains an electronic microprocessor,
an electronic impact sensor, an electromechanical saf-
ing sensor, and an energy storage capacitor. TheACM is connected to the vehicle electrical system
through a take out and connector of the instrument
panel wire harness.
The ACM cannot be repaired or adjusted and, if
damaged or faulty, it must be replaced.
OPERATION
The microprocessor in the ACM contains the airbag
system logic circuits, and it monitors and controls all
of the airbag system components. The ACM also uses
On-Board Diagnostics (OBD) and can communicate
with other electronic modules in the vehicle as well
as with the DRBIIItscan tool using the Chrysler
Collision Detection (CCD) data bus network. This
method of communication is used for control of the
airbag indicator in the ElectroMechanical Instrument
Cluster (EMIC) and for airbag system diagnosis and
testing through the 16-way data link connector
located on the lower left edge of the instrument
panel. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/COMMUNICATION - OPER-
ATION). The ACM microprocessor continuously mon-
itors all of the airbag system electrical circuits to
determine the system readiness. If the ACM detects
a monitored system fault, it sets an active Diagnostic
Trouble Code (DTC) and sends messages to the
EMIC over the CCD data bus to turn on the airbag
indicator. (Refer to 8 - ELECTRICAL/INSTRUMENT
CLUSTER/AIRBAG INDICATOR - OPERATION). If
the airbag system fault is still present when the igni-
tion switch is turned to the Off position, the DTC is
stored in memory by the ACM. However, if a fault
does not recur for a number of ignition cycles, the
ACM will automatically erase the stored DTC.
The ACM receives battery current through two cir-
cuits, on a fused ignition switch output (run) circuit
through a fuse in the Junction Block (JB), and on a
fused ignition switch output (start-run) circuit
through a second fuse in the JB. The ACM is
grounded through a ground circuit and take out of
the instrument panel wire harness. This take out has
a single eyelet terminal connector secured by a nut to
a ground stud located on the forward extension of the
left front fender wheel housing in the engine com-
partment. Therefore, the ACM is operational when-
ever the ignition switch is in the Start or On
positions. The ACM also contains an energy-storage
capacitor. When the ignition switch is in the Start or
On positions, this capacitor is continually being
charged with enough electrical energy to deploy the
airbags for up to one second following a battery dis-
connect or failure. The purpose of the capacitor is to
provide backup airbag system protection in case
there is a loss of battery current supply to the ACM
during an impact. The capacitor is only serviced as a
unit with the ACM.
Fig. 4 16-Way Data Link Connector - Typical
1 - 16±WAY DATA LINK CONNECTOR
2 - BOTTOM OF INSTRUMENT PANEL
Puller C-3428-B
8O - 6 RESTRAINTSBR/BE
RESTRAINTS (Continued)
Page 600 of 2255
Two sensors are contained within the ACM, an
electronic impact sensor and a safing sensor. The
electronic impact sensor is an accelerometer that
senses the rate of vehicle deceleration, which pro-
vides verification of the direction and severity of an
impact. A pre-programmed decision algorithm in the
ACM microprocessor determines when the decelera-
tion rate as signaled by the impact sensor indicates
an impact that is severe enough to require airbag
system protection. When the programmed conditions
are met, the ACM sends an electrical signal to deploy
the airbags. The safing sensor is an electromechani-
cal sensor within the ACM that is connected in series
between the ACM microprocessor airbag deployment
circuit and the airbags. The safing sensor is a nor-
mally open switch that is used to verify or confirm
the need for an airbag deployment by detecting
impact energy of a lesser magnitude than that of the
electronic impact sensor, and must be closed in order
for the airbags to deploy. The impact sensor and saf-
ing sensor are calibrated for the specific vehicle, and
are only serviced as a unit with the ACM.
REMOVAL
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE AIRBAG SYSTEM. FAILURE TO TAKE
THE PROPER PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI-
BLE PERSONAL INJURY.
WARNING: THE AIRBAG CONTROL MODULE CON-
TAINS THE IMPACT SENSOR, WHICH ENABLES
THE SYSTEM TO DEPLOY THE AIRBAGS. NEVER
STRIKE OR KICK THE AIRBAG CONTROL MODULE,
AS IT CAN DAMAGE THE IMPACT SENSOR OR
AFFECT ITS CALIBRATION. IF AN AIRBAG CON-
TROL MODULE IS ACCIDENTALLY DROPPED DUR-
ING SERVICE, THE MODULE MUST BE SCRAPPED
AND REPLACED WITH A NEW UNIT. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER AIRBAG
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
RIES.
(1) Disconnect and isolate the battery negative
cable. If either of the airbags has not been deployed,wait two minutes for the system capacitor to dis-
charge before further service.
(2) If the vehicle is equipped with a manual trans-
mission, remove the center floor console from the
floor panel transmission tunnel. (Refer to 23 - BODY/
INTERIOR/CENTER CONSOLE - REMOVAL).
(3) If the vehicle is equipped with an automatic
transmission, remove the two screws that secure the
trim cover to the Airbag Control Module (ACM)
mounting bracket on the floor panel transmission
tunnel and remove the trim cover (Fig. 5).
(4) Loosen the screw that secures each side of the
instrument panel center support bracket to the ACM
mounting bracket (Fig. 6). Do not remove these
screws.
(5) Remove the two nuts that secure the instru-
ment panel center support bracket to the studs on
the lower instrument panel structural support.
(6) Disengage the retainer on the instrument
panel wire harness take out to the ACM from the
retainer hole in the left side of the instrument panel
center support bracket.
(7) Pull the top of the instrument panel center
support bracket rearward and down from the instru-
ment panel studs. Fold it down over the top of the
ACM until it is laying flat on the floor panel trans-
mission tunnel.
(8) Disconnect the instrument panel wire harness
connector for the ACM from the ACM connector
receptacle. To disconnect this connector:
(a) Slide the red Connector Position Assurance
(CPA) lock on the top of the connector toward the
side of the vehicle.
Fig. 5 Airbag Control Module Trim Cover Remove/
Install
1 - INSTRUMENT PANEL SUPPORT BRACKET
2 - ACM MOUNTING BRACKET
3 - TRIM COVER
4 - SCREW
BR/BERESTRAINTS 8O - 7
AIRBAG CONTROL MODULE (Continued)
Page 601 of 2255
(b) Depress the connector latch tab and pull the
connector straight away from the ACM connector
receptacle.
NOTE: Always remove and replace the ACM and its
mounting bracket as a unit. Replacement modules
include a replacement mounting bracket. Do not
transfer the ACM to another mounting bracket.
(9) Remove the four screws that secure the ACM
mounting bracket to the floor panel transmission
tunnel.
(10) Remove the ACM, the mounting bracket, and
the instrument panel center support bracket from the
floor panel transmission tunnel as a unit.
INSTALLATION
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS ORSERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE AIRBAG SYSTEM. FAILURE TO TAKE
THE PROPER PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI-
BLE PERSONAL INJURY.
WARNING: THE AIRBAG CONTROL MODULE CON-
TAINS THE IMPACT SENSOR, WHICH ENABLES
THE SYSTEM TO DEPLOY THE AIRBAGS. NEVER
STRIKE OR KICK THE AIRBAG CONTROL MODULE,
AS IT CAN DAMAGE THE IMPACT SENSOR OR
AFFECT ITS CALIBRATION. IF AN AIRBAG CON-
TROL MODULE IS ACCIDENTALLY DROPPED DUR-
ING SERVICE, THE MODULE MUST BE SCRAPPED
AND REPLACED WITH A NEW UNIT. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER AIRBAG
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
RIES.
(1) Carefully position the Airbag Control Module
(ACM), the mounting bracket, and the instrument
panel center support bracket onto the floor panel
transmission tunnel as a unit (Fig. 6). When the
ACM is correctly positioned, the arrow on the ACM
label will be pointed forward in the vehicle.
(2) Install and tighten the four screws that secure
the ACM mounting bracket to the floor panel trans-
mission tunnel. Tighten the screws to 14 N´m (125
in. lbs.).
(3) With the instrument panel center support
bracket still folded down flat on the floor panel trans-
mission tunnel, reconnect the instrument panel wire
harness connector for the ACM to the ACM connector
receptacle. Be certain that the connector latch and
the red Connector Position Assurance (CPA) lock are
fully engaged.
(4) Fold the top of the instrument panel center
support bracket up over the top of the ACM and for-
ward over the studs on the lower instrument panel
structural support.
(5) Install and tighten the nuts that secure the
instrument panel center support bracket to the studs
on the lower instrument panel structural support.
Tighten the nuts to 14 N´m (125 in. lbs.).
(6) Engage the retainer on the instrument panel
wire harness take out for the ACM in the retainer
hole on the left side of the instrument panel center
support bracket.
(7) Tighten the screws that secure each side of the
instrument panel center support bracket to the ACM
mounting bracket. Tighten the screws 14 N´m (125
in. lbs.).
(8) If the vehicle is equipped with an automatic
transmission, position the ACM trim cover to the
ACM mounting bracket on the floor panel transmis-
sion tunnel (Fig. 5).
Fig. 6 Airbag Control Module Remove/Install
1 - INSTRUMENT PANEL
2 - SUPPORT BRACKET
3 - SCREW (2)
4 - FLOOR PANEL
5 - SCREW (4)
6 - MOUNTING BRACKET
7 - CONNECTOR
8 - ACM
9 - RETAINER
10 - NUT
8O - 8 RESTRAINTSBR/BE
AIRBAG CONTROL MODULE (Continued)
Page 602 of 2255
(9) If the vehicle is equipped with an automatic
transmission, install and tighten the two screws that
secure the ACM trim cover to the ACM mounting
bracket. Tighten the screws to 2.2 N´m (20 in. lbs.).
(10) If the vehicle is equipped with a manual
transmission, reinstall the center floor console onto
the floor panel transmission tunnel. (Refer to 23 -
BODY/INTERIOR/CENTER CONSOLE - INSTALLA-
TION).
(11) Do not reconnect the battery negative cable at
this time. The airbag system verification test proce-
dure should be performed following service of any
airbag system component. (Refer to 8 - ELECTRI-
CAL/RESTRAINTS - STANDARD PROCEDURE -
VERIFICATION TEST).
CHILD TETHER
REMOVAL
Standard cab models have two child tether anchors
secured near the top of the cab back panel. Club cab
and quad cab models have three child tethers
secured near the top of the cab back panel.
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELTTHAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
(1) Remove the trim from the inside of the cab
back panel. (Refer to 23 - BODY/INTERIOR/REAR
CLOSURE PANEL TRIM - REMOVAL).
(2) Remove the screw that secures the child tether
anchor (standard cab) or child tether (club/quad cab)
to the cab back panel (Fig. 7).
(3) Remove the child tether anchor (standard cab)
or child tether (club/quad cab) from the cab back
panel.
INSTALLATION
Standard cab models have two child tether anchors
secured near the top of the cab back panel. Club cab
and quad cab models have three child tethers
secured near the top of the cab back panel.
Fig. 7 Child Tether Anchor
1 - CHILD TETHER (CLUB/QUAD CAB) (3)
2 - SCREW (3)3 - CHILD TETHER ANCHOR (STANDARD CAB) (2)
4 - SCREW (2)
BR/BERESTRAINTS 8O - 9
AIRBAG CONTROL MODULE (Continued)
Page 624 of 2255
SPEED CONTROL
TABLE OF CONTENTS
page page
SPEED CONTROL
DESCRIPTION
DESCRIPTION - SPEED CONTROL SYSTEM . 1
DESCRIPTION - VEHICLE SPEED INPUT....2
OPERATION - SPEED CONTROL SYSTEM....2
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - VACUUM
SUPPLY TEST.........................3
DIAGNOSIS AND TESTING - ROAD TEST....4
SPECIFICATIONS
TORQUE - SPEED CONTROL SYSTEM.....4
CABLE
DESCRIPTION..........................4
OPERATION............................4
REMOVAL
REMOVAL - GAS ENGINES...............4
REMOVAL - DIESEL WITH AUTO. TRANS. . . . 5
INSTALLATION
INSTALLATION - GAS ENGINES...........5
INSTALLATION - DIESEL WITH AUTO.
TRANS...............................6SPEED CONTROL SERVO
DESCRIPTION..........................6
OPERATION............................6
REMOVAL
REMOVAL............................6
REMOVAL - DIESEL WITH AUTO. TRANS. . . . 9
INSTALLATION
INSTALLATION.......................11
INSTALLATION - DIESEL WITH AUTO.
TRANS..............................12
SWITCH
DESCRIPTION.........................12
OPERATION...........................12
REMOVAL.............................13
INSTALLATION.........................14
VACUUM RESERVOIR
DESCRIPTION.........................14
REMOVAL.............................14
INSTALLATION.........................15
SPEED CONTROL
DESCRIPTION
DESCRIPTION - SPEED CONTROL SYSTEM
Gas Engines and/or Diesel With Automatic Trans.
The speed control system is operated by the use of
a cable and a vacuum controlled servo. Electronic
control of the speed control system is integrated into
the Powertrain Control Module (PCM). The controls
consist of two steering wheel mounted switches. The
switches are labeled: ON/OFF, RES/ACCEL, SET,
COAST, and CANCEL.
The system is designed to operate at speeds above
30 mph (50 km/h).
WARNING: THE USE OF SPEED CONTROL IS NOT
RECOMMENDED WHEN DRIVING CONDITIONS DO
NOT PERMIT MAINTAINING A CONSTANT SPEED,
SUCH AS IN HEAVY TRAFFIC OR ON ROADS THATARE WINDING, ICY, SNOW COVERED, OR SLIP-
PERY.
Diesel With Manual Trans.
The speed control system is fully electronically con-
trolled by the Engine Control Module (ECM).A
cable and a vacuum controlled servo are not
used if the vehicle is equipped with a manual
transmission and a diesel engine. This is a ser-
vo-less system.The controls consist of two steering
wheel mounted switches. The switches are labeled:
ON/OFF, RES/ACCEL, SET, COAST, and CANCEL.
The system is designed to operate at speeds above
30 mph (50 km/h).
WARNING: THE USE OF SPEED CONTROL IS NOT
RECOMMENDED WHEN DRIVING CONDITIONS DO
NOT PERMIT MAINTAINING A CONSTANT SPEED,
SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT
ARE WINDING, ICY, SNOW COVERED, OR SLIP-
PERY.
BR/BESPEED CONTROL 8P - 1
Page 625 of 2255
DESCRIPTION - VEHICLE SPEED INPUT
Gas Engines and/or Diesel With Automatic Trans.
The Vehicle Speed Sensor (VSS) is no longer used
for any Dodge Truck.
Vehicle speed and distance covered are measured
by the Rear Wheel Speed Sensor. The sensor is
mounted to the rear axle. A signal is sent from this
sensor to the Controller Antilock Brake (CAB) com-
puter. A signal is then sent from the CAB to the Pow-
ertrain Control Module (PCM) to determine vehicle
speed and distance covered. The PCM will then
determine strategies for speed control system opera-
tion.
Diesel With Manual Trans.
The Vehicle Speed Sensor (VSS) is no longer used
for any Dodge Truck.
Vehicle speed and distance covered are measured
by the Rear Wheel Speed Sensor. The sensor is
mounted to the rear axle. A signal is sent from this
sensor to the Controller Antilock Brake (CAB) com-
puter. A signal is then sent from the CAB to the
Engine Control Module (ECM) to determine vehicle
speed and distance covered. The ECM will then
determine strategies for speed control system opera-
tion.
OPERATION - SPEED CONTROL SYSTEM
Gas Engines and/or Diesel With Automatic Trans.
When speed control is selected by depressing the
ON switch, the PCM allows a set speed to be stored
in PCM RAM for speed control. To store a set speed,
depress the SET switch while the vehicle is moving
at a speed between 35 and 85 mph. In order for the
speed control to engage, the brakes cannot be
applied, nor can the gear selector be indicating the
transmission is in Park or Neutral.
The speed control can be disengaged manually by:
²Stepping on the brake pedal.
²Depressing the OFF switch.
²Depressing the CANCEL switch.
²Depressing the clutch pedal (if equipped).
NOTE: Depressing the OFF switch or turning off the
ignition switch will erase the set speed stored in
the PCM.
For added safety, the speed control system is pro-
grammed to disengage for any of the following condi-
tions:
²An indication of Park or Neutral.
²A rapid increase of rpm (indication that the
clutch has been disengaged).²Excessive engine rpm (indicates that the trans-
mission may be in a low gear).
²The speed signal increases at a rate of 10 mph
per second (indicates that the coefficient of friction
between the road surface and tires is extremely low).
²The speed signal decreases at a rate of 10 mph
per second (indicates that the vehicle may have
decelerated at an extremely high rate).
Once the speed control has been disengaged,
depressing the RES/ACCEL switch (when speed is
greater than 30 mph) restores the vehicle to the tar-
get speed that was stored in the PCM.
While the speed control is engaged, the driver can
increase the vehicle speed by depressing the RES/AC-
CEL switch. The new target speed is stored in the
PCM when the RES/ACCEL is released. The PCM
also has a9tap-up9feature in which vehicle speed
increases at a rate of approximately 2 mph for each
momentary switch activation of the RES/ACCEL
switch.
A ªtap downº feature is used to decelerate without
disengaging the speed control system. To decelerate
from an existing recorded target speed, momentarily
depress the COAST switch. For each switch activa-
tion, speed will be lowered approximately 1 mph.
Diesel With Manual Trans.
When speed control is selected by depressing the
ON switch, the Engine Control Module (ECM) allows
a set speed to be stored in ECM RAM for speed con-
trol. To store a set speed, depress the SET switch
while the vehicle is moving at a speed between 35
and 85 mph. In order for the speed control to engage,
the brakes cannot be applied.The speed control can
be disengaged manually by:
²Stepping on the brake pedal.
²Depressing the OFF switch.
²Depressing the CANCEL switch.
²Depressing the clutch pedal.
NOTE: Depressing the OFF switch or turning off the
ignition switch will erase the set speed stored in
the ECM.
For added safety, the speed control system is pro-
grammed to disengage for any of the following condi-
tions:
²A rapid increase of rpm (indication that the
clutch has been disengaged).
²Excessive engine rpm (indicates that the trans-
mission may be in a low gear).
²The speed signal increases at a rate of 10 mph
per second (indicates that the coefficient of friction
between the road surface and tires is extremely low).
²The speed signal decreases at a rate of 10 mph
per second (indicates that the vehicle may have
decelerated at an extremely high rate).
8P - 2 SPEED CONTROLBR/BE
SPEED CONTROL (Continued)
Page 626 of 2255
Once the speed control has been disengaged,
depressing the RES/ACCEL switch (when speed is
greater than 30 mph) restores the vehicle to the tar-
get speed that was stored in the ECM.
While the speed control is engaged, the driver can
increase the vehicle speed by depressing the RES/AC-
CEL switch. The new target speed is stored in the
ECM when the RES/ACCEL is released. The ECM
also has a9tap-up9feature in which vehicle speed
increases at a rate of approximately 2 mph for each
momentary switch activation of the RES/ACCEL
switch.
A ªtap downº feature is used to decelerate without
disengaging the speed control system. To decelerate
from an existing recorded target speed, momentarily
depress the COAST switch. For each switch activa-
tion, speed will be lowered approximately 1 mph.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - VACUUM SUPPLY
TEST
Gas Powered Engines
On gasoline powered engines: actual engine vac-
uum, a vacuum reservoir, a one-way check valve and
vacuum lines are used to supply vacuum to the speed
control servo.
(1) Disconnect vacuum hose at speed control servo
and install a vacuum gauge into the disconnected
hose.
(2) Start engine and observe gauge at idle. Vac-
uum gauge should read at least ten inches of mer-
cury.
(3) If vacuum is less than ten inches of mercury,
determine source of leak. Check vacuum line to
engine for leaks. Also check actual engine intake
manifold vacuum. If manifold vacuum does not meet
this requirement, check for poor engine performance
and repair as necessary.
(4) If vacuum line to engine is not leaking, check
for leak at vacuum reservoir. To locate and gain
access to reservoir, refer to Vacuum Reservoir Remov-
al/Installation in this group. Disconnect vacuum line
at reservoir and connect a hand-operated vacuum
pump to reservoir fitting. Apply vacuum. Reservoir
vacuum should not bleed off. If vacuum is being lost,
replace reservoir.
(5) Verify operation of one-way check valve and
check it for leaks.
(a) Locate one-way check valve. The valve is
located in vacuum line between vacuum reservoirand engine vacuum source. Disconnect vacuum
hoses (lines) at each end of valve.
(b) Connect a hand-operated vacuum pump to
reservoir end of check valve. Apply vacuum. Vac-
uum should not bleed off. If vacuum is being lost,
replace one-way check valve.
(c) Connect a hand-operated vacuum pump to
vacuum source end of check valve. Apply vacuum.
Vacuum should flow through valve. If vacuum is
not flowing, replace one-way check valve. Seal the
fitting at opposite end of valve with a finger and
apply vacuum. If vacuum will not hold, diaphragm
within check valve has ruptured. Replace valve.
Diesel Engines With Automatic Trans.
On diesel powered engines equipped with an auto-
matic transmission: an engine driven vacuum pump,
a one-way check valve and vacuum lines are used to
supply vacuum to the speed control servo. A vacuum
reservoir is not used.
(1) Disconnect vacuum hose at speed control servo
and install a vacuum gauge into the disconnected
hose.
(2) Start engine and observe gauge at idle. For
vacuum testing and vacuum specifications, refer to
Vacuum Pump OutputÐDiesel Engine in 9, Engines.
(3) If vacuum pump output is OK, determine other
source of leak. Check all vacuum lines to: speed con-
trol servo, engine vacuum pump and heating/air con-
ditioning system for leaks.
(4) Verify operation of one-way check valve and
check it for leaks.
(a) Locate one-way check valve. The valve is
located in vacuum line between speed control servo
and engine vacuum pump. Disconnect vacuum
hoses (lines) at each end of valve.
(b) Connect a hand-operated vacuum pump to
reservoir end of check valve. Apply vacuum. Vac-
uum should not bleed off. If vacuum is being lost,
replace one-way check valve.
(c) Connect a hand-operated vacuum pump to
vacuum source end of check valve. Apply vacuum.
Vacuum should flow through valve. If vacuum is
not flowing, replace one-way check valve. Seal the
fitting at opposite end of valve with a finger and
apply vacuum. If vacuum will not hold, diaphragm
within check valve has ruptured. Replace valve.
Diesel Engine With Manual Trans.
Vacuum is not used for any part of the speed con-
trol system if equipped with a diesel engine and a
manual transmission.
BR/BESPEED CONTROL 8P - 3
SPEED CONTROL (Continued)
Page 635 of 2255
(4) Insert servo studs through holes in servo cable
sleeve.
(5) Install servo mounting nuts and tighten to 8.5
N´m (75 in. lbs.) torque.
(6) Connect vacuum line to servo.
(7) Connect electrical connector to servo terminals.
(8) Connect servo cable to throttle body. Refer to
Servo Cable Removal/Installation in this group.
(9) Install battery tray. Tighten all battery tray
mounting hardware to 16 N´m (140 in. lbs.) torque.
(10) Position battery into battery tray.
(11) If equipped, install battery heat shield.
(12) Install battery holddown clamp. Tighten bolt
to 4 N´m (35 in. lbs.) torque.
(13) Connect positive battery cable to battery.
(14) Connect negative battery cable to battery.
(15) Before starting engine, operate accelerator
pedal to check for any binding.
INSTALLATION - DIESEL WITH AUTO. TRANS.
(1) Position servo to mounting bracket.
(2) Align hole in cable connector with hole in servo
pin. Install cable-to-servo retaining clip.
(3) Insert servo studs through holes in servo
mounting bracket.
(4) Insert servo studs through holes in servo cable
sleeve.
(5) Install servo mounting nuts and tighten to 8.5
N´m (75 in. lbs.) torque.
(6) Connect vacuum line to servo.
(7) Connect electrical connector to servo terminals.
(8) Connect servo cable to throttle lever by push-
ing cable connector rearward onto lever pin while
holding lever forward.
(9) Install battery tray. Tighten all battery tray
mounting hardware to 16 N´m (140 in. lbs.) torque.
(10) Position battery into battery tray.
(11) If equipped, install battery heat shield.
(12) Install battery holddown clamp. Tighten bolt
to 4 N´m (35 in. lbs.) torque.
(13) Connect positive battery cable to battery.
(14) Connect negative battery cables to both bat-
teries.
(15) Before starting engine, operate accelerator
pedal to check for any binding.
(16) Install cable/lever cover.
SWITCH
DESCRIPTION
Gas Engines and Diesel With Auto. Trans.
There are two separate switch pods that operate
the speed control system. The steering-wheel-
mounted switches use multiplexed circuits to provideinputs to the Powertrain Control Module (PCM) for
ON, OFF, RESUME, ACCELERATE, SET, DECEL
and CANCEL modes. Refer to the owner's manual for
more information on speed control switch functions
and setting procedures.
The individual switches cannot be repaired. If one
switch fails, the entire switch module must be
replaced.
Diesel With Manual Trans.
There are two separate switch pods that operate
the speed control system. The steering-wheel-
mounted switches use multiplexed circuits to provide
inputs to the Engine Control Module (ECM) for ON,
OFF, RESUME, ACCELERATE, SET, DECEL and
CANCEL modes. Refer to the owner's manual for
more information on speed control switch functions
and setting procedures.
The individual switches cannot be repaired. If one
switch fails, the entire switch module must be
replaced.
OPERATION
Gas Engines and Diesel With Auto. Trans.
When speed control is selected by depressing the
ON, OFF switch, the Powertrain Control Module
(PCM) allows a set speed to be stored in its RAM for
speed control. To store a set speed, depress the SET
switch while the vehicle is moving at a speed
between approximately 35 and 85 mph. In order for
the speed control to engage, the brakes cannot be
applied, nor can the gear selector be indicating the
transmission is in Park or Neutral.
The speed control can be disengaged manually by:
²Stepping on the brake pedal.
²Depressing the OFF switch.
²Depressing the CANCEL switch.
The speed control can be disengaged also by any of
the following conditions:
²An indication of Park or Neutral.
²The vehicle speed signal increases at a rate of
10 mph per second (indicates that the co-efficient of
friction between the road surface and tires is
extremely low).
²Depressing the clutch pedal.
²Excessive engine rpm (indicates that the trans-
mission may be in a low gear).
²The vehicle speed signal decreases at a rate of
10 mph per second (indicates that the vehicle may
have decelerated at an extremely high rate).
²If the actual speed is not within 20 mph of the
set speed.
The previous disengagement conditions are pro-
grammed for added safety.
8P - 12 SPEED CONTROLBR/BE
SPEED CONTROL SERVO (Continued)
Page 637 of 2255
INSTALLATION
(1) Install electrical connector to switch.
(2) Install switch and mounting screws.
(3) Tighten screws to 3 N´m (26 in. lbs. +/± 2 in.
lbs.) torque.
(4) Install airbag module. Refer to 8, Restraint
Systems for procedures.
(5) Connect negative battery cable(s).
VACUUM RESERVOIR
DESCRIPTION
Gasoline Powered Engines :A vacuum reservoir
is used to supply the vacuum needed to maintain
proper speed control operation when engine vacuum
drops, such as in climbing a grade while driving. A
one-way check valve is used in the vacuum line
between the reservoir and the vacuum source. This
check valve is used to trap engine vacuum in the res-
ervoir. On certain vehicle applications, this reservoir
is shared with the heating/air-conditioning system.
The vacuum reservoir cannot be repaired and must
be replaced if faulty.
Diesel Powered Engines With Auto. Trans. :A
vacuum reservoir is not used if equipped with a die-
sel powered engine. Instead, an engine driven pump
(vacuum pump) is used to supply vacuum for speed
control operation. This vacuum pump is used with
the diesel engine only if it is equipped with an auto-
matic transmission. Refer to Vacuum Pump in 9,
Engines for information.
REMOVAL
The vacuum reservoir is located under the plastic
cowel plenum cover at lower base of windshield. The
vacuum reservoir is not used if equipped with a die-
sel engine.
(1) Disconnect and isolate battery negative cable.
(2) Remove both windshield wiper arm/blade
assemblies. Refer to 8, Wiper and Washer Systems.
(3) Remove rubber weather-strip at front edge of
cowel grill (Fig. 21).
(4) Release cowel grill plastic anchor screws (Fig.
22).
Fig. 20 Speed Control Switches
1 - MOUNTING SCREWS (2)
2 - SPEED CONTROL SWITCHES (2)
Fig. 21 Cowel Grille Panel Weather-strip
1 - COWL GRILLE
2 - WEATHERSTRIP
Fig. 22 Plastic Anchor Screws Remove/Install
1 - PLASTIC SCREW ANCHOR
2 - COWL GRILLE
8P - 14 SPEED CONTROLBR/BE
SWITCH (Continued)
Page 657 of 2255
cover/grille panel to drive the wiper arms and blades
are the only visible components of the wiper module.
The wiper module consists of the following major
components:
²Bracket- The wiper module bracket consists of
a long tubular steel main member that has a
stamped pivot bracket formation near each end
where the two wiper pivots are secured. A stamped
steel mounting plate for the wiper motor is secured
with welds near the center of the main member.
²Crank Arm- The wiper motor crank arm is a
stamped steel unit that has a slotted hole on the
driven end that is secured to the wiper motor output
shaft with a nut, and has a ball stud secured to the
drive end.
²Linkage- The two wiper linkage members are
each constructed of stamped steel. A driver side drive
link with a plastic socket-type bushing in the left
end, and a plastic sleeve-type bushing in the right
end. Socket bushing is snap-fit over the pivot ball
stud on the left pivot, while the sleeve bushing is fit
over the longer wiper motor crank arm pivot stud.
The passenger side drive link has a plastic socket-
type bushing on each end. One end of this drive link
is snap-fit over the pivot ball stud on the right pivot,
while the other end is snap-fit over the exposed end
of the longer ball stud on the wiper motor crank arm.
²Motor- The wiper motor is secured with three
screws to the motor mounting plate near the center
of the wiper module bracket. The wiper motor output
shaft passes through a hole in the module bracket,
where a nut secures the wiper motor crank arm to
the motor output shaft. The two-speed permanent
magnet wiper motor features an integral transmis-
sion, an internal park switch, and an internal Posi-
tive Temperature Coefficient (PTC) circuit breaker.
²Pivots- The two wiper pivots are secured to the
ends of the wiper module bracket. The crank arms
that extend from the bottom of the pivot shafts each
have a ball stud on their end. The upper end of each
pivot shaft where the wiper arms will be fastened
each has an externally serrated drum secured to it.
The wiper module cannot be adjusted or repaired.
If any component of the module is faulty or damaged,
the entire wiper module unit must be replaced.
OPERATION
The wiper module operation is controlled by the
vehicle operator through battery current inputs
received by the wiper motor from the multi-function
switch on the steering column. The wiper motor
speed is controlled by current flow to either the low
speed or the high speed set of brushes. The park
switch is a single pole, single throw, momentary
switch within the wiper motor that is mechanically
actuated by the wiper motor transmission compo-nents. The park switch alternately closes the wiper
park switch sense circuit to ground or to battery cur-
rent, depending upon the position of the wipers on
the glass. This feature allows the motor to complete
its current wipe cycle after the wiper system has
been turned Off, and to park the wiper blades in the
lowest portion of the wipe pattern. The automatic
resetting circuit breaker protects the motor from
overloads. The wiper motor crank arm, the two wiper
linkage members, and the two wiper pivots mechan-
ically convert the rotary output of the wiper motor to
the back and forth wiping motion of the wiper arms
and blades on the glass.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the wiper arms from the wiper pivots.
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER ARMS - REMOVAL).
(3) Remove the cowl plenum cover/grille panel
from the cowl plenum. (Refer to 23 - BODY/EXTERI-
OR/COWL GRILLE - REMOVAL).
(4) Remove the four screws that secure the wiper
module bracket to the cowl plenum panel and the
dash panel (Fig. 8).
(5) Reach into the cowl plenum to move the wiper
module far enough to access the wiper module elec-
trical connections (Fig. 9).
(6) Disconnect the headlamp and dash wire har-
ness connector for the wiper motor from the wiper
motor pigtail wire connector.
(7) Disconnect the headlamp and dash wire har-
ness ground connector from the wiper motor ground
terminal.
(8) Remove the wiper module from the cowl ple-
num as a unit.
INSTALLATION
(1) Position the wiper module into the cowl ple-
num as a unit.
Fig. 8 Wiper Module Remove/Install
1 - WIPER MODULE MOUNTING SCREWS
8R - 14 WIPERS/WASHERSBR/BE
WIPER MODULE (Continued)