DODGE RAM SRT-10 2006 Service Repair Manual

REMOVAL
WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering
wheel, steering column, or instrument panel component diagnosis or service. Disconnect 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 disable the airbag system. Failure to
take the proper precautions could result in accidental airbag deploymentand possible personal injury or
death.
1. Disconnect and isolate the negative battery cable.
2. Remove the glove box from the instrument panel
(Refer to 23 - BODY/INSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
3. Remove the two screws (1) that secure the recircu-
lation door actuator (2) to the side of the HVAC air
inlet housing (3).
4. Remove the recirculation door actuator from the air
inlet housing and disconnect the HVAC wire har-
ness connector (4) from the actuator.
5. Remove the recirculation door actuator from the
vehicle.
INSTALLATION
1. Install the recirculation door actuator (1) onto the
side of the HVAC air inlet housing (2). If necessary,
rotate the actuator slightly to align the splines on
the actuator output shaft (3) with those in the recir-
culation door actuator coupler (4).

2. Install the two screws (1)that secure the recircula-
tion door actuator (2) to the air inlet housing (3).
Tighten the screws to 2.2 Nꞏm (20 in. lbs.).
3. Connect the HVAC wire harness connector (4) to
the recirculation door actuator.
4. Install the glove box (Refer to 23 - BODY/INSTRU-
MENT PANEL/GLOVE BOX - INSTALLATION).
5. Reconnect the negative battery cable.

CLUTCH-A/C COMPRESSOR
DESCRIPTION
NOTE: Denso 10S17 A/C clutch assembly shown.
Visteon HS-18 compressor similar.
The A/C compressor clutch assembly consists of a
stationary electromagnetic field coil (4), bearing and
pulley assembly (3), shims (7) and a clutch plate (2)
that is splined to the compressor shaft and secured by
a bolt (1). These components provide the means to
engage and disengage the A/C compressor from the
engine accessory drive belt.
The A/C clutch bearing and pulley assembly on both
A/C compressors are retained to the front of the com-
pressor with a snap ring (6). The A/C clutch field coil
on the Denso 10S17 A/C compressor is also retained
to the front of the compressor using a snap ring (5).
The field coil on the Visteon HS-!8 compressor is
pressed onto the front of the compressor.
OPERATION
The A/C compressor clutch components provide the means to engage and disengage the A/C compressor from the
engine accessory drive belt. When the electromagnetic A/C clutch field coil is energized, it magnetically draws the
clutch plate into contact with the clutch pulley and drives the compressorshaft. When the coil is not energized, the
pulley freewheels on the clutch hub bearing, which is part of the pulley assembly.
A/C compressor clutch engagement is controlled by the powertrain controlmodule (PCM) or the engine control mod-
ule (ECM), depending on engine application. When the A/C-heater control is set to any A/C position, it sends a
request signal on the CAN-B bus to the totally integrated power module (TIPM), which then transfers the request on
the CAN-C Bus to the PCM/ECM, which determines if operating conditions arecorrect for A/C clutch engagement.
When all operating conditions have been met, the PCM/ECM sends a signal on adedicated hard-wired circuit back
to the totally integrated power module (TIPM) to energize the internal A/Cclutch high side driver. When energized,
the A/C clutch high side driver provides battery current to the A/C clutch field coil.
The A/C clutch control system is diagnosed using a scan tool (Refer to 24 - HVAC Electrical Diagnostics and to 9
- Engine Electrical Diagnostics for more information).
The A/C compressor clutch components cannot be repaired and, if faulty or damaged, they must be replaced.
DIAGNOSIS AND TESTING
A/CCOMPRESSORCLUTCHCOIL
The A/C compressor clutch coil electrical circuit is controlled by the powertrain control module (PCM) or the engine
control module (ECM) (depending on engine application) through the totally integrated power module (TIPM) (Refer
to 24 - HEATING & AIR CONDITIONING/CONTROLS/COIL-A/C COMPRESSOR CLUTCH -OPERATION for more
information). Begin testing of a suspected compressor clutch coil problem by performing the preliminary checks.
PRELIMINARY CHECKS
1. Using a scan tool, check for diagnostic trouble codes (DTCs) in the A/C-heater control, TIPM, PCM/ECM and if
equipped with the 8.3L engine, the gateway module. If no DTCs are found, go to Step 2. If any DTCs are found,
repair as required.
2. If the A/C compressor clutch still will not engage, verify the refrigerant charge level (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM LEAKS). If the refrig-
erant charge level is OK, go to TESTS . If the refrigerant charge level is notOK, adjust the refrigerant charge as
required.

TESTS
1. Verify the battery state of charge (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - DIAGNOSIS AND
TESTING).
2. Connect an ammeter (0 to 10 ampere scale selected) in series with the clutch coil feed terminal. Connect a
voltmeter (0 to 20 volt scale selected) to measure voltage across the battery and the clutch coil.
3. With the A/C-heater control in the A/C mode and the blower motor at low speed, start the engine and allow it to
run at a normal idle speed.
4. The A/C compressor clutch should engage immediately, and the clutch coil supply voltage should be within two
volts of the battery voltage. If the coil supply voltage is OK, go to Step 5. If the coil supply voltage is not within
two volts of battery voltage, test the clutch coil feed circuit for excessive voltage drop and repair as necessary.
5. For the acceptable A/C clutch coil current draw specifications refer to24 - HEATING & AIR CONDITIONING -
SPECIFICATIONS. Specifications apply for a work area temperature of 21° C(70° F). If voltage is more than
12.5 volts, add electrical loads by turning on electrical accessories until voltage reads below 12.5 volts.
STANDARD PROCEDURE
A/C CLUTCH PLATE INSPECTION
NOTE: The A/C clutch can be serviced inthe vehicle. The refrigerant systemcan remain fully-charged dur-
ing compressor clutch, pulley and bearing assembly, or coil replacement.
Examine the friction surfaces of the pulley and the
clutch plate (2) for wear. The pulley and clutch plate
should be replaced if there is excessive wear or scor-
ing.
If the friction surfaces are oily, inspect the shaft and
nose area of the A/C compressor (1) for refrigerant oil.
If refrigerant oil is found, the compressor shaft seal is
leaking and the A/C compressor must be replaced.
Check the pulley bearing for roughness or excessive
leakage of grease. Replace the pulley and bearing
assembly, if required.
A/C CLUTCH BREAK-IN
After a new A/C compressor clutch hasbeen installed, cycle the compressorclutch approximately 20 times (5 sec-
onds on, then 5 seconds off). During this procedure, set the A/C-heater controls to the A/C Recirculation Mode, the
blower motor 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
DENSO A/C COMPRESSOR
NOTE: The compressor clutch assembly can be serviced with the refrigerantsystem fully-charged.
NOTE: Typical A/C compressor shown in illustrations.
1. Disconnect and isolate the negative battery cable.
2. Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/BELTS-DRIVE -
REMOVAL).
3. Disconnect the engine wire harness from the com-
pressor clutch field coilconnector (1) located on
the top of the A/C compressor (5).
4. Remove the bolts that secure the A/C compressor
to the engine and support the A/C compressor.
5. Carefully remove the compressor clutch field coil
connector and wire lead from the connector bracket
(2).
6. Remove the compressor shaft bolt (3). A band-type
oil filter wrench or a strap wrench may be used to
hold the clutch plate (4) from rotating during bolt
removal.
CAUTION: Do not pry between the clutch plate and
the pulley and bearing assembly to remove the
clutch plate from the compressor shaft as this
may damage the clutch plate.
NOTE: Use care not to lose any clutch shim(s)
during removal of the clutch plate, as they may be
reused during the clutch plate installation process.
7. Tap the clutch plate (2) lightly with a plastic mallet
to release it from the splines on the compressor
shaft (1) and remove the clutch plate and shim(s)
(3).

8. Using snap ring pliers (2), remove the snap ring (1)
that secures the pulley and bearing assembly (3) to
the front of the A/C compressor and remove the
pulley and bearing assembly.
9. Using snap ring pliers (Special Tool C-4574 or
equivalent) (1), remove the snap ring (4) that
secures the compressor clutch field coil (2) to the
front of the A/C compressor (3) and remove the
field coil.
VISTEON A/C COMPRESSOR
NOTE: The A/C compressor clutch can be serviced in the vehicle. The refrigerant system can remain fully-
charged during compressor clutch, pulley and bearing assembly or field coil replacement.

1. Disconnect and isolate negative battery cable.
2. Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/BELTS-DRIVE -
REMOVAL).
3. Raise and support the vehicle.
4. Disconnect the engine wire harness from the clutch
field coil connector (4).
5. Remove the bolts that secure the A/C compressor
(5)tothemountingbracket(Referto24-HEAT-
ING & AIR CONDITIONING/PLUMBING/COM-
PRESSOR-A/C - REMOVAL).
6. Remove the A/C compressor from the mounting
bracket and support the compressor while servicing
the clutch.
7. Using compressor clutch holding fixture (Special
Tool 9351 in Kit 9349) (1), remove the bolt (2) that
secures the clutch plate (3) to the compressor
shaft.
NOTE: The clutch plate can be removed from the compressor shaft by hand or, if required, pressed off with
an 8 x 1.25 mm bolt.
NOTE: Clutch plate shim(s) may remain inside the hub of the clutch plate. Besure to remove all of the
shims from inside the hub or from the end of the compressor shaft.
8. Remove the clutch plate and shim(s) from the A/C compressor. If required, install a 8 x 1.25 mm bolt into the
centeroftheclutchplateandturntheboltclockwiseuntiltheclutchplate is completely removed from the A/C
compressor.
9. Using snap ring pliers (1), remove the snap ring (2)
that secures the pulley and bearing assembly (3) to
the front of the A/C compressor (4).

NOTE: The pulley and bearing assembly can be
removed from the compressor by hand or, if
required, with a two jaw puller.
10. Remove the pulley and bearing assembly (1) from
the front of the A/C compressor (2). If required,
install a two jaw puller (3) and turn the puller cen-
ter-bolt clockwise until the pulley and bearing
assembly is completely removed.
11. Remove the plastic retaining clip (1) and the
screw (2) that secures the clutch field coil wire
lead and connector (3) to the A/C compressor (4).
12. Using compressor field coil remover (Special Tool
9354 in Kit 9349) (1) and a two jaw puller (2),
remove the clutch field coil (3) from the front of
the A/C compressor (4).

INSTALLATION
DENSO A/C COMPRESSOR
NOTE: Typical A/C compressor shown in illustrations.
1. Align the dowel pin on the back of the compressor
clutch field coil (2) with the hole in the front of the
A/C compressor (3) and position the field coil onto
the compressor. Be certain that the compressor
clutch field coil wire lead is properly routed so that
it is not pinched between the A/C compressor and
the field coil.
CAUTION:Thesnapringmustbefullyandprop-
erly seated in the groove or it will vibrate out,
resulting in a clutch failure and severe damage to
the A/C compressor.
NOTE:Anewsnapringmustbeusedtosecure
the compressor clutch field coil to the A/C com-
pressor. The bevel side of the snap ring must face
outward and both snap ring eyelets must be ori-
ented to the right or to the left of the field coil
dowel pin location on the A/C compressor.
2. Using snap ring pliers (Special Tool C-4574 or
equivalent) (1), install the snap ring (4) that
secures the compressor clutch field coil to the front of the A/C compressor. Be certain that the snap ring is fully
and properly seated in the groove and oriented correctly.
CAUTION:Becertaintopositionthecompressor
clutch field coil wire lead so that it is not damaged
during A/C compressor pulley and bearing instal-
lation.
CAUTION: When installing the pulley and bearing
assembly, DO NOT mar the friction surfaces of the
pulley or premature failure of the clutch will result.
3. Install the pulley and bearing assembly (1) onto the
front of the A/C compressor. If necessary, tap the
pulley gently with a block of wood (2) placed on the
pulley friction surface.

CAUTION:Thesnapringmustbefullyandprop-
erly seated in the groove or it will vibrate out,
resulting in a clutch failure and severe damage to
the A/C compressor.
NOTE:Anewsnapringmustbeusedtosecure
the pulley and bearing assembly to the A/C com-
pressor. The bevel side of the snap ring must face
outward.
4. Using snap ring pliers (2), install the snap ring (1)
that secures the pulley and bearing assembly (3) to
the front of the A/C compressor. Be certain that the
snap ring is fully and properly seated in the groove.
5. If the original clutch plate (2) and pulley and bear-
ing assembly are to be reused, reinstall the original
shim(s) (3) onto the compressor shaft (1). If a new
clutch plate and pulley and bearing assembly are
being used, install a trial stack of shims 2.54 mm
(0.010 in.) thick onto the compressor shaft.