DODGE TRUCK 1993 Service Repair Manual

8P
- 2 POWER DOOR LOCKS
• SERVICE PROCEDURES
DOOR LOCK MOTOR REPLACEMENT

REMOVAL
(1) Remove remote control handle (Fig. 2).
TRIM

PANEL
TRIM
PANEL

CLIPS
(6)

REMOTE

CONTROL
HANDLE

SCREW

TRIM
PANEL
CLIPS
J908P-12

Fig.
2
Door
Trim
Panel
(2) Remove power window/lock switch by inserting
a standard blade screwdriver into notch on forward
end of switch housing and push to depress locking

tab.
Pull out and forward to remove switch bezel
from door panel.
(3) Remove 2 screws at bottom front and rear of
trim panel.
(4) Remove screw behind remote handle.
(5) Using a device such as a trim stick, pry trim
panel away from door around perimeter.
(6) Roll door watershield away from lower rear cor­
ner of door to reveal inside panel access opening.
(7) Remove motor link at motor (Fig. 3).
(8) Disconnect motor lead wires.
(9) Remove 2 motor mounting bracket screws and
remove motor assembly from mounting.
DOOR
LOCK

MOTOR

J918P-9

Fig.
3
Door
Lock
Motor Replacement
INSTALLATION

(1) Attach motor mounting bracket to door inside
panel and install 2 screws. (2) Connect link to motor rod and connect wires.
(3) Reset watershield at lower rear corner of door.
(4) Install door trim panel. (5) Install door panel attaching screws.
(6) Install remote control handle.
(7) Install power window/lock switch.

•

POWER
WINDOWS
8S - 1
POWER WINDOWS
CONTENTS
page

SERVICE
PROCEDURES
3

GENERAL
INFORMATION
Power window motors are of the permanent mag­
net type. A positive and negative battery connection
to either of the two motor terminals will cause the motor to rotate in one direction. Reversing current
through these same two connections will cause the motor to rotate in the opposite direction. Both motors are grounded through the master
switch by a black wire attached to a ground stud.
The stud is located on the back of the instrument
panel, on the right side of the steering column. It is necessary that the window be free to slide up
page

TEST
PROCEDURES
....................... 1
and down in the glass channels or tubes and tracks.
If the window is not free to move up and down, the
window motor will not be able to move the glass.
To determine if the glass is free, disconnect the
electric window regulator lift arm sliders from the
glass lift channels. Slide the window up and down by
hand.
A less positive method is to shake the glass in the
door, (with glass positioned between the up and down
stop positions). If the glass will move slightly from
side to side, front to rear, and up and down, the win­
dow is probably not bound tight in the tracks.

TEST
PROCEDURES

SWITCH
VOLTAGE TEST
The following wiring test sequence determines
whether or not voltage is continuous through the
body harness to switch. (1) Remove power window/lock switch by inserting
a standard blade screwdriver into notch on forward
end of switch housing. Push screwdriver to depress
locking tab. Pull bezel out and forward to remove
from door panel. (2) Carefully separate multiple terminal block on
wiring harness from switch body. (3) Connect one lead of test light to black (BK)
wire terminal. Touch other test light lead to tan (TN)
wire terminal. If test light comes on, the wiring cir­ cuit between the battery and switch is functional. If
light does not come on, check 30 amp circuit breaker,
or for a broken wire or poor ground.

CIRCUIT
BREAKER
TEST
Locate the circuit breaker in fuse cavity number 12
on fuse block. Pull out slightly but be sure that cir­
cuit breaker terminals still contact terminals in fuse
block. Connect ground wire of voltmeter to a good ground. With probe of voltmeter positive wire, check both terminals of circuit breaker for battery voltage.
If only one terminal checks at battery voltage, circuit
breaker is defective and must be replaced. If neither
terminal shows battery voltage, check for open or shorted circuit to circuit breaker.

SWITCH TEST
For switch testing, remove the switch from its
mounting location. Using an ohmmeter, refer to Figs. 1 and 2 to determine if continuity is correct in the
UP and DOWN switch positions. If continuity is cor­
rect perform window lift motor test.

WINDOW
MOTOR TEST
(1) Connect positive lead (from a test battery) to
either of the two motor terminals. (2) Connect negative lead (from test battery) to re­
maining motor terminal. (3) The motor should now rotate in one direction to
either move window up or down. (a) If window happens to already be in full UP
position and motor is connected to rotate in UP di­ rection, no movement will be observed.

8S
- 2 POWER WINDOWS
•
POWER
WINDOW
SYSf
EM
DIAGNOSIS

SYSTEM
OPERATES
BUT
GLASS

TRAVEL IS COCKED OR INCOMPLETE
I
MANUALLY

CHECK
TRAVEL OF
GLASS

I

GLASS
TRAVEL
OKAY
REMOVE MOTOR
FROM REGULATOR
ASSEMBLY

REPLACE

ARM & SECTOR PORTION OF REGULATOR
I

REASSEMBLE
REGULATOR
REINSTALL
REGULATOR

INTO
DOOR
IF PROBLEM
STILL EXISTS
CORRECT GLASS GUIDANCE PROBLEM SYSTEM

DOES
NOT OPERATE
CHECK

SYSTEM

OPERATION SYSTEM

OPERATES

CORRECTLY

CHECK
FOR
12 VOLTS AT MOTOR
TERMINAL
I NO VOLTAGE

CHECK
WIRING
AND/OR SWITCHES
VOLTAGE OKAY REMOVE
REGULATOR
FROM DOOR

GLASS
MOVES FREELY
CHECK
FOR
BINDING OF GLASS GUIDANCE SYSTEM

*
COUNTERBALANCE SPRING MUST BE REMOVED BEFORE REMOVING MOTOR FROM
REGULATOR. IF NOT,
INJURY MAY RESULT
BENCH
TEST
REGULATOR
ASSEMBLY

REMOVE
MOTOR FROM REGULATOR* I SYSTEM BINDING
CORRECT BINDING
CONDITION
REGULATOR
OPERATES

CORRECTLY
REGULATOR
DOES
NOT OPERATE I
REINSTALL
REGULATOR

INTO
DOOR

CHECK

ARM & SECTOR
ASSEMBLY
FOR

FREE
MOVEMENT,

MISSING
AND/OR DAMAGED

GEAR
TEETH,

MISSING
OR DAMAGED ROLLER,
OR BENT ARM ANY OF THESE
CONDITIONS EXIST
REPLACE

ARM & SECTOR
ASSEMBLY

PINION DOES NOT ROTATE
REMOVE GEAR & PINION AND EXAMINE FOR
MISSING
AND/OR
DAMAGED GEAR
TEETH
APPLY VOLTAGE TO
MOTOR AND CHECK FOR PINION ROTATION NONE OF THESE
CONDITIONS EXIST
PINION ROTATES CORRECTLY

REASSEMBLE

REGULATOR AND
INSTALL
INTO
DOOR

MISSING
AND/OR
DAMAGED GEAR
TEETH
REPLACE

GEAR
& PINION
ASSEMBLY
GEAR
& PINION

ASSEMBLY

TEETH
CHECK OKAY

REASSEMBLE
REGULATOR
ASSEMBLY
ARMATURE SHAFT

DOES
NOT ROTATE
REPLACE
MOTOR
WITH

GEAR
& PINION REMOVED
APPLY VOLTAGE TO MOTOR TERMINAL AND CHECK FOR
ARMATURE
SHAFT ROTATION
I
ARMATURE SHAFT ROTATES
CORRECTLY
J918S-7

•

POWER
WINDOWS
8S - 3

FROM PIN
SIDE
OF
SWITCH

MASTER
WINDOW
LIFT
SWITCH
SWITCH
POSITION CONTINUITY

BETWEEN

OFF
PINS
1 & 2

PINS
2 & 3

PINS
2 &4

PINS
2 & 6

DRIVER'S

MP
PINS
3 & 5

PINS
2 & 6

PASSENGER'S
PINS
1 & 5

PINS
2 &4

DRIVER'S
PINS
5 & 6

PINS
2 & 3

TOWN
PASSENGER'S
PINS
1 & 2

PINS
4 & 5 898S-11

Fig.
1 Master Window
Lift
Switch
Continuity
(b) Likewise, motor connected to DOWN direc­
tion rotation, no movement will be observed if win­
dow is already in full down position.
PIN IDENTIFICATION SHOWN
FROM
PIN
SIDE
OF
SWITCH
SWITCH CONTINUITY
POSITION
BETWEEN

PINS
1 & 4

OFF
PINS
2 & 5

PINS
3 & 4

UP
PINS
2 & 5

PINS
2 & 3

DOWN
PINS
1 & 4
898S-12
Fig.
2
Passenger's Door
Mounted
Switch
Continuity
(4) Reverse battery leads (opposite to steps 1 and
2) and window should now move. If window does not
move, remove motor. Refer to Service Procedures for
motor removal from vehicle for bench test.
If window moved completely up or down, motor
should be reversed one more time (reverse leads from
step 4) to complete a full window travel inspection.

SERVICE
PROCEDURES

GEAR
AND PINION
REPLACEMENT
AND
LUBRICATION
If gear and pinion assembly are replaced in gear
box, lubrication of gear box, gear pinion and seal is necessary. In the event there is no lubricant in gear box, fill
with MOPAR, multi-mileage lubricant or equivalent. Apply a liberal amount of lubricant to inside area of seal and sealing surface at center area of gear and
pinion coupling. Also lubricate center housing shaft and worm gear.

REGULATOR
AND
MOTOR
ASSEMBLY

REMOVAL To repair or inspect the entire electric window reg­
ulator, remove from door as follows: (1) Remove remote control handle (Fig. 3).
(2) Remove power window/lock switch by inserting
a standard blade screwdriver into notch on forward
end of switch housing. Push screwdriver to depress
locking tab. Pull bezel out and forward to remove
from door panel.
(3) Remove screws at bottom front and rear of trim
panel.
(4) Remove screw behind remote handle.

(5)
Using a device such as a trim stick, pry trim
panel away from door around perimeter and remove
trim panel. (6) Roll door watershield away from bottom of door
to reveal inside panel access opening. (7) Remove speaker if equipped.
(8) Lower glass to full down position.
(9) Disconnect wiring connectors from motor.

8S
- 4
POWER WINDOWS

•

Fig.
3
Door
Trim
Panel
(10) Remove inner weatherstrip being careful not
to scratch the belt-line paint.
(11) Free the clip on the inner section of the
weatherstrip with a wire hook or suitable tool.
(12) Pull back upper glass run 8 to 20-25 cm (10
inches). (13) Remove upper and lower vent wing attaching
screws.
(14) Remove vent wing, being careful to avoid
paint damage from glass lower pivot adjusting screws.
(15) Remove down stop bumper bracket (Fig. 4).

Fig.
4 Electric Window Regulator
Mounting

(16) Disengage glass from regulator arms and
lower to door bottom. (17) Remove regulator mounting screws.
(18) Remove regulator through large access hole.
BENCH REPAIR

If entire regulator is not being replaced, repair as
follows: (1) Remove regulator as previously described.

WARNING:
STEPS
(2) AND (3) ARE
VERY IMPOR-

TANT.
IF NOT
DONE BEFORE MOTOR REMOVAL
INJURY
MAY
RESULT.

(2) Secure regulator in vise to prevent sector gear
from rotating.
(3) Remove counter balance spring. (Must be done
for safety before removing motor). (4) Remove 3 motor attaching screws and remove
motor (Fig. 5).

Fig.
5 Motor Attaching
Screws

(5) Inspect regulator for: (a) Sector gear teeth must not be broken or se­
verely worn. (b) All rivets and sliders must be securely at­
tached.
(c) Parts must not be bent or cracked.
(d) Sector gear must rotate freely.
(e) Perform window lift motor test as described
above.
(6) Install motor and attach with three motor at­
taching screws.
(7) Install counter balance spring.

INSTALLATION
(1) Insert upper regulator arm into door mounted
channel. (2) Mount regulator to door panel with
1/4-20

screws torqued to 11 N*m (105 in. lbs.).
(3) Slide glass onto regulator arms and into rear
glass run.

•

POWER
WINDOWS
88 - § (4) Connect motor electrical connector.
(5) Install plastic nut and "U" nut on vent wing
assembly.
(6) Install vent wing assembly into door.
(7) Install upper and lower vent wing attachment
screws. (8) Move glass run back to vent wing by placing
run adjacent to door channel and press into channel
using wide blade screwdriver or similar tool. Press in
both inside corners to ensure hidden lip engages in channel. (9) Install belt weatherstrip by aligning clips to
holes in door and press in.
(10) Raise or lower vent to maintain a 1.6mm (.06
in.) fore-aft glass free-play then with glass up,
tighten upper screws.
(11) Hold vent against glass (glass down) and
tighten lower screws.
(12) Raise glass to full up position.
(13) Install speaker if equipped.
(14) Install down stop bumper.
(15) Install watershield and trim panel.

POWER
MIRRORS

CONTENTS
page
SERVICE PROCEDURES
2

GENERAL
INFORMATION
Electrically-operated remote control mirrors are
available as an option on D-body vehicles. The mir­
rors are controlled by a single switch assembly lo­
cated on the instrument panel to the right of the
headlamp switch (Fig. 1). D-body vehicles use a toggle-type switch. The
switch is rotated clockwise (Right mirror) or counter­
clockwise (Left mirror) for mirror selection. The
switch is moved UP, DOWN, RIGHT, or LEFT for
mirror movement direction. The motors which operate the mirrors are part of
the mirror assembly and cannot be serviced sepa­
rately.
page
TEST PROCEDURES
...................... 1 Fig. 1 Power Mirror and Headlamp Switches

TEST
PROCEDURES

MIRROR MOTOR TEST PROCEDURE
(1) Remove power mirror switch from mounting
position (refer to Service Procedures). (2) Disconnect wiring harness at switch connector.
(3) Use 2 jumper wires. Connect one to a
12-volt

source, and the other to a good body ground. Refer to
the MIRROR TEST CHART for wire hookups at the switch connector (harness side, not switch side), (4) If results shown in chart are not obtained,
check for broken or shorted circuit, or replace mirror assembly as necessary. MIRROR
TEST
CHART

12 Volts Ground MIRROR REACTION
12 Volts Ground Right
Left

Yl/BK
1
WT/BK UP
YL WT UP
WT/BK
YL/BK
DOWN
WT YL DOWN
WT/BK DB/WT RIGHT
WT
DB
RIGHT
DB/WT WT/BK LEFT

DB
WT LEFT
J908K-22

8T - 2
POWER MIRRORS

•
MIRROR
SWITCH TEST PROCEDURE

(1) Remove power mirror switch from mounting
position (refer to Service Procedures). (2) Disconnect wiring harness at switch connector.
(3) Test for continuity (no resistance) between the
terminals of the switch as shown in the MIRROR SWITCH CONTINUITY CHART. (4) If results shown in the chart are not obtained,
replace the switch.
MIRROR
SWITCH
CONTINUITY
CHART

MIRROR SELECTOR KNOB
IN
"L"
POSITION Move
Lever Continuity Between

WT
and BK

YL
and
PK
and
YL/BK
and PK

WT
and
PK,
DB/WT
and
BK
and
DB
&
BK

YL/BK
and
BK, YL
and
BK WT and PK
WT
and
BK, DB/WT
and PK
DB
and
PK
MIRROR SELECTOR KNOB
IN "R"
POSITION Move
Lever Continuity Between

WT/BK
and
BK,
YL and PK
YL/BK
and PK

•
WT/BK
and
PK, DB
and
BK
DB/WT
and
BK
WT/BK
and
PK, YL
and
BK
YL/BK
and
BK

«
WT/BK
and
BK, DB
and PK

DB/WT
and PK

J928T-6
SERVICE PROCEDURES

MIRROR
SWITCH REMOVAL AND INSTALLATION
(1) Disconnect negative cable from battery.
(2) Remove 2 screws holding map lamp and re­
move map lamp. (3) Remove 6 screws which attach instrument clus­
ter bezel to instrument panel (Fig. 2). Make sure the screw below the Heater/C control is removed.
INSTRUMENT

CLUSTER
BEZEL
J938E-51
Fig.
2 Instrument
Cluster
Bezel

(4) Place column shift lever in Position 1. (5) Remove bezel by pulling top edge rearward to
clear brow. Disengage attaching clips around bottom
of bezel and complete removal of bezel.
(6) If the bezel has a four wheel drive indicator, re­
move bulb socket as bezel is removed. (7) Disconnect message center wires.
(8) Remove instrument cluster bezel assembly.
(9) Pull headlamp switch to ON position.
(10) Reach under instrument panel and depress
button on side of switch while pulling stem out.
(11) Remove switch bezel retaining screws and pull
bezel out of instrument panel (Fig. 1). (12) Pull harness out through opening in instru­
ment panel and disconnect mirror switch connector.
(13) Remove 2 switch mounting-plate-to-bezel re­
taining screws.
(14) Remove switch-to-mounting-plate nut.
For Installation, reverse removal procedures.

MIRROR
ASSEMBLY
REMOVAL
AND

INSTALLATION
(1) Remove remote control handle (Fig. 3).
(2) Remove power window/lock switch by inserting
a standard blade screwdriver into notch on forward
end of switch housing and push to depress locking

tab.
Pull out and forward to remove switch bezel
from door panel.

•

POWER
MIRRORS
8T - 3

Fig.
3
Door
Trim
Panel
(3) Remove 2 screws at bottom front and rear of
trim panel. (4) Remove screw behind remote handle.
(5) Using a device such as a trim stick, pry trim
panel away from door around perimeter.
(6) Roll door watershield away from lower rear cor­
ner of door to reveal inside panel access opening. (7) Reach inside door and disconnect mirror wiring
at connector. Spray grommet on mounting bracket cover
with silicone to avoid grommet coming off when
cover is moved up on mirror stem. (8) Remove mirror mounting bracket cover (1
screw) and slide up on mirror stem (Fig. 4).

Fig.
4
Power
Mirror Replacement
(9) Remove 3 mirror mounting bracket nuts.
(10) Pull mirror loose from door, and feed wiring
harness out through hole in outer door panel.
For Installation, reverse Removal procedure.