1998 DODGE RAM 1500 trailer

C219 - (HEADLAMP AND DASH SIDE)
CAV CIRCUIT
35 -
36 F984 18PK/YL
37 -
38 F951 16PK/LG
39 T917 20YL/TN (DIESEL A/T)
40 -
41 A951 16RD
42 F202 20PK/GY
43 A72 18RD/OR (TRAILER TOW)
44 D16 18WT/OR (GAS)
45 -
46 K77 18BR/WT (MAUAL TRANSFER
CASE)
47 T117 20DG/YL (MANUAL TRANSFER
CASE EXCEPT NGC)
48 A205 18RD/OR
49 A116 18YL/RD
50 -
51 -
52 -
53 R79 20LB/VT (NGC EXCEPT 5.7L ABS)
54 R81 20LB/WT (NGC EXCEPT 5.7L ABS)
55 -
56 F100 18PK/VT
57 R80 20VT/LB (NGC EXCEPT 5.7L ABS)
58 R82 20WT/LB (NGC EXCEPT 5.7L ABS)
59 -
60 A981 14RD
61 F982 14PK/YL
62 -
63 -
64 -
65 -
66 F922 16PK/YL
67 F201 18PK/OR
68 L89 18WT/YL (TRAILER TOW)
69 B29 20DG/WT
70 A919 20RD
71 -
72 D25 20VT/PK
73 F983 20PK/YL
74 -
8W - 80 - 28 8W-80 CONNECTOR PIN-OUTSDR

ELECTRIC BRAKE PROVISION-4WAY
CAV CIRCUIT FUNCTION
A A400 14TN/RD FUSED B(+)
B B40 14DG TRAILER TOW BRAKE B(+)
C L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
D Z998 18BK GROUND
ELECTRIC THROTTLE CONTROL MODULE - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 K22 18BR/OR TP NO. 1 SIGNAL
2 F855 18PK/YL 5 VOLT SUPPLY
3 K447 18TN/YL ETC MOTOR (+)
4 K122 18BR/DG TP NO. 2 SIGNAL
5 K448 18TN/OR ETC MOTOR (-)
6 K922 18BR/DB TP SENSOR RETURN
ENGINE CONTROL MODULE C1 (DIESEL) - 60 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3- -
4 D72 18WT/LB CCD BUS (+)
5 D71 18WT/DB CCD BUS (-)
6 K65 18BR/LB FUEL PUMP RELAY RETURN
7 K20 18BR/GY GEN FIELD CONTROL
8- -
9- -
10 - -
11 K2 18TN/BK (A/T) ECT SIGNAL
11 K2 18VT/OR (M/T) ECT SIGNAL
12 K181 18BR/YL FUEL PUMP DRIVER
13 - -
14 K22 18BR/WT (A/T) TP SIGNAL
14 K23 18DB/WT (M/T) APPS NO. 1 SIGNAL
15 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL
16 - -
16 K29 18WT/BR (M/T) APPS NO. 2 SIGNAL
17 - -
18 - -
19 K31 18BR FUEL PUMP RELAY CONTROL
20 - -
21 - -
22 K24 18LB/BR (A/T) CKP SIGNAL
22 K24 18BR/LB (M/T) CKP SIGNAL
23 K914 18RD/WT (A/T) SENSOR GROUND
23 K914 18BR/WT (M/T) SENSOR GROUND
24 K44 18DB/GY CMP SIGNAL
25 K668 18LG (A/T) SUPPLY VOLTAGE
25 K688 18BR (M/T) SUPPLY VOLTAGE
8W - 80 - 58 8W-80 CONNECTOR PIN-OUTSDR

INTAKE AIR TEMPERATURE SENSOR (GAS) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K900 18DB/DG SENSOR GROUND
2 K21 18DB/LG IAT SIGNAL
INTAKE AIR TEMPERATURE/MANIFOLD ABSOLUTE PRESSURE SENSOR (DIESEL)-4WAY
CAV CIRCUIT FUNCTION
A K916 18BR/OR SENSOR GROUND
B K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL
C F855 18PK/YL 5 VOLT SUPPLY
D K37 18LB (A/T) BOOST PRESSURE SENSOR SIGNAL
D K37 18BR/OR (M/T) BOOST PRESSURE SENSOR SIGNAL
INTEGRATED POWER MODULE C1 - 26 WAY
CAV CIRCUIT FUNCTION
1 A960 14RD (DIESEL) FUSED B(+)
1 A16 16RD/BR (NGC) FUSED B(+)
2 F21 20PK/DG FUSED IGNITION SWITCH OUTPUT (RUN-START)
3- -
4 F500 20DG/PK FUSED IGNITION SWITCH OUTPUT (RUN)
5 L673 18YL TRAILER TOW LEFT TURN RELAY OUTPUT
6- -
7 L674 18LG TRAILER TOW RIGHT TURN RELAY OUTPUT
8 A981 14RD FUSED B(+)
9 A114 18GY/RD FUSED B(+)
10 L70 18WT/GY FUSED PARK LAMP RELAY OUTPUT
11 F951 16PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 A941 18RD FUSED B(+)
13 A919 20RD FUSED B(+)
14 X2 18DG/OR HORN RELAY OUTPUT
15 - -
16 A103 18GY/RD FUSED B(+)
17 L678 18BR PARK LAMP RELAY OUTPUT
18 - -
19 L7 18WT/YL FUSED PARK LAMP RELAY OUTPUT
20 - -
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -
DR8W-80 CONNECTOR PIN-OUTS 8W - 80 - 73

THROTTLE POSITION SENSOR (4.7L)-3WAY
CAV CIRCUIT FUNCTION
1 F855 18PK/YL 5 VOLT SUPPLY
2 K22 18BR/OR TP NO. 1 SIGNAL
3 K900 18DB/DG SENSOR GROUND
TOW/HAUL OVERDRIVE SWITCH - WHITE 2 WAY
CAV CIRCUIT FUNCTION
1 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SENSE
2 Z71 20LB/BK GROUND
TRAILER TOW CONNECTOR-4WAY
CAV CIRCUIT FUNCTION
1 Z999 14BK GROUND
2 L678 18BR PARK LAMP RELAY OUTPUT
3 L673 18YL TRAILER TOW LEFT TURN RELAY OUTPUT
4 L674 18LG TRAILER TOW RIGHT TURN RELAY OUTPUT
TRAILER TOW CONNECTOR-ADD ON - 10 WAY
CAV CIRCUIT FUNCTION
1- -
2 L674 18LG TRAILER TOW RIGHT TURN RELAY OUTPUT
3 L1 18WT/LG BACKUP LAMP FEED
4 A100 14RD/VT FUSED B(+)
5 L678 18BR PARK LAMP RELAY OUTPUT
6- -
7 B40 14DG TRAILER TOW BRAKE B(+)
8 Z999 14BK GROUND
9 Z999 14BK GROUND
10 L673 18YL TRAILER TOW LEFT TURN RELAY OUTPUT
DR8W-80 CONNECTOR PIN-OUTS 8W - 80 - 99

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Speed Control Switch-Right (ETC) WT At Steering Wheel N/S
Starter Solenoid Left Engine 23
Tail/Stop/Turn Signal Lamp-Left BK At Lamp 50, 51
Tail/Stop/Turn Signal Lamp-Right BK At Lamp 50, 51
Throttle Position Sensor NAT Throttle Body 6
Trailer Tow Connector BK At Trailer Hitch 51
Trailer Tow Connector-Add On BK At Trailer Hitch 51, 53
Transfer Case Control Module C1 BK Left Side of Instrument Panel 35, 38
Transfer Case Control Module C2 GY Left Side of Instrument Panel 35, 38
Transfer Case Control Module C3 BK Left Side of Instrument Panel 35, 38
Transfer Case Mode Sensor BK Left Front Side of Transfer Case 13, 14, 16, 20
Transfer Case Position Sensor BK Front Middle of Transfer Case 20
Transfer Case Selector Switch BK Center of Instrument Panel 11, 12, 33, 35, 36
Transfer Case Shift Motor BK Left Rear of Transmission 13, 14, 20
Transmission Range Sensor BK Left side of Transmission 11, 14
Transmission Solenoid Assembly BK Left Side of Transmission 14, 11
Transmission Solenoid/TRS
Assembly (3.7L/4.7L)BK Left Side of Transmission 15, 16
Underhood Lamp BK Underside of Hood 29
Vacuum Pump (Diesel) Right Rear Engine Compartment 21
Vistronic Fan Drive Front Engine Compartment 28
Washer Fluid Level Switch BK At Reservoir 21, 23, 26, 28
Washer Pump Motor-Front BK At Washer Fluid Reservoir 21, 23, 26, 28
Water In Fuel Sensor (Diesel) BK Right Side Engine 10
Wheel Speed Sensor-Left Front BK Left Rear Lower Side of Engine
Compartment22, 29
Wheel Speed Sensor-Rear BK Right Rear of Body 51
Wheel Speed Sensor-Right Front GY Right Rear Lower Side of Engine
Compartment21
Wiper Motor-Front BK Left Side of Cowl 22, 25
8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONDR
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

FRAMES & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE...............1
FRONT AIR DAM
REMOVAL.............................2
INSTALLATION..........................2
FRONT BUMPER
REMOVAL.............................2
INSTALLATION..........................2
FRONT FASCIA
REMOVAL.............................2
INSTALLATION..........................3
REAR BUMPER
REMOVAL.............................3
INSTALLATION..........................4
FRAME
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 4
STANDARD PROCEDURE
STANDARD PROCEDURE - LIGHT DUTY
FRONT FRAME RAIL TIP REPLACEMENT....4
STANDARD PROCEDURE - HYDROFORM
FENDER RAIL REPAIR.................11
STANDARD PROCEDURE - REAR FRAME
H-SECTION REPLACEMENT.............13SPECIFICATIONS
SPECIFICATIONS - WELD PROCESS......15
SPECIFICATIONS - FRAME DIMENSIONS . . . 16
SPECIFICATIONS - TORQUE............22
FRONT CROSSMEMBER
REMOVAL.............................22
INSTALLATION.........................22
FRONT SKID PLATE
REMOVAL.............................23
INSTALLATION.........................23
FRONT TOW HOOK ASSEMBLY
REMOVAL.............................23
INSTALLATION.........................23
TRANSMISSION CROSSMEMBER
REMOVAL.............................24
INSTALLATION.........................24
TRAILER HITCH
REMOVAL.............................25
INSTALLATION.........................25
TRANSFER CASE SKID PLATE
REMOVAL.............................26
INSTALLATION.........................26
BUMPERS
SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front bumper center bracket nuts 95 70 Ð
Front bumper stud plate nuts 95 70 Ð
License plate hitch reinforcement bolts 54 40 Ð
Rear bumper support bracket stud plate nuts 54 40 Ð
Rear bumper support bracket to hitch bolts 54 40 Ð
Rear bumper to hitch bolts 54 40 Ð
DRFRAMES & BUMPERS 13 - 1

SPORT FASCIA REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Remove the three screws at each trailing edge
of the fascia. (Fig. 3)
(3) Remove the five lower screws.
(4) Remove and discard the four upper push pins.
(5) Using a trim stick C-4755 or equivalent, care-
fully release the six lower clips and remove the close
out panel.
(6) Using a trim stick C-4755 or equivalent, care-
fully remove the step pad.
(7) Spread the fascia out at the wheels and remove
from the vehicle.
INSTALLATION
NOTE: The left and right inboard bumper to bracket
attachments must be secured before installing the
fascia and step pad.
ST/SLT/SLT+ FASCIA INSTALLATION
(1) Install the fascia.
(2) Position the close out panel and seat the 6
lower clips fully.
(3) Install four new upper push pin fasteners.
(4) Position the step pad onto the fascia and fully
seat the attachment clips.(5) Align the fascia to the fender with a 19 mm
(0.75 inch) gap and install the two screws at each
trailing edge of the fascia.
SPORT FASCIA INSTALLATION
(1) Position the fascia onto the bumper.
(2) Position the step pad onto the fascia and fully
seat the attachment clips.
(3) Install four new upper push pin fasteners.
(4) Install the five lower screws.
(5) Install the three screws at each trailing edge of
the fascia.
REAR BUMPER
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Remove the license plate.
(3) Remove the bolts behind the plate.
(4) Disconnect the license plate light electrical con-
nectors.
(5) Disconnect the trailer light connector electrical
connection, if equipped.
(6) Remove the two bolts along the front upper
edge of the bumper near the frame tips.
(7) Support the bumper with a suitable lifting
device.
(8) Remove the bolts attaching the bumper support
brackets to the trailer hitch. (Fig. 4)
Fig. 3 SPORT FASCIA
1 - STEP PAD
2 - FASCIA (SPORT MODEL ONLY)
3 - SCREWS (3 PER SIDE)
4 - UPPER FASCIA SUPPORT BRACKET
5 - WHEELHOUSE SPLASH SHIELD BRACKET
6 - INBOARD BUMPER BRACKET ATTACHMENTS
7 - PUSH PIN FASTENERS (4)
8 - LOWER SCREWS (5)
Fig. 4 TRAILER HITCH
1 - HITCH
2 - LD HITCH BOLTS (4)/HD (6)
3 - BUMPER BRACKET BOLTS (4)
4 - BUMPER SUPPORT BRACKETS
DRFRAMES & BUMPERS 13 - 3
FRONT FASCIA (Continued)

INSTALLATION
(1) Align the holes in the bumpers to the trailer
hitch pins and install the bumper.
(2) Install the support bracket to the hitch bolts,
loosely.
(3) Install the front upper edge to the trailer hitch
bolts and tighten to 54 N´m (40 ft. lbs.).
(4) Install the license plate reinforcement to hitch
bolts and tighten to 54 N´m (40 ft. lbs.).
(5) Tighten the left bumper bracket bolts to 54
N´m (40 ft. lbs.).
(6) Tighten the right bumper bracket bolts to 54
N´m (40 ft. lbs.).
(7) Connect the trailer light connector electrical
connection, if equipped.
(8) Connect the license plate light electrical con-
nectors.
(9) Install the license plate.
FRAME
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT.
²BEFORE PROCEEDING WITH FRAME REPAIR
INVOLVING GRINDING OR WELDING, VERIFY THAT
VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN
CONTACT WITH REPAIR AREA, PERSONAL INJURY
CAN RESULT.
²DO NOT ALLOW OPEN FLAME OR HEAT AND
METAL SPATTER FROM ARC WELDING, TO CON-
TACT PLASTIC BODY PANELS. FIRE OR EXPLO-
SION CAN RESULT.
²WHEN WELDED FRAME COMPONENTS ARE
REPLACED, ENSURE COMPLETE PENETRATION
WELD IS ACHIEVED DURING INSTALLATION. IF
NOT, DANGEROUS OPERATING CONDITIONS CAN
RESULT.
²STAND CLEAR OF CABLES OR CHAINS ON
PULLING EQUIPMENT DURING FRAME STRAIGHT-
ENING OPERATIONS, PERSONAL INJURY CAN
RESULT.
²DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT SUPPORTED ON SAFETY
STANDS, PERSONAL INJURY CAN RESULT.
CAUTION: 1500 series Dodge Ram Trucks (2002 and
later) are not designed for snow plow equipment.The front collision repair tips must not be installed
on any truck equipped with a snow plow, or even
intended to be equipped with a snow plow.
CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect. Failure to use only pro-
duction fasteners or fasteners of equivalent hard-
ness can result in loosening or failure. Do not drill
any holes in the frame that are not specifically out-
lined in this or other, DaimlerChrysler procedure as
frame rail failure can result. When using heat to
straighten frame components do not exceed 566ÉC
(1050ÉF), metal fatigue can result.
STANDARD PROCEDURE
STANDARD PROCEDURE - LIGHT DUTY FRONT
FRAME RAIL TIP REPLACEMENT
CAUTION: This procedure is designed to replace
the front frame rail tips that have been damaged in
the crush initiator zones. Prior to any cutting, the
vehicle must be mounted on the appropriate frame
repair equipment (ªframe rackº), checked with three
dimensional measuring equipment, and the neces-
sary pull corrections made. If damage remains in
the frame beyond the area covered by this service
part after the pull, the frame must be replaced in its
entirety.
NOTE: Procedures for 4X2 and 4X4 are common
except as noted in this procedure.
(1) Before proceding with this repair procedure
review the required service warnings and precau-
tions. (Refer to 13 - FRAME & BUMPERS/FRAME -
WARNING)
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the front wheelhouse splash shield.
(Refer to 23 - BODY/EXTERIOR/FRONT WHEEL-
HOUSE SPLASH SHIELD - REMOVAL)
(4) Remove the bolts and position aside the wire
harness and grounds, if required.
(5) Remove the front bumper. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/FRONT BUMPER
- REMOVAL)
(6) Loosen and lower the stabilizer bar mount and
bar. (Refer to 2 - SUSPENSION/FRONT/STABI-
LIZER BAR - REMOVAL)
13 - 4 FRAMES & BUMPERSDR
REAR BUMPER (Continued)