Dodge RAM TRUCK 1500 1995 Service Manual page 532

8W - 01 - 6 — — 8W-01 GENERAL INFORMATION—WIRING DIAGRAMS
(1) Verify the problem.
(2) Verify any related symptoms. Do this by per­
forming operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
(3) Analyze the symptoms. Use the wiring dia­
grams to determine what the circuit is doing, where
the problem most likely is occurring and where the
diagnosis will continue.
(4) Isolate the problem area.
(5) Repair the problem.
(6) Verify proper operation. For this step, check for
proper operation of all items on the repaired circuit.
Refer to the wiring diagrams.
WIRING REPAIR
When replacing or repairing a wire, it is important
that the correct gauge be used as shown in the wir­
ing diagrams. The wires must also be held securely
in place to prevent damage to the insulation.
(1) Disconnect battery negative cable.
(2) Remove 1 inch of insulation from each end of
the wire.
(3) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(4) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 11 example 1).
(5) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 11 ex­
ample 2).
(6) Twist the wires together (Fig. 11 example 3).
(7) Solder the connection together using rosin core
type solder only. Do not use acid core solder.
(8) Center the heat shrink tubing over the joint,
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(9) Secure the wire to the existing ones to prevent
chafing or damage to the insulation.
(10) Connect battery and test all affected systems.
TERMINAL/CONNECTOR REPAIR—MOLEX
CONNECTORS
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Insert the terminal releasing special tool 6742
into the terminal end of the connector (Fig. 12).
(4) Using special tool 6742, release the locking fin­
gers on the terminal (Fig. 13).
(5) Pull on the wire to remove it from the connec­
tor.
(6) Repair or replace the connector or terminal as
necessary.
CONNECTOR REPLACEMENT
(1) Disconnect battery.
918W-20
Fig. 11 Wire Repair
SPECIAL TOOL
6742 948W-234
Fig. 12 Molex Connector Repair
(2) Disconnect the connector that is to be repaired
from its mating half/component.
(3) Remove connector locking wedge, if required
(Fig. 14).
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 15, and Fig. 16).
(5) Reset the terminal locking tang, if it has one.
(6) Insert the removed wire in the same cavity on
the repair connector.
(7) Repeat steps four through six for each wire in
the connector, being sure that all wires are inserted
into the proper cavities. For additional connector pin-
out identification, refer to the wiring diagrams.
(8) Insert the connector locking wedge into the re­
paired connector, if required.