Dodge Ram Truck 1500-2500-3500. Manual - part 563

INSTALLATION

WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental
restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact
sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative
(ground) cable, then wait two minutes for the system capacitor to discharge before performing further diag-
nosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the
proper precautions could result in accidental airbag deployment.

1. Position the passenger airbag on/off switch and

face plate unit (3) to the back of the center bezel
(1).

2. Install and tighten the three screws (2) that secure

the passenger airbag on/off switch face plate to the
back of the center bezel. Tighten the screws to 2
N·m (17 in. lbs.).

3. Reinstall the center bezel onto the instrument

panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL - INSTAL-
LATION).

4. Do not reconnect the battery negative cable at this

time. The supplemental restraint system verification
test procedure should be performed following ser-
vice of any supplemental restraint system compo-
nent. (Refer to 8 - ELECTRICAL/RESTRAINTS -
STANDARD PROCEDURE - VERIFICATION TEST).

AIR BAG-PASSENGER

DESCRIPTION

The rearward facing surface of the injection molded,
thermoplastic passenger airbag door (1) is the most
visible part of the passenger airbag. The passenger
airbag door is located above the glove box opening on
the instrument panel in front of the front seat passen-
ger seating position.

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SRT-10 models also have a unique instrument panel
trim bezel (3) with the SRT-10 logo secured to the
lower edge of the airbag door (1).

The upper and outboard edges of the airbag door (1)
are secured with seven integral snap features (3) 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
integral to the instrument panel structural support. The
passenger airbag door includes an air conditioning
panel outlet and housing (2). The panel outlet housing
features four snap features that secure it to the back
of the airbag door and a mounting tab that is also
secured with one screw to the upper glove box open-
ing reinforcement.

Located behind the passenger airbag door within the instrument panel is the passenger airbag unit. The passenger
airbag housing (8) 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 fasteners
and mounting flange are concealed beneath the instrument panel center bezel, while the lower fasteners and
mounting flange are concealed beneath the instrument panel lower surround. The passenger airbag unit is secured
by four screws through two front (7) and two rear (4) brackets integral to the base of the airbag housing to the
instrument panel structural support.

The passenger airbag unit used in this model is a multistage, Next Generation-type that complies with revised fed-
eral airbag standards to deploy with less force than those used in some prior models. The passenger airbag unit
consists of a stamped and welded metal housing, the airbag cushion, the airbag inflator initiators (6), 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 approximately 80 centimeter (31.5 inch) wide
by 90 centimeter (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 airbag housing. A
short four-wire pigtail harness with a keyed, yellow connector insulator (5) connects the two inflator initiators to the
vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness.

The passenger airbag includes the airbag door, the panel outlet housing and for SRT-10 models only, the instrument
panel trim bezel. This unit cannot be repaired, and must be replaced if deployed, faulty, or in any way damaged.

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OPERATION

The multistage passenger airbag is deployed by electrical signals generated by the Airbag Control Module (ACM)
through the passenger airbag squib 1 and squib 2 circuits to the two initiators in the airbag inflator. By using two
initiators, the airbag can be deployed at multiple levels of force. The force level is controlled by the ACM to suit the
monitored impact conditions by providing one of four delay intervals between the electrical signals provided to the
two initiators. The longer the delay between these signals, the less forcefully the airbag will deploy.

When the ACM sends the proper electrical signals to each 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
chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the airbag cushion
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 passenger airbag door will split at predetermined tear seam lines concealed on the inside sur-
face of the door, then the door will pivot up over the top of the instrument panel and out of the way. Following an
airbag deployment, the airbag cushion quickly deflates by venting the inert gas through vent holes within the fabric
used to construct the back (instrument panel side) of the airbag cushion.

Typically, both initiators are used during an airbag deployment event. However, it is possible for only one initiator to
be used during a deployment due to an airbag system fault; therefore, it is necessary to always confirm that both
initiators have been used in order to avoid the improper disposal of potentially live pyrotechnic materials. (Refer to
8 - ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT
DEPLOYMENT).

REMOVAL

WARNING: To avoid personal injury or death, when removing a deployed airbag, rubber gloves, eye protec-
tion, 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.

NOTE: 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 recommended procedures for handling non-deployed sup-
plemental restraints. (Refer to 8 - ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE - HANDLING NON-
DEPLOYED 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 PROCEDURE - SERVICE AFTER A
SUPPLEMENTAL RESTRAINT DEPLOYMENT).

1. Disconnect and isolate the battery negative cable.

Wait two minutes for the system capacitor to dis-
charge before further service.

2. Remove the lower surround from the instrument

panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
LOWER SURROUND - REMOVAL).

3. Remove the screw (2) that secures the mounting

tab of the panel outlet housing to the upper glove
box opening reinforcement (3).

4. Remove the six screws (4) that secure the inboard

and lower flanges of the passenger airbag door (1)
to the instrument panel.

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5. Reach through and above the glove box opening to

access and remove the two screws (4) that secure
the passenger airbag rear brackets to the upper
glove box opening reinforcement (2).

6. Reach through and above the glove box opening to

access and remove the two screws (3) that secure
the passenger airbag front brackets to the instru-
ment panel structural support.

7. Using a trim stick (1) or another suitable wide flat-

bladed tool, gently pry the upper and outboard
edges of the passenger airbag door (2) away from
the instrument panel (3) far enough to disengage
the seven snap features on the door from the
receptacles in the instrument panel base trim.

8. Pull the passenger airbag housing and door unit

straight back from the instrument panel far enough
to access the instrument panel wire harness take
out and connector for the airbag located on the
inboard side of the airbag housing.

9. Disconnect the passenger airbag pigtail wire con-

nector from the instrument panel wire harness con-
nector for the airbag. To disconnect the connector:

a. Slide the red Connector Position Assurance

(CPA) lock on the connector toward the side of
the connector.

b. Depress the connector latch tab and pull the two halves of the connector straight away from each other.

10. Remove the passenger airbag and airbag door from the instrument panel as a unit.

INSTALLATION

WARNING: To avoid personal injury or death, the passenger airbag door must never be painted. Replace-
ment 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.

WARNING: To avoid personal injury or death, the trim bezel on the lower edge of the passenger airbag door
on SRT-10 models must never be removed or transferred to another passenger airbag door. Replacement
passenger airbag units are serviced with doors that include a replacement trim bezel. Failure to observe
this warning could result in trim bezel separation and occupant injuries upon airbag deployment.

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