2006 DODGE RAM SRT-10 battery

6. Connect the drain tubes (1) to the sunroof.
7. Adjust the sunroof glass. (Refer to 23 - BODY/
SUNROOF/GLASS PANEL - ADJUSTMENTS)
8. Connect battery negative cable.
9. Install the vehicle headliner, (Refer to 23 - BODY/
INTERIOR/HEADLINER - INSTALLATION).
10. Perform the sunroof position calibration, (Refer to
8 - ELECTRICAL/POWER TOP/MOTOR - STAN-
DARD PROCEDURE - SUNROOF POSITION
CALIBRATION).
11. Perform the Excessive Force Limitation (EFL) cal-
ibration, (Refer to 8 - ELECTRICAL/POWER TOP/
MOTOR - STANDARD PROCEDURE -
EXCESSIVE FORCE LIMITATION (EFL) CALI-
BRATION).
12. Verify proper operation of the power sunroof
system.

WINCH
DESCRIPTION
The winch uses the electrical power from the vehicle charging system to power a motor that winds wire rope into
the winch drum by means of planetary gear reduction.
The winch assembly includes the following:
Motor:The winch motor is powered by the vehicle electrical system and features a thermal protection switch
that automatically stops the motor function in the power-in direction if the motor gets too hot.
Winch Drum:The winch drum allows the wire rope to be stored on the winch and transmits forcetothewire
rope.
Wire Rope:The wire rope allows the winch to be connected to an anchor to provide a pulling force.
Fairlead:The fairlead consists of four rollers and acts as guide for the wire rope andminimizes damage to the
rope.
Automatic Brake:The winch is equipped with an automatic brake that will stop rotation of thewinch drum if
the winch motor is stopped.
Clutch Lever:The clutch lever allows the winch drum to be disconnected from the winch motor to allow the
wire rope to be pulled from the winch by hand.
Remote Socket:The remote socket allows the remote control to be attached to the control pack to allow the
winchtofunction.
Remote Control:The remote control provides the interface between the winch operator and the winch. The
remote control provides the ability to power the winch in, out, and stop thewinch.
OPERATION
Winch:The winch uses the electrical power from the vehicle charging system to power a motor that winds wire rope
into the winch drum via planetary gear reduction. By nature, a winch is capable of generating very high forces and
should be used with care. Do not operate the winch without reading and understanding the complete winch owner’s
manual.
Low Voltage Interrupt:The winch is equipped with a device that will interrupt winch function if the vehicle charging
system voltage drops to a low level. The winch will not power-in or out for 30seconds if this device is tripped. If the
interrupt is tripped, the vehicle should be operated at high idle for a few minutes to allow the vehicle charging sys-
tem to recover before continuing to winch.
Winch Motor Thermal Protection:The winch is equipped with athermalprotectiondeviceinthemotor.Ifthe
winch is operated for an excessive duration, the device may interrupt motor function to protect the winch motor.
During this time the winch will power-out but will not power-in. Allow the winch motor to cool for a few minutes
before continuing operation of the winch. The winch will resume normal function once the motor cools.
Remote Control:Tooperatethewinch,thetoggleswitchispresseddowntopowerthewinchinand up to power
the winch out. The winch will stop if the switch is left in the neutral (center) position.
Clutch Lever:The clutch lever is used to allow free spooling of the winch drum. Rotate theclutch lever on the
winch to disengage the clutch.
WARNING
WARNING: Disconnect and isolate battery negative cable before attempting any troubleshooting or repairs.
Do not disengage the clutch if the winch is under a load or wire rope is under tension.
Do not route electrical cables across sharp edges.
Do not route electrical cables through or near moving parts.
Always wear heavy leather gloves when handling a wire rope.
Never let wire rope slip through your hands.
Always keep hands clear of wire rope, hook loop, hook and fairlead opening during installation, opera-
tion, and when spooling in or out.
Always use supplied hook strap whenever spooling wire rope in or out, during installation or operation.
Failure to follow these instructions may result in personal injury.

CAUTION: Do not leave the remote plugged into the winch when not in use. Leaving the remote plugged in,
may result in a dangerous condition and/or battery drain.
Always make sure the clutch is fully engaged or disengaged.
DIAGNOSIS AND TESTING – WINCH
CONDITION POSSIBLE CAUSES CORRECTION
Winch does not hold the load. Faulty winch drum brake. Replace the winch assembly.
(Refer to 23 - BODY/WINCH -
REMOVAL)
Load exceeds rating for the winch. Refer to operators manual for the
correct line pull rating for the winch.
Brake overheats and will not
hold the load.The wire rope is on the drum backwards. Remove all the wire rope and
respool in the proper direction.
Thewireropeisspoolontothedrumin
the wrong direction and working against
the brake in the
power inmode.The wire rope must always spool
onto the drum as indicated by the
drum rotation label on the winch.
Winches are equipped with an
automatic brake andWILL NOT
FUNCTIONif the wire rope spools
intheoppositedirection.Thewire
rope spooling can accidentally be
reversed by running the wire rope
all the way out and re-spooling in
with the control switch in the
power
out
mode.
Load exceeds rating for winch Refer to operators manual for the
correct line pull rating for the winch.
After a very long
power outcycle, in
excess of 50 feet under high loads, the
brake has overheated and needs a cool
down cycle of approximately 30 minutes.These winches are rated for
intermittent duty operations only. As
the load is increased, the duration
of power out cycles must be
reduced to limit the brake
temperature. Allow adequate time
for the brake to cool between uses
when performing extended power
out cycles.

CONDITION POSSIBLE CAUSES CORRECTION
Difficult to spool the wire rope
off the drum by hand.Bent drum flanges or worn drum
bushings.Rotate the drum while it is still on
the winch to see if the drum flanges
appear to be bent. If the flanges
appear to be bent, the winch will
have to be replaced.
Free spool clutch is damaged inside the
gear train.Replace winch.
(Refer to 23 - BODY/WINCH -
REMOVAL)
Wire rope is bound up on the drum. Should the wire rope become
bound onto the drum, connect the
hook to a load, then by alternately
powering inthenpowering out,
the wire rope will usually work itself
free.WARNING:
Do not put your hands anywhere
near the wire rope when working a
bind free.
Winch is not mounted correctly, causing
the drum to bind.Check winch mounting and repair
as necessary.
Winch lacks power or will not
run at all.Faulty ground cable attachment to the
motor housing.Verify that the ground cable is
correctly installed to the threaded
hole in the motor housing. See
Motor Ground Test below.
The vehicle battery is inadequate in size,
terminals are corroded, is defective or
worn out, or is not fully charged.Use a fully charged conventional
automotive battery with a minimum
of650coldcrankingampsratingto
obtain peak performance from the
winch. Make sure all terminals are
clean and the battery is fully
charged. Replace battery if
necessary.
Faulty cable connections on battery or
motor terminalsClean and tighten all terminals.
Faulty power supply to the winch. Check for proper power supply. See
Power Test below.
Faulty remote control switch or cord. Check for faulty switch. See
Remote Switch Test below.
Replace the remote switch is
necessary.

CONDITION POSSIBLE CAUSES CORRECTION
When remote control switch is
activated, there is only a
clickingsound, and the winch
does not operate in either
power inorpower out
modes.Low battery charge, corroded terminals,
defective battery.Use a fully charged conventional
automotive battery with a minimum
of650coldcrankingampsratingto
obtain peak performance from the
winch. Make sure all terminals are
clean and the battery is fully
charged. Replace battery if
necessary.
Check for proper power supply. See
Power Test below.
Faulty ground cable attachment to the
motor housing.Check for proper ground. See
Motor Ground Test below.
Faulty motor armature, brushes, or water
in the motor.Replace the motor.
(Refer to 23 - BODY/WINCH/
MOTOR - REMOVAL)
Faulty control relay. Check and replace relays as
necessary. See Relay Pack Test
below
(Refer to 23 - BODY/WINCH/
RELAY - REMOVAL)
Winchrunsslowlyandlacks
power when pulling a load,
won’t pull load, or stalls easily.Thewireropeisspoolontothedrumin
the wrong direction and working against
the brake in the
power inmode.The wire rope must always spool
onto the drum as indicated by the
drum rotation label on the winch.
Winches are equipped with an
automatic brake and WILL NOT
FUNCTION if the wire rope spools
intheoppositedirection.Thewire
rope spooling can accidentally be
reversed by running the wire rope
all the way out and re-spooling in
with the control switch in the
power
out
mode.
When the remote control is
activated, the winch will
operate only in one direction.One or more of the control pack relays is
damagedCheck and replace relays as
necessary. See Relay Pack Test
below
(Refer to 23 - BODY/WINCH/
RELAY - REMOVAL)
The remote control switch is damaged. Check and replace switch as
necessary. See Remote Switch Test
below.
Power-out mode only. Tripped or damaged thermal switch Let motor cool for atleast30
minutes, then try to power-in again.
Check thermal switch. See Thermal
Switch Test below.
Replace the motor if the thermal
switch is faulty.
(Refer to 23 - BODY/WINCH/
MOTOR - REMOVAL)

CONDITION POSSIBLE CAUSES CORRECTION
When the remote control is
activated, the winch will not
operate and no “clicking” sound
is heard.Tripped or damaged Low Voltage
Interrupt (LVI)Use a fully charged conventional
automotive battery with a minimum
of650coldcrankingampsratingto
obtain peak performance from the
winch. Make sure all terminals are
clean and the battery is fully
charged. Replace battery if
necessary.
Check LVI. See Low Voltage
Interrupt (LVI) Test below.
Replace the relay pack if the LVI is
faulty.
(Refer to 23 - BODY/WINCH/
RELAY PACK - REMOVAL)
Relay Test
1. Disconnect the red (+) battery cable (1).

Low Voltage Interrupt (LVI) Test
If the LVI is suspected to be failing check the following:
1. Check to make sure the battery has 10.5 to 12 volts.
2. If low, charge battery.
3. Wait for 30 seconds or more.
4. Check for a ground on pin 4.
5. If no ground then check control ground Relay Pack Test .
6. If ground good then replace the relay pack (Refer to 23 - BODY/WINCH/RELAYPACK-REMOVAL).
Motor Test
If the motor is suspected to be failing check the following:
1. Disconnect the motor power connectors F1, F2 and A.
2. Measure the resistance between F1 and F2. Resistance should be less than1
.
3. Measure the resistance between A and ground. Resistance should be less than 1
.
4. If the resistance is greater than 1
the motor brushes could be worn or the internal wiring could be burned.
Replace the motor (Refer to 23 - BODY/WINCH/MOTOR - REMOVAL).
Power Test
1. Check for a tight fit of all connections.
2. Using a volt meter, verify 12 ± 2 volts a the bus bar connecting relays #1 and#3.
Motor Ground Test
1. Check for continuity between the ground stud and the battery.
2. If no continuity then repair the ground cable from the batter to the motor.
Relay Pack Test

Measurement
between pinsResistance Voltage
Results Correction
(V)
“4” to “5” 2 - Yes Relay pack OK.
No 1. Check for any faulty relay or
motor electrical connections and
repair if necessary.
2. Check for a faulty relay and
replace as necessary. Refer to
Relay Test .
“4” to “2” 2 - Yes Relay pack OK.
No 1. Check for any faulty relay or
motor electrical connections and
repair if necessary.
2. Check for a faulty relay and
replace as necessary. Refer to
Relay Test .
“1” to “2”
100K - Yes Relay pack OK.
No Check for shorted Thermal Switch.
Refer to Thermal Switch Test .
“1” to “3” - 12 Yes Relay pack OK.
No 1. Check for any faulty relay or
motor electrical connections and
repair if necessary.
2. Check for faulty LVI, Refer to
Low Voltage Interrupt (LVI) Test .
REMOVAL
1. Disconnect and isolate battery negative (3) and
positive (1) cables.