05 Service Info

7/29/2019 05 Service Info

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Updated 4/28/2005

SERVICE INFORMATION UPDATES(Formerly Known as Service Information Tune-Ups)

NEW RELEASES

00 Lubrication & Maintenance

o 1/18/2005 2005 NDo Add statement in Fluid Capacities: **Add 118 ml (4 oz.) of Limited Slip Additive with

Trac-Lok And add asterisk to 9 and 8 rear axle.o Add statement in Fluid types. Note: TRAC LOK differentials require Limited Slip

Additive in the lubricant

03 Differential & Drivelineo 3/7/2005 2005 DRo The air gap specification on the 10 electric locker differential sensor has changed to

5.5 mm plus or minus 0.25 mm ( 0.21 in. plus or minus 0.01 in.)

08 Electricalo 3/7/2005 2004-2005 KJ Libertyo Revised Caution in Restraints for ACM/OCM Removal and Installation procedures.

o 3/21/2005 2005 CS Pacifica, 2005 RS Town & Country, Caravan and Voyagero Restraints. Revised warning in Removal and Installation, and Operation to include an

Ignition-On time of at least one minute before replacing the ORC or OCM. Both theORC and the OCM store OCS calibration data, which they transfer to one anotherduring the first minute of Ignition-On time after one of them is replaced. If bothmodules are replaced at the same time, an irreversible fault will be set in bothmodules.

o 3/17/2005 2001-2004 LH 300M, Concorde and Intrepido Restraints. Service Procedure was changed since the seat back does not have to be

removed from seat bottom to service the seat airbag. Seat airbag Removal andInstallation procedure may be done in the vehicle with seat installed.

o 2/22/2005 2005 LX SRT8o Decklid Latch switch shown wired backwards. Cavity #2 and 3 are now corrected on

page 8w-39-4 (Vehicle Theft Security System), for the Latch-Door-Decklid.

19 Steeringo

1/5/2005 2005 LX SRT8o Added 05 LX SRT8 Column Electrical Diagnosis missing in last release.

23 Bodyo 1/18/2005 2004-2005 HB Durangoo Sunroof installation procedure. Special Tool was canceled. Removed all references

to the cancelled tool and replaced with wording directing technicians to line up thealignment holes by eye.


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PREVIOUS RELEASES

00 Lubrication & Maintenanceo 12/1/04 2005 DR Ram Trucko Change Lube Capacity Table To Include 5.7L Engine G56 Manual Transmission

o 05/10/04 2002 BE Ram Trucko Maintenance Schedule Information Is Located In The Appropriate Owner's Manual.

02 Suspensiono 09/8/04 2002-2005 KJ Libertyo Lower Ball Joint Installation Procedures For The Years 2002 Thru 2005 Will Have A

Note Before Step #1 That Reads: The Plastic Shipping Cover Must Be In Place OverThe Ball Joint Boot While Pressing The Ball Joint Into The Knuckle.

o 03/24/04 2002-2004 DR Light Duty Ram Trucko Stabilizer bar to stabilizer link nut torque specs were changed from 38 N.m (27 Ft lbs)

to a new spec of 27 N.m (20 Ft lbs)

03 Differential & Driveline

o 12/17/04 2005 DR SRT10o Revised 248 RBI Rear Axle Rear Pinion Bearing Installation Procedure To Reflect Use

Of New Special Installation Tool #9679

05 Brakeso 03/16/04 2004 HB Durangoo A Note In The Service Manual Will State:

The ABS G-Sensor Can Be Mounted Incorrectly In The Area Designed For The GPSAntenna, The G-Sensor Will Be Off 90 Degrees; And Not Function Properly.The G-Sensor Is Located Under The Instrument Panel Top Cover. The Sensor MustBe Mounted With The Electrical Connector Facing The Passenger Side Of TheVehicle To Function Properly

o 03/24/04 2002-2004 DR Light Duty Ram Trucko Minimum Rear Rotor Thickness Was 28.39 Mm (1.117 In) The New Minimum Rotor

Thickness Should Be 20.4 Mm (.803 In)

08 Electricalo 11/11/04 2005 JR Sebring/Stratus

o Revision Of Wiring Section Including But Not Limited To Consolidating Schematics,Updated Page References, Corrected Connector Face Graphics, Corrected WireColor And Gauges, And Connector Pin Number Assignments.


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08 Electrical (Cont.)

o 11/23/04 2005 KJ Libertyo Removed Variable Pressure Sensor From Transmission Wiring, Consolidate

Schematic Pages, Update Page References, And Correct Wire Color And Gauges.

o 11/23/04 2005 TJ Wranglero Removed Variable Pressure Sensor From Transmission Wiring, Consolidate

Schematic Pages, Update Page References, And Correct Wire Color And Gauges.

o 10/21/04 2003-2005 ZB Vipero Corrected The Headlamp Horizontal Centerline, Fog Lamp Horizontal Centerline, And

Tire Callouts In The Callout Table For The Headlamp Alignment Graphic.

o 11/23/04 2005 KJ Libertyo Added Warnings And Caution To Spiral Plate Battery Charging Standard Procedure.

Added A Caution In The Gasoline Battery Charging Standard Procedure To Use The

Spiral Plate Procedure For All Diesel Batteries.

o 12/3/04 2003-2004 AN Dakotao PCM Circuit K107 Wire Color Changed From OR To VT/WTo PCM Circuit K106 Wire Color Changed From WT/DG To VT/GY

o 12/3/04 2004 DR Ram Trucko 8w-10-53: Corrected Cavity Numbers On Rear Window Defogger Relayo 8w-15-4: Replaced Transfer Case Selector Switch With 4wd Switcho 8w-15-18: Added Electric Backlite With Ground G303o 8w-31-14: Changed 4wd Switch Cavity Numbers (1, 2) To Letters (A, B)o

8w-34-3: Added Wheel Speed Sensor-Left Front To This Pageo 8w-39-4: Updated Both Instrument Cluster Cavity Numbers From C1 To C3o 8w-48-2: Corrected Rear Window Defogger Relay Internal Schematic, Added Ground

Circuit To Electric Backliteo 8w-53-4: Updated Front Wiper Motor Cavity Qualifiers: Cavity C Is SRT, Cavity B Is

Except SRTo 8w-55-2: Circuit F983 Should Be In Instrument Cluster C3, Cavity 23. Circuit X703

Should Go To Radio C2 Cavity 6.o 8w-63-7, 8w-80-81, 8w-80-82, 8w-80-114: Updated Circuit Function Names In Heated

Seat Sectionso Powertrain Control Module (SRT) Connector Images And Pinout Charts Corrected.

They Were (NGC).o Powertrain Control Module (NGC) Connector Images And Pinout Charts Corrected.

They Were (SRT).


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08 Electrical (Cont.)

o 12/4/04 2004 HB Durangoo Made The Following Changes On 8W-15-7, 8W-64-3, 8W-80-75, 8W-80-105:o Changed Cavity Numbers 1-4 To A-D On Sunroof Switch Connectoro Function Name Of Circuit Q4 Changed From Sunroof Close To Sunroof Vent.

o Function Name Of Circuit Q5 Changed From Sunroof Motor B(+) To Sunroof Close.o 8W-35-2: Changed Function Name Of Circuit D65 From CAN C BUS (-) To CAN C

BUS (+)o 8W-52-2: Changed Wire Color Of Circuit L61 From WT/TN To WT/DG.o 8W-40-3: Changed Wire Color Of Circuit F983 From PK/VT To PK/YL.

o 12/4/04 2005 HB Durangoo 8W-80-26: Switched Cavities A And H On C352 Connector Face Graphic

o 10/28/04 2005 LX 300/Magnum/Chargero Nine Rain Sensor Module DTCs Have Been Added To The 05 Lx 8r-Wipers/Washers-

Electical Diagnostics Section.o B210d-Battery Voltage Low (Rsm),o B210e-Battery Voltage High (RSM),o B2211-Rain Sensor Module Initialization Performanceo B221d-(RSM) Rain Sensor Module Internal,o B2329-Rain Sensor Optical Path 1 Performance,o B232a-Rain Sensor Optical Path 2 Performance,o B232b-Rain Sensor Optical Path 3 Performance,o B232c-Rain Sensor Optical Path 4 Performance,o U0019Can B Bus (RSM)

o

6/21/04 2005 LX 300/Magnumo Added DTC's B2315 Wiper ON/OFF Control Circuit Open And B2319- Wiper HI/LOW

Control Circuit Open To Wipers/Washers Diagnosis And Testing.

o 8/26/04 2004 HB Durangoo Non-Trouble Code Power Door Lock Symptoms Have Been Added To The 2004 HB

Service Info, Diagnosis & Testing.

o 04/26/04 2003 DN Durangoo Multiple Wiring Changes - Removed The Word Off From Function Name Of Circuito A81 And Circuit F11. Function Was Fused Ignition Switch Output (Off-Run-Start). It

Has Been Changed To Fused Ignition Switch Output (Run-Start).

09 Engine

o 11/24/04 2003-2005 JR Sebring/Stratuso 2.0/2.4L Engines. Do not use any sealer on Multi-Layer Steel (MLS) head gaskets

o 11/24/04 2003-2005 PL Neono 1.6/2.0/2.4L Engines. Do not use any sealer on Multi-Layer Steel (MLS) head gaskets


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09 Engine (cont.)

o 11/24/04 2003-2005 PT Cruisero 1.6/2.0/2.4L Engines. Do not use any sealer on Multi-Layer Steel (MLS) head gaskets

o 11/24/04 2003-2005 RS Caravan/Town & Countryo 2.4L Engines. Do not use any sealer on Multi-Layer Steel (MLS) head gaskets

o 2/25/05 2004 DR 5.9L Ram Trucko Added two steps and modify one for top side removal and installation of Turbocharger

o 1/14/05 2005 ZH Crossfireo In Step # 6 Of The P0410 Secondary Air Injection System Diagnostic, The Rcm A

Harness Connector Cavity # 1 Was Changed To Cavity # 2.

o 9/14/04 2004-2005 CS Pacificao Added A Note To Service Manual To Use Adapters 6886 (Shorter Mounting Studs),

(Compression Arm) 6887 Along With Adapter 6885, To Remove Right Cylinder HeadExhaust Valve Springs.

o 9/1/04 2005 JR Sebring/Stratus 2.7L Engineo Rear Main Seal is now serviced as an assembly. Updated installation procedure to

reflect assembly installation.

o 9/1/04 2005 LX 300/Magnum 2.7L, 3.5L Engineso Changed Torque Spec in specification table for oil cooler fastener to 61 Nm (45-ft lbs).

o Changed Torque Spec in Installation procedure for oil cooler fastener torque to 61 Nm(45-ft lbs)

o 7/7/04 2003 DR Ram Truck W/NGC Controllero Added Diagnostics For P0421-Warm Up Catalytic 1/1 Efficiency Below Threshold And

P0431-Warm Up Catalytic 2/1 Efficiency Below Threshold.

o 10/1/04 2005 LX 300/Magnumo The P0457- Loose Fuel Cap Diagnostic Test Is Being Added To The 2005 LX

Powertrain Diagnostic Information

o 10/12/04 2005 LX 300/Magnumo Diagnostic Procedures For Codes: P0440-General Evap System Failure, P0441-Evap

Purge System Performance, P0442-Evap Medium Leak, P0443-Evap Purge SolenoidCircuit, P0452-Nvld Pressure Switch Stuck Closed, P0453-Nvld Pressure SwitchStuck Open, P0455-Evap System Large Leak, P0456-Evap System Small Leak,P0498-Nvld Canister Vent Valve Solenoid Circuit Low, And P0499-Nvld Canister VentValve Solenoid Circuit High Have Been Updated.


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09 Engine (cont.)

o 3/30/04 2004 VA Sprintero Updated Graphic For High Pressure Pump Removal And Installation Procedure.

Powertrain Diagnosticso 8/19/04 2004 JR Sebring/Stratuso The P2098 - Down Stream Fuel System 2/2 Lean And P2099 - Down Stream Fuel

System 2/2 Rich Diagnostic Tests Are Being Added To The 2004 JR PowertrainDiagnostic Information.

o 8/19/04 2004-2005 CS, 2003-2005 RS Caravan/Town & Countryo The P0508 And P0509 Diagnostic Test Callout The Incorrect Circuit Ids For IAC

Return Circuit And The IAC Motor Control Circuit. The Correct Circuit Ids Are AsFollowed: (K961) IAC Return Circuit And (K61) IAC Motor Control Circuit Which IsNow Reflected In The New DTC Test.

o 10/04/04 2001-2003 AB, 2001-2002 BE/BR, 2001-2003 AN, 2001-2003 DN, 2001-2004 WJ, 2001-2004 TJ, 2001 XJ, 2001-2002 SR, 2002-2003 DR, 2003 KJ, 2003 ZB

o Diagnostic Procedures For Codes: P0441-Evap Purge Flow Monitor, P0442-EvapLeak Monitor Medium (0.040) Leak Detected, P0443-Evap Purge Solenoid Circuit,P0455-Evap Leak Monitor Large Leak Detected, P0456-Evap Leak Monitor Small(0.020) Leak Detected, P1486-Evap Leak Monitor Pinched Hose Found, P1494-LeakDetection Pump Switch Or Mechanical Fault, P1495-Leak Detection Pump SolenoidCircuit, Have Been Updated.

o 10/04/04 2002-2003 DN, 2003-2004 AN, 2003-2004 DR, 2004-2005 KJ, 2005 TJ,

2002-2003 LH, 2003-2005 JR, 2003-2005 RS, 2003-2005 PT, 2003-2005 PL, 2003SRT4, 2004 LH, 2004-2005 CS

o Diagnostic Procedures For Codes: P0440-General Evap System Failure, P0441-EvapPurge System Performance, P0442-Evap Medium Leak, P0443-Evap Purge SolenoidCircuit, P0452-Nvld Pressure Switch Stuck Closed, P0453-Nvld Pressure SwitchStuck Open, P0455-Evap System Large Leak, P0456-Evap System Small Leak,P0498-Nvld Canister Vent Valve Solenoid Circuit Low, And P0499-Nvld Canister VentValve Solenoid Circuit High Have Been Updated.

o 7/7/04 2003 DR Ram Trucko Added Diagnostics For P0421 And P0431.

o 8/19/04 2004 JR Sebring/Stratuso The P2098 - Down Stream Fuel System 2/2 Lean And P2099 - Down Stream Fuel

System 2/2 Rich Diagnostic Tests Added To The 2004 JR Powertrain DiagnosticInformation.


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Powertrain Diagnostics (cont.)

o 8/19/04 2003-2005 RS Caravan/Town & Country, 2004-2005 CS Pacificao The P0508 And P0509 Diagnostic Test Callout The Incorrect Circuit Ids For IAC

Return Circuit And The IAC Motor Control Circuit. The Correct Circuit Ids Are As

Followed: (K961) IAC Return Circuit And (K61) IAC Motor Control Circuit Which IsNow Reflected In The New DTC Test.

14 Fuelo 05/10/04 2004 VA Sprintero Fuel System Codes Updated Fuel Quantity Solenoid Diagnostics.o Rain Sensor System Added To Body Diagnostics.o Revised High Pressure Pump Removal & Installation Procedures With Improved

Graphics & Special Tool Reference.o Revised Diagnosis & Testing To Include Leak Quantity Specifications Based On New

Special Tool.

19 Steeringo 2/22/05 2003-2005 VA Sprintero Added Statement To Steering Column Intermediate Shaft Installation Procedure To:

Make Sure To Install The Steering Shaft Universal Joint Onto The Steering Gear ShaftAll The Way Down Until The Hole Lines Up With The Radial Groove In The SteeringShaft.

21 Transmissiono 9/01/04 2005 ZH Crossfireo Transmission Output Shaft Torque Changed From 120 Nm (88.5 Ft. Lbs) To 200 Nm

(147 Ft. Lbs)

o 11/30/04 2005 ND Dakota, DR Ram Trucko Update Specifications By Adding Gear Ratio Table For The Getrag 238 Transmission.

o 11/30/04 2005 DR Ram Trucko Update Specifications By Adding Gear Ratio Table For The G56 Manual

Transmission.

o 11/30/04 2005 KJ Liberty, 2005 TJ Wranglero Update Specifications By Adding Gear Ratio Table For The Nsg350 Manual

Transmission.

o 09/02/04 2003-2005 TJ Wranglero After Installing The Transmission, Apply RTV To The Adapter Slot Located At The Top

Of The Adapter Plate And The Engine


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Transmission Diagnosticso 10/12/04 2003-2004 2004 KJ Liberty, TJ Wranglero DTC P1776 Was Modified To Assist The Technician In Identifying A Misadjusted

Shifter Cable, And/Or If The Shift Lever Was Not Fully Moved Into OD When Paced InGear Thus Causing The Manual Valve To Be In The T2 Position.

23 Body

o 1/14/05 2005 CS Pacificao Removal And Installation Procedures Were Developed For The New Header Bow And

Rear Bow Service Kits.

o 9/21/04 2005 PT Cruisero Convertible Models Now Require Replacement Of The Snap-Type Retaining Clips

When Removing And Reinstalling The Exterior Header Molding.

o 9/01/04 2005 ZH Crossfire

o Updated Door Panel Removal And Installation Procedures.

o 5/10/04 2004 HB Durango, KJ Libertyo Repositioning Of Passive Restraint Warnings.

o 9/1/04 2005 ZH Crossfireo Updated Door Panel Removal And Installation Procedures

Body Diagnosticso 1/21/05 2005 KJ Libertyo Added The Following Dtcs To Support The Premium TPM That Is Equipped On The

2005 KJ. Left Front Tire Pressure Transponder Module Performance, Right Front TirePressure Transponder Module Performance, Right Rear Tire Pressure TransponderModule Performance, Left Front Tire Pressure Transponder Module Voltage High,Right Front Tire Pressure Transponder Module Voltage High And Right Rear TirePressure Transponder Module Voltage High.

o 1/7/05 2004-2005 CS Pacificao The No Response From Driver Door Module Diagnostic Procedure Has Been

Updated. In Step 2 Of Test It Is Only Necessary To Check One Ground Circuit (Cav8) For Continuity To Ground.

o 10/2/04 2004-2005 CS Pacificao Added A Non Trouble Code Test For An Inoperative Power Seat Motor(S) That Has

No DTCs Set.

o 8/25/04 2004 HB Durangoo An Additional Step Has Been Added To Instrument Cluster DTC 2213 Module

Internal Fault To Verify The Proper Operation Of The Instrument Cluster BeforeDiagnosing The DTC.


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Body Diagnostics (cont.)

o 06/21/04 2005 LX 300/Magnumo Added DTCs B2319 And B2315 To Wiper System.

24 Heating & Air Conditioning

o 2/8/05 2005 VA Sprintero Service Procedures For The New High Performance Rear A/C System (Sales Code

H08) Have Been Added To Group 24

o 9/23/04 2002-2005 RS Caravan/Town & Countryo When Servicing The Front Blower Motor, It Is NOT Necessary To Remove The HVAC

Assembly. The Blower Motor Can Be Serviced From Under The Instrument Panel ByRepositioning The Carpet To Access All Retaining Screws.

o 9/14/04 2005 LX 300/Magnumo

New Fresh Air Inlet Housing Requires Stud To Be Removed From Dash Panel PriorTo Installing New Design Housing.

o 08/09/04 1999-2004 LH 300M/Concorde/Intrepid, 2004-2005 JR Sebring/Stratuso Revised Procedures For Diagnostic Trouble Codes For Vehicles With Auto

Temperature Control Systems. The Revised Procedures Include Diagnosis Of TheSun Sensor Circuits As A Possible Cause For Setting A DTC And Diagnosing BlendDoor Feedback Failure, Blend Door Stall Test Failure, Mode Door Feedback Failure,

And Mode Door Stall Test Failure

o 10/18/04 2005 LX 300/Magnumo Torque Specifications And Tightening Patterns For A/C Compressor Mounting Bolts

Have Been Revised. (All Engines)

o 9/10/04 2004 HB Durangoo Added A Cautionary Note Reminding The Technician Not To Exchange A/C Heater

Controls From Vehicle To Vehicle Due To Differences In Software And HardwareBetween Vehicles And Model Years. Updated On-Board Diagnostics And System TestInstructions.

Vehicle Datao 2/1/05 2005 VA Sprintero Updated Vin Decoding Chart To Reflect Additional Manufacturing Codes.

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05 Service Info