1998 DODGE RAM 1500 Sensor

WARNING: TO AVOID PERSONAL INJURY OR
DEATH, THE DRIVER AIRBAG TRIM COVER MUST
NEVER BE PAINTED. REPLACEMENT TRIM COV-
ERS ARE SERVICED IN THE ORIGINAL COLORS.
PAINT MAY CHANGE THE WAY IN WHICH THE
MATERIAL OF THE TRIM COVER RESPONDS TO AN
AIRBAG DEPLOYMENT. FAILURE TO OBSERVE
THIS WARNING COULD RESULT IN OCCUPANT
INJURIES UPON AIRBAG DEPLOYMENT.
(1) Disconnect and isolate the battery negative
cable. Wait two minutes for the system capacitor to
discharge before further service.
(2) Remove the driver airbag from the steering
wheel (Refer to 8 - ELECTRICAL/RESTRAINTS/
DRIVER AIRBAG - REMOVAL).
(3) Place the driver airbag on a suitable clean and
dry work surface with the trim cover facing down. If
the trim cover will be reused, be certain to take the
proper precautions to prevent the trim cover from
receiving cosmetic damage during the following pro-
cedures.
(4) Carefully pry the horn switch feed pigtail wire
connector away from the back of the driver airbag
housing far enough to disengage the integral connec-
tor retainer from the locator hole just above the
upper right inflator mounting stud (Fig. 25).
(5) Remove the nut that secures the horn switch
ground pigtail wire eyelet terminal to the upper rightinflator stud on the back of the driver airbag hous-
ing.
(6) Remove the horn switch ground pigtail wire
eyelet terminal from the upper right inflator stud on
the back of the driver airbag housing.
(7) Disengage each of the twelve hooks of the air-
bag housing from the twelve windows in the vertical
walls of the trim cover, one wall at a time. Start by
disengaging the upper wall, then do each of the two
side walls, and finish with the lower wall. To disen-
gage the hooks, use hand pressure to push firmly
and evenly downward into the receptacle on the adja-
cent edge of the airbag housing, while at the same
time pushing outward on the upper edge of the
receptacle wall.
(8) With all of the hooks disengaged, lift the hous-
ing, inflator, and cushion as a unit from the recepta-
cle on the back of the driver airbag trim cover.
ASSEMBLY
The following procedures can be used to replace
the driver airbag trim cover and horn switch unit for
service. If the driver airbag is faulty or deployed, the
entire driver airbag, trim cover and horn switch must
be replaced as a unit.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT
TENSIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, SERVICE OF THIS UNIT SHOULD BE PER-
FORMED ONLY BY DAIMLERCHRYSLER-TRAINED
AND AUTHORIZED DEALER SERVICE TECHNI-
CIANS. FAILURE TO TAKE THE PROPER PRECAU-
TIONS OR TO FOLLOW THE PROPER
PROCEDURES COULD RESULT IN ACCIDENTAL,
INCOMPLETE, OR IMPROPER AIRBAG DEPLOY-
MENT AND POSSIBLE OCCUPANT INJURIES.
Fig. 25 Driver Airbag Disassembly
1 - HORN SWITCH FEED CONNECTOR
2 - HORN SWITCH GROUND EYELET TERMINAL
3 - HOUSING
4 - TRIM COVER
5 - HOOK (4 LOWER EDGE, 4 UPPER EDGE)
6 - HOOK (2 ON EACH SIDE)
8O - 26 RESTRAINTSDR
DRIVER AIRBAG (Continued)

driver airbag housing. Tighten the nut to 7 N´m (65
in. lbs.).
(11) Using hand pressure, push the integral
retainer of the horn switch feed pigtail wire connec-
tor into the locator hole just above the upper right
inflator mounting stud on the back of the driver air-
bag.
(12) Reinstall the driver airbag onto the steering
wheel (Refer to 8 - ELECTRICAL/RESTRAINTS/
DRIVER AIRBAG - INSTALLATION).
INSTALLATION
The following procedure is for replacement of a
faulty or damaged driver airbag. If the airbag is
faulty or damaged, but not deployed, review the rec-
ommended procedures for handling non-deployed
supplemental restraints. (Refer to 8 - ELECTRICAL/
RESTRAINTS - STANDARD PROCEDURE - HAN-
DLING NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS). If the driver airbag has been
deployed, review the recommended procedures for
service after a supplemental restraint deployment
before removing the airbag from the vehicle. (Refer to
8 - ELECTRICAL/RESTRAINTS - STANDARD PRO-
CEDURE - SERVICE AFTER A SUPPLEMENTAL
RESTRAINT DEPLOYMENT).
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT
TENSIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE DRIVER
AIRBAG, OR BECOMING ENTRAPPED BETWEEN
THE DRIVER AIRBAG CUSHION AND THE DRIVER
AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.WARNING: TO AVOID PERSONAL INJURY OR
DEATH, THE DRIVER AIRBAG TRIM COVER MUST
NEVER BE PAINTED. REPLACEMENT AIRBAGS
ARE SERVICED WITH TRIM COVERS IN THE ORIG-
INAL COLORS. PAINT MAY CHANGE THE WAY IN
WHICH THE MATERIAL OF THE TRIM COVER
RESPONDS TO AN AIRBAG DEPLOYMENT. FAIL-
URE TO OBSERVE THIS WARNING COULD RESULT
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(1) Position the driver airbag close enough to the
steering wheel to reconnect the three electrical con-
nections on the back of the airbag housing (Fig. 24).
(2) When installing the driver airbag, reconnect
the two clockspring driver airbag pigtail wire connec-
tors to the airbag inflator connector receptacles by
pressing straight in on the connector. Be certain to
engage each keyed and color-coded connector to the
matching connector receptacle. You can be certain
that each connector is fully engaged in its receptacle
by listening carefully for a distinct, audible click as
the connector latches snap into place.
(3) Reconnect the steering wheel wire harness con-
nector for the horn switch to the horn switch feed
pigtail wire connector, which is located on the back of
the driver airbag housing.
(4) Carefully position the driver airbag in the
steering wheel (Fig. 23). Be certain that the clock-
spring pigtail wires and the steering wheel wire har-
ness in the steering wheel hub area are not pinched
between the driver airbag and the steering wheel
armature.
(5) From the underside of the steering wheel,
install and tighten the two screws that secure the
driver airbag to the steering wheel armature.
Tighten the screws to 10 N´m (90 in. lbs.).
(6) Do not reconnect the battery negative cable at
this time. The supplemental restraint system verifi-
cation test procedure should be performed following
service of any supplemental restraint system compo-
nent. (Refer to 8 - ELECTRICAL/RESTRAINTS -
STANDARD PROCEDURE - VERIFICATION TEST).
8O - 28 RESTRAINTSDR
DRIVER AIRBAG (Continued)

(1) From the front of the front seat, position the
front center seat belt buckle, lap belt unit, or unique
black, keyed front center seat belt lower anchor
buckle between the center seat cushion and the adja-
cent right or left front outboard seat cushion.
(2) From the front of the front seat, reach between
the center seat cushion and the adjacent right or left
front outboard seat cushion to route the front center
seat belt buckle, lap belt unit lower anchor, or unique
black, keyed front center seat belt lower anchor
buckle through the elastic strap on the side of the
center seat cushion (Fig. 30).
(3) From behind the front seat, position the front
center seat belt buckle, lap belt lower anchor, or
unique black, keyed front center seat belt lower
anchor buckle to the center seat support bracket.
(4) Install and tighten the screw that secures the
front center seat belt buckle, lap belt lower anchor, or
unique black, keyed front center seat belt lower
anchor buckle to the center seat support bracket.
Tighten the screw to 40 N´m (29 ft. lbs.).
(5) Move the adjacent right or left front outboard
seat section (40 percent) back to its rearward posi-
tion.
FRONT OUTBOARD SEAT
BELT & RETRACTOR
REMOVAL
REMOVAL - STANDARD CAB
The following procedure is for replacement of a
faulty or damaged front outboard seat belt and
retractor unit, which includes a seat belt tensioner
for this model.(Refer to 8 - ELECTRICAL/RE-
STRAINTS/SEAT BELT TENSIONER - DESCRIP-
TION). The only component of this seat belt and
retractor unit that is available for individual service
replacement is the plastic web stop button that pre-
vents the latch plate from falling to the floor while in
the stored position. Refer to the instructions supplied
with the service kit for the proper web stop button
replacement procedures.
The seat belt retractor on the driver's side of stan-
dard cab models only also includes a tension reducer.
(Refer to 8 - ELECTRICAL/RESTRAINTS/TENSION
REDUCER - DESCRIPTION). The seat belt retractor
on the passenger's side of all models includes a swit-
chable automatic locking mechanism. (Refer to 8 -
ELECTRICAL/RESTRAINTS/AUTOMATIC LOCK-
ING RETRACTOR - DESCRIPTION).
If the seat belt or retractor is faulty or damaged,
but the seat belt tensioner is not deployed, review
the recommended procedures for handling non-de-ployed supplemental restraints. (Refer to 8 - ELEC-
TRICAL/RESTRAINTS - STANDARD PROCEDURE
- HANDLING NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS). If the seat belt tensioner has been
deployed, review the recommended procedures for
service after a supplemental restraint deployment
before removing the front outboard seat belt and
retractor from the vehicle. (Refer to 8 - ELECTRI-
CAL/RESTRAINTS - STANDARD PROCEDURE -
SERVICE AFTER A SUPPLEMENTAL RESTRAINT
DEPLOYMENT).
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT
TENSIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, DURING AND FOLLOWING ANY SEAT BELT
OR CHILD RESTRAINT ANCHOR SERVICE, CARE-
FULLY INSPECT ALL SEAT BELTS, BUCKLES,
MOUNTING HARDWARE, RETRACTORS, TETHER
STRAPS, AND ANCHORS FOR PROPER INSTALLA-
TION, OPERATION, OR DAMAGE. REPLACE ANY
BELT THAT IS CUT, FRAYED, OR TORN.
STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT
BELT OR CHILD RESTRAINT COMPONENT.
ALWAYS REPLACE DAMAGED OR FAULTY SEAT
BELT AND CHILD RESTRAINT COMPONENTS WITH
THE CORRECT, NEW AND UNUSED REPLACEMENT
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR
PARTS CATALOG.
(1) Move the front seat to its most forward position
for easiest access to the lower seat belt anchor and
the B-pillar trim.
8O - 32 RESTRAINTSDR
FRONT CENTER SEAT BELT (Continued)

before removing the front outboard seat belt and
retractor from the vehicle. (Refer to 8 - ELECTRI-
CAL/RESTRAINTS - STANDARD PROCEDURE -
SERVICE AFTER A SUPPLEMENTAL RESTRAINT
DEPLOYMENT).
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT
TENSIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, DURING AND FOLLOWING ANY SEAT BELT
OR CHILD RESTRAINT ANCHOR SERVICE, CARE-
FULLY INSPECT ALL SEAT BELTS, BUCKLES,
MOUNTING HARDWARE, RETRACTORS, TETHER
STRAPS, AND ANCHORS FOR PROPER INSTALLA-
TION, OPERATION, OR DAMAGE. REPLACE ANY
BELT THAT IS CUT, FRAYED, OR TORN.
STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT
BELT OR CHILD RESTRAINT COMPONENT.
ALWAYS REPLACE DAMAGED OR FAULTY SEAT
BELT AND CHILD RESTRAINT COMPONENTS WITH
THE CORRECT, NEW AND UNUSED REPLACEMENT
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR
PARTS CATALOG.
(1) Move the front seat to its most forward position
for easiest access to the lower seat belt anchor and
the B-pillar trim.
(2) Disconnect and isolate the battery negative
cable. Wait two minutes for the system capacitor to
discharge before further service.
(3) Remove the screw that secures the lower seat
belt anchor to the floor panel near the base of the
inner B-pillar (Fig. 32).(4) Remove the lower seat belt anchor from the
floor panel near the base of the inner B-pillar.
(5) Unsnap and remove the trim cover from the
front outboard seat belt turning loop to access the
screw that secures the turning loop to the height
adjuster on the upper inner B-pillar. Discard the
removed turning loop trim cover as it is not intended
for reuse.
(6) Remove the screw that secures the seat belt
turning loop to the height adjuster.
(7) Remove the seat belt turning loop from the
height adjuster.
(8) Remove the upper and lower trim from the
inner B-pillar. (Refer to 23 - BODY/INTERIOR/B-
PILLAR UPPER TRIM - REMOVAL) and (Refer to
23 - BODY/INTERIOR/B-PILLAR LOWER TRIM -
REMOVAL).
Fig. 32 Front Outboard Seat Belt & Retractor
Remove/Install - Quad Cab
1 - ADJUSTER
2 - UPPER TRIM PANEL
3 - B-PILLAR
4 - TURNING LOOP
5 - SCREW
6 - TRIM COVER
7 - SEAT BELT
8 - LOWER TRIM PANEL
9 - SCREW
10 - LOWER ANCHOR
11 - SCREW
12 - RETRACTOR
13 - WIRE HARNESS CONNECTOR
14 - SCREW
15 - WEB GUIDE
8O - 34 RESTRAINTSDR
FRONT OUTBOARD SEAT BELT & RETRACTOR (Continued)

(9) Remove the screw that secures the seat belt
web guide to the inner B-pillar near the belt line.
(10) Remove the seat belt web guide from the
inner B-pillar.
(11) Disengage the seat belt tensioner pigtail wire
retainer from the hole in the inner B-pillar sheet
metal.
(12) Disconnect the yellow seat belt tensioner pig-
tail wire connector from the body wire harness take
out and connector for the tensioner.
(13) Remove the screw that secures the lower
retractor bracket to the lower inner B-pillar below
the retractor mounting hole.
(14) Disengage the hooks on the upper retractor
bracket from the slots in the lower inner B-pillar
above the retractor mounting hole.
(15) Remove the front outboard seat belt and
retractor from the retractor mounting hole in the
lower inner B-pillar.
INSTALLATION
INSTALLATION - STANDARD CAB
The following procedure is for replacement of a
faulty or damaged front outboard seat belt and
retractor unit, which includes a seat belt tensioner
for this model. (Refer to 8 - ELECTRICAL/RE-
STRAINTS/SEAT BELT TENSIONER - DESCRIP-
TION). The only component of this seat belt and
retractor unit that is available for individual service
replacement is the plastic web stop button that pre-
vents the latch plate from falling to the floor while in
the stored position. Refer to the instructions supplied
with the service kit for the proper web stop button
replacement procedures.
The seat belt retractor on the driver's side of stan-
dard cab models only also includes a tension reducer.
(Refer to 8 - ELECTRICAL/RESTRAINTS/TENSION
REDUCER - DESCRIPTION). The seat belt retractor
on the passenger's side of all models includes a swit-
chable automatic locking mechanism. (Refer to 8 -
ELECTRICAL/RESTRAINTS/AUTOMATIC LOCK-
ING RETRACTOR - DESCRIPTION).
If the seat belt or retractor is faulty or damaged,
but the seat belt tensioner is not deployed, review
the recommended procedures for handling non-de-
ployed supplemental restraints. (Refer to 8 - ELEC-
TRICAL/RESTRAINTS - STANDARD PROCEDURE
- HANDLING NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS). If the seat belt tensioner has been
deployed, review the recommended procedures for
service after a supplemental restraint deployment
before removing the front outboard seat belt and
retractor from the vehicle. (Refer to 8 - ELECTRI-
CAL/RESTRAINTS - STANDARD PROCEDURE -SERVICE AFTER A SUPPLEMENTAL RESTRAINT
DEPLOYMENT).
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT
TENSIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, DURING AND FOLLOWING ANY SEAT BELT
OR CHILD RESTRAINT ANCHOR SERVICE, CARE-
FULLY INSPECT ALL SEAT BELTS, BUCKLES,
MOUNTING HARDWARE, RETRACTORS, TETHER
STRAPS, AND ANCHORS FOR PROPER INSTALLA-
TION, OPERATION, OR DAMAGE. REPLACE ANY
BELT THAT IS CUT, FRAYED, OR TORN.
STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT
BELT OR CHILD RESTRAINT COMPONENT.
ALWAYS REPLACE DAMAGED OR FAULTY SEAT
BELT AND CHILD RESTRAINT COMPONENTS WITH
THE CORRECT, NEW AND UNUSED REPLACEMENT
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR
PARTS CATALOG.
(1) Position the front outboard seat belt and
retractor to the retractor mounting hole in the lower
inner B-pillar (Fig. 31).
(2) Engage the hooks on the upper retractor
bracket into the slots in the lower inner B-pillar
above the retractor mounting hole.
(3) Install and tighten the screw that secures the
lower retractor bracket to the lower inner B-pillar
below the retractor mounting hole. Tighten the screw
to 40 N´m (29 ft. lbs.).
DRRESTRAINTS 8O - 35
FRONT OUTBOARD SEAT BELT & RETRACTOR (Continued)

(4) Reconnect the yellow seat belt tensioner pigtail
wire connector to the body wire harness take out and
connector for the tensioner.
(5) Engage the seat belt tensioner pigtail wire
retainer into the hole in the inner B-pillar sheet
metal.
(6) On the driver side only, reconnect the body
wire harness take out and white connector to the
seat belt tension reducer connector receptacle near
the bottom of the retractor.
(7) Position the seat belt web guide to its mount-
ing location on the inner B-pillar near the belt line.
(8) Install and tighten the screw that secures the
seat belt web guide to the inner B-pillar. Tighten the
screw to 2 N´m (20 in. lbs.).
(9) Reinstall the upper and lower trim onto the
inner B-pillar. (Refer to 23 - BODY/INTERIOR/B-
PILLAR UPPER TRIM - INSTALLATION) and
(Refer to 23 - BODY/INTERIOR/B-PILLAR LOWER
TRIM - INSTALLATION).
(10) Position the seat belt turning loop onto the
height adjuster on the upper inner B-pillar.
(11) Install and tighten the screw that secures the
seat belt turning loop to the height adjuster. Tighten
the screw to 40 N´m (29 ft. lbs.).
(12) Engage the lower snap features of the new
trim cover over the front outboard seat belt turning
loop and, using hand pressure, press firmly and
evenly on the top of the trim cover until it snaps into
place.
(13) Position the lower seat belt anchor to the
lower inner B-pillar.
(14) Install and tighten the screw that secures the
lower seat belt anchor to the B-pillar. Tighten the
screw to 40 N´m (29 ft. lbs.).
(15) Do not reconnect the battery negative cable at
this time. The supplemental restraint system verifi-
cation test procedure should be performed following
service of any supplemental restraint system compo-
nent. (Refer to 8 - ELECTRICAL/RESTRAINTS -
STANDARD PROCEDURE - VERIFICATION TEST).
(16) Move the front seat back to its rearward posi-
tion.INSTALLATION - QUAD CAB
The following procedure is for replacement of a
faulty or damaged front outboard seat belt and
retractor unit, which includes a seat belt tensioner
for this model. (Refer to 8 - ELECTRICAL/RE-
STRAINTS/SEAT BELT TENSIONER - DESCRIP-
TION). The only component of this seat belt and
retractor unit that is available for individual service
replacement is the plastic web stop button that pre-
vents the latch plate from falling to the floor while in
the stored position. Refer to the instructions supplied
with the service kit for the proper web stop button
replacement procedures.
The seat belt retractor on the passenger's side of
all models includes a switchable automatic locking
mechanism. (Refer to 8 - ELECTRICAL/RE-
STRAINTS/AUTOMATIC LOCKING RETRACTOR -
DESCRIPTION).
If the seat belt or retractor is faulty or damaged,
but the seat belt tensioner is not deployed, review
the recommended procedures for handling non-de-
ployed supplemental restraints. (Refer to 8 - ELEC-
TRICAL/RESTRAINTS - STANDARD PROCEDURE
- HANDLING NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS). If the seat belt tensioner has been
deployed, review the recommended procedures for
service after a supplemental restraint deployment
before removing the front outboard seat belt and
retractor from the vehicle. (Refer to 8 - ELECTRI-
CAL/RESTRAINTS - STANDARD PROCEDURE -
SERVICE AFTER A SUPPLEMENTAL RESTRAINT
DEPLOYMENT).
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT
TENSIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
8O - 36 RESTRAINTSDR
FRONT OUTBOARD SEAT BELT & RETRACTOR (Continued)

OPERATION
The multistage passenger airbag is deployed by
electrical signals generated by the Airbag Control
Module (ACM) through the passenger airbag squib 1
and squib 2 circuits to the two initiators in the air-
bag inflator. By using two initiators, the airbag can
be deployed at multiple levels of force. The force level
is controlled by the ACM to suit the monitored
impact conditions by providing one of four delay
intervals between the electrical signals provided to
the two initiators. The longer the delay between
these signals, the less forcefully the airbag will
deploy.
When the ACM sends the proper electrical signals to
each initiator, the electrical energy generates enough
heat to initiate a small pyrotechnic charge which, in
turn ignites chemical pellets within the inflator. Once
ignited, these chemical pellets burn rapidly and pro-
duce a large quantity of inert gas. The inflator is
sealed to the airbag cushion and a diffuser in the infla-
tor directs all of the inert gas into the airbag cushion,
causing the cushion to inflate. As the cushion inflates,
the passenger airbag door will split at predetermined
tear seam lines concealed on the inside surface of the
door, then the door will pivot up over the top of the
instrument panel and out of the way. Following an air-
bag deployment, the airbag cushion quickly deflates by
venting the inert gas through vent holes within the
fabric used to construct the back (instrument panel
side) of the airbag cushion.
Typically, both initiators are used during an airbag
deployment event. However, it is possible for only one
initiator to be used during a deployment due to an
airbag system fault; therefore, it is necessary to
always confirm that both initiators have been used in
order to avoid the improper disposal of potentially
live pyrotechnic materials. (Refer to 8 - ELECTRI-
CAL/RESTRAINTS - STANDARD PROCEDURE -
SERVICE AFTER A SUPPLEMENTAL RESTRAINT
DEPLOYMENT).
REMOVAL
The following procedure is for replacement of a
faulty or damaged passenger airbag. If the airbag is
faulty or damaged, but not deployed, review the rec-
ommended procedures for handling non-deployed
supplemental restraints. (Refer to 8 - ELECTRICAL/
RESTRAINTS - STANDARD PROCEDURE - HAN-
DLING NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS). If the passenger airbag has been
deployed, review the recommended procedures for
service after a supplemental restraint deployment
before removing the airbag from the vehicle. (Refer to
8 - ELECTRICAL/RESTRAINTS - STANDARD PRO-
CEDURE - SERVICE AFTER A SUPPLEMENTAL
RESTRAINT DEPLOYMENT).WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT
TENSIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, WHEN REMOVING A DEPLOYED AIRBAG,
RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG UNIT AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
(1) Disconnect and isolate the battery negative
cable. Wait two minutes for the system capacitor to
discharge before further service.
(2) Remove the lower surround from the instru-
ment panel. (Refer to 23 - BODY/INSTRUMENT
PANEL/LOWER SURROUND - REMOVAL).
(3) Remove the screw that secures the mounting
tab of the panel outlet housing to the upper glove box
opening reinforcement (Fig. 36).
(4) Remove the six screws that secure the inboard
and lower flanges of the passenger airbag door to the
instrument panel.
Fig. 36 Passenger Airbag Door Screws
1 - PASSENGER AIRBAG DOOR
2 - PANEL OUTLET SCREW (1)
3 - GLOVE BOX OPENING UPPER REINFORCEMENT
4 - DOOR SCREW (6)
8O - 40 RESTRAINTSDR
PASSENGER AIRBAG (Continued)

(5) Reach through and above the glove box opening
to access and remove the two screws that secure the
passenger airbag rear brackets to the upper glove
box opening reinforcement (Fig. 37).
(6) Reach through and above the glove box opening
to access and remove the two screws that secure the
passenger airbag front brackets to the instrument
panel structural support.
(7) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the upper and outboard
edges of the passenger airbag door away from the
instrument panel far enough to disengage the seven
snap features on the door from the receptacles in the
instrument panel base trim (Fig. 38).
(8) Pull the passenger airbag housing and door
unit straight back from the instrument panel far
enough to access the instrument panel wire harness
take out and connector for the airbag located on the
inboard side of the airbag housing.(9) Disconnect the passenger airbag pigtail wire
connector from the instrument panel wire harness
connector for the airbag. To disconnect the connector:
(a) Slide the red Connector Position Assurance
(CPA) lock on the connector toward the side of the
connector.
(b) Depress the connector latch tab and pull the
two halves of the connector straight away from
each other.
(10) Remove the passenger airbag and airbag door
from the instrument panel as a unit.
INSTALLATION
The following procedure is for replacement of a
faulty or damaged passenger airbag. If the airbag is
faulty or damaged, but not deployed, review the rec-
ommended procedures for handling non-deployed
supplemental restraints. (Refer to 8 - ELECTRICAL/
RESTRAINTS - STANDARD PROCEDURE - HAN-
DLING NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS). If the passenger airbag has been
deployed, review the recommended procedures for
service after a supplemental restraint deployment
before removing the airbag from the vehicle. (Refer to
8 - ELECTRICAL/RESTRAINTS - STANDARD PRO-
CEDURE - SERVICE AFTER A SUPPLEMENTAL
RESTRAINT DEPLOYMENT).
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT
TENSIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, WHEN REMOVING A DEPLOYED AIRBAG,
RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG UNIT AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
Fig. 37 Passenger Airbag Remove/Install
1 - PASSENGER AIRBAG DOOR
2 - UPPER GLOVE BOX OPENING REINFORCEMENT
3 - FRONT BRACKET SCREW (2)
4 - REAR BRACKET SCREW (2)
Fig. 38 Passenger Airbag Door Disengage
1 - TRIM STICK
2 - PASSENGER AIRBAG DOOR
3 - INSTRUMENT PANEL
DRRESTRAINTS 8O - 41
PASSENGER AIRBAG (Continued)