1998 DODGE RAM 1500 diagram

8W-97 POWER DISTRIBUTION
TABLE OF CONTENTS
page page
POWER DISTRIBUTION
DESCRIPTION..........................1
OPERATION............................1
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS.........2
CIGAR LIGHTER OUTLET
DESCRIPTION..........................2
OPERATION............................2
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET.............................2
INTEGRATED POWER MODULE
DESCRIPTION..........................3
OPERATION............................3
REMOVAL.............................3
INSTALLATION..........................4
FRONT CONTROL MODULE
DESCRIPTION..........................5OPERATION............................5
DIAGNOSIS AND TESTING - FRONT
CONTROL MODULE....................5
REMOVAL.............................6
INSTALLATION..........................6
IOD FUSE
DESCRIPTION..........................6
OPERATION............................6
REMOVAL.............................7
INSTALLATION..........................7
POWER OUTLET
DESCRIPTION..........................7
OPERATION............................7
DIAGNOSIS AND TESTING - POWER
OUTLET.............................7
REMOVAL.............................8
INSTALLATION..........................8
POWER DISTRIBUTION
DESCRIPTION
This group covers the various standard and
optional power distribution components used on this
model. The power distribution system for this vehicle
consists of the following components:
²Integrated Power Module (IPM)
²Front Control Module (FCM)
²Power Distribution Center (PDC)
²Power Outlets
²Cigar Lighter Outlets
²Relays
Refer to Wiring Diagrams for complete circuit sche-
matics.
The power distribution system also incorporates
various types of circuit control and protection fea-
tures, including:
²Automatic resetting circuit breakers
²Blade-type fuses
²Cartridge fuses
²Relays
Following are general descriptions of the major
components in the power distribution system. See the
owner's manual in the vehicle glove box for more
information on the features and use of all of the
power distribution system components.
OPERATION
The power distribution system for this vehicle is
designed to provide safe, reliable, and centralized dis-
tribution points for the electrical current required to
operate all of the many standard and optional facto-
ry-installed electrical and electronic powertrain,
chassis, safety, security, comfort and convenience sys-
tems. At the same time, the power distribution sys-
tem was designed to provide ready access to these
electrical distribution points for the vehicle techni-
cian to use when conducting diagnosis and repair of
faulty circuits. The power distribution system can
also prove useful for the sourcing of additional elec-
trical circuits that may be required to provide the
electrical current needed to operate many accessories
that the vehicle owner may choose to have installed
in the aftermarket.
DR8W-97 POWER DISTRIBUTION 8W - 97 - 1

SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
CIGAR LIGHTER OUTLET
DESCRIPTION
On models equipped a cigar lighter outlet is
installed to the left of the center stack area in the
lower instrument panel. The cigar lighter outlet is
secured by a snap fit within the bezel.
The cigar lighter outlet, plastic cap and the knob
and heating element unit are available for service
replacement. These components cannot be repaired
and, if faulty or damaged, they must be replaced.
OPERATION
The cigar lighter consists of two major components:
a knob and heating element unit, and the cigar
lighter base or outlet shell. The receptacle shell is
connected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The cigar lighter receives battery voltage from a fuse
in the junction block when the ignition switch is in
the Accessory or Run positions.
The cigar lighter knob and heating element are
encased within a spring-loaded housing, which also
features a sliding protective heat shield. When the
knob and heating element are inserted in the outlet
shell, the heating element resistor coil is grounded
through its housing to the outlet shell. If the cigar
lighter knob is pushed inward, the heat shield slides
up toward the knob exposing the heating element,
and the heating element extends from the housing
toward the insulated contact in the bottom of the
outlet shell.
Two small spring-clip retainers are located on
either side of the insulated contact inside the bottom
of the outlet shell. These clips engage and hold the
heating element against the insulated contact longenough for the resistor coil to heat up. When the
heating element is engaged with the contact, battery
current can flow through the resistor coil to ground,
causing the resistor coil to heat.
When the resistor coil becomes sufficiently heated,
excess heat radiates from the heating element caus-
ing the spring-clips to expand. Once the spring-clips
expand far enough to release the heating element,
the spring-loaded housing forces the knob and heat-
ing element to pop back outward to their relaxed
position. When the cigar lighter knob and element
are pulled out of the outlet shell, the protective heat
shield slides downward on the housing so that the
heating element is recessed and shielded around its
circumference for safety.
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET
For complete circuit diagrams, refer toWiring
Diagrams.
(1) Check the fused B(+) fuse in the integrated
power module. If OK, go to Step 2. If not OK, repair
the shorted circuit or component as required and
replace the faulty fuse.
(2) Turn the ignition switch to the Run position.
Check for battery voltage at the fused B(+) fuse in
the integrated power module. If OK, go to Step 3. If
not OK, repair the open or short as required.
(3) Remove the cigar lighter knob and element
from the cigar lighter outlet shell. Check for continu-
ity between the inside circumference of the cigar
lighter outlet shell and a good ground. there should
be continuity. If OK, go to Step 4. If not OK, go to
Step 5.
(4) Turn the ignition switch to the Run position.
Check for battery voltage at the insulated contact
located at the back of the cigar lighter outlet shell. If
OK, replace the faulty cigar lighter knob and ele-
ment. If not OK, go to Step 5.
(5) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Check for continuity between the ground circuit cav-
ity of the cigar lighter wire harness connector and a
good ground. There should be continuity. If OK, go to
Step 6. If not OK, repair the open ground circuit to
ground as required.
(6) Connect the battery negative cable. Turn the
ignition switch to the Accessory or Run positions.
Check for battery voltage at the fused B(+) circuit
cavity of the cigar lighter wire harness connector. If
OK, replace the faulty cigar lighter outlet. If not OK,
repair the open fused B(+) circuit to the integrated
power module fuse as required.Terminal Pick Kit 6680
8W - 97 - 2 8W-97 POWER DISTRIBUTIONDR
POWER DISTRIBUTION (Continued)

becomes transparent and the fuse that has been
assigned the IOD designation becomes only another
Fused B(+) circuit fuse.
The IOD fuse can be used by the vehicle owner as
a convenient means of reducing battery depletion
when a vehicle is to be stored for periods not to
exceed about thirty days. However, it must be
remembered that disconnecting the IOD fuse will not
eliminate IOD, but only reduce this normal condition.
If a vehicle will be stored for more than about thirty
days, the battery negative cable should be discon-
nected to eliminate normal IOD; and, the battery
should be tested and recharged at regular intervals
during the vehicle storage period to prevent the bat-
tery from becoming discharged or damaged.
REMOVAL
The Ignition-Off Draw (IOD) fuse is disconnected
from Integrated Power Module fuse cavity # 51 when
the vehicle is shipped from the assembly plant.
Dealer personnel must reconnect the IOD fuse when
the vehicle is being prepared for delivery in order to
restore full electrical system operation.
(1) Turn the ignition switch to the Off position.
(2) Remove the Integrated Power Module cover.
(3) Grasp the outer tabs of the IOD fuse holder
unit in fuse cavity # 51 between the thumb and fore-
finger and pull the unit firmly upward.
(4) Install the Integrated Power Module cover.
INSTALLATION
(1) Turn the ignition switch to the Off position.
(2) Remove the Integrated Power Module cover.
(3) To install the IOD fuse, use a thumb to press
the IOD fuse holder unit in fuse cavity # 51 firmly
into the Integrated Power Module.
(4) Install the Integrated Power Module cover.
POWER OUTLET
DESCRIPTION
Two power outlets are utilized on this model. One
in the instrument panel center lower bezel and the
other in the center console. The power outlet bases
are secured by a snap fit within the instrument
panel or trim panel. A plastic protective cap snaps
into the power outlet base when the power outlet is
not being used, and hangs from the power outlet base
mount by an integral bail strap while the power out-
let is in use.The power outlet receptacle unit and the accessory
power outlet protective cap are available for service.
The power outlet receptacle cannot be repaired and,
if faulty or damaged, it must be replaced.
OPERATION
The power outlet base or receptacle shell is con-
nected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The power outlet receives battery voltage from a fuse
in the integrated power module at all times.
While the power outlet is very similar to a cigar
lighter base unit, it does not include the two small
spring-clip retainers inside the bottom of the recepta-
cle shell that are used to secure the cigar lighter
heating element to the insulated contact.
DIAGNOSIS AND TESTING - POWER OUTLET
For complete circuit diagrams, refer toWiring
Diagrams.
(1) Check the fused B(+) fuse in the integrated
power module. If OK, go to Step 2. If not OK, repair
the shorted circuit or component as required and
replace the faulty fuse.
(2) Check for battery voltage at the fused B(+) fuse
in the integrated power module. If OK, go to Step 3.
If not OK, repair the open fused B(+) circuit to the
battery as required.
(3) Remove the plastic protective cap from the
power outlet receptacle. Check for continuity between
the inside circumference of the power outlet recepta-
cle and a good ground. There should be continuity. If
OK, go to Step 4. If not OK, go to Step 5.
(4) Check for battery voltage at the insulated con-
tact located at the back of the power outlet recepta-
cle. If not OK, go to Step 5.
(5) Disconnect and isolate the battery negative
cable. Remove the power outlet receptacle from the
instrument panel. Disconnect the wire harness con-
nector from the power outlet receptacle. Check for
continuity between the ground circuit cavity of the
power outlet wire harness connector and a good
ground. There should be continuity. If OK, go to Step
6. If not OK, repair the open ground circuit to ground
as required.
(6) Connect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
power outlet wire harness connector. If OK, replace
the faulty power outlet receptacle. If not OK, repair
the open fused B(+) circuit to the integrated power
module fuse as required.
DR8W-97 POWER DISTRIBUTION 8W - 97 - 7
IOD FUSE (Continued)

(51) Remove two cylinder head bolts according to
the diagram below and install Tool # 9009. Torque
bolts to 105N´m (77ft. lbs.) (Fig. 3).
(52) Loosen but do not remove engine mount
through bolts and nuts.
(53) Disconnect hood support struts and position
hood out of the way.
(54) Attach a chain with two hooks to the engine
lift brackets.
(55) While keeping engine level, lift straight up
out of the mounts.
(56) Rotate nose of engine upward and pull out of
chassis.
REMOVALÐCRANKCASE BREATHER
(1) Remove the oil fill cap.
(2) Remove the breather cover bolts (Fig. 4).
(3) Remove breather cover.
(4) Disconnect breather tube and lube oil drain
tube from breather.
(5) Remove breather mounting bolts.
(6) Remove breather from cylinder head cover.
INSTALLATION
INSTALLATION - ENGINE
(1) Remove cylinder head bolts according to the
diagram below. Install special Tool 9009. Torque bolts
to 105N´m (77ft. lbs.)
(2) Lower engine into the engine compartment and
install the engine the engine mount through bolts
and nuts.
(3) Tighten the mount through bolts and nuts to
88 N-m (65 ft-lbs) torque.
(4) Remove the engine lifting device (Tool 9009).
(5) Check cylinder head capscrew length and
install into cylinder head.
(6) Torque in 4 steps to:
²Step 1ÐTighten to 70 N´m (52 ft. lbs.) torque.
²Step 2ÐBack off 360É.
²Step 3ÐTighten to 105 N´m (77 ft. lbs.) torque.
²Step 4ÐRotate 90É.
(7) Install rocker housing. Torque to 24 N-m (18 ft-
lbs). Refer to (Refer to 9 - ENGINE/CYLINDER
HEAD/CYLINDER HEAD COVER(S) - INSTALLA-
TION).
Fig. 3 ENGINE LIFT BRACKET
1 - Head bolt
2 - Engine Lift Bracket
3 - Head Bolt
Fig. 4 Crankcase Breather Vapor Canister
1 - BREATHER COVER BOLT
2 - BREATHER COVER
3 - BREATHER TUBE
4 - ROCKER COVER
5 - BREATHER TUBE MOUNTING BRACKET
6 - LUBE OIL DRAIN TUBE
7 - O-RING
8 - BREATHER
9- BREATHER MOUNTING BOLT
9 - 242 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

(8) For columns without tilt remove the bracket to
gain access to the ignition switch mounting screws.
(Fig. 10)
(9) Disconnect the electrical connector at rear of
ignition switch (Fig. 11).
(10) Remove ignition switch mounting screw.
(11) Using a small screwdriver, push on locking
tab and remove switch from steering column.
INSTALLATION
The ignition key must be in the key cylinder for
cylinder removal. The key cylinder must be removed
first before installing ignition switch.
(1) Before installing ignition switch, rotate the slot
in the switch to the ON position.(2) Connect the electrical connector to rear of the
ignition switch. Make sure that locking tabs are fully
seated into wiring connector.
(3) Position switch to column and install the
mounting screw. Tighten screw to 3 N´m (26 in. lbs.).
(4) Install the tilt lever bracket mounting screws.
Tighten screws to 4.5 N´m (40 in. lbs.).
(5) If the column is non-tilt install the bracket.
Tighten screws to 4.5 N´m (40 in. lbs.) (Fig. 10)
(6) Position the wire retainer into the tilt lever
bracket.
(7) Reconnect the lower clockspring connectors.
(8) Install the key cylinder.
(9) Install steering column upper and lower
shrouds.
(10) Enable the airbag system. (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/DRIVER AIRBAG - INSTAL-
LATION).
KEY-IN IGNITION SWITCH
DESCRIPTION
The key-in ignition switch is integral to the igni-
tion switch, which is mounted on the left side of the
steering column. It closes a path to ground for the
Central Timer Module (CTM) when the ignition key
is inserted in the ignition key cylinder and the driver
door ajar switch is closed (driver door is open). The
key-in ignition switch opens the ground path when
the key is removed from the ignition key cylinder.
The ground path is also opened when the driver door
ajar switch is open (driver door is closed).
The key-in ignition switch cannot be repaired and,
if faulty or damaged, the entire ignition switch must
be replaced, (Refer to 19 - STEERING/COLUMN/IG-
NITION SWITCH - REMOVAL).
DIAGNOSIS AND TESTING - IGNITION SWITCH
AND KEY LOCK CYLINDER
ELECTRICAL DIAGNOSIS
For ignition switch electrical schematics, refer to
Ignition Switch in the appropriate section of Electri-
cal Wiring Diagrams.
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO
ROTATE)
(Refer to 19 - STEERING/COLUMN/IGNITION
SWITCH - DIAGNOSIS AND TESTING).
Fig. 10 IGNITION SWITCH WITHOUT TILT
1 - Ignition Switch Mounting Screws
2 - Non-Tilt Mounitng Bracket Screws
Fig. 11 IGNITION SWITCH
1 - Ignition Switch
2 - Ignition Switch Mounting Screws
DRCOLUMN 19 - 11
IGNITION SWITCH (Continued)

AUTOMATIC TRANSMISSION - 48RE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 48RE
DESCRIPTION........................132
OPERATION..........................134
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION.....................140
DIAGNOSIS AND TESTING - PRELIMINARY . 140
DIAGNOSIS AND TESTING - ROAD
TESTING...........................140
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TEST....................141
DIAGNOSIS AND TESTING - AIR TESTING
TRANSMISSION CLUTCH AND BAND
OPERATION........................144
DIAGNOSIS AND TESTING - CONVERTER
HOUSING FLUID LEAK................144
DIAGNOSIS AND TESTING - DIAGNOSIS
CHARTS...........................145
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR.....................158
REMOVAL............................158
DISASSEMBLY........................160
CLEANING...........................166
INSPECTION.........................166
ASSEMBLY...........................166
INSTALLATION........................174
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS.............176
SPECIFICATIONS
TRANSMISSION.....................189
SPECIAL TOOLS
RE TRANSMISSION..................191
ACCUMULATOR
DESCRIPTION........................193
OPERATION..........................193
INSPECTION.........................194
BANDS
DESCRIPTION........................194
OPERATION..........................194
ADJUSTMENTS
ADJUSTMENT - BANDS...............195
BRAKE TRANSMISSION SHIFT INTERLOCK
SYSTEM
DESCRIPTION........................196
OPERATION..........................196
DIAGNOSIS AND TESTING - BRAKE
TRANSMISSION SHIFT INTERLOCK......196
ADJUSTMENTS - BRAKE TRANSMISSION
SHIFT INTERLOCK...................196ELECTRONIC GOVERNOR
DESCRIPTION........................197
OPERATION..........................198
REMOVAL............................199
INSTALLATION........................200
EXTENSION HOUSING SEAL
REMOVAL............................201
INSTALLATION........................201
FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL.............201
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID.......................201
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION....................202
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK............................202
STANDARD PROCEDURE - FLUID AND
FILTER REPLACEMENT...............203
STANDARD PROCEDURE - TRANSMISSION
FILL...............................204
FRONT CLUTCH
DESCRIPTION........................205
OPERATION..........................205
DISASSEMBLY........................205
INSPECTION.........................206
ASSEMBLY...........................207
FRONT SERVO
DESCRIPTION........................208
OPERATION..........................208
DISASSEMBLY........................209
CLEANING...........................209
INSPECTION.........................209
ASSEMBLY...........................209
GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE.............................210
REMOVAL............................210
INSTALLATION........................211
ADJUSTMENTS
GEARSHIFT CABLE..................212
OIL PUMP
DESCRIPTION........................213
OPERATION..........................213
DISASSEMBLY........................214
CLEANING...........................214
INSPECTION.........................214
ASSEMBLY...........................214
21 - 130 AUTOMATIC TRANSMISSION - 48REDR

TORQUE CONVERTER LEAK POINTS
Possible sources of converter leaks are:
²Leaks at the weld joint around the outside diam-
eter weld.
²Leaks at the converter hub weld.
CONVERTER HOUSING AREA LEAK CORRECTION
(1) Remove converter.
(2) Tighten front band adjusting screw until band
is tight around front clutch retainer. This prevents
front/rear clutches from coming out when oil pump is
removed.
(3) Remove oil pump and remove pump seal.
Inspect pump housing drainback and vent holes for
obstructions. Clear holes with solvent and wire.(4) Inspect pump bushing and converter hub. If
bushing is scored, replace it. If converter hub is
scored, either polish it with crocus cloth or replace
converter.
(5) Install new pump seal, O-ring, and gasket.
Replace oil pump if cracked, porous or damaged in
any way. Be sure to loosen the front band before
installing the oil pump, damage to the oil pump seal
may occur if the band is still tightened to the front
clutch retainer.
(6) Loosen kickdown lever pin access plug three
turns. Apply LoctiteŸ 592, or PermatextNo.2to
plug threads and tighten plug to 17 N´m (150 in. lbs.)
torque.
(7) Adjust front band.
(8) Lubricate pump seal and converter hub with
transmission fluid or petroleum jelly and install con-
verter.
(9) Install transmission and converter housing
dust shield.
(10) Lower vehicle.
DIAGNOSIS AND TESTING - DIAGNOSIS
CHARTS
The diagnosis charts provide additional reference
when diagnosing a transmission fault. The charts
provide general information on a variety of transmis-
sion, overdrive unit and converter clutch fault condi-
tions.
The hydraulic flow charts in the Schematics and
Diagrams section of this group, outline fluid flow and
hydraulic circuitry. Circuit operation is provided for
PARK, NEUTRAL, FIRST, SECOND, THIRD,
FOURTH, MANUAL FIRST, MANUAL SECOND,
and REVERSE gear ranges. Normal working pres-
sures are also supplied for each of the gear ranges.
Fig. 11 Converter Housing Leak Paths
1 - PUMP SEAL
2 - PUMP VENT
3 - PUMP BOLT
4 - PUMP GASKET
5 - CONVERTER HOUSING
6 - CONVERTER
7 - REAR MAIN SEAL LEAK
DRAUTOMATIC TRANSMISSION - 48RE 21 - 145
AUTOMATIC TRANSMISSION - 48RE (Continued)

SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS
HYDRAULIC FLOW IN PARK
21 - 176 AUTOMATIC TRANSMISSION - 48REDR
AUTOMATIC TRANSMISSION - 48RE (Continued)