INSTALLATION GUIDE 1998.5-2002 98.5-02 DODGE RAM 24V 5.9L CUMMINS
1998.5-2002 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 24V 5.9L CUMMINS TABLE OF CONTENTS SECTION 1 Boost Gauge Installation 1 SECTION 2 Pyrometer/EGT Gauge Installation 3 SECTION 3 Transmission Temp Gauge Installation 4 SECTION 4 Fuel Pressure Gauge Installation 5 SECTION 5 Preparing The Pillar Pod 6 SECTION 6 Mounting The Pillar Pod 7 SECTION 7 Connecting to Power 8 • Safety Glasses & Gloves • Assorted Wrenches • Socket Set • Flat Head Screwdriver • Phillips Screwdriver • Center Punch • Marker • Drill & Drill Bits • Tap Handle • Tape Measure • Multi-Meter/Test Light • Wire Strippers & Crimper • 3 Gauge Wiring Kit • Boost Bolt Adapter • Banjo Bolt & Snubber Valve Combo Adapter • Transmission Test Port Adapter • Shop Vacuum • Pen Magnet • Panel Pop Tool • Cutting Oil • Pick Tool • Zip Ties • Grommet • Drain Pan • Teflon Tape • Wire Connectors • Anti-Seize • Transmission Fluid • Expandable Circuits • 1/8-27 NPT Drill and Tap set TOOLS & ACCESSORIES NOT INCLUDED OPTIONAL ADD-ONS AND ADAPTERS SOLD SEPARATELY AT GLOWSHIFT.COM GlowShift Installation Guides are designed so that you don’t need to be a professional mechanic to install our products. Whether you’re a beginner or a seasoned pro, we’ll walk any Do-It-Yourselfer through every step of the process for installing our gauges, gauge pods and accessories. The custom gauge package featured in this guide is a popular combination gauge and pod set for the 1998.5-2002 Dodge Ram 2500 & 3500 with a 24v 5.9L Cummins. Before getting started, confirm you have the tools and accessories below and let’s get to work. CHECK OUT THE FULL INSTALL VIDEO FOR THIS CUMMINS: GLOWSHIFT.COM/9802RAM For MaxTow® Gauges, the wire colors on the gauge power harnesses are different than what appears in this installation guide. Additionally, for the Boost Gauge, please follow the same steps but instead of installing the brass compression fittings and boost line, thread the 1/8-27 NPT boost sensor into your desired location and tighten with a 22mm Wrench. Please note that in some applications additional adapters may also be required.
1998.5-2002 INSTALLATION GUIDE 1 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 24V 5.9L CUMMINS Boost Gauge Installation SECTION 1 PREPARING THE INSTALLATION • Check that you have all parts required for installation, and that the engine is cool. • Open the hood and locate the truck’s batteries. Using a wrench, disconnect the negative terminal of each battery to ensure there is no power running through the truck during the installation. Note: When it comes time to wire and connect the gauges to their power source, we will reconnect the negative terminals on the batteries. The boost gauge can be installed one of two ways: using a boost bolt adapter that threads into the intake manifold horn or by drilling and tapping the intake manifold horn using GlowShift’s drill and tap kit that comes with a size R drill bit and a 1/8-27 NPT tap. OPTION A: BOOST BOLT INSTALLATION 1. The boost gauge can be installed by using a boost bolt adapter that threads directly to the intake manifold horn and replaces the front inner intake heater grid bolt. 2. Locate and remove the front inner intake heater grid bolt using a 10mm Socket. 3. Thread the boost bolt adapter where you removed the front inner intake heater grid bolt and tighten using a 5/8” Wrench. Note: Torque to 12ft lbs using a Torque Wrench. 4. Prepare the boost hose for installation by installing the compression nut and ferrule fitting over the boost hose. Note: Wrap Teflon tape clockwise on the male threads. 5. Install the compression adapter into the boost bolt adapter using an 11mm Wrench. Using a 3/8” Wrench, tighten the compression nut until the boost hose is snug. Note: Do not overtighten. 6. Route the boost hose up to the firewall to the driver side of the engine bay and use zip ties to secure the boost hose to ensure there is no contact with any direct heat source or moving parts of the truck. 2. 3. 4.
1998.5-2002 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 2 DODGE RAM 24V 5.9L CUMMINS 3. 4. 6. OPTION B: DRILLING AND TAPPING THE INTAKE MANIFOLD 1. The boost gauge can also be installed by drilling and tapping the intake manifold horn to 1/8-27 NPT. First, mark the drilling location on the intake manifold horn using a Marker and a Center Punch. 2. Remove the intake manifold horn from the truck to ensure no shavings enter the intake during the drilling and tapping process. 3. Starting with a 1/8” Drill Bit, drill your pilot hole into the intake manifold horn and gradually step up in drill bit size until you reach the size R Drill Bit. 4. Take the 1/8-27 NPT Tap and slowly tap the size R hole in the intake manifold horn. Clean the manifold horn with a Vacuum to remove all shavings. 5. Prepare the boost hose for installation by installing the compression nut and ferrule fitting over the boost hose. Tip: Wrap Teflon tape clockwise on all male threads. 6. Install the compression adapter into the 1/8-27 NPT hole you tapped using an 11mm Wrench. Using a 3/8” Wrench, tighten the compression nut onto the fitting until the boost hose is snug. Note: Do not overtighten. 7. Route the boost hose up to the firewall to the driver side of the engine bay and use zip ties to secure the boost hose to ensure there is no contact with any direct heat source or moving parts of the truck. PROPER ORIENTATION
1998.5-2002 INSTALLATION GUIDE 3 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 24V 5.9L CUMMINS Pyrometer/EGT Gauge Installation SECTION 2 4. 5. 8. 1. Make sure the exhaust is cooled off before starting this process. 2. We are going to install the EGT probe in a pre-turbo location on the manifold to ensure the most accurate readings. Installing the EGT probe to any other location can cause significantly inaccurate readings. Optional: To install the EGT probe, we are going to use GlowShift’s Drill and Tap Kit. 3. Locate the exhaust manifold on the passenger side of the engine bay. You will see there is a collector between cylinder 4 and 5. Using a Center Punch, mark the location on the manifold where you are going to drill a hole for the EGT Probe. The hole’s location should be on the left side of the collector closer to cylinder 5. Note: There is a divider in the middle, so you will need to drill off to the side to ensure that it is an unobstructed hole. 4. Starting with a 1/8” Drill Bit, drill your pilot hole into the manifold and gradually step up in drill bit size until you reach the size R drill bit. Note: Clean the manifold with a Pen Magnet and Vacuum to ensure no shavings are present in the manifold. 5. Take the 1/8-27 NPT Tap and slowly tap the size R hole in the manifold using cutting oil. Again, clean the manifold with a Pen Magnet and Vacuum to remove all shavings. 6. We recommend using anti-seize on all EGT probe threads. Using a 14mm Wrench, slowly thread the ferrule fitting adapter into the 1/8-27 NPT hole you just tapped and tighten until snug. Note: Do not overtighten the ferrule fitting. 7. Slide the EGT probe into the ferrule fitting adapter and tighten until snug using a 14mm Wrench. Note: Probe depth should be in the center of the manifold. 8. Now that the EGT probe is installed, run the lead wires up to the firewall to the driver side of the engine bay and secure the wires using Zip Ties to ensure there is no contact with any direct heat source or moving parts of the truck.
1998.5-2002 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 4 DODGE RAM 24V 5.9L CUMMINS Transmission Temp Gauge Installation SECTION 3 1. Safely jack up the truck, if not raised already. Locate the middle test port plug on the passenger side of the transmission case. Using an 11mm Wrench, remove the test port plug. Note: Have a drain pan available for any fluid that will leak from the fitting. 2. Wrap Teflon Tape clockwise around the male threads of the sensor and test port extender adapter. Thread the sensor into the test port extender adapter and tighten using a 17mm Wrench and 14mm Wrench. 3. Thread the test port extender with the sensor attached into the transmission test port and tighten using a 17mm Wrench. 4. Connect the signal wire of the gauge to the white wire of the temperature sensor and connect the black wire of the sensor to any reliable grounding location. 5. Route the wires up to the firewall on the driver side of the engine bay and use Zip Ties to secure the sensor wires to ensure there is no contact with any direct heat source or moving parts. 1. 2. 3. TEST PORT EXTENDER
1998.5-2002 INSTALLATION GUIDE 5 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 24V 5.9L CUMMINS Fuel Pressure Gauge Installation SECTION 4 3. 4. 6. 1. The fuel pressure gauge will be installed to the fuel filter housing using a Banjo Bolt & Snubber Valve Adapter. Note: A snubber valve is required to install a fuel pressure gauge into a Dodge Cummins. The snubber valve regulates, normalizes and eliminates fuel pressure spikes that are present during the initial ignition and startup of the Dodge Cummins diesel engine. 2. Locate the fuel filter housing and drain the fuel. Note: Have a drain pan available to catch the fuel. 3. Remove the factory banjo bolt from the bottom of the fuel filter housing using a 17mm Wrench. The factory Banjo Bolt can be accessed from the driver side wheel well area. Note: Have a drain pan available for any remaining fuel that will leak from the housing and make sure to remove both crush washers from the line and/or fuel filter housing. 4. Place a new copper crush washer on the Banjo Bolt & Snubber Valve Adapter. Slide the Banjo Bolt & Snubber Valve Adapter into the banjo fitting and then place the second copper crush washer on the Adapter, so there is one crush washer on each side of the banjo fitting. Thread into the bottom of the fuel filter housing and tighten using a 19mm Torque Wrench. Torque to 18 foot pounds. 5. Thread the fuel pressure sensor into the Banjo Bolt & Snubber Valve Adapter and tighten with a 22mm wrench. Note: Tighten until snug to avoid any fuel leaks. 6. Insert the sensor harness into the sensor until the harness clips in place. Route the sensor harness up to the firewall to the driver side of the engine bay and use Zip Ties to secure the sensor harness to ensure there is no contact with any direct heat source or moving parts.
1998.5-2002 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 6 DODGE RAM 24V 5.9L CUMMINS Preparing The Pillar Pod SECTION 5 OPTION A: WITHOUT SPEAKER CUTOUT 1. Remove the factory trim by pulling and releasing the spring clips. 2. Insert the supplied plastic clip into the upper oval hole of the truck cab where the spring clip was secured. OPTION B: WITH SPEAKER CUTOUT OPTION 1. Remove the factory trim by pulling and releasing the spring clips. 2. Remove the speaker from the trim using a flat blade screwdriver. 3. Remove the speaker grill from the trim and install in the pod. Clip the speaker back into the speaker grill. 4. Insert the supplied plastic clip into the upper oval hole of the truck cab where the spring clip was secured. 1. Wrap Teflon Tape clockwise around the brass fitting on the back of the Boost Gauge, then attach the female brass fitting for the boost line using a 13mm wrench. Note: Do not overtighten the fitting. 2. Feed the wires from each gauge into the pillar pod. 3. Insert each gauge into the pod. 4. If using a 3 Gauge Wiring Harness, attach all of the wires. 5. Connect all yellow wires together using a splice connector. 6. Connect all red wires together using a splice connector. 7. Connect all orange wires together using a splice connector. 8. Connect all black wires together using a splice connector. 9. Secure all wires with Zip Ties. A2. & B4. 4.– 8. 1X..
1998.5-2002 INSTALLATION GUIDE 7 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 24V 5.9L CUMMINS 1. Now that all of your gauges are mounted, you can proceed with the installation of your pillar pod. 2. Remove the lower dash panel using a Phillips-head screwdriver in order to cleanly route the wires. 3. Route the wires through the firewall and into the cab of the truck, keeping clear of any moving parts. Note: You may need to drill a hole in the firewall if there isn’t one already. It is important to use a grommet on the hole to ensure the wires are not sliced or cut on the firewall. 4. Insert the boost line into the Ferrule Fitting Adapter, thread onto the back of the gauge and tighten with a 3/8” wrench. (Refer to diagram below) Note: Do not overtighten the Ferrule Fitting. 5. Plug the EGT Sensor Harness into the back of the EGT Gauge. (If used) 6. Plug the Fuel Pressure Sensor Harness into the back of the Fuel Pressure Gauge. (If used) 7. Splice the green signal wire from the Transmission Temperature Gauge to the green signal wire from the sensor. (If used) 8. Mount the pillar pod to the truck cab A-pillar, securing it to the installed plastic clip with the supplied screw. Mounting The Pillar Pod SECTION 6 3. 4. 7. PROPER ORIENTATION
1998.5-2002 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 8 DODGE RAM 24V 5.9L CUMMINS Connecting to Power SECTION 7 1. Attach expandable circuits to both the yellow wire and the red wire. 2. Remove the fuse from fuse location 14 for the cluster B circuit. Plug the fuse into the open section of the expandable circuit for the yellow wire and install it in the fuse box. 3. Remove the fuse from fuse location 8 for the radio circuit. Plug the fuse into the open section of the expandable circuit for the red wire and install it in the fuse box. 4. Using a #2 Phillips-head screwdriver, remove the cup holder and ashtray slides and carefully remove the dash trim. Remove the headlight switch as well. 5. Route the orange wire to the headlight switch: OPTION A: PUSH/PULL STYLE HEADLIGHT SWITCH ASSEMBLY 1. Using a #2 Phillips head screwdriver, remove the screw at the power plug and carefully remove the dash trim and headlight switch. 2. Route the orange wire to the headlight switch. Splice into the solid green wire to obtain the correct voltage for the dimming feature of the gauges. 3. Reinstall the headlight switch and the dash trim. 2.–3. A2. A3.
1998.5-2002 INSTALLATION GUIDE 9 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 24V 5.9L CUMMINS B6. B2. 8. 10. OPTION B: TWIST STYLE HEADLIGHT SWITCH ASSEMBLY 1. Using a #2 Phillips head screwdriver, remove the screw at the power plug and carefully remove the dash trim and headlight switch. 2. Route the orange wire to the headlight switch. Splice into the black wire with a yellow strip located at pin #1 in the headlamp switch connector, in order to obtain the correct voltage for the dimming feature of the gauges. 3. Reinstall the headlight switch and the dash trim. 4. Reconnect the batteries and test the operation of the gauges. 5. Power the truck to ensure the gauges are functioning properly and check for any leaks or loose sensor connections. 6. Reinstall the headlight switch and dash trim. 6. Connect the black wire to a reliable, clean and unpainted ground source. 7. Reinstall the lower dash trim. 8. Reconnect the negative cables of both batteries by tightening with a wrench. 9. Power up the truck to see if the gauges are functioning properly and check for any leaks or loose sensor connections. With the vehicle running, cycle through the gears to help the transmission fluid circulate through the transmission. Top off any fluids if necessary. 10. Press the Color Changing Button on the gauges to ensure they are working correctly. 11. Test drive your vehicle to ensure all gauges are functioning properly. Note: The Boost Gauge will only read while driving.
2-23 ADDRESS: 444 COMMERCE LANE SUITE A • WEST BERLIN, NJ 08091 EMAIL: TECHSUPPORT@GLOWSHIFTGAUGES.COM PHONE: 1.888.GS.GAUGE WEB: WWW.GLOWSHIFT.COM
RkJQdWJsaXNoZXIy MTIxODAy