1993 DODGE TRUCK horn

10 INTRODUCTION
•
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS

ID

HIGH
BEAM P
FOG UGHTS -&
HEADLIGHTS,
PARKING UGHTS, PANEL UGHTS TURN SIGNAL A
HAZARD WARNING WINDSHIELD
WASHER
WINDSHIELD WIPER WINDSHIELD WIPER
AND WASHER WINDSCREEN DEMISTING
AND DEFROSTING *

VENTILATING
FAN 8
M f

REAR
WINDOW DEFOGGER
sp

REARWINLX)W WIPER
CD
l
m

REAR
WINDOW WASHER FUEL ENGINE COOLANT
TEMPERATURE BATTERY CHARGING
CONDITION ENGINE OIL

SEAT
BELT

(©) (®) ky

11 J

LIGHTER

BRAKE
FAILURE
PARKING
BRAKE
FRONT HOOD
REAR
HOOD

(TRUNK)
HORN
11 J

LIGHTER
93IN-9

INTERNATIONAL VEHICLE CONTROL AND DISPLAY

SYMBOLS
The graphic symbols illustrated in the chart below
are used to identify various instrument controls. The
symbols correspond to the controls and displays that are located on the instrument panel.

•

ELECTRICAL
ELECTRICAL
8A - 1

Group

AUDIO
SYSTEMS
8F
BATTERY/STARTER/GENERATOR
SERVICE
.. 8B
BATTERY/STARTING/CHARGING
SYSTEMS

DIAGNOSTICS
8A

HORNS
8G

IGNITION
SYSTEMS
8D
INSTRUMENT PANEL AND
GAUGES
8E

LAMPS
8L

POWER
LOCKS
8P
INDEX

Group

POWER
MIRRORS
8T

POWER
WINDOWS 8S

REAR
WINDOW DEFOGGER 8N
TURN
SIGNALS
AND HAZARD WARNING
FLASHERS
8J
VEHICLE
SPEED
CONTROL SYSTEM 8H WARNING BUZZER SYSTEM 8U
WINDSHIELD WIPERS AND
WASHERS
8K
WIRING DIAGRAMS 8W

BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
CONTENTS
page
page
BATTERY TEST
PROCEDURES
2 GENERATOR TEST
PROCEDURES
ON VEHICLE . 13

ENGINE
STARTER MOTOR TEST
PROCEDURES
..9 SPECIFICATIONS 18

GENERAL
INFORMATION 1

GENERAL INFORMATION

The Battery, Starting, and Charging Systems oper­
ate with one another, and therefore, must be thor­
oughly tested as a complete system. In order for the
vehicle to start and charge properly, it must have a
battery that will perform to specifications. The starter
motor, generator, wiring, and electronics also must
perform within specifications. Group 8A covers Start­ ing (Fig. 1) and Charging (Fig. 2) System diagnostic
procedures. These procedures include the most basic
conventional methods to On-Board Diagnostics (OBD)
built into the Powertrain Control Module (PCM).
Use of an ammeter, volt/ohmmeter, battery
charger, carbon pile rheostat (load tester), and 12
volt test light will be required.
All OBD sensing systems are monitored by the
PCM. The PCM will store in memory any detectable
failure in the monitored circuits. Refer to Using On-
Board Diagnostic System in this group for more in­ formation.
NEGATIVE

BATTERY
CABLE

A
7

POSITIVE

BATTERY
CABLE
BATTERY

J918A-11

Fig.
1 Starting
System
Components—Typical

•

INSTRUMENT PANEL
AND
GAUGES
8E - 19

MESSAGE
CENTER
PRINTED CIRCUIT BOARD
J918E-33

Fig.
5
Message
Center Printed Circuit
Board—Manual
Transmission

LOW FUEL MODULE
>

PRINTED CIRCUIT BOARD
J918E-34

Fig.
6
Message
Center Printed Circuit
Board—Diesel
(5) Remove overdrive lockout switch from module.

INSTALLATION
(1) Install overdrive lockout switch into module.
(2) Position module on bezel and install screws and

clip.

(3) Connect lockout switch and message center
connectors.
(4) Install instrument cluster bezel to panel.
(5) Install map lamp.

FUSE
BLOCK AND
FLASHERS

FUSE
BLOCK
The fuse block is located directly below the steer­
ing column, on the lower steering column cover.

REMOVAL
Push fuse block locking tab on column cover down­
ward and lower fuse block. The following components
plug into the fuse block.
• Fuses. • 30 amp circuit breakers.
• Turn signal flasher. • Horn relay.
• Hazard Warning Flasher.

INSTALLATION
(1) Position fuse block to steering column cover. (2) Push locking tab to lock fuse block in position.

HOOD
RELEASE

REMOVAL
(1) Disengage cable from hood latch in engine com­
partment. (2) Remove 4 screws holding handle assembly to
instrument panel.
(3) Remove assembly by pulling cable rearward
through dash panel grommet.

INSTALLATION
(1) Feed cable assembly forward through dash
panel grommet.
(2) Mount handle assembly to instrument panel
with four screws.
(3) Connect cable to hood latch.

FOUR
WHEEL
DRIVE
INDICATOR
REMOVAL
(1) Remove map lamp.
(2) Remove cluster bezel (refer to Cluster Bezel Re­
moval).
(3) Remove 2 screws and remove indicator from be­
zel (Fig. 7).
o

J928E-48

Fig.
7
Four
Wheel
Drive Indicator
Bezel

•

HORNS
8G - 1
HORNS
CONTENTS

SERVICE
PROCEDURES
page

.. 3
TEST PROCEDURES
page

.. 1

GENERAL
INFORMATION plied from the fuse block and grounded in the horn The horn system consists of a horn switch, horn re- switch. When the horn switch on the steering column
lay (located on the fuse block), horns, and all their is pressed, the ground circuit is completed, energiz-
wiring and connections. The circuit voltage is sup- ing the relay, and supplying power to the horns.

TEST PROCEDURES
HORNS
WILL
NOT
SOUND
If the horns do not sound, check for a blown horn
fuse in cavity number 4 of the fuse block. If the fuse is blown, replace it with the same type fuse. If the
horns fail to sound and the newly replaced fuse blows
the horn switch is depressed, check for one of the fol­ lowing:
• a short circuit in the horn
• the horn wiring between the fuse terminal and the
horn is faulty. If the fuse is intact, unplug wire connector at horn.
Connect one lead of a test lamp to the wire connector and the other lead to a good body ground (Fig. 1).
Depress the horn switch. Should test lamp illuminate
the horn is ungrounded or faulty. Ground can be checked by using a jumper wire between horn
bracket (scratch through paint) and the battery neg­ ative terminal. If the horn still fails to sound with
the ground jumper wire still intact and the horn re­ connected, replace the horn. If the lamp fails to illuminate, check for a defective
horn relay by substituting a known good horn relay in the circuit. If the lamp illuminates when depress­
ing the horn switch, the original relay is defective. If
the lamp fails to illuminate with a known good relay, unplug that relay. Connect a jumper wire from the
battery terminal to the horn terminal on the relay
terminal board. If the lamp, connected in place of the
horns, fails to illuminate, inspect for an open circuit
between the horn fuse and the horn terminal on the relay. Also check between relay terminal board and
the horn terminals. Should the lamp illuminate, a defective horn switch or an open circuit in the wiring
between the relay terminal and the horn switch is at fault.

HORNS SOUND CONTINUOUSLY
Should the horns sound continuously, unplug the
horn relay from the relay connector inside the pas-
HORN
TEST LAMP TO RELAY
AND

HORN
BUTTON
-

TO GOOD BODY GROUND HORN,
CONNECTOR
PR714

Fig.
1 Testing for Voltage
senger compartment (Fig. 2). Plug in a known good
relay. If the horns stop blowing, relay is defective and must be replaced. Should the horns still sound,
proceed with Horn Diagnosis Chart.
HORN RELAY
FUSE BLOCK

RB1359

Fig.
2
Horn
Relay
Remove steering wheel pad and disconnect wire
from horn switch. Repeat the above test and if the
test lamp still illuminates, wire is shorted and should be repaired. If test lamp does not illuminate,
horn switch is defective and must be replaced.

8G
- 2
HORNS
•
HORN
DOES NOT
SOUND HORN SOUNDS
INTERMITTENTLY

TEST FUSE
HORN SOUNDS
CONTINUOUSLY

HORN SWITCH
OR
WIRE TO HORN SWITCH GROUNDING
OUT

FUSE BLOWN
REMOVE
HORN
PAD AND

CHECK
CONTINUITY
BE­

TWEEN STEERING SHAFT AND BODY GROUND
NOTE:
IMMEDIA1

RELAY
AND
Dl
FRO/V
rELY UNPLUG HORN

SCONNECT
WIRES

\HORNS

USE
TEST LIGHT BETWEEN HORN
RELAY
SOCKETS
t AND 3
(SEE
INSET DIAGRAM)

HORN CIRCUIT
WIRING SHORTED TO GROUND

USE
TEST
LIGHT
AT

HORNS
(DEPRESS
HORN
BUTTON)
(FIG.
2)
TEST LIGHT' ON
TEST
UGHT
"OFF" TEST LIGHT "OFF"

INTERNAL
SHORT CIRCUIT IN HORN
HORN
NOT*
GROUNDED

REPLACE
HORN
RELAY
WITH
A

KNOWN GOOD
ONE
(FIG.
3)
TEST LIGHT "ON"

FAULTY
HORN RELAY

SHORTED

HORN RELAY WIRE
TO
HORN
BUTTON SWITCH
GROUNDED
OR
HORN BUTTON SWITCH
GROUNDED

REFER
TO
TEST
PROCEDURES

FAULTY HORN WRONG

FUSE
SIZE

TEST LIGHT "ON"

FAULTY ORIGINAL
RELAY
TEST LIGI

HT
"OFF"

UNPLUG REPLACEMENT

RELAY
FROM SOCKET
AND
CONNECT
A
JUMPER
WIRE BETWEEN RELAY
SOCKET
1
AND
2

SEE
INSET DIAGRAM

INSPECT
FOR
OPEN
CIRCUIT
IN
WIRING FROM
FUSE
BLOCK THROUGH

RELAY
BOARD
TO
HORN TERMINAL FAULTY HORN SWITCH

OR
WIRING BETWEEN
RELAY
TERMINAL
AND
HORN SWITCH
HORN
RELAY CONNECTOR ALL MODELS
TO HORN SWITCH

TO

HORNS
TO
FUSE

BLOCK
*IT
IS
IMPORTANT
THAT
HORNS

BE
ADEQUATELY GROUNDED. GROUNDING

CAN
BE
VERIFIED
BY
MAKING
A

TEMPORARY
JUMPER WIRE CONNECTION BETWEEN HORN BRACKET (SCRATCH
THROUGH
PAINT)
AND THE
BATTERY
NEGATIVE TERMINAL.
J918G-5

•

HORNS
8G - 3
SERVICE
PROCEDURES

HORN
SWITCH (HORN PAD ASSEMBLY)

REPLACEMENT

REMOVAL (1) From underside of steering wheel, remove horn
pad mounting screws (Figs. 3 and 4). (2) Pull pad up from wheel and disconnect electri­
cal leads. (3) Remove pad.

INSTALLATION
(1) Connect electrical leads to switch terminal on
horn pad. (2) Position pad into place on steering wheel, install
mounting screws and tighten to 1.5 N*m (15 in. lbs.).
NUT
&

WASHER
SOURCE

FOR HORN
RELAY GROUND STEERING
WHEEL
STEERING SHAFT
COVER

(WITHOUT
SPEED

CONTROL
SWITCHES) HORN
RELAY
GROUND WIRE COVER
RETAINING
SCREW
J9119-9

Fig.
3 Standard Steering
Wheel

HORN
PAD
COLUMN
HORN

LEADS
STEERING WHEEL
J9219-55

Fig.
4 Optional Steering
Wheel

HORN
REPLACEMENT
-
GAS ENGINE
The horns are located on either side of the radiator
support (Fig. 5). (1) Raise the hood.
(2) Disconnect the horn electrical connector.
(3) Remove bolt holding the horn bracket to the ra­
diator support and remove the horn. (4) To install the horns reverse the removal proce­

dures.
Tighten the bolts to 200 in. lbs.
HORN

(HI-NOTE)

HORN

(LOW-NOTE)

HORN

MOUNTING

BOLTS

J908G-10

Fig.
5
Horn
Removal
and Installation—Gas
Engine
HORN
REPLACEMENT
-
DIESEL ENGINE

The horns are located on the inside of the left front
fender behind the battery (Fig. 6). (1) Raise the hood.
(2) Remove screw and washer holding the horn
bracket to the fender. (3) Lower the horn and bracket toward the rear of
the battery. (4) Disconnect the horn electrical connector.
(5) Remove the horn and bracket assembly by
working it under the battery tray brace (Fig. 6). (6) To install the horns reverse the removal proce­

dures.
LEFT

FENDER
HI NOTE
HORN
&
BRACKET
ASSEMBLY
LOW NOTE
HORN
&
BRACKET
ASSEMBLY
J908G-11

Fig.
6
Horn
Removal
and Installation—Diesel
Engine

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.

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