I do have tilt. I'll check that whole switch assembly next.

 

Only thing not attached to the engine are valve covers and water pump.


Valve covers'll do it every time!!!

 

Checked the switch. No scorched connections and power to it where it should be.
I'll have to go through the diagnostic steps again to rule it out, but I cleaned the contacts with contact cleaner.
Only thing that looked bad was the steering lock flag that comes out of the back had the tip snapped off, which explains why the steering lock is jacked up and only kind of works.
I'll have to junkyard one of those.
Nothing to do with the no start problem, but it's something wrong I can fix for nothing.

 

Did you find any tight or stretched wires in the column while you had the covers off and in full up tilt?

 

I did not. It was just really really coated in dirt, crumbs, and stuff. It seemed to function normally after I cleaned it and then hit the connectors with contact cleaner. Maybe it was just filled with gak. I don't know. I'm going to keep an eye on it and report back any further dysfunction so anyone using the search function for similar stuff can see how it resolves.

 

Hey, Kraven, didja fix it?

 

Here is some more information. It may or may not the problem you are having. But it is information.

NOTE: BEFORE ATTEMPTING THIS RECALL, REVIEW VIP OR VEHICLE HISTORY TAB TO VERIFY THAT THE RECALL APPLIES TO THIS VEHICLE AND HAS NOT BEEN COMPLETED.




June 2000

Dealer Service Instructions for:


Safety Recall No. 875
Ignition Switch Wiring




Models




1994-1996

(BR)

Dodge Ram Trucks


NOTE: This recall applies only to the above vehicles built at the:
•Warren Assembly Plant ("S" in the 11th VIN position) through April 4, 1996 (MDH 0404XX);
•St. Louis North Assembly Plant ("J" in the 11th VIN position) through March 23, 1996 (MDH 0323XX);
•Lago Alberto Assembly Plant ("M" in the 11th VIN position) through April 14, 1996 (MDH 0414XX); or
•Saltillo Assembly Plant ("G" in the 11th VIN position) through April 14, 1996 (MDH 0414XX).


IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System.




Subject


The ignition switch and/or steering column wiring on about 710,000 of the above vehicles may overheat when the blower motor is operated at high speed for an extended period of time. This can cause stalling, loss of blower motor or power window operation, ABS or airbag lamp illumination or a steering column/instrument panel fire.


Repair


A blower motor relay and overlay harness must be installed to remove the blower motor circuit from the ignition switch. In addition, the ignition switch and electrical connector must be inspected for damage and replaced if necessary.


Parts Information

A.Ignition Switch Wiring Package




Part Number

Description


CBXR8750

Ignition Switch Wiring Package


Each package contains the following components:


Quantity

Description


1

Blower Motor Relay and Overlay Harness


1

Ignition Switch Wiring Pigtail


1

Key Cylinder Retaining Bracket


1

Retaining Bracket Screw


1

Ignition Switch Screw


1

Washer


1

Wiring Clip


3

Push Clips


8

Heat Shrink Tubing


10

Tie Straps


Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Ignition Switch Wiring Packages to service about 10% of those vehicles.
A.Ignition Switch Assembly


Part Number

Description


04326622

Ignition Switch Assembly


Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive two (2) ignition switch assemblies.

Additional ignition switches should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require ignition switch replacement.


Service Procedure

A.Inspect for Blower Motor Relay:

NOTE: Very few vehicles are expected to already be equipped with a blower motor relay.
1.Inspect the brake pedal support bracket for the presence of a blower motor relay attached to the brake lamp switch bracket (Figure 1) or locate a blower motor relay that is secured near the brake pedal bracket with a tie strap.

NOTE: 1995 model year vehicles that were built with original equipment foglamps will have two (2) foglamp relays mounted on this bracket.
2.If a blower motor relay is NOT found, inspect the area near the 84-way bulkhead connector for a WHITE single wire connector with BLACK ends that connects two PINK with BLACK tracer wires (Figure 2). If the connector and wires are present, follow the wiring harness to locate the blower motor relay that is secured under the instrument panel.
3.If a relay was located in either Step 1 or Step 2, verify that this is a blower motor relay as follows:
a.Turn the ignition switch to the ON position.
b.Turn the blower motor on LOW and verify that the blower is operating.
c.Disconnect the relay.

Ø If the blower motor stops, this relay is for the blower motor.

Ø If the blower motor does not stop, this relay is NOT for the blower motor.
d.Turn the ignition switch OFF and connect the relay.

4.ØIf a blower motor relay is NOT present, continue with Section "B – Inspect Ignition Switch and Wiring."

ØIf a blower motor relay is present, no further action is necessary. Return the vehicle to the customer.
A.Inspect Ignition Switch and Wiring:


1.Disconnect the negative battery cable(s).

NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure.
2.Remove the five (5) screws that secure the knee blocker to the lower instrument panel and then remove the knee blocker (Figure 3).
3.Remove the steering column tilt lever by turning it counter-clockwise.
4.Remove the upper and lower steering column covers (Figure 4).
5.Remove the lower steering column shroud (Figure 4).
6.Disconnect the 7-way ignition switch electrical connector (Figure 5).
7.Inspect the 7-way ignition switch connector for heat damage near the 4th and 5th terminals (BLACK with ORANGE tracer and PINK with BLACK tracer wires) (Figure 5).

ØLook for brown or black discoloration of the wire insulation or melting of the wire insulation near the connector.

ØCheck the wiring terminals for discoloration.

Ø(Inspect the connector for indications of melting or deformation.
8.Inspect the ignition switch assembly for heat damage near the 4th and 5th terminals (Figure 6).

ØCheck the ignition switch terminals for discoloration.

ØInspect the ignition switch connector and body for indications of melting or deformation.
9.ØIf the wiring connector and switch assembly are NOT damaged, continue with Section "E – Install Blower Motor Relay and Overlay Harness."

ØIf the 7-way switch wiring connector has indications of heat damage, the ignition switch wiring harness pigtail must be replaced. Continue with Section "C – Replace Ignition Switch Wiring Pigtail."

ØIf the ignition switch assembly has indications of heat damage, the ignition switch assembly and the wiring harness pigtail must be replaced. Continue with Section "C – Replace Ignition Switch Wiring Pigtail."
A.Replace Ignition Switch Wiring Pigtail:

IMPORTANT: Only those vehicles that had wiring and/or ignition switch damage as determined by the inspection in Section "B" require ignition switch wiring pigtail replacement. Very few vehicles are expected to require this repair.
1.Disconnect the ignition switch key-in/halo light electrical connector (Figure 7).
2.Disconnect the clockspring electrical connector from the clockspring (Figure 7).
3.Disconnect the multi-function switch electrical connector (Figure 7).
4.Remove the plastic steering column wiring trough from the steering column. The trough is attached to the column with three push clips.
5.Remove the ignition switch wires from the wiring trough. Remove any tape from the ignition switch wires.
6.Stagger cut all of the ignition switch wires (7) on the vehicle harness side about ½" apart. Make sure that all wires are cut so that the wire splices will be located inside the wiring trough and towards the bottom of the steering column.

NOTE: Splices that are located towards the top of the steering column are more susceptible to damage.
7.Strip about 1" of wire insulation from each wire on the vehicle wire harness.
8.Stagger cut the matching wires on the supplied ignition switch pigtail to match up with the harness side. Allow sufficient length for the soldered connections. Make sure that the overall length of the wiring is the same as the original harness.

NOTE: Be sure to cut the supplied ignition switch pigtail wires so that they match the wire color of the vehicle wire harness. On some vehicles, the YELLOW harness wire matches with the BLUE/YELLOW* vehicle wire and the BLACK harness wire matches with the GRAY/BLACK* vehicle wire.
9.Strip about 1" of wire insulation from each wire on the ignition switch pigtail.
10.Slide a piece of heat shrink tubing onto each wire of the new pigtail.
11.Connect the supplied switch pigtail harness to the vehicle harness by twisting all wire ends together. Be sure to match all wire colors.
12.Solder the twisted wire ends using rosin core solder.

CAUTION: Wire splices must be soldered. Do NOT use solderless connectors.
13.Center the pieces of heat shrink tubing over each of the splices. Heat the tubing with a heat source until sealant comes out each end of the tubing.
14.Connect the multi-function switch electrical connector (Figure 7).
15.Connect the clockspring electrical connector (Figure 7).
16.ØIf the ignition switch was damaged and must be replaced, as determined by the inspection in Section "B," continue with Section "D -- Replace Ignition Switch Assembly."

ØIf the ignition switch was NOT damaged, as determined by the inspection in Section "B," continue with Section "E – Install Blower Motor Relay and Overlay Harness."
A.Replace Ignition Switch Assembly:

IMPORTANT: Only those vehicles that had ignition switch damage as determined by the inspection in Section "B," require ignition switch replacement. Very few vehicles are expected to require this repair.
1.Remove the ignition switch mounting screws (Figure 8). Use a tamper-proof torx bit (Snap-on PN TTXR20A2 or equivalent) to remove the screws.
2.Remove the ignition switch from the steering column.
3.Insert the ignition key into the key cylinder and turn the key to the LOCK position.
4.Depress the key cylinder retaining pin or, if equipped, use the tamper-proof torx bit to remove the key cylinder retaining screw and bracket (Figure 9).
5.Turn the ignition key to the OFF position. The key cylinder will then unseat from the ignition switch. When the key cylinder is unseated, it will be approximately 1/8" away from the ignition switch halo light ring. Do NOT attempt to remove the key cylinder at this time.
6.With the key cylinder unseated, turn the ignition key to the LOCK position and then remove the key.
7.Remove the key cylinder from the ignition switch (Figure 10).
8.Place the new ignition switch in the LOCK position. The switch is in the LOCK position when the column lock flag is parallel to the ignition switch terminals (Figure 11).
9.With the key cylinder in the LOCK position, insert the key cylinder into the new ignition switch until it bottoms.
10.Insert the ignition key into the key cylinder. While gently pushing the key cylinder in toward the ignition switch, rotate the ignition key clockwise to the end of travel (START position) and then back to the LOCK position.
11.If equipped, install the key cylinder retaining bracket and screw (Figure 9). Tighten the screw to 26 in-lbs (3 N×m).
12.Apply a light coating of grease to the ignition switch column lock flag and the park lock dowel pin (Figure 11).
13.Make sure that the transmission gear shift selector is in the PARK position. The park lock dowel pin must be properly indexed before installing the ignition switch (Figure 12).
14.Place the ignition switch against the lock housing opening on the steering column. Ensure that the ignition switch park lock dowel pin enters the slot in the park lock slider linkage in the steering column.
15.Install the ignition switch screws (Figure 8). Tighten the screws to 26 in-lbs (3 N×m).
16.Connect the key-in/halo light electrical connector to the new ignition switch (Figure 7).

NOTE: Do NOT connect the 7-way ignition switch connector.
A.Install Blower Motor Relay and Overlay Harness:


1.Remove the 30-amp fuse from the fuseblock F2 -- Blower Motor location (Figure 13).
2.Remove the TAN wedge from the fuseblock (Figure 13).
3.Remove the BLACK with ORANGE tracer (A22) wire from cavity 11 of the fuseblock (Figure 13); then cut the terminal off and tape the wire back to the harness.
4.Remove the DARK GREEN (C1) wire from cavity 12 of the fuseblock (Figure 13).
5.Disconnect the 84-way bulkhead connector.
6.Remove the cover from the rear of the 84-way connector.
7.Remove the BLUE wedge from the 84-way connector.
8.Remove the PINK with BLACK tracer (A2) wire from cavity 43 of the 84-way bulkhead connector (Figure 14).
9.Remove the RED wedge from the 7-way ignition switch connector (Figure 15).
10.Remove the BLACK with ORANGE tracer (A22) wire from cavity 5 of the 7-way ignition switch connector (Figure 15). Then, remove the wire from the wiring takeout bundle back to the base of the steering column.
11.Install the supplied blower relay wiring harness so that the X-wrap is located near the base of the steering column (Figure 16). Secure the harness with a tie strap.
12.Install the PINK with BLACK tracer blower relay harness wire (with a blade terminal) into cavity 43 of the 84-way connector (Figure 14 and Figure 16).
13.Install the BLUE wedge into the 84-way connector.
14.Install the cover onto the rear of the 84-way connector.
15.Connect the 84-way bulkhead connector.
16.Disconnect the WHITE electrical connector on the blower relay harness. Install the PINK with BLACK tracer wire that was removed from the 84-way connector into the WHITE connector opening (Figure 16). Reconnect the WHITE connector. Secure the connector near the bulkhead connector with a tie strap.
17.Install the BLACK with ORANGE tracer blower relay harness wire into cavity 5 of the 7-way ignition switch connector (Figure 16).
18.Disconnect the BLACK 2-way electrical connector on the blower relay harness (Figure 16). Remove the BLUE wedge and then install the BLACK with ORANGE tracer wire that was removed from the ignition switch connector into cavity 2 of the BLACK connector. Install the wedge and reconnect the BLACK 2-way connector. Secure the connector and any excess wiring near the base of the steering column with a tie strap.
19.Cut off the terminal and then strip about 1" of wire insulation from the end of the DARK GREEN wire that was removed from the fuseblock earlier.
20.Strip about 1" of wire insulation from the end of the DARK GREEN with WHITE blower relay harness wire (Figure 16).
21.Slide a piece of heat shrink tubing onto the wire.
22.Connect the DARK GREEN and DARK GREEN with WHITE tracer wires by twisting the wire ends together.
23.Solder the twisted wire ends using rosin core solder.

CAUTION: Wire splice must be soldered. Do NOT use a solderless connector.
24.Center the piece of heat shrink tubing over the splice. Heat the tubing with a heat source until sealant comes out each end of the tubing.
25.Install the DARK GREEN blower relay harness wire into cavity 12 of the fuseblock (Figure 16).
26.Install the PINK with BLACK tracer blower relay harness wire into cavity 11 of the fuseblock (Figure 16).
27.Install the TAN fuseblock wedge (Figure 13).
28.Reinstall the 30-amp fuse in the fuseblock F2 – Blower Motor location (Figure 13).
29.Disconnect the ground eyelet near the airbag squib connector (Figure 17).
30.Double stack the ground eyelet on the BLACK blower relay harness wire onto the ground screw. Install the ground screw and tighten securely.
31.Attach the blower relay onto one of the horizontal relay mounting tabs on the bracket located on the brake pedal support just above the brake lamp switch and pedal (Figure 18).

NOTE: For early 1994 model year vehicles that do not have a relay bracket or if two relays are already attached to the bracket, secure the relay to the wiring harness with a tie strap.
32.Re-tape all of the portions of the ignition switch wiring harness from which tape was removed.
33.Position the ignition switch wires back inside of the wiring trough.
34.Snap the steering column wiring trough back on to the steering column using the supplied clips as necessary.
35.Connect the 7-way ignition switch electrical connector.
36.Install the lower steering column shroud (Figure 4).
37.Install the upper and lower steering column covers (Figure 4).
38.Install the steering column tilt lever (Figure 4).
39.Install the knee blocker and tighten the screws securely (Figure 3).
40.Connect the negative battery cable(s).
41.Verify that the blower motor operates properly.


Completion Reporting and Reimbursement


Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments.

Use one of the following labor operation numbers and time allowances:


Labor Op. No.

Description

Time


08875181

Inspect for blower motor relay

0.2 hours


08875182

Install blower relay/overlay harness

0.7 hours


08875183

Install blower relay/overlay harness and replace the ignition switch wiring pigtail

1.2 hours


08875184

Install blower relay/overlay harness, replace the ignition switch wiring pigtail and the ignition switch assembly

1.4 hours

 

Jeez. That sounds serious. Thanks for the TSB. I need to see if I can get the build sheet and service history for this pile.

Yes, the problem is fixed for now. The truck starts and cranks just fine, and does so under various temps and conditions. I did just get the rear end put back together, so I'll be road testing it pretty soon. I'll update if there are any changes.

 

thanks for letting us know