DODGE TRUCK 1993 Service Repair Manual

•

WINDSHIELD WIPER
AND
WASHER SYSTEMS
8K - 1
WINDSHIELD WIPER
AND
WASHER SYSTEMS
CONTENTS
page

INTERMITTENT WINDSHIELD WIPER FUNCTION AND SWITCH TESTING PROCEDURES
6

TWO SPEED WINDSHIELD WIPER MOTOR
AND
SWITCH TESTING PROCEDURES
1

GENERAL
INFORMATION
The windshield wipers
can be
operated with
the

windshield wiper switch only when
the
ignition switch
is in the
ACCESSORY
or RUN
position.
A

fuse located
in the
fuse block protects
the
circuitry
of
the wiper system
and the
vehicle. The same motor
is
used
for
standard
and
intermit­
tent wipe systems. The wiper motor
has
permanent magnet fields.
The

speeds
are
determined
by
current flow
to the
appro­
priate
set of
brushes. The intermittent wipe system
in
addition
to low
page

WINDSHIELD WASHERS .. 10
WINDSHIELD WIPER SYSTEM SERVICE PROCEDURES 7

and high speed,
has a
delay mode.
The
delay mode
has
a
range
of 2 to 15
seconds. This
is
accomplished
by
a
variable resistor
in the
wiper switch
and is
con­ trolled electrically
by a
control module.
The wiper system completes
the
wipe cycle when
the switch
is
turned
OFF. The
blades park
in the
lowest portion
of the
wipe pattern.
Depressing
the
washer knob while
the
system
is in

the
OFF
position, • turns
the
wiper motor
on

• allows
the
motor
to
operate through
3-4
wipe
cy­

cles
and
then turn
OFF.
TWO SPEED WINDSHIELD WIPER MOTOR
AND
SWITCH TESTING PROCEDURES INDEX

page

Multifunction
(Two
Speed
Wiper) Switch Testing
Procedures
4
TWO SPEED WIPER MOTOR TESTING PROCEDURES
The following
is a
list
of
general wiper motor sys­
tem problems.
It
contains
the
tests that
are to be
per­
formed
to
locate
the
faulty part,
and the
corrective action
to be
taken.
The
same motor
is
used
for
stan­
dard
and
optional systems.
If the
malfunction
in­

volves only
the
Delay mode, switch,
or
wiring, refer
to
the
Intermittent Windshield Wiper Motor
and
Switch Service Procedures.

CONDITION
Motor will
not run in any
switch position.

PROCEDURE
(1) Check
for a
blown fuse
in the
fuse block.
(a)
If
fuse
is
good, proceed
to
step
No. 2.

(b)
If
fuse
is
defective, replace
and
check motor
operation
in all
switch positions.
(c)
If
motor
is
still inoperative
and the
fuse does
not blow, proceed
to
step
No. 2.
page

Two Speed
Wiper Motor Testing Procedures
1

(d)
If
replacement fuse blows, proceed
to
step
No.

5.

(2) Place switch
in low
speed position.
(3) Listen
to
motor.
If you
cannot hear
it
running,
proceed
to
step
No. 4. If you
hear
it
running, check
motor output shaft.
If
output shaft
is not
turning,
re­

place motor assembly.
If it is
turning, crank
arm or
drive link
is not
properly connected. Replace worn
parts and/or properly connect drive link
to the
motor output shaft.
(4) Connect
a
voltmeter between motor terminal

"L"
and
ground strap
(Fig. 1). If
there
is no
voltage
or very little voltage (less than
one
volt) present,
move negative test lead from
the
ground strap
to
bat­
tery negative terminal.
(a)
If an
increase
in
voltage
is
noticed,
the
prob­
lem
is a bad
ground circuit. Make sure
the
motor
mounting
is
free
of
paint
and
that nuts
or
bolts
are

tight.

8K - 2 WINDSHIELD WIPER AND WASHER SYSTEMS

MOTOR RUNS
BLADES
DO
NOT PARK

•

MOTOR STOPS
IN
ANY

POSITION

WHEN SWITCH
IS
TURNED
"OFF"

3 I
MOTOR RUNS
|

BUT
OUTPUT
CRANK DOES NOT TURN BLADES SLAP
AGAINST
WINDSHIILD
MOULDINGS

ION DRY
GLASS
•MOTOR STOPS! BLADES
DO
NOT PARK PROPERLY MOTOR WILL
NOT STOP

I
WHEN SWITCH
|
IS
TURNED "OFF" X

LINKAGE NOT FASTENED
PROPERLY TO

MOTOR
OUTPUT
SHAFT

J ARMS
LOOSE
ON
PIVOT
SHAFT
BLADES
CHATTER

FOREIGN

SUBSTANCE
SUCH
AS
BODY POLISH ON
GLASS
OR
BLADES
OUTPUT

SHAFT

STATIONARY
T

REPLACE
MOTOR
JE

OUTPUT

SHAFT

ROTATES
t
LOOSE

MOTOR
CRANK
BAD

LINKAGE

CONNECTION
ARMS
LOOSE
ON
PIVOT
SHAFT
TWISTED
ARM
HOLDS BLADE AT WRONG ANGLE TO
GLASS
1__
REPLACE

MOTOR
FUSE

BLOWS

f

CHECK

WIRING
CHECK

SWITCH

RF80B

WINDSHIELD
WIPER
AND
WASHER
SYSTEMS
8K - 3

VOLTMETER

TERMINAL
"L"

GROUND
J928K-13

Fig.
1
Voltmeter
Between Terminal "L" and
Ground
(b) If there is still no indication of voltage, the
problem is an open circuit in the wiring harness or
wiper switch.
(c) If no noticeable increase (greater than 3 volts)
in voltage is observed, the problem is a faulty mo­
tor assembly.
(5) Disconnect motor wiring connector and replace

fuse.
(a) If fuse does not blow, motor is defective. (b) If fuse blows, switch or wiring is at fault.
CONDITION Motor runs slowly at all speeds.
PROCEDURE (1) Disconnect wiring harness connector at motor.
Remove wiper arms and blades. Connect an ammeter
between battery and terminal "L" on motor (Fig. 2).

TERMINAL
"L
AMMETER
WIPER

MOTOR

J928K-14

Fig.
2 Ammeter Between Terminal "L" and
Battery
(a) If motor runs and average ammeter reading
is more than 6 amps, proceed to step 2.
(b) If motor runs and average ammeter reading
is less than 6 amps, proceed to step 3.
(2) Check to see if wiper linkage or pivots are
binding or caught. Disconnect drive link from motor. (a) If motor now runs and draws less than 3

amps,
repair linkage system.
(b) If motor continues to draw more than 3 amps,
replace motor assembly. (3) Check motor wiring harness for shorting be­
tween high and low speed wires as follows:
(a) Connect a voltmeter or test lamp to motor
ground strap. (b) Set wiper switch to LOW position.
(c) Connect other lead of voltmeter (test lamp) to
terminal "H" of the wiring harness. (d) If voltage is present, there is a short in the
wiring or wiper switch. If no voltage is present pro­ ceed to step (e).
(e) Set wiper switch to HIGH position.
(f) Move voltmeter (test lamp) lead from termi­
nal "H" to terminal "L" of the wiring harness.
(g) If voltage is present, there is a short in the
wiring or wiper switch.
CONDITION Motor will run at high speed, but not at low
speed. Motor will run at low speed, but not at
high speed.
PROCEDURE (1) If motor will not run on high speed, put switch
in HIGH position and connect a test lamp between
motor terminal "H" and ground (Fig. 3).

TERMINAL
"H"
TEST
LAMP
WIPER

MOTOR
J928K-15

Fig.
3 Test
Lamp
Between Terminal "H" and
Ground

If motor will not run on low speed, put switch in
LOW position and connect a test lamp between motor
terminal "L" and ground.
(2) If test lamp does not light at motor terminal,
there is an open in wiring or switch. If test lamp lights at motor terminal, replace motor assembly.
CONDITION Motor will keep running with switch in OFF
position.

8K - 4
WINDSHIELD WIPER
AND
WASHER
SYSTEMS

•
PROCEDURE (1) Remove wiring harness. Connect jumper from
Terminal P2 to terminal "L" of wiper motor (Fig, 4).

TERMINALS

Fig. 4 Om Jumper Wire Between Terminal "P2" and
"L".
One Jumper Wire Between Terminal "P1" and "B+" (2) Connect second jumper from terminal "PI" to
battery. If motor runs to PARK position and stops,
wiper switch is faulty. If motor keeps running and
does not park, replace motor assembly.
CONDITION Motor will stop wherever it is, when column
switch is put in OFF position. (Wipers do not
continue running to PARK position).

PROCEDURE
(1) Remove motor wiring connector and clean ter­
minals. Reconnect connector and test motor. If prob­ lem persists, proceed to step No. 2.
(2) Put wiper switch to OFF and ignition switch to
ACC position. Disconnect motor wiring connector. Connect a voltmeter or test lamp to the motor
ground strap. Connect the other lead to terminal

"PI"
of wiring connector.
(a) If voltage is not present, check for an open
circuit in the wiring harness or wiper control
switch or fuse. (b) If voltage is present, proceed to step (3).
(3) Remove wiper motor from vehicle and connect
an ohmmeter or continuity tester between terminals

"L"
and "P2" (Fig. 5).
(a) If there is continuity between these termi­

nals,
the problem is a defective motor. Fig. 5 Ohmmeter Between Terminal "L" and "P2"
(b) If there is no continuity, the problem is an
open circuit in the wiper control switch or wiring
harness.

MULTIFUNCTION
(TWO
SPEED WIPER) SWITCH
TESTING PROCEDURES
The multifunction switch contains circuitry for:
• turn signal
• hazard warning
• headlamp beam select
• headlamp optical horn
• windshield wiper
• pulse wipe
• and windshield washer switching. This integrated switch assembly is mounted to the
left-hand side of the steering column. Should any
function of the switch fail, the entire switch assem­
bly must be replaced. To test the switch: (1) Disconnect negative cable from battery.
(2) Remove tilt lever (Tilt column only).

(3)
Remove upper and lower column covers to gain
access to the switch connector (Fig. 6). (4) Remove lower fixed column cover.
(5) Loosen steering column upper bracket nuts. Do
Not remove nuts.
(6)
Move upper fixed column cover to gain access
to rear of multifunction switch.
(7)
Remove switch connector (Figs. 7 and 8).

(8)
Using an ohmmeter, test for continuity (no re­
sistance) between the terminals of the switch as
shown in the following continuity chart (Fig. 9).
(9)
Refer to Service Procedures for assembly.

WINDSHIELD
WIPER
AND
WASHER SYSTEMS
8K - §
UPPER SHROUD GROUND
CLIP UPPER
FIXED SHROUD
SUPPORT BRACKET
STUD NUT WASHER
LOWER
SHROUD LOWER
FIXED
SHROUD J9119-22

Fig.
6 Steering
Column Covers

STEERING
COLUMN
ASSY.
J918J-1

TURN SIGNAL
MULTI SWITCH
AND

FUNCTION LEVER SWITCH
CONNECTOR Fig.
7
Multifunction
Switch
Connector KEY-IN SWITCH
&

HALO LIGHT MULTIFUNCTION
SWITCH IGNITION
SWITCH TURN SIGNAL
SWITCH
&
LEVER

SPEED

CONTROL
J918J-2

Fig.
8 Steering
Column Connectors
MULTIFUNCTION SWITCH PINS
TWO
SPEED
WIPER SWITCH CONTINUITY CHART
SWITCH
POSITION CONTINUITY

BETWEEN

OFF
&
PARK PIN
1 & PIN 2

LOW PIN
1 & PIN 4

HIGH PIN
4 & PIN 5

WASH
PIN
3 & PIN 4 J918K-5

Fig.
9 Standard Two
Speed
Wipe Switch Continuity Chart

8K
- 6
WINDSHIELD WIPER
AND
WASHER SYSTEMS
• INTERMITTENT WINDSHIELD WIPER FUNCTION
AND
SWITCH TESTING
PROCEDURES

INTERMITTENT
WIPER
FUNCTION
TESTING

PROCEDURES
The intermittent wipe and standard two speed mo­
tors are identical. Refer to previous sections for diag­
nosis of system problems which do not involve the
DELAY function. If problem occurs only in the DE­ LAY mode, the following tests are to be performed.
These tests involve disconnecting the intermittent wipe control unit which can be found on the steering column support bracket (Fig. 2).
CONDITION Excessive delay (more than 30 seconds) or in­
adequate variation in delay.
PROCEDURE Variations in delay should be as follows: (1) Minimum delay (delay control to extreme coun­
terclockwise position before first detent) 1/2 to 2 sec­
onds.

(2) Maximum delay (delay control to extreme
clockwise position before off detent) 10 to 30 seconds.
(3) If there is excessive delay or no variations in
delay proceed to intermittent wipe switch test.
CONDITION In DELAY mode wipers run continually when
wash is operated but do not provide an extra
wipe when the wash control is released.
PROCEDURE Replace the control unit.
CONDITION ' Wipers start erratically during DELAY mode.
PROCEDURE (1) Verify that the ground connection at the in­
strument panel is making good connection (free from
paint) and is tight.
(2) Verify that the motor ground strap is making
good contact and that the motor mounting bolts are
tight.
(3) Verify that the wiring ground connections for
the intermittent wipe control unit and the wiper switch are tight.
(4) If condition is not corrected, replace control
unit.

MULTIFUNCTION (INTERMITTENT WIPER) SWITCH

TESTING
PROCEDURES
Refer to Multifunction (Two Speed Wiper) Switch
Testing Procedures using the following continuity chart.
i

24 23 22
21 20 19

17 16 15 14
/V~\M3
12 11 10 9 8
7
6 V5^4 3
.
2 1

EZJ
CZ3 CZ3 C3 Jr

L
JT

MULTIFUNCTION
SWITCH
PINS

SWITCH

POSITION
CONTINUITY

BETWEEN

OFF
PIN
6 AND PIN 7

DELAY
PIN 8 AND PIN 9
PIN 2 AND PIN 4
PIN
1
AND PIN 2
PIN
1
AND PIN 4
LOW PIN 4 AND PIN 6

HIGH
PIN 4 AND PIN 5

WASH
PIN 3 AND PIN 4

*
RESISTANCE
AT
AAAXIMUM
DELAY
POSITION
SHOULD
BE
BETWEEN
270,000
OHMS
AND
330,000
OHMS.

•RESISTANCE
AT
MINIMUM
DELAY
POSITION
SHOULD
BE
ZERO
WITH
OHMMETER
SET ON
HIGH
OHM
SCALE.

918J-4

Fig.
11ntermittent
Wipe
Switch
Continuity Chart

INTERMITTENT WIPE MODULE LOCATION
The intermittent wipe module is located to the
right of the steering column on the back side of the instrument panel (Fig. 2).
BUZZER

MODULE

INTERMITTENT

WIPE
MODULE
Fig.
2
Intermittent
Wipe
Module
Location

•

WINDSHIELD WIPER
AND
WASHER
SYSTEMS
8K - 7
WINDSHIELD WIPER SYSTEM SERVICE PROCEDURES
INDEX

page

Installation
9

Linkage
Replacement (Fig. 6) 8
Wiper Arm Replacement 7
Wiper Blade Element
Change
7

WIPER
BLADES

Wiper blades exposed to the weather for a long pe­
riod of time tend to lose their wiping effectiveness.
Periodic cleaning of the wiper blade is suggested to
remove the accumulation of salt and road film. The wiper blades, arms and windshield should be cleaned
with a sponge or cloth and a mild detergent or nona-
brasive cleaner. If the blades continue to streak or smear, they should be replaced.

WIPER BLADE ELEMENT CHANGE
There are two types of wiper blade assemblies. The
assemblies are identified as "Type A" (Fig. 1) and
"Type B" (Figs. 2 and 3).
Fig.
1
Removing
Blade and Wiping Element from

Blade
Assembly
Type'A"

Fig.
2
Removing
Blade from Arm Type "B" (1) Turn wiper switch ON, position blades to a con­
venient place by turning the ignition switch ON and

OFF.
(2) Lift wiper arm to raise blade off glass.
(3) Remove blade assembly from arm and wiping
element from blade, depending on type, as follows: page
Wiper Blades 7
Wiper Motor Replacement ................... 8
Wiper Switch Replacement .................. 9
TYPE A— To remove blade assembly from arm,
insert a small screwdriver blade into release slot of
wiper blade and pry slightly upward (Fig. 1).
To remove wiping element from blade assembly,
pinch lock on end of blade assembly and withdraw
wiping element (blade) out of claws.
Check each release point for positive locking when
installing blade element and blade assembly.
Type B—To remove blade, lift up on release tab on
center bridge pivot (Fig. 2).
Lift lock tab on one of end links and squeeze link
to remove from center bridge. Slide end link off ele­ ment and slide element from claws of other link (Fig,

3).
LIFT RELEASE TAB END LINK RH526

Fig.
3
Removing
Wiping Element From Blade
Assembly
Type "B" Check each release point for positive locking when
installing blade element and blade assembly.

WIPER
ARM REPLACEMENT
REMOVAL
(1) Lift the arm to permit the latch (Fig. 4) to be
pulled out to the holding position and remove the arm from the pivot using a rocking motion.
Fig.
4
Removing
Wiper Arm

8K
- 8
WINDSHIELD WIPER
AND
WASHER
SYSTEMS
•

CAUTION:
The use of a screwdriver or other prying
tool to remove an arm may distort it.
This
distortion
could
allow the arm to
come
off the pivot
shaft,
re­

gardless
of how carefully it is installed.

INSTALLATION
With wiper motor in park position, mount arms on
pivot shafts. Choose a serration engagement which locates blades so that distance between the intersec­
tion of arm and the blade and the weatherstrip is as shown in Fig. 5.

ADJUST WIPER ARM
SO
TIP OF
BLADE
IS
ABOVE
THE WEATHERSTRIP
IN
PARK
POSITION
AS
SHOWN
J908K-34

Fig.
5 Adjusting Wiper
Arms
WIPER MOTOR REPLACEMENT
REMOVAL
(1) Disconnect negative cable from battery.
(2) Disconnect wires from wiper motor.
(3) Remove motor mounting screws.
(4) Lower motor down far enough to gain access to
crank arm to drive link retainer bushing. (5) Remove crank arm from drive link by prying
retainer bushing from crank arm pin with a suitable size screwdriver.
(6) Remove motor.
(7) Remove nut attaching crank arm to motor
drive shaft.
(8) Remove crank arm.

INSTALLATION
(1) Position crank arm on motor drive shaft, mak­
ing sure slot is indexed properly. Install mounting
nut and tighten to 11 N»m (95 in. lbs.) torque.
(2) Install crank arm pin in drive link retainer
bushing by snapping together with channel lock pli­
ers.

(3) Position motor into place, install mounting
screws, and tighten to 6 N»m (55 in. lbs.) torque. (4) Connect wires to wiper motor. (5) Connect battery cable.
LINKAGE
REPLACEMENT
(Fig. 8)

CRANK
ARM

REMOVAL
(1) Remove wiper motor as previously described. (2) Remove nut attaching crank arm to motor
drive shaft.
(3) Remove crank arm.

INSTALLATION
(1) Position crank arm on motor drive shaft, mak­
ing sure slot is indexed properly. Install mounting
nut and tighten to 11 N*m (95 in. lbs.) torque.
(2) Install wiper motor.

DRIVE LINK ASSEMBLY
LEFT
PIVOT

ASSEMBLY

REMOVAL
(1) Remove wiper arms.
(2) Remove screws attaching louvered cowl cover
to cowl panel. (3) Remove cowl cover by pulling forward with a
slight upward movement.
(4) Reach through access hole and remove drive
link from right pivot by prying retainer bushing from pivot pin with a suitable size screwdriver.
(5) Remove crank arm from drive link by prying
retainer bushing from crank arm pin with a suitable size screwdriver.
(6) Remove left pivot mounting screws and let
pivot hang loose.
(7) Working through access holes remove drive
links and left pivot as an assembly. (8) Remove drive link from left pivot by prying re­
tainer bushing from pivot pin with a suitable size screwdriver.

INSTALLATION
(1) Install left pivot pin in drive link retainer
bushing by snapping together with channel lock pli­
ers.
(2) Maneuver drive links and pivot assembly
through access hole and position into place.
(3) Position left pivot into place, install mounting
screws and tighten to 11 N*m (95 in. lbs.) torque. (4) Install crank arm pin in drive link retainer
bushing by snapping together with channel lock pli­
ers.

(5) Install right pivot pin in drive link retainer
bushing by snapping together with channel lock pli­
ers.
(6) Position cowl cover into place, install mounting
screws and tighten securely. (7) Install wiper arms, refer to wiper arm adjust­
ment procedure.

WINDSHIELD
WIPER
AND
WASHER
SYSTEMS
8K - S

BLADE
PIVOT
ASSEMBLY

WIPER MOTOR
RK755

Fig.
6 Wiper
Linkage
RIGHT PIVOT ASSEMBLY
REMOVAL
(1) Remove wiper arms.
(2) Remove screws attaching louvered cowl cover
to dash panel. (3) Remove cowl cover by pulling forward with a
slight upward movement.

(4)
Reach through access hole and remove drive
link from right pivot by prying retainer bushing
from pivot pin with a suitable size screwdriver.
(5) Remove right pivot mounting screws.
(6) Remove pivot through access hole.
INSTALLATION (1) Position pivot into place, install mounting
screws, and tighten to 11 N*m (95 in. lbs.) torque. (2) Install right pivot pin in drive link retainer
bushing by snapping together with channel lock pli­
ers.

(3) Position cowl cover into place, install mounting
screws and tighten securely.

(4)
Install wiper arms.

WIPER SWITCH REPLACEMENT
(1) Disconnect negative cable from battery.
(2) Remove tilt lever (Tilt column only).
(3) Remove both upper and lower steering column
covers.
(4)
Remove multifunction switch tamper proof
mounting screws.
(5) Gently pull switch away from column. Loosen
connector screw. The screw will remain in the con­
nector.
(6) Remove wiring connector from multifunction
switch (Fig. 7).
HAZARD WARNING
BUTTON
WINDSHIELD WASHER BUTTON
WINDSHIELD WIPER CONTROL MULTI-FUNCTION
SWITCH

908J-9

Fig.
7 Multifunction
Switch

INSTALLATION
(1) Install wiring connector to switch and tighten
connector retaining screw to 2 Nnn (17 in. lbs.).