1993 DODGE TRUCK Service Repair Manual

8H
- 10
VEHICLE
SPEED
CONTROL
SYSTEM

•

18PK ADJUSTMENT CLIP PULLED
OUT
OF
SLOT

18WT

STOP LAMP
SWITCH
WITH

SPEED
CONTROL
J938H-9

Fig.
5
Stop
Lamp
Switch
Connector

Fig.
6
Vacuum
Gauge
Test
sleeve into housing to decrease gap or pull sleeve out
of housing to increase gap (Fig. 7). (2) Install adjustment clip.
SPEED
CONTROL CABLE ATTACHMENT

DIESEL
ENGINE
(1) The clevis of the speed control cable is retained
to the bellcrank by a washer and hairpin clip.
-TfiROTTLE/SPEED CONTROL

CABLE
BRACKET
RR8HC22

Fig.
7 Adjustment Clip
Pulled
Out of
Slot
to
Move
Sleeve

(2) Visual inspection will verify that the cable is
securely attached. If the cable is not attached, the
speed control system will be inoperative. Refer to Ca­
ble Adjustment. GAS ENGINE
The clevis of the speed control cable is retained to
the throttle body lever by slipping the clevis into the slot on the lever. Visual inspection will verify that
the cable is securely attached. If the cable is not at­
tached, the speed control system will be inoperative.

SPEED
CONTROL CABLE ATTACHMENT-SERVO
The speed control cable is attached to the servo
with a wire clip (Fig. 8). A check should be made to verify that the clip is in place. If the clip is missing
the speed control system will be inoperative.
HAIRPIN CLIP

/ J918H-9

Fig.
8
Speed
Control Cable Attachment at
Servo

•

VEHICLE
SPEED
CONTROL SYSTEM
8H - 11
SERVICE
PROCEDURES

INDEX

page

Servo
Throttle
Cable Assembly—Diesel Engine
. . 12

Servo
Throttle
Cable Assembly—Gas Engine
... 11

Servo
Unit
11
Speed
Control
Switch Replacement
12
page

Speed
Control
Vacuum Reservoir Replacement—Gas Engine
12

Vacuum Pump—Diesel Engine
. 12

SERVO
UNIT
REMOVAL
(1) Disconnect vacuum hose at servo.
(2)
Disconnect electrical connector at servo.

(3)
Remove 2 nuts from servo mounting bracket.

(4)
Pull servo away from mounting bracket.

(5)
Remove and discard push nuts on servo studs.

(6)
Pull speed control cable away from servo to ex­
pose cable retaining clip.
(7) Remove clip attaching cable to servo.

INSTALLATION
(1) Block throttle to full open position (gas engine),
pivot bellcrank full rearward (diesel engine), and align hole in cable sleeve with hole in servo pin. In­
stall retaining clip.
(2)
Insert servo studs through holes in the cable.

(3)
Install new push nuts on the servo studs.

(4)
Insert servo studs through holes in servo
mounting bracket. One stud mounts reservoir.
(5)
Install the 2 attaching nuts and tighten to 6
N*m (50 in. lbs.).

(6)
Connect vacuum hose to servo. (7) Connect the electrical connector to servo termi­

nals.

SERVO
THROTTLE CABLE ASSEMBLY-GAS
ENGINE

REMOVAL
(1) Remove air cleaner.
(2)
Using finger pressure only, remove speed con­
trol cable connector at bell crank by PUSHING con­ nector off the bell crank (Fig. 1). DO NOT try to pull
connector off perpendicular to the bell crank.
(3)
Squeeze tabs on speed control cable and push
out of locking plate.

(4)
Remove 2 nuts from servo mounting bracket.

(5)
Pull servo away from mounting bracket.
(6)
Remove and discard push nuts on servo studs.
(7) Pull speed control cable away from servo to ex­
pose cable retaining clip.

(8)
Remove clip attaching cable to servo.
Fig.
1
Remove
Bell
Crank
Connector—
Typical

(9) Disconnect cable at servo and remove cable as­
sembly.
INSTALLATION

(1) Locate cable through servo mounting bracket.

(2)
Connect cable sleeve to servo stud, align holes,
and install hairpin clip.

(3)
Insert servo studs through holes in cable.

(4)
Install new push nuts on servo studs.

(5)
Insert servo studs through holes in bracket. In­
stall nut washers and torque to 6 Nnn (50 in. lbs.).

(6)
Route cable from servo, through cable support
bracket, and install cable on nail head stud.
(7) Install air cleaner.

8H
- 12
VEHICLE SPEED CONTROL SYSTEM

•
SERVO
THROTTLE CABLE ASSEMBLY—DIESEL
ENGINE

REMOVAL (1) Remove hairpin clip and washer retaining ca­
bles on bellcrank. Remove servo throttle cable from bellcrank.
(2) Remove servo throttle cable from cable support
bracket.
(3) Remove 2 nuts from servo mounting bracket.
(4) Pull servo away from mounting bracket.
(5) Remove and discard push nuts on servo studs. (6) Pull speed control cable away from servo to ex­
pose cable retaining clip. (7) Remove clip attaching cable to servo.
(8) Disconnect cable at servo and remove cable as­
sembly.
INSTALLATION (1) Locate cable through servo mounting bracket.
(2) Connect cable sleeve to servo stud, align holes,
and install hairpin clip.
(3) Insert servo studs through holes in cable.
(4) Install new push nuts on servo studs.
(5) Insert servo studs through holes in bracket. In­
stall nut washers and torque to 6 N*m (50 in. lbs.).
(6) Route cable from servo, to cable support
bracket, (7) Install cable end on bellcrank rod.
(8) Adjust cable as described under speed control
cable adjustment. (9) Install washer and hairpin clip on end of bell­
crank rod.

SPEED
CONTROL
SWITCH
REPLACEMENT
(1) Disconnect negative cable from battery.
(2) From underside of steering wheel, remove horn
pad mounting screws (Fig. 2).
(3) Pull pad up from wheel and disconnect electri­
cal leads.
(4) Remove pad.
(5) Unplug 4-way electrical connector from clock-
spring. (6) Remove 4 screws holding switches and remove
switches (Fig. 3) (7) Install new switches with 4 screws.
(8) Connect 4-way electrical connector from clock-
spring to switches. (9) Connect electrical leads to horn pad.
(10) Install horn pad with 3 screws.
HORN
PAD
Fig. 2 Sport Steering Wheel
CLOCKSPRING

Fig. 3 Speed Control Switches

SPEED
CONTROL VACUUM RESERVOIR
REPLACEMENT-GAS
ENGINE

REMOVAL (1) Disconnect all hoses.
(2) Remove nuts and slide vacuum reservoir off

studs.

INSTALLATION (1) Install vacuum reservoir onto bracket studs.
(2) Install nut washers and torque to 6 Nrn (50 in.

lbs.).

(3) Connect vacuum hoses.

VACUUM PUMP-DIESEL ENGINE
Refer to Group 5 - Brakes for removal and instal­
lation of the vacuum pump.

•
TURN SIGNALS
AND
HAZARD WARNING FLASHER
8J - 1

CONTENTS

page page

GENERAL
INFORMATION
1
MULTIFUNCTION SWITCH TESTING MULTIFUNCTION SWITCH SERVICE PROCEDURES
2
PROCEDURES
3

GENERAL
INFORMATION

TURN SIGNALS

DESCRIPTION With
the
ignition
key ON and the
multi-function
lever
in its UP or
DOWN position, current flows
through
the:
• turn signal flasher canister • Turn/Hazard switch
• turn indicator lamp
• front
and
rear bulbs. The selected turn signal indicator with front
and

rear turn signal bulbs will flash.
DIAGNOSIS High generator output voltage
can
burn
out

lamps rapidly. (1) Remove
and
inspect fuse
in
cavity
#9 of
fuse
block. Replace
if
necessary.
The
fuse block
is
behind
the lower instrument panel cover under steering wheel. (2) Turn
key to
ACCY. There should
be
battery
voltage
at the
fuse side
of the
turn signal flasher (bottom terminal).
If
not,
repair open circuit
in
wir­
ing between fuse
and
flasher.
(3) Replace Turn Flasher with
2
lamp
12
volt rated
flasher that
is
know
to be
good.
The
lamps should
flash. If
not,
replace with original flasher
and
go to

next step.
(4) Measure voltage
at the
Turn/Hazard switch
connector cavity
#17.
Meter should read battery volt­

age.
If
OK,
replace Turn/Hazard switch assembly.
If

not, repair open circuit
in
wiring between flasher
and Turn/Hazard switch connector.
HAZARD WARNING SYSTEM

DESCRIPTION
With
the
hazard switch
OUT,
current flows
through
the

• hazard flasher canister
• hazard switch
•
two
front turn signal bulbs
•
two
rear turn signal bulbs
• both indicator bulbs.
All
of the
turn lamps
and
both indicators will
flash.
DIAGNOSIS Hazard switch
in
ON.
The
park
and
stop lamps
should light.
If
not
replace
the 20
amp
fuse
in
fuse
block cavity
#13.

(1) Measure voltage
at
the
fuse side
of
the
flasher
(side terminal). Meter should read battery voltage.
If

not, repair open circuit
in
wiring
to
fuse. (2) Replace Hazard flasher with known good
flasher. Lamps should flash.
If
not, replace with orig­
inal flasher
and go
to
next step.
(3) Measure voltage
at the
Turn/Hazard switch
connector cavity #13. Meter should read battery volt­

age.
If
not,
repair open circuit
in
wiring
to
hazard
flasher.

TURN
SIGNAL AND HAZARD
WARNING
FLASHER
LOCATION

The turn signal
and
hazard warning flasher
are

both located
on the
fuse block (Fig.
1). The
fuse block is
on the
lower instrument panel cover under
the
steering column.
TURN SIGNALS AND HAZARD WARNING
FLASHER

8J
- 2
TURN SIGNALS AND HAZARD WARNING FLASHER

•

FUSE

BLOCK
INSTRUMENT

PANEL

REAR
VIEW

HAZARD

WARNING
FLASHER

VIEW
IN DIRECTION OF
ARROW
RR8JC10

Fig.
1 Turn
Signal
and Hazard Warning
Flashers
MULTIFUNCTION
SWITCH TESTING PROCEDURES
The multifunction switch contains electrical cir­
cuitry for:
• turn signal
• hazard warning
• headlamp beam select
• headlamp optical horn
• windshield wiper
• pulse wipe • 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 upper and lower column covers to gain
access to the switch connector. (3) Remove switch connector (Figs. 2 and 3).

Fig.
2 Multifunction
Switch
Connector
Fig.
3 Steering
Column
Connectors

•

TURN
SIGNALS
AND
HAZARD WARNING FLASHER
8J - 3 (4) Using an ohmmeter, test for continuity (no re­
sistance) between the terminals of the switdh as shown in the following continuity chart (Pig. 4).
VIEW
FROM TERMINAL CASE
SWITCH POSITIONS

TURN
SIGNAL HAZARD WARNING
CONTINUITY
BETWEEN

NEUTRAL
OFF 12
AND 14 AND 15

LEFT
LEFT
LEFT
OFF
OFF
OFF 15
AND 16 AND 17

12
AND 14

22
AND 23 WITH OPTIONAL CORNER LAMPS

RIGHT
RIGHT
RIGHT
OFF
OFF
OFF 11
AND 12 AND 17

14
AND 15

23
AND 24 WITH OPTIONAL CORNER LAMPS

NEUTRAL
ON 11
AND 12 AND 13 AND 15 AND 16

908J-4
Fig.
4 Turn
Signal
and Hazard Switch Continuity Chart

MULTIFUNCTION SWITCH SERVICE PROCEDURES
REMOVAL
(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 (tamper proof torx bit Snap On
TTXR20B2 or equivalent required). (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. 5).

INSTALLATION
(1) Install wiring connector to switch and tighten
connector retaining screw to 17 in. lbs. (2) Mount multifunction switch to column and
torque retaining screws to 17 in. lbs. (3) Install steering column covers. Torque retain­
ing screws to 17 in. lbs. (4) Install tilt lever (tilt column only).
(5) Install negative cable to battery.
(6) Check all functions of switch for proper opera­
tion.
HAZARD
WARNING

908J-9

Fig.
5 Muitifunction Switch

•

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.