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designed to rotate the same number of turns (about five complete rotations) as the steering wheel can be turned from stop to stop. Centering the clockspring indexes the clockspring tape to other steering compo- nents so that it can operate within its designed travel limits. The rotor of a centered clockspring can be rotated two and one-half turns in either direction from the centered position, without damaging the clockspring tape.
However, if the clockspring is removed for service or if the steering column is disconnected from the steering gear, the clockspring tape can change posi-
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8O - 19
replacement
tion relative to the other steering components. The clockspring must then be re-centered following com- pletion of such service or the clockspring tape may be damaged. Service clocksprings are shipped pre-centered, with a plastic locking pin installed (Fig. 19). This locking pin should not be removed until the clockspring has been installed on the steering column. If the locking pin is removed before the clockspring is installed on a steering col- umn, the clockspring centering procedure must be performed.
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCON- NECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
THE
Fig.19ClockspringandMulti-FunctionSwitch
1 - CLOCKSPRING 2 - LOCATING PIN 3 - SCREW (2) 4 - LOCKING PIN 5 - ENGAGEMENT DOWEL BOOT
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8O - 20
CLOCKSPRING (Continued)NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position.
(1) Place the front wheels in the straight-ahead
position.
(2) Remove the clockspring from the steering col- (Refer to 8 - ELECTRICAL/RESTRAINTS/
umn. CLOCKSPRING - REMOVAL).
(3) Rotate the clockspring rotor clockwise to the end of its travel. Do not apply excessive torque. (4) From the end of the clockwise travel, rotate the rotor about two and one-half turns counterclockwise. The engagement dowel and yellow rubber boot should end up at the bottom, and the arrows on the clockspring rotor and case should be in alignment. The clockspring is now centered.
(5) The front wheels should still be in the straight- ahead position. Reinstall the clockspring onto the steering column. (Refer to 8 - ELECTRICAL/RE- STRAINTS/CLOCKSPRING - INSTALLATION).
REMOVAL
The clockspring cannot be repaired. It must be replaced if faulty or damaged, or if the driver airbag has been deployed.
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCON- NECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
THE
NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position.
(1) Place the front wheels in the straight ahead
position.
(2) Remove the driver airbag from the steering (Refer to 8 - ELECTRICAL/RESTRAINTS/
wheel. DRIVER AIRBAG - REMOVAL).
(3) Disconnect the steering wheel wire harness connectors from the upper clockspring connector receptacles.
DR
CAUTION: Be certain that the screws that secure the steering wheel puller to the steering wheel are fully engaged in the steering wheel armature with- out passing through the steering wheel and damag- ing the clockspring.
(4) Remove the steering wheel from the steering column. (Refer to 19 - STEERING/COLUMN/STEER- ING WHEEL - REMOVAL).
(5) Remove the steering column opening cover from the instrument panel. (Refer to 23 - BODY/IN- STRUMENT PANEL/STEERING COLUMN OPEN- ING COVER - REMOVAL).
(6) If the vehicle is so equipped, grasp the steering column tilt knob firmly and pull it straight rearward to remove it from the tilt adjuster mechanism lever located on the left side of the column just below the multi-function switch control stalk.
(7) From below the steering column, remove the two outboard screws that secure the upper shroud to the lower shroud.
(8) Using hand pressure, push gently inward on both sides of the upper shroud near the parting line between the upper and lower shrouds to release the snap features that secure it to the lower shroud.
(9) Remove the upper shroud from the lower
shroud.
column.
(10) From below the steering column, remove the one center screw that secures the lower shroud to the steering column lock housing.
(11) Remove the lower shroud from the steering
(12) Disconnect the two instrument panel wire harness connectors for the clockspring from the two connector receptacles below the steering column on the back of the clockspring housing.
(13) Remove the two screws that secure the clock- spring to the multi-function switch mounting housing (Fig. 20).
(14) Remove the clockspring from the multi-func- tion switch mounting housing. The clockspring can- not be repaired. It must be replaced if faulty or damaged, or if the driver airbag has been deployed. (15) If the removed clockspring is to be reused, be certain to secure the clockspring rotor to the clock- spring case to maintain clockspring centering until it is reinstalled on the steering column. If clockspring centering is not maintained, the clockspring must be centered again before it is reinstalled. (Refer to 8 - ELECTRICAL/RESTRAINTS/CLOCKSPRING STANDARD PROCEDURE - CLOCKSPRING CEN- TERING).
DR CLOCKSPRING (Continued)
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8O - 21
THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
THE
NOTE: Before starting this procedure, be certain that the front wheels are still in the straight-ahead position.
(1) Carefully slide the centered clockspring down over the steering column upper shaft until the hole in the locating tab at the eleven o’clock position on the clockspring case is engaged over the locating pin on the multi-function switch mounting housing (Fig. 20).
(2) Install and tighten the two screws that secure the clockspring to the multi-function switch mount- ing housing. Tighten the screws to 2 N·m (20 in. lbs.).
(3) Reconnect the two instrument panel wire har- ness connectors for the clockspring to the two connec- tor receptacles below the steering column on the back of the clockspring housing.
(4) Position the lower shroud onto the steering col-
umn.
(5) From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column lock housing. Tighten the screw to 2 N·m (20 in. lbs.).
(6) Position the upper shroud onto the steering col- umn. If the vehicle is equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the openings in the right side of the upper and lower shrouds.
(7) Align the snap features on the upper shroud with the receptacles on the lower shroud and apply hand pressure to snap them together.
(8) From below the steering column, install and tighten the two screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N·m (20
in. lbs.).(9) If the vehicle is equipped with the optional tilt steering column, align the steering column tilt knob with the tilt adjuster mechanism lever located on the left side of the column just below the multi-function switch control stalk and, using hand pressure, push the knob firmly onto the lever.
(10) Reinstall the steering column opening cover onto the instrument panel. (Refer to 23 - BODY/IN- STRUMENT PANEL/STEERING COLUMN OPEN- ING COVER - INSTALLATION).
(11) If a new clockspring has been installed, remove the locking pin that is securing the clock- spring rotor to the clockspring case to maintain clockspring centering.
Fig.20ClockspringandMulti-FunctionSwitch
1 - CLOCKSPRING 2 - LOCATING PIN 3 - SCREW (2) 4 - LOCKING PIN 5 - ENGAGEMENT DOWEL BOOT
INSTALLATION
The clockspring cannot be repaired. It must be replaced if faulty or damaged, or if the driver airbag has been deployed.
(Refer
it may be damaged.
If the clockspring is not properly centered in rela- tion to the steering wheel, steering shaft and steer- to 8 - ing gear, ELECTRICAL/RESTRAINTS/CLOCKSPRING STANDARD PROCEDURE - CLOCKSPRING CEN- TERING). Service clocksprings are shipped pre-centered, with a plastic locking pin installed. This locking pin should not be removed until the clockspring has been installed on the steer- ing column. If the locking pin is removed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed.
replacement
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCON- NECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE.
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8O - 22
CLOCKSPRING (Continued)NOTE: When reinstalling the steering wheel, be cer- tain to index the yellow rubber booted engagement dowel on the upper surface of the clockspring rotor between the two fins cast into the lower surface of the steering wheel armature hub.
(12) Reinstall the steering wheel onto the steering column. (Refer to 19 - STEERING/COLUMN/STEER- ING WHEEL - INSTALLATION).
(13) Reconnect the steering wheel wire harness connectors to the upper clockspring connector recep- tacles. Be certain that the steering wheel wire har- ness is routed between the steering wheel back trim cover and the steering wheel armature.
(14) Reinstall the driver airbag onto the steering (Refer to 8 - ELECTRICAL/RESTRAINTS/
wheel. DRIVER AIRBAG - INSTALLATION).
DRIVER AIRBAG DESCRIPTION
Fig.21DriverAirbagTrimCover
1 - STEERING WHEEL 2 - TRIM COVER
The color-keyed,
injection molded, thermoplastic driver airbag protective trim cover is the most visible part of the driver airbag (Fig. 21). The driver airbag is located in the center of the steering wheel, where it is secured with two screws to the armature of the four-spoke steering wheel. All models have a Dodge Ram logo embossed in the center of the trim cover. Concealed beneath the driver airbag trim cover are the horn switch, the folded airbag cushion, the airbag cushion retainer, the airbag housing, the airbag infla- tor, and the retainers that secure the inflator to the airbag housing.
The airbag cushion, housing, and inflator are secured within an integral receptacle molded into the
DR
back of the trim cover. The stamped metal airbag housing is secured by integral tabs that engage slot- ted locking blocks at the top and bottom of the trim cover receptacle, an integral metal hook inserted through a window in the vertical wall of the trim cover receptacle at each side, and by three aluminum blind rivets. This combination of fasteners locks the trim cover securely in place on the airbag housing.
The
resistive membrane-type horn switch is secured with heat stakes to the inside surface of the driver airbag trim cover, between the trim cover and the folded airbag cushion. The horn switch ground pigtail wire has an eyelet terminal connector that is captured beneath a flanged nut on the upper right inflator mounting stud on the back of the housing (Fig. 22). The horn switch feed pigtail wire has a black, molded plastic insulator that is secured by an integral retainer in a locator hole near the upper left corner of the airbag housing and is connected to the vehicle electrical system through a dedicated take out of the steering wheel wire harness. Both horn switch wires are routed through integral routing slots in the upper locking block of the trim cover receptacle.
Fig.22DriverAirbagHousing
1 - HOUSING 2 - HORN SWITCH FEED WIRE 3 - INFLATOR 4 - TRIM COVER RECEPTACLE 5 - HORN SWITCH GROUND WIRE
The airbag used in this model is a Next Genera- tion-type that complies with revised federal airbag standards to deploy with less force than those used in some prior models. A 71.1 centimeter (28 inch) diameter, radial deploying fabric cushion with inter- nal tethers is used. The airbag inflator is a non- azide, pyrotechnic-type unit and is secured by four flanged hex nuts to four studs on the airbag cushion retainer ring to the back of the stamped metal airbag housing. A connector receptacle on the driver airbag
DR DRIVER AIRBAG (Continued)
inflator connects the inflator initiator to the vehicle electrical system through a yellow-jacketed, two-wire pigtail harness of the clockspring.
The driver airbag cannot be repaired, and must be
replaced if deployed or in any way damaged.
OPERATION
The driver airbag is deployed by electrical signals generated by the Airbag Control Module (ACM) through the driver airbag squib circuit to the initia- tor in the airbag inflator. When the ACM sends the proper electrical signal to the initiator the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these chem- ical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the back of the airbag housing and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the driver airbag trim cover will split at predetermined breakout lines, then fold back out of the way along with the horn switch unit. Following an airbag deployment, the airbag cushion quickly deflates by venting the inert gas towards the instrument panel through vent holes within the fabric used to con- struct the back (steering wheel side) panel of the air- bag cushion.
Some of the chemicals used to create the inert gas may be considered hazardous while in their solid state before they are burned, but they are securely sealed within the airbag inflator. Typically, all poten- tially hazardous chemicals are burned during an air- bag deployment event. The inert gas that is produced when the chemicals are burned is harmless. How- ever, a small amount of residue from the burned chemicals may cause some temporary discomfort if it contacts the skin, eyes, or breathing passages. If skin or eye irritation is noted, rinse the affected area with plenty of cool, clean water. If breathing passages are irritated, move to another area where there is plenty of clean, fresh air to breath. If the irritation is not alleviated by these actions, contact a physician.
REMOVAL
The following procedure is for replacement of a faulty or damaged driver airbag. If the airbag is faulty or damaged, but not deployed, review the rec- ommended procedures for handling non-deployed supplemental restraints. (Refer to 8 - ELECTRICAL/ RESTRAINTS - STANDARD PROCEDURE - HAN- DLING SUPPLEMENTAL the driver airbag has been RESTRAINTS).
NON-DEPLOYED
If
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8O - 23
deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. (Refer to 8 - ELECTRICAL/RESTRAINTS - STANDARD PRO- CEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT).
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCON- NECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
THE
WARNING: WHEN REMOVING A DEPLOYED AIR- BAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG CUSHION AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES.
(1) Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service.
(2) From the underside of
the steering wheel, remove the two screws that secure the two trim cov- ers or speed control switches to each side of the driver airbag trim cover.
(3) From the top of the steering wheel, remove the two trim covers or speed control switches from the pockets on each side of the driver airbag trim cover to access the driver airbag mounting screws.
(4) Remove the two screws that secure the driver
airbag to the steering wheel armature (Fig. 23).
(5) Pull the driver airbag away from the steering wheel far enough to access the two electrical connec- tions at the back of the airbag housing.
(6) Disconnect the steering wheel wire harness horn switch feed take out connector from the horn switch feed pigtail wire connector insulator located on the back of the driver airbag housing.
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8O - 24
DRIVER AIRBAG (Continued)Fig.23DriverAirbagRemove/Install
1 - CLOCKSPRING 2 - STEERING WHEEL 3 - HORN SWITCH FEED TAKE OUT 4 - DRIVER AIRBAG 5 - SCREW (2) 6 - CLOCKSPRING PIGTAIL WIRE
CAUTION: Do not pull on the clockspring pigtail wires or pry on the connector insulator to disen- gage the connector from the driver airbag inflator connector receptacle. these pigtail wires and their connector insulators can result in damage to the airbag circuits or connector insulators.
Improper removal of
(7) The clockspring driver airbag pigtail wire con- nector is secured by integral latches to the airbag inflator connector receptacle, which is located on the back of the driver airbag housing. Depress the latches on each side of the connector insulator and pull the insulator straight out from the airbag infla- tor to disconnect it from the connector receptacle.
(8) Remove the driver airbag from the steering
wheel.
(9) If the driver airbag has been deployed, the clockspring must be replaced. (Refer to 8 - ELECTRI- CAL/RESTRAINTS/CLOCKSPRING - REMOVAL).
INSTALLATION
The following procedure is for replacement of a faulty or damaged driver airbag. If the airbag is faulty or damaged, but not deployed, review the rec- ommended procedures for handling non-deployed supplemental restraints. (Refer to 8 - ELECTRICAL/ RESTRAINTS - STANDARD PROCEDURE - HAN- DLING SUPPLEMENTAL RESTRAINTS). the driver airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. (Refer to 8 - ELECTRICAL/RESTRAINTS - STANDARD PRO-
NON-DEPLOYED
If
DR
CEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT).
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCON- NECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
THE
WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE DRIVER AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT.
WARNING: THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT AIR- BAGS ARE SERVICED WITH TRIM COVERS IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAIL- URE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOY- MENT.
(1) Position the driver airbag close enough to the steering wheel to reconnect the two electrical connec- tions at the back of the airbag housing.
(2) When installing the driver airbag, reconnect the clockspring driver airbag pigtail wire connector to the airbag inflator connector receptacle by press- ing straight in on the connector (Fig. 23). You can be certain that the connector is fully engaged in its receptacle by listening carefully for a distinct, audi- ble click as the connector latches snap into place.
(3) Reconnect
the steering wheel wire harness horn switch feed take out connector to the horn switch feed pigtail wire connector insulator located on the back of the driver airbag housing.
(4) Carefully position the driver airbag in the steering wheel. Be certain that the clockspring pig- tail wire and the steering wheel wire harness in the
DR DRIVER AIRBAG (Continued)
steering wheel hub area are not pinched between the driver airbag and the steering wheel armature.
(5) Install and tighten the two screws that secure the driver airbag to the steering wheel armature. Tighten the screws to 14 N·m (120 in. lbs.).
(7) From the underside of
(6) From the top of the steering wheel, position the two trim covers or speed control switches into the pockets on each side of the driver airbag trim cover. the steering wheel, install and tighten the two screws that secure the two trim covers or speed control switches to each side of the driver airbag trim cover. Tighten the screws to 2 N·m (15 in. lbs.).
(8) Do not reconnect the battery negative cable at this time. The supplemental restraint system verifi- cation test procedure should be performed following service of any supplemental restraint system compo- nent. (Refer to 8 - ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE - VERIFICATION TEST).
FRONT CENTER SEAT BELT & RETRACTOR REMOVAL
A front center seat belt and retractor is used only on standard cab models. Quad cab models have a lap belt in the front center seating position. (Refer to 8 - ELECTRICAL/RESTRAINTS/FRONT CENTER SEAT BELT BUCKLE - REMOVAL).
THAT
IS CUT,
WARNING: DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLA- TION, OPERATION, OR DAMAGE. REPLACE ANY BELT FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG.
(1) Reach between the center of the front seat cushion and front seat back to access and unbuckle
RESTRAINTS
8O - 25
the front center seat belt lower anchor latch plate from the unique black, keyed lower anchor buckle. Use an ignition key or a small screwdriver to depress the small white release button on the anchor buckle. (2) Move the front seat to its most forward position for easiest access to the front center seat belt and retractor unit.
(3) Using a trim stick or another suitable wide flat-bladed tool, gently pry at each side of the front center seat belt bezel on the cab back trim panel to release the snap features that secure the bezel to the panel (Fig. 24).
Fig.24FrontCenterSeatBeltBezel
1 - TRIM PANEL 2 - BODY BRACKET 3 - SEAT BELT BRACKET 4 - SEAT BELT 5 - BEZEL
(4) Remove the bezel from the webbing of the front
center seat belt.
(5) Remove the trim from the cab back panel. (Refer to 23 - BODY/INTERIOR/REAR CAB BACK PANEL TRIM - REMOVAL).
(6) Remove the two screws that secure the belt bracket of the front center seat belt to the body bracket on the upper cab back panel reinforcement (Fig. 25).
(7) Remove the belt bracket of the front center seat belt from the body bracket on the upper cab back panel reinforcement.
(8) Remove the two screws that secure the front center seat belt retractor bracket to the floor panel near the base of the cab back panel.
RESTRAINTS
8O - 26
FRONT CENTER SEAT BELT & RETRACTOR (Continued)DR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG.
(1) Position the front center seat belt and retractor unit to the floor panel at the base of the cab back panel to the right of center (Fig. 25).
(2) Install and tighten the two screws that secure the front center seat belt retractor bracket to the floor panel near the base of the cab back panel. Tighten the screws to 40 N·m (29 ft. lbs.).
(3) Position the belt bracket of the front center seat belt to the body bracket on the upper cab back panel reinforcement.
(4) Install and tighten the two screws that secure the belt bracket of the front center seat belt to the body bracket on the upper cab back panel reinforce- ment. Tighten the screws to 20 N·m (15 ft. lbs.).
(5) Reinstall the trim onto the cab back panel. (Refer to 23 - BODY/INTERIOR/REAR CAB BACK PANEL TRIM - INSTALLATION).
(6) Route the webbing of the front center seat belt through the bezel and position the bezel to the belt opening near the top of the cab back trim panel (Fig. 24).
(7) Using hand pressure, press firmly and evenly on each side of the front center seat belt bezel until it snaps into place on the cab back trim panel.
(8) Move the front seat back to its rearward posi-
tion.
(9) Reach between the center of the front seat cushion and front seat back to access and buckle the front center seat belt lower anchor latch plate to the unique black, keyed lower anchor buckle.
FRONT CENTER SEAT BELT REMOVAL
A fixed position front center seat belt buckle is located on the left side of the front center seat sec- tion (20 percent) used on all models. Standard cab models also have a unique fixed position black, keyed front center seat belt lower anchor buckle for the three-point center seat belt lower anchor located on the right side of the front center seat section. The fol- lowing procedure also applies to the fixed position front center seat lap belt located on the right side of the front center seat section of all quad cab models. The three-point front center seat belt and retractor unit is only used on standard cab models. (Refer to 8
- ELECTRICAL/RESTRAINTS/FRONT CENTER SEAT BELT & RETRACTOR - REMOVAL).Fig.25FrontCenterSeatBelt&RetractorRemove/
Install
1 - BODY BRACKET 2 - BELT BRACKET 3 - SCREW (2) 4 - SCREW (2) 5 - RETRACTOR 6 - FLOOR PANEL 7 - SEAT BELT 8 - CAB BACK PANEL
(9) Remove the front center seat belt and retractor
unit from the floor panel.
INSTALLATION
A front center seat belt and retractor is used only on standard cab models. Quad cab models have a lap belt in the front center seating position. (Refer to 8 - ELECTRICAL/RESTRAINTS/FRONT CENTER SEAT BELT BUCKLE - INSTALLATION).
THAT
WARNING: DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLA- TION, OPERATION, OR DAMAGE. REPLACE ANY BELT FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
IS CUT,
DR FRONT CENTER SEAT BELT (Continued)
RESTRAINTS
8O - 27
THAT
IS CUT,
WARNING: DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLA- TION, OPERATION, OR DAMAGE. REPLACE ANY BELT FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG.
(1) Move the adjacent right or left front outboard seat section (40 percent) to its most forward position for easiest access to the front center seat belt buckle, lap belt lower anchor, or unique black, keyed front center seat belt lower anchor buckle (Fig. 26).
Fig.26FrontCenterSeatBeltRemove/Install
1 - FRONT CENTER SEAT BELT 2 - ELASTIC STRAP 3 - CENTER SEAT SUPPORT BRACKET 4 - INBOARD FRONT SEAT TRACK 5 - SCREW 6 - CENTER SEAT SECTION
(2) From behind the front seat, remove the screw that secures the front center seat belt buckle, lap belt
lower anchor, or unique black, keyed front center seat belt lower anchor buckle to the center seat sup- port bracket.
(3) From the front of the front seat, reach between the center seat cushion and the adjacent right or left front outboard seat cushion to access and remove the front center seat belt buckle, lap belt unit, or unique black, keyed front center seat belt lower anchor buckle through the elastic strap on the side of the center seat cushion.
(4) Remove the front center seat belt buckle, lap belt unit, or unique black, keyed front center seat belt lower anchor buckle from the front seat.
INSTALLATION
A fixed position front center seat belt buckle is located on the left side of the front center seat sec- tion (20 percent) used on all models. Standard cab models also have a unique fixed position black, keyed front center seat belt lower anchor buckle for the three-point center seat belt lower anchor located on the right side of the front center seat section. The fol- lowing procedure also applies to the fixed position front center seat lap belt located on the right side of the front center seat section of all quad cab models. The three-point front center seat belt and retractor unit is only used on standard cab models. (Refer to 8
- ELECTRICAL/RESTRAINTS/FRONT CENTER SEAT BELT & RETRACTOR - INSTALLATION).THAT
IS CUT,
WARNING: DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLA- TION, OPERATION, OR DAMAGE. REPLACE ANY BELT FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG.
(1) From the front of the front seat, position the front center seat belt buckle, lap belt unit, or unique black, keyed front center seat belt lower anchor
RESTRAINTS
8O - 28
FRONT CENTER SEAT BELT (Continued)DR
buckle between the center seat cushion and the adja- cent right or left front outboard seat cushion.
(2) From the front of the front seat, reach between the center seat cushion and the adjacent right or left front outboard seat cushion to route the front center seat belt buckle, lap belt unit lower anchor, or unique black, keyed front center seat belt lower anchor buckle through the elastic strap on the side of the center seat cushion (Fig. 26).
(3) From behind the front seat, position the front center seat belt buckle, lap belt lower anchor, or unique black, keyed front center seat belt lower anchor buckle to the center seat support bracket.
(4) Install and tighten the screw that secures the front center seat belt buckle, lap belt lower anchor, or unique black, keyed front center seat belt lower anchor buckle to the center seat support bracket. Tighten the screw to 40 N·m (29 ft. lbs.).
(5) Move the adjacent right or left front outboard seat section (40 percent) back to its rearward posi- tion.
FRONT OUTBOARD SEAT BELT & RETRACTOR
REMOVAL
REMOVAL - STANDARD CAB
this model.(Refer
The following procedure is for replacement of a faulty or damaged front outboard seat belt and retractor unit, which includes a seat belt tensioner for to 8 - ELECTRICAL/RE- STRAINTS/SEAT BELT TENSIONER - DESCRIP- TION). The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that pre- vents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures.
The seat belt retractor on the driver’s side of stan- dard cab models only also includes a tension reducer. (Refer to 8 - ELECTRICAL/RESTRAINTS/TENSION REDUCER - DESCRIPTION). The seat belt retractor on the passenger’s side of all models includes a swit- chable automatic locking mechanism. (Refer to 8 - ELECTRICAL/RESTRAINTS/AUTOMATIC LOCK- ING RETRACTOR - DESCRIPTION).
If the seat belt or retractor is faulty or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-de- ployed supplemental restraints. (Refer to 8 - ELEC- TRICAL/RESTRAINTS - STANDARD PROCEDURE - HANDLING NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS). If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the front outboard seat belt and retractor from the vehicle. (Refer to 8 - ELECTRI- CAL/RESTRAINTS - STANDARD PROCEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT).
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCON- NECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
THE
THAT
IS CUT,
WARNING: DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLA- TION, OPERATION, OR DAMAGE. REPLACE ANY BELT FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG.
(1) Move the front seat to its most forward position for easiest access to the lower seat belt anchor and the B-pillar trim.
(2) Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service.
DR FRONT OUTBOARD SEAT BELT & RETRACTOR (Continued)
RESTRAINTS
8O - 29
(3) Remove the screw that secures the lower seat
belt anchor to the lower inner B-pillar (Fig. 27).
Fig.27FrontOutboardSeatBelt&Retractor
Remove/Install-StandardCab
1 - ADJUSTER 2 - UPPER TRIM PANEL 3 - TURNING LOOP 4 - SCREW 5 - TRIM COVER 6 - LOWER TRIM PANEL 7 - LOWER ANCHOR 8 - SCREW 9 - SCREW 10 - RETRACTOR 11 - WIRE HARNESS CONNECTOR 12 - SCREW 13 - WEB GUIDE 14 - B-PILLAR
(4) Remove the lower seat belt anchor from the
lower inner B-pillar.
(5) Unsnap and remove the trim cover from the front outboard seat belt turning loop to access the screw that secures the turning loop to the height adjuster on the upper inner B-pillar. Discard the removed turning loop trim cover as it is not intended for reuse.
(6) Remove the screw that secures the seat belt
turning loop to the height adjuster.
(7) Remove the seat belt turning loop from the
height adjuster.
(8) Remove the upper and lower trim from the inner B-pillar. (Refer to 23 - BODY/INTERIOR/B- PILLAR UPPER TRIM - REMOVAL) and (Refer to 23 - BODY/INTERIOR/B-PILLAR LOWER TRIM - REMOVAL).
(9) Remove the screw that secures the seat belt
web guide to the inner B-pillar near the belt line.
(10) Remove the seat belt web guide from the
inner B-pillar.
(11) On the driver side only, disconnect the body wire harness take out and white connector from the connector receptacle for the seat belt tension reducer located near the bottom of the retractor.
(12) Disengage the seat belt tensioner pigtail wire retainer from the hole in the inner B-pillar sheet metal.
(13) Disconnect the yellow seat belt tensioner pig- tail wire connector from the body wire harness take out and connector for the tensioner.
(14) Remove the screw that secures the lower retractor bracket to the lower inner B-pillar below the retractor mounting hole.
(15) Disengage the hooks on the upper retractor bracket from the slots in the lower inner B-pillar above the retractor mounting hole.
(16) Remove the front outboard seat belt and retractor from the retractor mounting hole in the lower inner B-pillar.
REMOVAL - QUAD CAB
The following procedure is for replacement of a faulty or damaged front outboard seat belt and retractor unit, which includes a seat belt tensioner for this model. (Refer to 8 - ELECTRICAL/RE- STRAINTS/SEAT BELT TENSIONER - DESCRIP- TION). The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that pre- vents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures.
The seat belt retractor on the passenger’s side of all models includes a switchable automatic locking mechanism. - ELECTRICAL/RE- STRAINTS/AUTOMATIC LOCKING RETRACTOR - DESCRIPTION).
(Refer
to
If the seat belt or retractor is faulty or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-de- ployed supplemental restraints. (Refer to 8 - ELEC- TRICAL/RESTRAINTS - STANDARD PROCEDURE - HANDLING NON-DEPLOYED SUPPLEMENTAL RESTRAINTS). If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the front outboard seat belt and retractor from the vehicle. (Refer to 8 - ELECTRI- CAL/RESTRAINTS - STANDARD PROCEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT).
RESTRAINTS
8O - 30
FRONT OUTBOARD SEAT BELT & RETRACTOR (Continued)DR
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCON- NECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
THE
THAT
IS CUT,
WARNING: DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLA- TION, OPERATION, OR DAMAGE. REPLACE ANY BELT FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG.
(1) Move the front seat to its most forward position for easiest access to the lower seat belt anchor and the B-pillar trim.
(2) Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service.
(3) Remove the screw that secures the lower seat belt anchor to the floor panel near the base of the inner B-pillar (Fig. 28).
(4) Remove the lower seat belt anchor from the
floor panel near the base of the inner B-pillar.
(5) Unsnap and remove the trim cover from the front outboard seat belt turning loop to access the screw that secures the turning loop to the height adjuster on the upper inner B-pillar. Discard the
Fig.28FrontOutboardSeatBelt&Retractor
Remove/Install-QuadCab
1 - ADJUSTER 2 - UPPER TRIM PANEL 3 - B-PILLAR 4 - TURNING LOOP 5 - SCREW 6 - TRIM COVER 7 - SEAT BELT 8 - LOWER TRIM PANEL 9 - SCREW 10 - LOWER ANCHOR 11 - SCREW 12 - RETRACTOR 13 - WIRE HARNESS CONNECTOR 14 - SCREW 15 - WEB GUIDE
removed turning loop trim cover as it is not intended for reuse.
(6) Remove the screw that secures the seat belt
turning loop to the height adjuster.
(7) Remove the seat belt turning loop from the
height adjuster.
(8) Remove the upper and lower trim from the inner B-pillar. (Refer to 23 - BODY/INTERIOR/B- PILLAR UPPER TRIM - REMOVAL) and (Refer to 23 - BODY/INTERIOR/B-PILLAR LOWER TRIM - REMOVAL).
(9) Remove the screw that secures the seat belt
web guide to the inner B-pillar near the belt line.
(10) Remove the seat belt web guide from the
inner B-pillar.
DR FRONT OUTBOARD SEAT BELT & RETRACTOR (Continued)
RESTRAINTS
8O - 31
(11) Disengage the seat belt tensioner pigtail wire retainer from the hole in the inner B-pillar sheet metal.
(12) Disconnect the yellow seat belt tensioner pig- tail wire connector from the body wire harness take out and connector for the tensioner.
(13) Remove the screw that secures the lower retractor bracket to the lower inner B-pillar below the retractor mounting hole.
(14) Disengage the hooks on the upper retractor bracket from the slots in the lower inner B-pillar above the retractor mounting hole.
(15) Remove the front outboard seat belt and retractor from the retractor mounting hole in the lower inner B-pillar.
INSTALLATION
INSTALLATION - STANDARD CAB
The following procedure is for replacement of a faulty or damaged front outboard seat belt and retractor unit, which includes a seat belt tensioner for this model. (Refer to 8 - ELECTRICAL/RE- STRAINTS/SEAT BELT TENSIONER - DESCRIP- TION). The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that pre- vents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures.
The seat belt retractor on the driver’s side of stan- dard cab models only also includes a tension reducer. (Refer to 8 - ELECTRICAL/RESTRAINTS/TENSION REDUCER - DESCRIPTION). The seat belt retractor on the passenger’s side of all models includes a swit- chable automatic locking mechanism. (Refer to 8 - ELECTRICAL/RESTRAINTS/AUTOMATIC LOCK- ING RETRACTOR - DESCRIPTION).
If the seat belt or retractor is faulty or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-de- ployed supplemental restraints. (Refer to 8 - ELEC- TRICAL/RESTRAINTS - STANDARD PROCEDURE - HANDLING NON-DEPLOYED SUPPLEMENTAL RESTRAINTS). If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the front outboard seat belt and retractor from the vehicle. (Refer to 8 - ELECTRI- CAL/RESTRAINTS - STANDARD PROCEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT).
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCON- NECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
THE
THAT
IS CUT,
WARNING: DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLA- TION, OPERATION, OR DAMAGE. REPLACE ANY BELT FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG.
(1) Position the front outboard seat belt and retractor to the retractor mounting hole in the lower inner B-pillar (Fig. 27).
(2) Engage the hooks on the upper
retractor bracket into the slots in the lower inner B-pillar above the retractor mounting hole.
(3) Install and tighten the screw that secures the lower retractor bracket to the lower inner B-pillar below the retractor mounting hole. Tighten the screw to 40 N·m (29 ft. lbs.).
(4) Reconnect the yellow seat belt tensioner pigtail wire connector to the body wire harness take out and connector for the tensioner.
(5) Engage the seat belt tensioner pigtail wire retainer into the hole in the inner B-pillar sheet metal.
(6) On the driver side only, reconnect the body wire harness take out and white connector to the
RESTRAINTS
8O - 32
FRONT OUTBOARD SEAT BELT & RETRACTOR (Continued)DR
seat belt tension reducer connector receptacle near the bottom of the retractor.
(7) Position the seat belt web guide to its mount- ing location on the inner B-pillar near the belt line. (8) Install and tighten the screw that secures the seat belt web guide to the inner B-pillar. Tighten the screw to 2 N·m (20 in. lbs.).
(9) Reinstall the upper and lower trim onto the inner B-pillar. (Refer to 23 - BODY/INTERIOR/B- PILLAR UPPER TRIM - INSTALLATION) and (Refer to 23 - BODY/INTERIOR/B-PILLAR LOWER TRIM - INSTALLATION).
(10) Position the seat belt turning loop onto the
height adjuster on the upper inner B-pillar.
(11) Install and tighten the screw that secures the seat belt turning loop to the height adjuster. Tighten the screw to 40 N·m (29 ft. lbs.).
(12) Engage the lower snap features of the new trim cover over the front outboard seat belt turning loop and, using hand pressure, press firmly and evenly on the top of the trim cover until it snaps into place.
(13) Position the lower seat belt anchor to the
lower inner B-pillar.
(14) Install and tighten the screw that secures the lower seat belt anchor to the B-pillar. Tighten the screw to 40 N·m (29 ft. lbs.).
(15) Do not reconnect the battery negative cable at this time. The supplemental restraint system verifi- cation test procedure should be performed following service of any supplemental restraint system compo- nent. (Refer to 8 - ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE - VERIFICATION TEST). (16) Move the front seat back to its rearward posi-
tion.
INSTALLATION - QUAD CAB
The following procedure is for replacement of a faulty or damaged front outboard seat belt and retractor unit, which includes a seat belt tensioner for this model. (Refer to 8 - ELECTRICAL/RE- STRAINTS/SEAT BELT TENSIONER - DESCRIP- TION). The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that pre- vents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures.
The seat belt retractor on the passenger’s side of all models includes a switchable automatic locking mechanism. - ELECTRICAL/RE- STRAINTS/AUTOMATIC LOCKING RETRACTOR - DESCRIPTION).
(Refer
to
If the seat belt or retractor is faulty or damaged, but the seat belt tensioner is not deployed, review
the recommended procedures for handling non-de- ployed supplemental restraints. (Refer to 8 - ELEC- TRICAL/RESTRAINTS - STANDARD PROCEDURE - HANDLING NON-DEPLOYED SUPPLEMENTAL RESTRAINTS). If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the front outboard seat belt and retractor from the vehicle. (Refer to 8 - ELECTRI- CAL/RESTRAINTS - STANDARD PROCEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT).
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCON- NECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
THE
THAT
IS CUT,
WARNING: DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLA- TION, OPERATION, OR DAMAGE. REPLACE ANY BELT FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG.
(1) Position the front outboard seat belt and retractor to the retractor mounting hole in the lower inner B-pillar (Fig. 28).
DR FRONT OUTBOARD SEAT BELT & RETRACTOR (Continued)
RESTRAINTS
8O - 33
(2) Engage the hooks on the upper
retractor bracket into the slots in the lower inner B-pillar above the retractor mounting hole.
(3) Install and tighten the screw that secures the lower retractor bracket to the lower inner B-pillar below the retractor mounting hole. Tighten the screw to 40 N·m (29 ft. lbs.).
(4) Reconnect the yellow seat belt tensioner pigtail wire connector to the body wire harness take out and connector for the tensioner.
(5) Engage the seat belt tensioner pigtail wire retainer into the hole in the inner B-pillar sheet metal.
(6) Position the seat belt web guide to its mount- ing location on the inner B-pillar near the belt line. (7) Install and tighten the screw that secures the seat belt web guide to the inner B-pillar. Tighten the screw to 2 N·m (20 in. lbs.).
(8) Reinstall the upper and lower trim onto the inner B-pillar. (Refer to 23 - BODY/INTERIOR/B- PILLAR UPPER TRIM - INSTALLATION) and (Refer to 23 - BODY/INTERIOR/B-PILLAR LOWER TRIM - INSTALLATION).
(9) Position the seat belt turning loop onto the
height adjuster on the upper inner B-pillar.
(10) Install and tighten the screw that secures the seat belt turning loop to the height adjuster. Tighten the screw to 40 N·m (29 ft. lbs.).
(11) Engage the lower snap features of the new trim cover over the front outboard seat belt turning loop and, using hand pressure, press firmly and evenly on the top of the trim cover until it snaps into place.
(12) Position the lower seat belt anchor to the floor
panel near the base of the inner B-pillar.
(13) Install and tighten the screw that secures the lower seat belt anchor to the floor panel near the base of the inner B-pillar. Tighten the screw to 40
N·m (29 ft. lbs.).(14) Do not reconnect the battery negative cable at this time. The supplemental restraint system verifi- cation test procedure should be performed following service of any supplemental restraint system compo- nent. (Refer to 8 - ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE - VERIFICATION TEST). (15) Move the front seat back to its rearward posi-
tion.
FRONT OUTBOARD SEAT BELT BUCKLE REMOVAL
A traveling front outboard seat belt buckle is located on the inboard side of each front outboard seat section (40 percent) used on all models. The seat
belt buckle on the driver’s side front seat for all mod- els also includes a seat belt switch. (Refer to 8 - ELECTRICAL/RESTRAINTS/SEAT BELT SWITCH - DESCRIPTION).
THAT
IS CUT,
WARNING: DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLA- TION, OPERATION, OR DAMAGE. REPLACE ANY BELT FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG.
(1) Move the right or left front outboard seat sec- tion (40 percent) to its most rearward position and tilt the seat back forward for easiest access to the front outboard seat belt buckle lower anchor.
(2) For easiest access to the front outboard seat belt buckle lower anchor on standard cab models, also move the outboard seat section (40 percent) opposite the side from which the buckle is to be removed to its most forward position and tilt the seat back forward.
(3) On standard cab models only, remove the stow- age tray from the rear floor panel behind the seat. (Refer to 23 - BODY/INTERIOR/REAR FLOOR STOWAGE TRAY - REMOVAL).
(4) From behind the front seat on the driver side only, disconnect the seat belt switch pigtail wire con- nector from the seat wire harness take out and con- nector for the switch located below the inboard edge of the driver side inboard seat track just forward of the buckle lower anchor (Fig. 29).
(5) From behind the front seat, remove the screw that secures the front outboard seat belt buckle lower anchor to the bracket on the inboard seat track.
(6) From the front of the front seat, reach between the center seat cushion and the adjacent right or left front outboard seat cushion to access and remove the front outboard seat belt buckle from the seat.
RESTRAINTS
8O - 34
FRONT OUTBOARD SEAT BELT BUCKLE (Continued)DR
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG.
(1) From the front of the front seat, reach between the center seat cushion and the adjacent right or left front outboard seat cushion to position the front out- board seat belt buckle to the seat (Fig. 29).
(2) From behind the front seat, install and tighten the screw that secures the front outboard seat belt buckle lower anchor to the bracket on the inboard seat track. Tighten the screw to 25 N·m (18 ft. lbs.). (3) From behind the front seat on the driver side only, reconnect the seat belt switch pigtail wire con- nector to the seat wire harness take out and connec- tor for the switch located below the inboard edge of the driver side inboard seat track just forward of the buckle lower anchor.
(4) On standard cab models only, reinstall the stowage tray onto the rear floor panel behind the seat. (Refer to 23 - BODY/INTERIOR/REAR FLOOR STOWAGE TRAY - INSTALLATION).
(5) On standard cab models, move the outboard seat section (40 percent) opposite the side from which the buckle was replaced to its most rearward position and tilt the seat back to its upright position.
PASSENGER AIRBAG DESCRIPTION
Fig.30PassengerAirbagDoor
1 - PASSENGER AIRBAG DOOR 2 - PANEL OUTLET (2) 3 - GLOVE BOX DOOR
The rearward facing surface of
the injection molded, thermoplastic passenger airbag door is the most visible part of the passenger airbag (Fig. 30). The passenger airbag door is located above the glove box opening on the instrument panel in front of the front seat passenger seating position. The upper and outboard edges of the airbag door are secured with
Fig.29FrontOutboardSeatBeltBuckleRemove/
Install
1 - DRIVER SIDE FRONT OUTBOARD SEAT BELT BUCKLE 2 - SEAT CUSHION 3 - PIGTAIL WIRE 4 - INBOARD SEAT TRACK 5 - SCREW
INSTALLATION
A traveling front outboard seat belt buckle is located on the inboard side of each front outboard seat section (40 percent) used on all models. The seat belt buckle on the driver’s side front seat for all mod- els also includes a seat belt switch. (Refer to 8 - ELECTRICAL/RESTRAINTS/SEAT BELT SWITCH - DESCRIPTION).
THAT
IS CUT,
WARNING: DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLA- TION, OPERATION, OR DAMAGE. REPLACE ANY BELT FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT
DR PASSENGER AIRBAG (Continued)
seven integral snap features to the instrument panel base trim, while two screws secure the integral inboard mounting flange to the base trim, and four screws secure the lower mounting flange to the upper glove box opening reinforcement to the instrument panel structural support. The passenger airbag door includes two air conditioning panel out- lets and their housings. Each of the panel outlet housings feature four snap features that secure them to the back of the airbag door and two mounting tabs that are also secured with one screw each to the upper glove box opening reinforcement.
integral
Located behind the passenger airbag door within the instrument panel is the passenger airbag unit (Fig. 31). The passenger airbag housing fits into a molded receptacle on the back of the airbag door, where six stamped hook formations on the upper and lower edges of the airbag housing are engaged in six small window openings on the upper and lower flanges of the receptacle to secure the airbag door to the airbag housing. The inboard airbag door fasten- ers and mounting flange are concealed beneath the instrument panel center bezel, while the lower fas- teners and mounting flange are concealed beneath the instrument panel lower surround. The passenger airbag unit is secured by four screws through four brackets (two front and two rear) that are integral to the base of the airbag housing to the instrument panel structural support.
Fig.31PassengerAirbagUnit
1 - DOOR 2 - PANEL OUTLET HOUSING (2) 3 - SNAP FEATURE (7) 4 - REAR BRACKET (2) 5 - PIGTAIL WIRE CONNECTOR 6 - INFLATOR 7 - FRONT BRACKET (2) 8 - HOUSING
The passenger airbag unit used in this model is a Next Generation-type that complies with revised fed- eral airbag standards to deploy with less force than
RESTRAINTS
8O - 35
those used in some prior models. The passenger air- bag unit consists of a stamped and welded metal housing, the airbag cushion, the airbag inflator, and a stamped metal airbag and inflator retainer plate that is secured to the airbag housing with six studs and nuts. The airbag housing contains the airbag inflator and the folded airbag cushion. An approxi- mately 80 centimeter (31.5 inch) wide by 90 centime- ter (35.5 inch) high rectangular fabric cushion is used. The airbag inflator is a non-azide, pyrotechnic- type unit that is secured to and sealed within the air- bag housing. The inflator initiator is connected to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire har- ness.
The passenger airbag includes the airbag door and the two panel outlet housings. This unit cannot be repaired, and must be replaced if deployed, faulty, or in any way damaged.
OPERATION
The passenger airbag is deployed by an electrical signal generated by the Airbag Control Module (ACM) through the passenger airbag squib circuits to the initiator in the airbag inflator. The hybrid-type inflator assembly includes a small canister of highly compressed inert gas. When the ACM sends the proper electrical signal to the airbag inflator, the ini- tiator converts the electrical energy into chemical energy. This chemical energy produces the pressure necessary to rupture a burst disk in the inert gas canister.
The inflator is sealed to the airbag cushion so that all of the released inert gas is directed into the air- bag cushion, causing the cushion to inflate. As the cushion inflates, the passenger airbag door will split at predetermined tear seam lines concealed on the inside surface of the door, then the door will pivot up over the top of the instrument panel and out of the way. Following a passenger airbag deployment, the airbag cushion quickly deflates by venting the inert gas through vent holes within the fabric used to con- struct the back (instrument panel side) of the airbag cushion.
REMOVAL
The following procedure is for replacement of a faulty or damaged passenger airbag. If the airbag is faulty or damaged, but not deployed, review the rec- ommended procedures for handling non-deployed supplemental restraints. (Refer to 8 - ELECTRICAL/ RESTRAINTS - STANDARD PROCEDURE - HAN- DLING SUPPLEMENTAL RESTRAINTS). If the passenger airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment
NON-DEPLOYED
RESTRAINTS
8O - 36
PASSENGER AIRBAG (Continued)before removing the airbag from the vehicle. (Refer to 8 - ELECTRICAL/RESTRAINTS - STANDARD PRO- CEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT).
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCON- NECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
THE
WARNING: WHEN REMOVING A DEPLOYED AIR- BAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG UNIT AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES.
(1) Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service.
(2) Remove the lower surround from the instru- (Refer to 23 - BODY/INSTRUMENT
ment panel. PANEL/LOWER SURROUND - REMOVAL).
(3) Remove the two screws that secure the mount- ing tabs of the two panel outlet housings to the upper glove box opening reinforcement (Fig. 32).
DR
(4) Remove the six screws that secure the inboard and lower flanges of the passenger airbag door to the instrument panel.
(5) Reach through and above the glove box opening to access and remove the two screws that secure the passenger airbag rear brackets to the upper glove box opening reinforcement (Fig. 33).
Fig.33PassengerAirbagRemove/Install
1 - PASSENGER AIRBAG DOOR 2 - UPPER GLOVE BOX OPENING REINFORCEMENT 3 - FRONT BRACKET SCREW (2) 4 - REAR BRACKET SCREW (2)
(6) Reach through and above the glove box opening to access and remove the two screws that secure the passenger airbag front brackets to the instrument panel structural support.
(7) Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper and outboard edges of the passenger airbag door away from the instrument panel far enough to disengage the seven snap features on the door from the receptacles in the instrument panel base trim (Fig. 34).
Fig.32PassengerAirbagDoorScrews
1 - PASSENGER AIRBAG DOOR 2 - PANEL OUTLET SCREW (2) 3 - GLOVE BOX OPENING UPPER REINFORCEMENT 4 - DOOR SCREW (6)
Fig.34PassengerAirbagDoorDisengage
1 - TRIM STICK 2 - PASSENGER AIRBAG DOOR 3 - INSTRUMENT PANEL
(8) Pull the passenger airbag housing and door unit straight back from the instrument panel far enough to access the instrument panel wire harness
DR PASSENGER AIRBAG (Continued)
take out and connector for the airbag inflator located on the inboard side of the housing.
(9) Disconnect the instrument panel wire harness connector for the passenger airbag from the connec- tor receptacle on the airbag inflator.
(10) Remove the passenger airbag and airbag door
from the instrument panel as a unit.
INSTALLATION
The following procedure is for replacement of a faulty or damaged passenger airbag. If the airbag is faulty or damaged, but not deployed, review the rec- ommended procedures for handling non-deployed supplemental restraints. (Refer to 8 - ELECTRICAL/ RESTRAINTS - STANDARD PROCEDURE - HAN- DLING SUPPLEMENTAL RESTRAINTS). If the passenger airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. (Refer to 8 - ELECTRICAL/RESTRAINTS - STANDARD PRO- CEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT).
NON-DEPLOYED
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCON- NECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
THE
WARNING: WHEN REMOVING A DEPLOYED AIR- BAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG UNIT AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES.
WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PAS- SENGER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE PASSENGER AIRBAG CUSHION AND THE PASSENGER AIRBAG DOOR. FAILURE TO
RESTRAINTS
8O - 37
OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOY- MENT.
WARNING: THE PASSENGER AIRBAG DOOR MUST NEVER BE PAINTED. REPLACEMENT PASSENGER AIRBAG UNITS ARE SERVICED WITH DOORS IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE AIRBAG DOOR RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT.
(1) Carefully position the passenger airbag and
airbag door to the instrument panel as a unit.
(2) Reconnect the instrument panel wire harness connector for the passenger airbag to the connector receptacle on the airbag inflator. Be certain that the connector latches are fully engaged.
(3) Position the passenger airbag housing and door
unit into the instrument panel.
(4) Using hand pressure, press firmly and evenly over each of the seven snap features on the upper and outboard edges of the passenger airbag door until they snap into their receptacles in the instru- ment panel base trim.
(5) Reach through and above the glove box opening to install and tighten the two screws that secure the passenger airbag front brackets to the instrument panel structural support (Fig. 33). Tighten the screws to 6 N·m (55 in. lbs.).
(6) Reach through and above the glove box opening to install and tighten the two screws that secure the passenger airbag rear brackets to the upper glove box opening reinforcement. Tighten the screws to 6
N·m (55 in. lbs.).(7) Install and tighten the six screws that secure the inboard and lower flanges of the passenger air- bag door to the instrument panel (Fig. 32). Tighten the screws to 2 N·m (20 in. lbs.).
(8) Install and tighten the two screws that secure the mounting tabs of the two panel outlet housings to the upper glove box opening reinforcement. Tighten the screws to 2 N·m (20 in. lbs.).
(9) Reinstall the lower surround onto the instru- (Refer to 23 - BODY/INSTRUMENT
ment panel. PANEL/LOWER SURROUND - INSTALLATION).
(10) Do not reconnect the battery negative cable at this time. The supplemental restraint system verifi- cation test procedure should be performed following service of any supplemental restraint system compo- nent. (Refer to 8 - ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE - VERIFICATION TEST).
8O - 38
RESTRAINTS
DR
PASSENGER AIRBAG ON/OFF SWITCH DESCRIPTION
connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The molded plastic harness connector insulator is keyed and latched to ensure proper and secure switch electrical connec- tions. The passenger airbag on/off switch cannot be adjusted or repaired and, if faulty or damaged, the switch must be replaced.
OPERATION
The passenger airbag on/off switch allows the cus- tomer to turn the passenger airbag function On or Off to accommodate certain uses of the right front seating position where airbag protection may not be desired. See the owner’s manual in the vehicle glove box for specific recommendations on when to enable or disable the passenger airbag. The Off indicator of the switch will be illuminated whenever the switch is turned to the Off position and the ignition switch is in the On position.
The ignition key is the only key or object that should ever be inserted into the key cylinder actuator of the switch. The on/off switch requires only a par- tial key insertion to fully depress a spring-loaded locking plunger. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. To actuate the passenger airbag on/off switch, insert the ignition key into the switch key actuator far enough to fully depress the plunger, then rotate the actuator to the desired switch position. When the switch key actuator is rotated to its clock- wise stop (the key actuator slot will be aligned with the Off indicator), the Off indicator is illuminated and the passenger airbag is disabled. When the switch is rotated to its counterclockwise stop (the key actuator slot will be in a vertical position), the Off indicator will be extinguished and the passenger air- bag is enabled.
The passenger airbag on/off switch connects one of two internal resistors in series between the passen- ger airbag mux switch sense and passenger airbag mux switch return circuits of the Airbag Control Module (ACM). The ACM continually monitors the resistance in these circuits to determine the switch position that has been selected. When the switch is in the Off position, the ACM provides a ground input to the switch through the passenger airbag indicator driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the Off indicator of the switch.
The ACM will also illuminate the Off indicator of the switch for about seven seconds each time the ignition switch is turned to the On position as a bulb test. The ACM will store a Diagnostic Trouble Code (DTC) for any fault it detects in the passenger airbag
Fig.35PassengerAirbagOn/OffSwitch
1 - SWITCH 2 - FACE PLATE 3 - OFF INDICATOR 4 - KEY CYLINDER ACTUATOR
The passenger airbag on/off switch is standard equipment on all standard cab versions of this model when they are equipped with the dual front airbag system (Fig. 35). This switch is a two-position, resis- tor multiplexed switch with a single integral red Light-Emitting Diode (LED), and a non-coded key cylinder-type actuator. The switch is located in the lower right corner of instrument panel center bezel, near the center of instrument panel to make the Off indicator visible to all front seat occupants. When the switch is in its installed position, the only compo- nents visible through the dedicated opening of the cluster bezel are the switch face plate and nomencla- ture, and the key cylinder actuator. The 9Off9 position of the switch is illuminated when this switch position is selected, while the “On” position of the switch is designated by text imprinted upon the face plate of the switch, but is not illuminated. The remainder of the switch is concealed behind the switch face plate and the instrument panel center bezel.
The passenger airbag on/off switch housing is con- structed of molded plastic and has three integral mounting tabs. These mounting tabs are used to secure the switch to the back of the molded plastic switch face plate with three small screws. The molded plastic face plate also has three integral mounting tabs that are used to secure the switch and face plate unit to the instrument panel center bezel with three additional screws. A molded plastic con- nector receptacle on the back of the switch housing
DR PASSENGER AIRBAG ON/OFF SWITCH (Continued)
RESTRAINTS
8O - 39
on/off switch or Off indicator circuits, and will illumi- nate the airbag indicator in the instrument cluster if a fault is detected. For proper diagnosis of the pas- senger airbag on/off switch or the ACM, a DRBIIIt scan tool is required. Refer to the appropriate diag- nostic information.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCON- NECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE PROPER PRECAUTIONS COULD
