1998 DODGE RAM 1500 one

TRANSFER CASE CONTROL
MODULE
DESCRIPTION
The Transfer Case Control Module (TCCM) (Fig. 8)
is a microprocessor-based assembly, controlling the
4X4 transfer case shift functions via the actuation of
a shift motor and utilizing the feedback of a mode
sensor assembly. Communication is via the PCI serial
bus. Inputs include user selectable 4X4 modes that
include 2WD, AWD, 4HI, 4LO, and Neutral. The logic
and driver circuitry is contained in a molded plastic
housing with an embedded heat-sink and is located
behind the left side of the lower instrument panel.
OPERATION
The Transfer Case Control Module (TCCM) utilizes
the input from the transfer case mounted mode sen-
sor, the instrument panel mounted selector switch,
and the following information from the vehicle's PCI
serial bus to determine if a shift is allowed.
²Engine RPM and Vehicle Speed
²Diagnostic Requests
²Manual Transmission and Brake Applied
²PRNDL
²Ignition Status
²ABS Messages
Once the TCCM determines that a requested shift
is allowed, it actuates the bi-directional shift motor
as necessary to achieve the desired transfer case
operating mode. The TCCM also monitors the mode
sensor while controlling the shift motor to determine
the status of the shift attempt.Several items can cause the requested shift not to
be completed. If the TCCM has recognized a fault
(DTC) of some variety, it will begin operation in one
of four Functionality Levels. These levels are:
²Level Zero- Normal Operation.
²Level One- Only Mode Shifts Are Allowed.
²Level Two- Only Mode Shifts and Shifts Into
LOW Are Allowed (No Neutral Shifts Are Allowed).
²Level Three- No Shifts Are Allowed
The TCCM can also be operating in one of three
possible power modes. These power modes are:
²Full Power Modeis the normal operational
mode of the module. This mode is achieved by normal
PCI bus traffic being present and the ignition being
in the RUN position.
²Reduced Power Modewill be entered when
the ignition has been powered off. In this state, the
module will shut down power supplied to external
devices, and to electronic interface inputs and out-
puts. From this state the module can enter either
Sleep Mode or Full Power Mode. To enter this mode,
the module must receive an ignition message denot-
ing that the ignition is off, or not receive any mes-
sages for 5  0.5 seconds. To exit this mode, the
module must receive one ignition message that
denotes that the ignition is in the RUN position.
²Sleep Modewill be entered, from the Reduced
Power Mode, when no PCI traffic has been sensed for
20  1 seconds. If during Sleep Mode the module
detects PCI bus traffic, it will revert to the Reduced
Power mode while monitoring for ignition messages.
It will remain in this state as long as there is traffic
other than run or start messages, and will return to
Sleep mode if the bus goes without traffic for 20  1
seconds.
SHIFT REQUIREMENTS
If the TCCM is in full power mode and at function-
ality level zero, it uses the following criteria to deter-
mine if a shift is allowed.
If any of the driver controllable conditions are not
met once the shift request is recognized, the TCCM
will solidly illuminate the source position's LED and
flash the desired position's LED for all shifts except
NEUTRAL. The NEUTRAL shift LED strategy will
be discussed later.
Mode shiftswill be allowed regardless of trans-
mission gear or vehicle speed, whenever the following
conditions are met:
²Front and rear wheel speed are within 21 km/hr
(13 mph).
²A change in the Selector switch state indicates
that a mode shift has been requested.
²A valid mode sensor signal is being sensed by
the TCCM.
Fig. 8 Transfer Case Control Module (TCCM)
Location
1 - INSTRUMENT PANEL
2 - TRANSFER CASE CONTROL MODULE (TCCM)
3 - TRANSFER CASE SELECTOR SWITCH
8E - 16 ELECTRONIC CONTROL MODULESDR

²Proper transmit/receive messages are occurring
on the PCI bus.
²Ignition key switch is in the RUN position.
Range shiftswill be allowed only if all of the fol-
lowing conditions are met:
²Front and rear wheel speed are within 21 km/hr
(13 mph).
²A change in the Selector Switch state indicating
a range shift has been requested.
²Transmission in NEUTRAL signal must be rec-
ognized for at least 1.5 seconds  100 msec. (Auto-
matic transmissions only)
²Proper transmit/receive messages are occurring
on the PCI bus.
²Clutch signal is recognized for 500 msec   50
msec (Manual transmissions only).
²Vehicle speed is less than or equal to 4.8 km/hr
(3 miles per hour).
²Ignition key switch is in the RUN position.
²A valid mode sensor signal is being sensed by
the TCCM.
Ashift into transfer case Neutralwill be
allowed only if all of the following conditions are met:
²Front and rear wheel speed are within 21 km/hr
(13 mph).
²The recessed Neutral Selection switch has been
depressed continuously for 4.0 seconds  100 msec
while all shift conditions have been continuously met.
²Transmission in NEUTRAL signal recognized
from the bus. (Automatic transmissions only)
²Clutch signal is recognized from the bus (Man-
ual transmissions only).
²Proper message transmissions/receptions are
occurring on the PCI bus.
²Vehicle speed is less than or equal to 4.8 km/hr
(3 miles per hour).
²Ignition key switch is in the RUN position,
engine off.
²Foot Brake is applied.
²A valid mode sensor signal is being sensed by
the TCCM.
Ashift out of transfer case Neutralwill be
allowed only if all of the following conditions are met:
²Front and rear wheel speed are within 21 km/hr
(13 mph).
²The recessed Neutral Selection switch has been
depressed continuously for 1.0 seconds  100 msec
while all shift conditions have been continuously met.
²Transmission in NEUTRAL signal recognized
from the bus.(Automatic transmissions only)
²Clutch signal is recognized from the bus (Man-
ual transmissions only).
²Proper message transmissions/receptions are
occurring on the PCI bus.
²Vehicle speed is less than or equal to 4.8 km/hr
(3 miles per hour).²Ignition key switch is in the RUN position.
²Foot Brake is applied.
²A valid mode sensor signal is being sensed by
the TCCM.
SHIFT SEQUENCES
Once all the driver controllable conditions for the
requested shift have been met, the TCCM begins a
shift timer with a maximum duration of 1 second per
'D' channel transition. If the shift timer expires
before the TCCM recognizes to correct mode sensor
code, the shift is considered to have been blocked.
The blocked shift will increment the blocked shift
counter by one. The TCCM strategy for handling
blocked shifts will be described later. The process the
TCCM performs for the various shifts will be
described first.
RANGE AND MODE SHIFTS
The process for performing all the range and mode
shifts are the same. The following steps describe the
process.
²Allow time for Selector Switch debounce; 250
msec  50 msec.
²Extinguish the source gear's LED while flashing
desired transfer case position's LED.
²Engage the shift motor for a maximum of 1 sec-
ond  100 msec per 'D' channel transition in the des-
tination gear's direction while monitoring the mode
sensor channel transitions.
²Disengage the shift motor when the correct
mode sensor code is recognized.
²Solidly illuminate the selected gear's LED.
²Transmit a bus message that the transfer case
shift is complete.
²If the desired mode sensor code is not received
after the shift timer expires (ie. a blocked or other
condition exists), stop driving the motor and wait for
200 msec  50 msec. The shift motor is then reversed
in the direction back toward the source gear for up to
1.0 seconds  100 msec. per 'D' channel. The TCCM
waits for 2.0 seconds  50 msec. and repeats the
attempt to shift to the desired position.
The exception to the preceding sequence is when a
shift from 4L to 2WD/AWD is requested. If 2WD/
AWD is requested from the 4L position, the transfer
case is first driven to the 4H position. If the 4H posi-
tion is reached, the transfer case is then driven back
to the 2WD/AWD position and the shift is considered
complete. If the transfer case does not reach any the
4H position, but is in the 2WD/AWD 'D' channel, or
the 2WD/AWD between gear position on the 4H side
of 2WD/AWD, the shift is also considered complete.
DRELECTRONIC CONTROL MODULES 8E - 17
TRANSFER CASE CONTROL MODULE (Continued)

SHIFT OUT OF NEUTRAL
The following steps describe the process for a shift
out of NEUTRAL.
²Extinguish the Neutral LED.
²Engage the shift motor for a maximum of 1 sec-
ond  100 msec toward the transfer case 4H mode
position while monitoring the mode sensor channel
transitions.
²Disengage the shift motor when the correct
mode sensor code is recognized.
²Extinguish the Neutral LED.
²Transmit a bus message that the transfer case
shift is complete.
²If the desired mode sensor code is not received
after the shift timer expires (ie. a blocked or other
condition exists), stop driving the motor and wait for
200 msec  50 msec. The shift motor is then reversed
in the direction back toward the source gear for up to
1.0 seconds 100 msec. The TCCM waits for 2.0 sec-
onds  50 msec. and repeats the attempt to shift to
the desired position.
²When the Neutral button is released, if the 4H
position is the desired position, the shift is complete.
Illuminate the 4H LED.
²Otherwise when the Neutral button is released,
if all of the shift requirements are being met then
engage the shift motor towards the desired position
for 1 second  100 msec per 'D' channel. (if require-
ments for shifting are not met, illuminate the 4H
LED and flash the destination LED as an indication
to the driver that all of the driver controllable shift
conditions are not being met). If this requires
another range or mode shift, begin the range/mode
shift process.
²If the desired mode sensor code is not received
after the shift timer expires (i.e. a blocked or other
condition exists), refer to the section on Blocked Shift
Strategy.
BLOCKED SHIFT STRATEGY
When a shift is commanded, the shift motor will be
driven towards its destination position, except in the
case of shifting out of Neutral if 4L was selected (the
transfer case will shift to the 4H position first, before
proceeding to 4L). If the shift is blocked on the way
to the destination, the TCCM may attempt to drivethe motor back to the original position. This process
will be allowed to occur 5 times. If the transfer case
has reached a non-NEUTRAL 'D' channel during the
shift re-attempts, the LED for the achieved gear posi-
tion is illuminated and the shift attempts are
stopped. To re-attempt the desired shift, the selector
switch will need to be rotated to the current position
until the switch debounce timer expires then a shift
will need to be requested again.
At the end of the 5th blocked attempt, the shift
motor is driven towards the last known 'D' channel
position. If this motor drive allows the transfer case
to reach the 2WD/AWD 'D' channel, or the 2WD/AWD
between gear position on the 4H side of 2WD/AWD,
the shift is considered complete and the shift
attempts are ended.
If the mode sensor is in the NEUTRAL region at
the expiration of the shift timer, the TCCM will con-
tinue to make the shift attempts according to the
blocked shift strategy independent of whether or not
the driver controlled conditions are met.
For shifts from NEUTRAL, if all 5 attempts fail to
reach the desired position (which by default is 4H),
the motor will be driven to stall in the direction of
4H or 4L, depending on the achieved position. If the
transfer case has reached the 2WD/AWD or 4L
between gear position nearest the NEUTRAL posi-
tions and the shift conditions are no longer being
met, the transfer case will be driven toward the cor-
responding 'D' channel. Otherwise, the transfer case
will be driven in the direction opposite the last
attempt with the desired target being 4H or 4L.
If the transfer case reaches the 2WD/AWD 'D'
channel when being driven in the 4H direction, then
one final 1.0 second drive toward 4H is attempted. If
the transfer case then reaches any of the 4H posi-
tions, the shift is considered complete and the 4H
LED is illuminated. If the transfer case is still the
2WD/AWD position, the shift is considered complete
and the 2WD/AWD LED is illuminated.
NOTE: If after the 5th blocked shift and reversal
attempt, if the transfer case position is in the NEU-
TRAL region, shift attempts will continue until a
non-NEUTRAL 'D' channel is reached.
8E - 18 ELECTRONIC CONTROL MODULESDR
TRANSFER CASE CONTROL MODULE (Continued)

TRANSMISSION CONTROL
MODULE
DESCRIPTION
The Transmission Control Module (TCM) (Fig. 9)
may be sub-module within the Powertrain Control
Module (PCM), Engine Control Module (ECM - Diesel
only) (Fig. 10), or a standalone module, depending on
the vehicle engine. The PCM, and TCM when
equipped, is located at the right rear of the engine
compartment, near the right inner fender.
OPERATION
The Transmission Control Module (TCM) controls
all electronic operations of the transmission. The
TCM receives information regarding vehicle opera-
tion from both direct and indirect inputs, and selects
the operational mode of the transmission. Direct
inputs are hardwired to, and used specifically by the
TCM. Indirect inputs are shared with the TCM via
the vehicle communication bus.
Some examples ofdirect inputsto the TCM are:
²Battery (B+) voltage
²Ignition ªONº voltage
²Transmission Control Relay (Switched B+)
²Throttle Position Sensor
²Crankshaft Position Sensor
²Transmission Range Sensor
²Pressure Switches
²Transmission Temperature Sensor
²Input Shaft Speed Sensor
²Output Shaft Speed Sensor
²Line Pressure Sensor
Some examples ofindirect inputsto the TCM
are:²Engine/Body Identification
²Manifold Pressure
²Target Idle
²Torque Reduction Confirmation
²Engine Coolant Temperature
²Ambient/Battery Temperature
²DRBIIItScan Tool Communication
Based on the information received from these var-
ious inputs, the TCM determines the appropriate
shift schedule and shift points, depending on the
present operating conditions and driver demand.
This is possible through the control of various direct
and indirect outputs.
Some examples of TCMdirect outputsare:
²Transmission Control Relay
²Solenoids
²Torque Reduction Request
Some examples of TCMindirect outputsare:
²Transmission Temperature (to PCM)
²PRNDL Position (to BCM)
In addition to monitoring inputs and controlling
outputs, the TCM has other important responsibili-
ties and functions:
²Storing and maintaining Clutch Volume Indexes
(CVI)
²Storing and selecting appropriate Shift Sched-
ules
²System self-diagnostics
Fig. 9 PCM/TCM Location
1 - RIGHT FENDER
2 - TRANSMISSION CONTROL MODULE
3 - POWERTRAIN CONTROL MODULE
Fig. 10 Diesel ECM
1 - ENGINE CONTROL MODULE (ECM)
2 - ECM MOUNTING BOLT
3 - 50-WAY CONNECTOR
4 - SUPPORT PLATE
5 - 60-WAY CONNECTOR
8E - 20 ELECTRONIC CONTROL MODULESDR

SHIFT SCHEDULES
As mentioned earlier, the TCM has programming
that allows it to select a variety of shift schedules.
Shift schedule selection is dependent on the follow-
ing:
²Shift lever position
²Throttle position²Engine load
²Fluid temperature
²Software level
As driving conditions change, the TCM appropri-
ately adjusts the shift schedule. Refer to the follow-
ing chart to determine the appropriate operation
expected, depending on driving conditions.
Schedule Condition Expected Operation
Extreme ColdOil temperature below -16É F -Park, Reverse, Neutral and 1st and
3rd gear only in D position, 2nd
gear only in Manual 2 or L
-No EMCC
Super ColdOil temperature between -12É F and
10É F- Delayed 2-3 upshift
- Delayed 3-4 upshift
- Early 4-3 coastdown shift
- High speed 4-2, 3-2, 2-1 kickdown
shifts are prevented
-Shifts at high throttle openings willl
be early.
- No EMCC
ColdOil temperature between 10É F and
36É F-Shift schedule is the same as
Super Cold except that the 2-3
upshifts are not delayed.
WarmOil temperature between 40É F and
80É F- Normal operation (upshift,
kickdowns, and coastdowns)
- No EMCC
HotOil temperature between 80É F and
240É F- Normal operation (upshift,
kickdowns, and coastdowns)
- Normal EMCC operation
OverheatOil temperature above 240É F or
engine coolant temperature above
244É F- Delayed 2-3 upshift
- Delayed 3-4 upshift
- 3rd gear FEMCC from 30-48 mph
- 3rd gear PEMCC above 35 mph
- Above 25 mph the torque
converter will not unlock unless the
throttle is closed or if a wide open
throttle 2nd PEMCC to 1 kickdown
is made
8E - 22 ELECTRONIC CONTROL MODULESDR
TRANSMISSION CONTROL MODULE (Continued)

ENGINE SYSTEMS
TABLE OF CONTENTS
page page
BATTERY SYSTEM......................... 1
CHARGING.............................. 19STARTING............................... 26
BATTERY SYSTEM
TABLE OF CONTENTS
page page
BATTERY SYSTEM
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING - BATTERY
SYSTEM.............................2
CLEANING.............................5
INSPECTION...........................5
SPECIFICATIONS........................6
SPECIAL TOOLS
BATTERY SYSTEM SPECIAL TOOLS.......7
BATTERY
DESCRIPTION..........................7
DIAGNOSIS AND TESTING - BATTERY.......7
STANDARD PROCEDURE
STANDARD PROCEDURE - BATTERY
CHARGING...........................8
STANDARD PROCEDURE - BUILT-IN
INDICATOR TEST.....................10
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST.......................10
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST.........................11STANDARD PROCEDURE - USING MICRO
420 BATTERY TESTER.................12
REMOVAL.............................13
INSTALLATION.........................14
BATTERY HOLDDOWN
DESCRIPTION.........................14
OPERATION...........................14
REMOVAL.............................14
INSTALLATION.........................14
BATTERY CABLES
DESCRIPTION.........................14
OPERATION...........................15
DIAGNOSIS AND TESTING - BATTERY
CABLES............................15
REMOVAL.............................16
INSTALLATION.........................17
BATTERY TRAY
DESCRIPTION.........................17
OPERATION...........................17
REMOVAL.............................17
INSTALLATION.........................18
BATTERY SYSTEM
DESCRIPTION
A single 12-volt battery is standard factory-in-
stalled equipment on gasoline engine equipped mod-
els. Diesel engine equipped vehicles utilize two
12-volt batteries connected in parallel. All of the com-
ponents of the battery system are located within the
engine compartment of the vehicle. The battery sys-
tem for this vehicle, covers the following related com-
ponents, which are covered in further detail later in
this section of the service manual:²Battery- The storage battery provides a reli-
able means of storing a renewable source of electrical
energy within the vehicle.
²Battery Cables- The battery cables connect
the battery terminal posts to the vehicle electrical
system.
²Battery Holddown- The battery holddown
hardware secures the battery in the battery tray in
the engine compartment.
²Battery Tray- The battery tray provides a
secure mounting location in the vehicle for the bat-
tery and an anchor point for the battery holddown
hardware.
DRENGINE SYSTEMS 8F - 1

For battery system maintenance schedules and
jump starting procedures, see the owner's manual in
the vehicle glove box. Optionally, refer to the Lubri-
cation and Maintenance section of this manual for
the proper battery jump starting procedure. While
battery charging can be considered a maintenance
procedure, the battery charging procedure and
related information are located later in this section of
the service manual. This was done because the bat-
tery must be fully-charged before any battery system
diagnosis or testing procedures can be performed.
OPERATION
The battery system is designed to provide a safe,
efficient, reliable and mobile means of delivering and
storing electrical energy. This electrical energy is
required to operate the engine starting system, as
well as to operate many of the other vehicle acces-
sory systems for limited durations while the engine
and/or the charging system are not operating. The
battery system is also designed to provide a reserve
of electrical energy to supplement the charging sys-
tem for short durations while the engine is running
and the electrical current demands of the vehicle
exceed the output of the charging system. In addition
to delivering, and storing electrical energy for the
vehicle, the battery system serves as a capacitor and
voltage stabilizer for the vehicle electrical system. It
absorbs most abnormal or transient voltages caused
by the switching of any of the electrical components
or circuits in the vehicle.
DIAGNOSIS AND TESTING - BATTERY SYSTEM
The battery, starting, and charging systems in the
vehicle operate with one another and must be tested
as a complete system. In order for the engine to start
and the battery to maintain its charge properly, all of
the components that are used in these systems must
perform within specifications. It is important thatthe battery, starting, and charging systems be thor-
oughly tested and inspected any time a battery needs
to be charged or replaced. The cause of abnormal bat-
tery discharge, overcharging or early battery failure
must be diagnosed and corrected before a battery is
replaced and before a vehicle is returned to service.
The service information for these systems has been
separated within this service manual to make it eas-
ier to locate the specific information you are seeking.
However, when attempting to diagnose any of these
systems, it is important that you keep their interde-
pendency in mind.
The diagnostic procedures used for the battery,
starting, and charging systems include the most
basic conventional diagnostic methods, to the more
sophisticated On-Board Diagnostics (OBD) built into
the Powertrain Control Module (PCM). Use of an
induction-type milliampere ammeter, a volt/ohmme-
ter, a battery charger, a carbon pile rheostat (load
tester), a 12-volt test lamp and/or special service
tools may be required. All OBD-sensed systems are
monitored by the PCM. Each monitored circuit is
assigned a Diagnostic Trouble Code (DTC). The PCM
will store a DTC in electronic memory for any failure
it detects. Always check the PCM for stored trouble
codes before returning the vehicle to service. Refer to
Charging System for the proper charging system test
procedures. Refer to Starting System for the proper
starting system test procedures.
MICRO 420 BATTERY TESTER
The Micro 420 automotive battery tester is
designed to help the dealership technician diagnose a
defective battery. Follow the instruction manual sup-
plied with the tester to properly diagnose a battery.
If the instruction manual is not available, refer to
the standard procedure in this section, which
includes the directions for using the Micro 420 bat-
tery tester.
8F - 2 BATTERY SYSTEMDR
BATTERY SYSTEM (Continued)

BATTERY SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
THE BATTERY STATE OF
CHARGE CANNOT BE
MAINTAINED.1. The battery has an
incorrect size or rating for
this vehicle.1. Refer to Battery System Specifications for the
proper specifications. Replace an incorrect
battery, as required.
2. The battery terminal
connections are loose or
corroded.2. Refer to Battery Cable for the proper cable
diagnosis and testing procedures. Clean and
tighten the battery terminal connections, as
required.
3. The electrical system
ignition-off draw is excessive.3. Refer to the IGNITION-OFF DRAW TEST
Standard Procedure for the proper test
procedures. Repair the faulty electrical system, as
required.
4. The battery is faulty. 4. Test the battery using the Micro 420 battery
tester. Refer to Standard Procedures for
additional test procedures. Replace the faulty
battery, as required.
5. The starting system is
faulty.5. Determine if the starting system is performing
to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
6. The charging system is
faulty.6. Determine if the charging system is performing
to specifications. Refer to Charging System for
additional charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
7. Electrical loads exceed the
output of the charging
system.7. Inspect the vehicle for aftermarket electrical
equipment which might cause excessive electrical
loads.
8. Slow driving or prolonged
idling with high-amperage
draw systems in use.8. Advise the vehicle operator, as required.
THE BATTERY WILL NOT
ACCEPT A CHARGE.1. The battery is faulty. 1. Test the battery using the Micro 420 battery
tester. Charge or replace the faulty battery, as
required.
ABNORMAL BATTERY DISCHARGING
Any of the following conditions can result in abnor-
mal battery discharging:
1. A faulty or incorrect charging system compo-
nent. Refer to Charging System for additional charg-
ing system diagnosis and testing procedures.
2. A faulty or incorrect battery. Use Micro 420 bat-
tery tester and refer to Battery System for additional
battery diagnosis and testing procedures.
3. A faulty circuit or component causing excessive
ignition-off draw.4. Electrical loads that exceed the output of the
charging system. This can be due to equipment
installed after manufacture, or repeated short trip
use.
5. A faulty or incorrect starting system component.
Refer to Starting System for the proper starting sys-
tem diagnosis and testing procedures.
6. Corroded or loose battery posts and/or terminal
clamps.
7. Slow driving speeds (heavy traffic conditions) or
prolonged idling, with high-amperage draw systems
in use.
8F - 4 BATTERY SYSTEMDR
BATTERY SYSTEM (Continued)