1998 DODGE RAM 1500 connector

(6) Remove generator support bracket nuts and
bolt (Fig. 4) and remove support bracket.
(7) Remove 2 generator mounting bolts (Fig. 5).
(8) Remove generator from vehicle.
5.9L Diesel
WARNING: DISCONNECT BOTH NEGATIVE CABLES
FROM BOTH BATTERIES BEFORE REMOVING BAT-
TERY OUTPUT WIRE (B+ WIRE) FROM GENERA-
TOR. FAILURE TO DO SO CAN RESULT IN INJURY
OR DAMAGE TO ELECTRICAL SYSTEM.
(1) Disconnect both negative battery cables at both
batteries.
(2) Remove generator drive belt. Refer to 7, Cool-
ing System for procedure.
(3) Unsnap plastic insulator cap from B+ output
terminal.
(4) Remove B+ terminal mounting nut at rear of
generator (Fig. 7). Disconnect terminal from genera-
tor.
(5) Disconnect field wire connector at rear of gen-
erator by pushing on connector tab.
(6) Remove upper mounting bracket bolt (Fig. 6).
(7) Remove lower mounting bracket bolt and nut
(Fig. 6).
(8) Remove generator from vehicle.
Fig. 4 GENERATOR SUPPORT BRACKET- 5.7L
1 - GENERATOR
2 - SUPPORT BRACKET
3 - BRACKET NUTS
4 - BRACKET BOLT
Fig. 5 REMOVE / INSTALL GENERATOR - 5.7L
1 - MOUNTING BOLT
2 - GENERATOR
3 - MOUNTING STUD / BOLT
Fig. 6 5.9L DIESEL GENERATOR
1 - GENERATOR
2 - MOUNTING BOLTS
DRCHARGING 8F - 23
GENERATOR (Continued)

INSTALLATION
3.7L / 4.7L
(1) Position generator to engine and install 2 hor-
izontal bolts and 1 vertical bolt.
(2) Tighten all 3 bolts. Refer to Torque Specifica-
tions.
(3) Snap field wire connector into rear of genera-
tor.
(4) Install B+ terminal eyelet to generator output
stud. Tighten mounting nut. Refer to Torque Specifi-
cations.
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
water pump may be rotating in the wrong direction
if the belt is installed incorrectly, causing the
engine to overheat. Refer to belt routing label in
engine compartment, or refer to Belt Schematics in
7, Cooling System.
(5) Install generator drive belt. Refer to 7, Cooling
System for procedure.
(6) Install negative battery cable to battery.5.7L
(1) Position generator to engine and install 2
mounting bolts.
(2) Tighten bolts. Refer to Torque Specifications.
(3) Position support bracket to front of generator
and install bolt and nuts. Tighten bolt / nuts. Refer
to Torque Specifications.
(4) Snap field wire connector into rear of genera-
tor.
(5) Install B+ terminal eyelet to generator output
stud. Tighten mounting nut. Refer to Torque Specifi-
cations.
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
water pump may be rotating in the wrong direction
if the belt is installed incorrectly, causing the
engine to overheat. Refer to belt routing label in
engine compartment, or refer to Belt Schematics in
7, Cooling System.
(6) Install generator drive belt. Refer to 7, Cooling
System for procedure.
(7) Install negative battery cable to battery.
5.9L Diesel
(1) Position generator to upper and lower mount-
ing brackets and install upper bolt and lower bolt /
nut.
(2) Tighten all bolts / nut. Refer to Torque Specifi-
cations.
(3) Snap field wire connector into rear of genera-
tor.
(4) Install B+ terminal eyelet to generator output
stud. Tighten mounting nut. Refer to Torque Specifi-
cations.
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
water pump may be rotating in the wrong direction
if the belt is installed incorrectly, causing the
engine to overheat. Refer to belt routing label in
engine compartment, or refer to Belt Schematics in
7, Cooling System.
(5) Install generator drive belt. Refer to 7, Cooling
System for procedure.
Fig. 7 5.9L DIESEL GENER. CONNECTORS
1 - B+ CONNECTOR
2 - GENERATOR
3 - FIELD WIRE CONNECTOR
8F - 24 CHARGINGDR
GENERATOR (Continued)

TESTING
COLD CRANKING TEST
For complete starter wiring circuit diagrams, refer
to 8, Wiring Diagrams. The battery must be fully-
charged and load-tested before proceeding. Refer to
Batteryin 8, Battery.
(1) Connect volt-ampere tester to battery terminals
(Fig. 1). See instructions provided by manufacturer of
volt-ampere tester being used.Note: Certain diesel
equipped models use dual batteries. If equipped
with dual battery system, tester should be con-
nected to battery on left side of vehicle only.
Also, tester current reading must be taken from
positive battery cable lead that connects to
starter motor.
(2) Fully engage parking brake.
(3) If equipped with manual transmission, place
gearshift selector lever in Neutral position and block
clutch pedal in fully depressed position. If equipped
with automatic transmission, place gearshift selector
lever in Park position.
(4) Verify that all lamps and accessories are
turned off.
(5) To prevent a gasoline engine from starting,
remove Automatic ShutDown (ASD) relay. To prevent
a diesel engine from starting, remove Fuel Pump
Relay. These relays are located in Power Distribution
Center (PDC). Refer to label on PDC cover for relay
location.
WARNING: IF EQUIPPED WITH DIESEL ENGINE,
ATTEMPT TO START ENGINE A FEW TIMES
BEFORE PROCEEDING WITH FOLLOWING STEP.(6) Rotate and hold ignition switch in Start posi-
tion. Note cranking voltage and current (amperage)
draw readings shown on volt-ampere tester.
(a) If voltage reads below 9.6 volts, refer to
Starter Motorin Diagnosis and Testing. If starter
motor is OK, refer toEngine Diagnosisin 9,
Engine for further testing of engine. If starter
motor is not OK, replace faulty starter motor.
(b) If voltage reads above 9.6 volts and current
(amperage) draw reads below specifications, refer
toFeed Circuit Testin this section.
(c) If voltage reads 12.5 volts or greater and
starter motor does not turn, refer toControl Cir-
cuit Testingin this section.
(d) If voltage reads 12.5 volts or greater and
starter motor turns very slowly, refer toFeed Cir-
cuit Testin this section.
NOTE: A cold engine will increase starter current
(amperage) draw reading, and reduce battery volt-
age reading.
FEED CIRCUIT TEST
The starter feed circuit test (voltage drop method)
will determine if there is excessive resistance in
high-amperage feed circuit. For complete starter wir-
ing circuit diagrams, refer 8, Wiring Diagrams.
When performing these tests, it is important to
remember that voltage drop is giving an indication of
resistance between two points at which voltmeter
probes are attached.
Example:When testing resistance of positive bat-
tery cable, touch voltmeter leads to positive battery
cable clamp and cable connector at starter solenoid.
If you probe positive battery terminal post and cable
connector at starter solenoid, you are reading com-
bined voltage drop in positive battery cable clamp-to-
terminal post connection and positive battery cable.
The following operation will require a voltmeter
accurate to 1/10 (0.10) volt. Before performing tests,
be certain that following procedures are accom-
plished:
²Battery is fully-charged and load-tested. Refer to
Batteryin 8, Battery.
²Fully engage parking brake.
²If equipped with manual transmission, place
gearshift selector lever in Neutral position and block
clutch pedal in fully depressed position. If equipped
with automatic transmission, place gearshift selector
lever in Park position.
²Verify that all lamps and accessories are turned
off.
Fig. 1 VOLTS-AMPS TESTER CONNECTIONS -
TYPICAL
1 - POSITIVE CLAMP
2 - NEGATIVE CLAMP
3 - INDUCTION AMMETER CLAMP
DRSTARTING 8F - 29
STARTING (Continued)

(6) Note reading on ammeter and compare reading
to free running test maximum amperage draw. Refer
to Specifications for starter motor free running test
maximum amperage draw specifications.
(7) If ammeter reading exceeds maximum amper-
age draw specification, replace faulty starter motor
assembly.
STARTER SOLENOID
This test can only be performed with starter motor
removed from vehicle.
(1) Remove starter motor from vehicle. Refer to
Starter Motor Removal and Installation.
(2) Disconnect wire from solenoid field coil termi-
nal.
(3) Check for continuity between solenoid terminal
and solenoid field coil terminal with a continuity
tester (Fig. 7). There should be continuity. If OK, go
to Step 4. If not OK, replace faulty starter motor
assembly.
(4) Check for continuity between solenoid terminal
and solenoid case (Fig. 8). There should be continuity.
If not OK, replace faulty starter motor assembly.REMOVAL
3.7L / 4.7L
(1) Disconnect and isolate negative battery cable.
(2) Raise and support vehicle.
(3) Note: If equipped with 4WD and certain trans-
missions, a support bracket is used between front
axle and side of transmission. Remove 2 support
bracket bolts at transmission. Pry support bracket
slightly to gain access to lower starter mounting bolt.
(4) Remove 1 bolt and 1 nut if equipped with a
manual transmission (Fig. 9).
(5) Remove 2 bolts if equipped with an automatic
transmission (Fig. 10).
(6) Move starter motor towards front of vehicle far
enough for nose of starter pinion housing to clear
housing. Always support starter motor during this
process, do not let starter motor hang from wire har-
ness.
(7) Tilt nose downwards and lower starter motor
far enough to access and remove nut that secures
battery positive cable wire harness connector eyelet
to solenoid battery terminal stud. Do not let starter
motor hang from wire harness.
(8) Remove battery positive cable wire harness
connector eyelet from solenoid battery terminal stud.
(9) Disconnect battery positive cable wire harness
connector from solenoid terminal connector recepta-
cle.
(10) Remove starter motor.
Fig. 7 CONTINUITY BETWEEN SOLENOID AND
FIELD COIL TERMINALS - TYPICAL
1 - OHMMETER
2 - SOLENOID TERMINAL
3 - FIELD COIL TERMINAL
Fig. 8 CONTINUITY BETWEEN SOLENOID
TERMINAL AND CASE - TYPICAL
1 - SOLENOID TERMINAL
2 - OHMMETER
3 - SOLENOID
Fig. 9 STARTER R/I - 3.7L/4.7L - MAN. TRANS.
1 - EYELET TERMINAL
2 - NUT
3 - BRACKET
4 - STUD
5 - STARTER MOTOR
6 - LOCK WASHER
7 - WIRE HARNESS CONNECTOR
8 - NUT
9 - SCREW AND WASHER (2)
DRSTARTING 8F - 33
STARTER MOTOR (Continued)

5.7L Gas
(1) Disconnect and isolate negative battery cable.
(2) Raise and support vehicle.
(3) Note: If equipped with 4WD and certain trans-
missions, a support bracket is used between front
axle and side of transmission. Remove 2 support
bracket bolts at transmission. Pry support bracket
slightly to gain access to lower starter mounting bolt.
(4) Remove 2 mounting bolts (Fig. 11).
(5) Move starter motor towards front of vehicle far
enough for nose of starter pinion housing to clear
housing. Always support starter motor during this
process, do not let starter motor hang from wire har-
ness.
(6) Tilt nose downwards and lower starter motor
far enough to access and remove nut that secures
battery positive cable wire harness connector eyelet
to solenoid battery terminal stud. Do not let starter
motor hang from wire harness.
(7) Remove battery positive cable wire harness
connector eyelet from solenoid battery terminal stud.
(8) Disconnect battery positive cable wire harness
connector from solenoid terminal connector recepta-
cle.
(9) Remove starter motor.
5.9L Diesel
(1) Disconnect and isolate both negative battery
cables at both batteries.
(2) Raise and support vehicle.
(3) Remove 3 starter mounting bolts (Fig. 12).(4) Move starter motor towards front of vehicle far
enough for nose of starter pinion housing to clear
housing. Always support starter motor during this
process. Do not let starter motor hang from wire har-
ness.
(5) Tilt nose downwards and lower starter motor
far enough to access and remove nuts securing
starter wiring harness to starter (Fig. 13). Do not let
starter motor hang from wire harness.
(6) Remove starter motor from engine. Note: Cer-
tain diesel engines use an aluminum spacer (Fig. 12).
Note position and orientation of spacer before
removal.
INSTALLATION
3.7L / 4.7L
(1) Connect solenoid wire to starter motor (snaps
on).
(2) Position battery cable to solenoid stud. Install
and tighten battery cable eyelet nut. Refer to Torque
Specifications. Do not allow starter motor to hang
from wire harness.
(3) Position starter motor to transmission.
(4) If equipped with automatic transmission, slide
cooler tube bracket into position.
(5) Install and tighten both bolts (auto. trans.), or
1 nut and 1 bolt (man. trans.). Refer to Torque Spec-
ifications.
(6) Lower vehicle.
(7) Connect negative battery cable.
Fig. 10 STARTER R/I - 3.7L/4.7L - AUTO. TRANS.
1 - EYELET TERMINAL
2 - NUT
3 - SCREW AND WASHER (2)
4 - STARTER MOTOR
5 - WIRE HARNESS CONNECTOR
Fig. 11 STARTER R/I - 5.7L
1 - STARTER MOTOR
2 - MOUNTING BOLTS
8F - 34 STARTINGDR
STARTER MOTOR (Continued)

5.7L
(1) Connect solenoid wire to starter motor (snaps
on).
(2) Position battery cable to solenoid stud. Install
and tighten battery cable eyelet nut. Refer to Torque
Specifications. Do not allow starter motor to hang
from wire harness.
(3) Position starter motor to engine.
(4) If equipped with automatic transmission, slide
cooler tube bracket into position.
(5) Install and tighten both mounting bolts. Refer
to Torque Specifications.
(6) Lower vehicle.
(7) Connect negative battery cable.
5.9L Diesel
(1)If Equipped:Position and hold aluminum
spacer to rear of starter while positioning starter to
engine.
(2) Connect solenoid wire to starter motor. Tighten
nut.
(3) Position battery cable to starter stud. Install
and tighten battery cable nut. Refer to Torque Spec-
ifications. Do not allow starter motor to hang from
wire harness.
(4) Position starter motor to transmission.
(5) If equipped with automatic transmission, slide
cooler tube bracket into position.
(6) Install and tighten 3 starter mounting bolts.
Refer to Torque Specifications.
(7) Lower vehicle.
(8) Connect both negative battery cables to both
batteries.
STARTER MOTOR RELAY
DESCRIPTION
The starter relay is an electromechanical device
that switches battery current to the pull-in coil of the
starter solenoid when ignition switch is turned to
Start position. The starter relay is located in the
Power Distribution Center (PDC) in the engine com-
partment. See PDC cover for relay identification and
location.
The starter relay is a International Standards
Organization (ISO) relay. Relays conforming to ISO
specifications have common physical dimensions, cur-
rent capacities, terminal patterns, and terminal func-
tions.
The starter relay cannot be repaired or adjusted. If
faulty or damaged, it must be replaced.
Fig. 12 STARTER R/I - 5.9L DIESEL
1 - MOUNTING BOLTS (3)
2 - STARTER MOTOR
3 - SPACER (CERTAIN TRANSMISSIONS)
Fig. 13 STARTER ELECTRICAL CONNECTORS -
5.9L DIESEL
1 - STARTER MOTOR
2 - BATTERY CABLE NUT
3 - SOLENOID NUT
4 - HARNESS ASSEMBLY
DRSTARTING 8F - 35
STARTER MOTOR (Continued)

REMOVAL
The starter relay is located in the Power Distribu-
tion Center (PDC) (Fig. 15). Refer to label on PDC
cover for relay location.
(1) Disconnect and isolate negative battery cable.
(2) Remove cover from Power Distribution Center
(PDC) for relay identification and location.
(3) Remove starter relay from PDC.
(4) Check condition of relay terminals and PDC
connector terminals for damage or corrosion. Repair
if necessary before installing relay.
(5) Check for pin height (pin height should be the
same for all terminals within the PDC connector).
Repair if necessary before installing relay.
INSTALLATION
(1) Push down firmly on starter relay until termi-
nals are fully seated into PDC receptacle.
(2) Install PDC cover.
(3) Connect battery cable.
Fig. 15 PDC LOCATION
1 - BATTERY
2 - INTEGRATED POWER MODULE (IPM)
DRSTARTING 8F - 37
STARTER MOTOR RELAY (Continued)

REAR WINDOW DEFOGGER GRID TERMINAL REPAIR
WARNING: THE REPAIR KIT CONTAINS EPOXY
RESIN AND AMINE TYPE HARDENER WHICH MAY
CAUSE SKIN OR EYE IRRITATION AND CAN BE
HARMFUL IF SWALLOWED. USE WITH ADEQUATE
VENTILATION. DO NOT USE NEAR FIRE OR OPEN
FLAME THE CONTENTS CONTAIN FLAMMABLE
SOLVENTS. KEEP OUT OF REACH OF CHILDREN.
²DO NOT TAKE INTERNALLY, IF SWALLOWED
INDUCE VOMITING AND CALL A PHYSICIAN IMME-
DIATELY.
²IF SKIN CONTACT OCCURS, WASH AFFECTED
AREAS WITH SOAP AND WATER.
²IF EYE CONTACT OCCURS, FLUSH WITH
PLENTY OF WATER.If the rear window defogger grid terminal(s) is
damaged or separated from the rear window, the
repair of the grid terminals is possible using the
MopartGrid Line Repair Package or an equivalent.
(1) If the grid terminal(s) is broken and a portion
of the terminal is still attached to the heating grid,
remove the portion of the clip remaining in the wire
harness connector(s).
(2) Mask the areas so the conductive epoxy can be
extended onto the adjacent grid line(s) as well as the
bus bar.
(3) Apply a thin layer of conductive epoxy to the
area where the terminal(s) where fastened and to the
adjacent grid line(s).
NOTE: To prevent the terminal(s) from moving while
the epoxy is curing, a wedge or clamp must be
used.
(4) Apply a thin layer of conductive epoxy on the
terminal(s) and properly orient the terminal(s) at the
desired location(s).
CAUTION: To prevent the glass from fracturing, do
not allow the glass surface to exceed 204É C (400É
F).
(5) Allow the epoxy to cure 24 hours at room tem-
perature or use a heat gun with a 260É to 371É C
(500É to 700É F) range for 15 minutes. Hold the heat
gun approximately 254 mm (10 inches) from repaired
area.
NOTE: To ensure proper installation, do not attach
the wire harness connector(s) to the terminal(s)
until the epoxy is completely cured.
(6) After the conductive epoxy has properly cured,
remove the wedge or clamp from the terminal(s),
reconnect the wire harness connector(s) and verify
operation of the rear window defogger.
Fig. 4 Grid Line Repair
1 - BREAK
2 - GRID LINE
3 - MASKING TAPE
DRHEATED GLASS 8G - 5
REAR WINDOW DEFOGGER GRID (Continued)