1993 DODGE TRUCK Service Repair Manual

8N
- 2
REAR WINDOW DEFOGGER

• (b) Rear window grid lines (all grid lines would
have to be broken) or one of the feed wires are not
connected for the system to be inoperative.
The following paragraphs outline component check­
out procedures.
If turning the switch ON produces severe voltmeter
deflection, the circuit should be closely checked for a shorting condition. If system operation has been verified but indicator
bulb does not light, check and replace bulb.
For detailed wiring information, refer to Group 8W
- Wiring Diagrams.

REAR
WINDOW GRID LINES TEST
Horizontal grid lines and vertical bus bar lines
printed and baked on inside surface of rear window glass (Fig. 1) comprise an electrical parallel circuit.
The electrically conductive lines are made of a silver- ceramic material. When baked onto glass they be­
come bonded to the glass and are highly resistant to abrasion. It is possible, however, that a break may
exist or occur in an individual grid line resulting in
no current flow through the line. To detect breaks in
grid lines, the following procedure is required: (1) Turn ignition on and push control switch to
ON. Indicator light should come on. (2) Contact negative lead of a DC voltmeter, to
vertical bus bar connecting grid lines on passenger side of vehicle (point A of Fig. 1). Contact positive
lead of voltmeter, to vertical bus bar on driver side of
vehicle (point B of Fig. 1). Voltmeter should read 10-14 volts. (3) With negative lead of voltmeter, contact a good
body ground point. Voltage reading should not change. A different reading indicates a poor ground connection. (4) Connect negative lead of voltmeter to Point A
on passenger side bus bar and touch each grid line at
Mid-Point with positive lead. A reading of approxi­ mately 6 volts indicates a line is good. A reading of 0
volts indicates a break in line between Mid-Point C and Point B. A reading of 10-14 volts indicates a
break between Mid-Point C and ground Point A. Move toward break and voltage will change as soon as break is crossed.

CONTROL SWITCH/TIMER MODULE TEST
Control switch/timer relay module may be tested
in-vehicle or bench tested. In vehicle testing is ac­
complished in the following manner: (1) Remove switch from instrument panel (refer to
Control Switch Replacement) and leave switch con­
nector plugged in. (2) Turn ignition ON.
(3) Using a DC voltmeter, check voltage at termi­ nals B, I and L (Figs. 2 and 3). Terminals B and I
should confirm a voltage of 10 to 14 volts to ground.
Terminal L should confirm 0 volts to ground. When terminals B and I show no voltage, trace circuit up­
stream of switch/relay module for cause:
• wiring cut
• fusible link faulty
• circuit breaker inoperative
• bulkhead connection bad, etc. If terminal L indicates voltage, place switch in
OFF position. If voltage at L is still indicated or in­
dicator lamp remains on, switch/relay module should
be replaced.
"XI
FUSE
#14
rr~
P 3
AAAP
P
FUSE
#3
20
AAAP
BATTERY

HEATED
REAR

WINDOW
DEFOGGER
SWITCH

(INSTRUMENT
PANEL)

ON/OFF
ILLUMINATION
LAMP

fez TIMER
L.E.I
INDICATOR
LIGHT
-©-
18
GAUGE

FUSIBLE
LINK

IGNITION POWER
MIDPOINT
"C"

CONNECTOR (TYPICAL)
POINT
"A"
POINT
"B"
GROUND
CONNECTOR

REAR
WINDOW
GRID
LINE
STRUCTURE
Fig.
2
Systems
Electrical Circuit
J928N-5

(4) If the relay checks out to this point, momen­
tarily operate switch to ON position. The indicator lamp should come on and remain on for approxi­
mately 10 minutes. Terminal L should confirm volt­
age.
If the indicator lamp fails to light or voltage at
terminal L is not confirmed the switch/relay module should be replaced.
Bench checking of the relay may be accomplished
in the following manner. By following the in-vehicle
procedure except Step 2: With a DC power supply, apply 12 volts to terminal B and I and ground termi­
nal G.

e
,
REAR
WINDOW
DEFOGGER
8N
- 3

L
-
TO
BACK GLASS

B
-
HIGH
AMP
SUPPLY

I
-
IGNITION

G
-
GROUND
S
-
ILLUMINATION
LIGHT

RELAY-TIMER

SWITCH
ASSEMBLY
J908N-8
Fig.
3
Rear Window Defogger
Switch,
Timer,
Relay
Connector
REPAIR
PROCEDURES
(GRID LINES, TERMINALS* AND PIGTAILS)

The
repair
of
grid lines
or the
terminal
is
possible
using
the
MOPAR Repair
Kit
No. 4267922
or
equiv­ alent.

WARNING: REPAIR
KIT
MAY
CAUSE SKIN
OR
EYE
IRRITATION.
CONTAINS EPOXY RESIN
AND
AMINE TYPE

HARDENER,
HARMFUL
IF
SWALLOWED. AVOID
CONTACT
WITH
SKIN
AND
EYES.
FOR
SKIN,
WASH
AFFECTED AREAS
WITH
SOAP
AND
WATER.
DO
NOT TAKE INTERNALLY.
IF
TAKEN INTERNALLY,
INDUCE VOMITING; CALL
A
PHYSICIAN IMMEDI­
ATELY.
IF IN
CONTACT
WITH
EYES,
FLUSH
WITH
PLENTY
OF
WATER.
USE WITH
ADEQUATE VENTI­
LATION.
DO
NOT USE
NEAR FIRE
OR
FLAME.
CONTENTS CONTAIN
3%
FLAMMABLE SOLVENTS.
KEEP
OUT
OF
REACH
OF
CHILDREN.

(1) Mask repair area
so
conductive epoxy
can be

extended onto
the
line
or the bus bar
(Fig.
4).
(2) Follow instructions
in
repair
kit for
preparing
damaged area.
(3) Remove package separator clamp
and mix
plas­
tic conductive epoxy thoroughly. Fold
in
half and
cut
center corner
to
dispense epoxy.
(4)
For
grid line, mark
off
area
to be
repaired with
masking tape
or a
template (Fig.
4).
(5) Apply epoxy through slit
in
masking tape.
Overlap both ends
of the
break
by at
least
19mm

(0.75
in).

(6)
For a
terminal
or
pigtail replacement, mask
ad­

jacent areas
so
epoxy
can be
extended onto line
as
BREAK
GRID
LINE

MASKING TAPE PR1509A

Fig.
4
Grid
Line
Repair
(Typical)
well
as bus bar.
Apply
a
thin layer
of
epoxy
to
area
where terminal
was
fastened
and to
adjacent line.
(7) Apply
a
thin layer
of
conductive epoxy
on
ter­
minal
and
place terminal
on
desired location.
To
pre­
vent terminal from moving while
the
epoxy
is
curing, it must
be
wedged
or
clamped.
(8) Carefully remove masking tape from grid line.

CAUTION:
Do not
allow
the
glass
surface
to
exceed

400°F,
glass
may
fracture.

(9) Allow epoxy
to
cure
24
hours
at
room tempera­
ture
or use
heat
gun
with
a
260°-371°C (500°-700°F) range
for 15
minutes. Hold
gun
approximately 254mm
(10
inches) from repaired area.
(10) After conductive epoxy
is
properly cured
re­

move wedge from terminal
and
check
out
operation
of rear window defogger.
Do not
attach connectors
until curing
is
complete.

81 - 4
REAR
WINDOW
DEFOGGER

•
SERVICE
PROCEDURES

HEATED
REAR
WINDOW
CONTROL
SWITCH
REPLACEMENT

REMOVAL (1) Locate chime module. Grasp chime module and
twist it to remove it from the bracket. (2) Squeeze rear window defogger switch retaining
tangs and pull switch from rear of bezel. (3) Remove connector from switch.
INSTALLATION (1) Connect electrical connector to switch.
(2) Insert switch into bezel making sure retaining
tangs lock into position.
(3) Install chime module on to bracket.

•

POWER DOOR LOCKS
8P - 1
POWER DOOR LOCKS
CONTENTS

SERVICE
PROCEDURES
page

..
2
TEST PROCEDURES
page

..
1
equipped,
can be

by operating
the
GENERAL
INFORMATION

Both doors, when electrically
locked
or
unlocked electrically switch
on a
door panel. Both doors
can be
locked
or
unlocked mechanically
with
the
locking knob regardless
of
electrical locking and unlocking actuation.

TEST
PROCEDURES
The right
and
left front door
on all
vehicles
can be

locked
or
unlocked mechanically from
the
outside
with
the key or
electrically
as
described above.
The
left door
can
also
be
unlocked
by
actuation
of
the
in­

side remote door handle.
FUSE
TEST

Locate
the
fuse
in
fuse cavity number
6 on the
fuse
block.
If
fuse
is
blown, replace
it. If
fuse blows again refer
to
Switch Test
and
Voltage Test procedures
to
find
the
short circuit.

SWITCH TEST
For switch testing, remove
the
switch from
its

mounting location. Using
an
ohmmeter, refer
to
(Fig. 1)
to
determine
if
continuity
is
correct
in the
Lock
and Unlock switch positions.
If
these results
are not

obtained, replace
the
switch. ®

3 SWITCH
POSITION
CONTINUITY

BOWEIN
OFF PINS
1 & 4

PINS
2 & 5

LOCK PINS
2 & 3

PINS
1 & 4

UNLOCK
PINS
3 &4

PINS
2 &5

PIN IDENTIFICATION
PIN SIDE
OF
SWITCH
Fig.
1
Door Lock
Switch
Continuity
VOLTAGE TEST

The following wiring test sequence determines
whether
or not
voltage
is
continuous through
the

body harness
to
switch. After removing switch from trim panel
for
testing
purposes, carefully separate multiple terminal block
on wiring harness from switch body. Connect
one

lead
of
test light
to
black wire terminal
and
touch other test light lead
to red
wire terminal.
If
the test
light comes
on, the
wiring circuit between
the
bat­
tery
and
switch
is
functional.
If
light does
not
come
on, check
20 amp
fuse
or for a
broken wire.

ELECTRIC MOTOR TEST
Make certain battery
is in
normal condition before
circuits
are
tested. To determine which motor
is
defective, check each
individual door switch
for
lock
and
unlock
or
discon­
nect
the
motors,
one at a
time, then operate
the
door lock switch.
In the
event that none
of the
motors
work,
the
problem may
be
caused
by a
shorted motor. Disconnecting
the
defective motor will allow
the

other
to
work. To test
an
individual door lock motor, disconnect
the wire connector
at the
motor. Apply
12
volts across
the
motor terminals
to
check
its
operation
in

one direction. Reverse
the
polarity
to
check
the
oper­ ation
in the
other direction.
If the
motor works,
check
the
wire harness
for
broken wires
or bad
con­
nections.
If
the motor does
not
work, replace
it.
Should
the
motor malfunction
be the
result
of
bro­
ken wiring
or an
internal open circuit,
it
should have no effect
on the
operation
of
the other motor.

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.