2003-2009 Dodge Ram Install Guide

INSTALLATION GUIDE 03-09 DODGE RAM 24V 5.9/6.7L CUMMINS 2003-2009

2003-2009 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 24V 5.9/6.7L CUMMINS TABLE OF CONTENTS SECTION 1 Boost Gauge Installation 1 SECTION 2 Pyrometer EGT Gauge Installation 3 SECTION 3 Transmission Temperature Gauge Installation 4 SECTION 4 Fuel Pressure Gauge Installation 6 SECTION 5 Rail Pressure Gauge Installation 7 SECTION 6 Installing The Pillar Pod 8 SECTION 7 Connecting to Power 9 • Safety Glasses & Gloves • Assorted Wrenches • Socket Set • Flat Head Screwdriver • Phillips Screwdriver • Center Punch • Marker • Drill & Drill Bits • Tap Handle • Multi-Meter/Test Light • Wire Strippers & Crimper • Shop Vacuum • 3 Gauge Wiring Kit • Boost Bolt Adapter • Banjo Bolt/Snubber Valve • 1/2" Transmission T-Fitting • Transmission Test Port Adapter • Inline Rail Pressure Pigtail Harness • Pen Magnet • Panel Pop Tool • Cutting Oil • Pick Tool • Zip Ties • Grommet • Drain Pan • Teflon Tape • Wire Connectors • Anti-Seize • Transmission Fluid • Mini-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 2003-2009 Dodge Ram 2500 & 3500 with a 24v 5.9L or 6.7L Cummins. Before getting started, confirm you have the tools and accessories below and let’s get to work. 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. CHECK OUT THE FULL INSTALL VIDEO FOR THIS DURAMAX: GLOWSHIFT.COM/0309CUMMINS

2003-2009 INSTALLATION GUIDE 1 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 24V 5.9/6.7L CUMMINS 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, you will be able to reconnect the negative terminals on the batteries. Note: If you are installing a MaxTow Boost Gauge, you will be installing an electronic Boost Pressure Sensor and Harness instead of the Boost Line and Ferrule Fittings. 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 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: 1. Remove the engine cover using an 8mm Socket. 2. Locate and remove the front inner intake heater grid bolt using a 10mm Socket with extension. 3. Attach the compression adapter to the Boost Bolt using a 17mm Wrench and 11mm Wrench. Note: Use Teflon Tape on the 1/8-27 NPT threads. 4. Install the Boost Bolt assembly using a 17mm Wrench and torque to 10 foot-pounds using a Torque Wrench. 5. Insert the boost line fitting cap on the boost line followed by the ferrule. 6. Insert the boost line into the boost line fitting and tighten the cap with a 3/8” wrench. (Refer to diagram) 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 hose. Ensure there is no contact with any direct heat source or moving parts of the truck. Boost Gauge Installation SECTION 1 2. 3. 6. BOOST BOLT ADAPTER

2003-2009 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 24V 5.9/6.7L CUMMINS 2 3. 1. 4. 5. 6. OPTION 2: DRILLING AND TAPPING THE INTAKE MANIFOLD 1. The boost gauge can also be installed by drilling and tapping the intake manifold to 1/8-27 NPT. First, mark the drilling location on the intake manifold using a Center Punch. 2. Remove the intake manifold 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. Clean the intake manifold with a Vacuum to remove all shavings. 5. Insert the boost line fitting cap on the boost line followed by the ferrule. 6. Insert the boost line into the boost line fitting and tighten the cap with a 3/8” wrench. (Refer to diagram below) 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 hose. Ensure there is no contact with any direct heat source or moving parts of the truck. PROPER ORIENTATION

2003-2009 INSTALLATION GUIDE 3 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 24V 5.9/6.7L CUMMINS Pyrometer EGT Gauge Installation SECTION 2 Warning: Make sure the exhaust is cooled off during this process. 1. 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 further downstream can display a lower temperature reading on the gauge. To install the EGT probe, we are going to use GlowShift’s Drill and Tap Kit. 2. Locate the exhaust manifold on the passenger side of the engine bay. You will see there is a collector between cylinders 4 and 5. Mark the manifold using a Center Punch and Marker on the left side of the collector closer to cylinder 5 to prepare the drilling and tapping process. 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. 3. Starting with a 1/8” drill bit, drill a pilot hole into the exhaust manifold. Continue increasing the size of the pilot hole using various drill bits until you reach size R. 4. Using cutting oil, tap the hole to 1/8-27 NPT. 5. Ensure all shavings are out of the manifold by periodically using a vacuum and a pen magnet to remove them. Warning: Failure to remove metal shavings can result in possible engine damage. 6. Apply anti-seize to the threads of the EGT ferrule fitting and thread the fitting into the exhaust manifold. Tighten the fitting with a 14mm wrench. 7. Install the gauge’s EGT Probe into the Ferrule Fitting Adapter, ensuring the sensor is positioned approximately halfway into the manifold. Tighten using a 14mm wrench. Note: Do not overtighten the ferrule fitting. 8. Plug the EGT Sensor Harness into the EGT Sensor. 9. Route the EGT Sensor Harness to an opening on the firewall on the driver’s side of the engine bay and use Zip Ties to secure. Make sure there is no contact with any direct heat source or moving parts. 3. 4. 7.

2003-2009 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 24V 5.9/6.7L CUMMINS 4 Warning : Be sure that the transmission is cool before removing the transmission cooler line. The transmission temperature gauge can be installed in one of two ways: using a transmission test port extender adapter or by using a 1/2” transmission line T-fitting adapter. On 03-07.5 48RE Transmissions either a Test Port Extender or Transmission T-Fitting adapter can be used. On 07.5-09 68RFE Transmissions ONLY a Transmission T-Fitting can be used. See Page 6. TRANSMISSION TEST PORT EXTENDER INSTALLATION: 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 on 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. 3. TEST PORT EXTENDER 1a. 1b. Transmission Temp Gauge Installation SECTION 3

2003-2009 INSTALLATION GUIDE 5 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 24V 5.9/6.7L CUMMINS Note: Required on 07.5-09 68RFE Transmissions 1/2” TRANSMISSION LINE T-FITTING ADAPTER INSTALLATION: 1. Safely jack up the truck, if not raised already. Using a 15/16” Wrench, hold the brass fitting on the transmission and use a 3/4” Wrench to unscrew the line fitting. Note: Have a drain pan available for any fluid that will leak. 2. Remove the retaining bracket using a Flat Head Screwdriver. Unscrew and remove the line from the torque converter cooler using a 7/8” Wrench. 3. Using a Marker, mark the cooler line where you will cut to remove approximately 1-7/8” of the line. Use the Pipe Cutter to cut the line where you have made your marks and then deburr the cut ends. Insert the nut and cutting ring onto the line where you have just made your cut and repeat on the other side. 4. Install the cooler line T-fitting female compression nuts over each end of the cut line. Then place the metal cutting rings over each end of the cooler line. 5. Hold the body of the T-fitting with a wrench and hand tighten each compression nut. Then tighten 1-1/4 more turns with a 7/8” Wrench to ensure proper sealing of the cutting rings. 6. Now you can install the 1/8-27 NPT temperature sensor into the port on the T-fitting housing. Note: Be sure to use Teflon Tape on the threads of the temperature sensor to prevent any leaks. 7. Reinstall the cooler line with the T-fitting adapter attached and refill the transmission with up to 4 quarts of proper grade transmission fluid. Note: Check the dipstick to ensure the proper amount of fluid is in the transmission. WIRING THE TRANSMISSION TEMPERATURE GAUGE: 1. 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. 2. 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. 3. 7a. 7b. T-Fitting

2003-2009 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 24V 5.9/6.7L CUMMINS 6 Fuel Pressure Gauge Installation SECTION 4 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 using the petcock. 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: On 07.5-09 6.7L Cummins, the Banjo bolt needs to be installed into the rear of the Fuel Filter housing. The sensor will be installed in a prefuel filter application. A Big Line Kit can be used with a T-Fitting to install the sensor for Pre-Fuel Filter applications. 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. 3. 6. Shown on 03-07.5 5.9L 24V Cummins 3 Note.

2003-2009 INSTALLATION GUIDE 7 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 24V 5.9/6.7L CUMMINS 1. The Fuel Rail Pressure Sensor Connector is located on the driver’s side of the engine bay on the back of the fuel rail. 2. Unplug the connector by releasing the clip. 3. Splice the gauge's green signal wire and black ground wire to the truck's corresponding signal and ground wires. 4. Plug the sensor harness back in. Optional: To make the installation easier, there is an available inline pigtail harness for some models on www.GlowShift.com. Simply unplug your 3 wire Fuel Rail Pressure Harness from the sensor and connect GlowShift’s Fuel Rail Pressure Gauge Wiring Harness, allowing you to keep your factory wiring intact. Once all of the connections are made, splice the 2 pigtail wires to the gauge harness: Green to Green and Black to Black. Rail Pressure Gauge Installation SECTION 5 YEAR SIGNAL WIRE GROUND SWITCH POSITION 03 (5.9L) Pink/Black Violet/Red 1 and 2 Up 04-07 (5.9L) Brown/Yellow Brown/White 1 and 2 Up 07-09 (6.7L) Brown/Yellow Brown/Orange 1 and 2 Down Rail Pressure Gauge Settings 1 2 ON

2003-2009 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 24V 5.9/6.7L CUMMINS 8 14. Install the new A-pillar gauge pod with the gauges mounted using the supplied bolt in the upper factory mounting location. To ensure a proper fit, screw the bolt into the threads, but do not completely tighten it. Adjust the gauge pod so that it lines up correctly and then tighten the bolt using a 4mm Allen Key. Note: Do not overtighten the bolt because it will cause the pod to bow. If this happens, loosen the bolt to refit the pod and tighten the bolt when the pod is properly aligned. 1. Remove the Factory A-Pillar Trim using a Flathead Screwdriver to remove the cover tabs and a 10mm Socket to remove the bolts. Be sure to store the factory A-pillar trim in a safe location. 2. Remove the dash side cover to gain more access by unclipping the spring tabs using a Panel Pop Tool. 3. Wrap Teflon tape 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. 4. Feed the wires from each gauge into the pillar pod. 5. Insert each gauge into the pod. 6. If you are using the optional 3 Gauge Wiring Kit, attach all of the wires together. 7. Connect all of the yellow wires together using a splice connector. Repeat this for the red, orange, and black wires respectively, and secure with Zip Ties. 8. Route the wires and boost line 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. 9. Insert the boost line fitting cap on the boost line followed by the ferrule. 10. Insert the boost line into the boost line fitting and tighten the cap with a 3/8” wrench. Note: Do not overtighten the Ferrule Fitting. (Refer to diagram) 11. Plug the EGT Sensor Harness into the back of the EGT Gauge. (If used) 12. Splice the Green signal wire from the Transmission Temperature Gauge to the signal wire from the sensor. (If used) 13. Plug the Rail Pressure Harness into the back of the Rail Pressure Gauge. (If used) Installing the Pillar Pod SECTION 6 3. 7. PROPER ORIENTATION

2003-2009 INSTALLATION GUIDE 9 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 24V 5.9/6.7L CUMMINS Reconnect the negative terminals of the two batteries to prepare power for the gauges and to test the fuses for power with a Test Light. 1. Run the power wires through the firewall and into the engine bay of the truck. Note: You may need to drill a hole in the firewall if there isn’t one present. It is important to use a Grommet on the hole to ensure the wires are not sliced or cut on the firewall. 2. Drill a hole in the side of the fuse box located under the hood in order to run the wires inside without them being pinched on the fuse box lid. Be careful not to damage anything while drilling. Note: Steps 3, 4, and 5 are based on a 2009 vehicle. Please refer to the chart below for the fuse locations for your specific vehicle. Be sure that two fuses are installed in each Expandable Circuit. 3. Locate and remove fuse #31 POWERTRAIN CONTROL MODULE (10A) from the fuse panel. Using the Expandable Circuit, crimp the yellow wires to the Expandable Circuit and insert the circuit into the empty fuse #31 slot. 4. Locate and remove fuse #33 HEATING AND A/C (10A) from the fuse panel. Using the Expandable Circuit, crimp the red wires to the Expandable Circuit and insert the circuit into the empty fuse #33 slot. 5. Locate and remove fuse #16 RIGHT FRONT PARKING / TURN LAMP (15A) from the fuse panel. Using GlowShift’s Expandable Circuit (Optional), crimp the orange wires to the Expandable Circuit and insert the circuit into the empty fuse #16 slot. 6. Connect the black wire to any bare metal grounding location. If the black wire is not connected to a bare metal grounding location the gauges will not power on. Tip: Remove all rust and paint from the grounding location for a better connection. 7. Secure any excess wiring with Zip Ties. 8. Reinstall the dash side cover and any interior trim that was removed. Check and fill the Transmission Fluid according to manufacturer specifications. 9. Power the truck on to see if the gauges are functioning properly and check for any leaks or loose sensor connections. 10. Press the Color Change Button on the gauges to ensure they are working correctly. Note: MaxTow Gauges do not change colors. The button allows you to change the 3 Daytime and 3 Nighttime Brightness Levels. 11. Test drive your vehicle to ensure all gauges are functioning properly. Note: The Boost Gauge will only read while driving. Connecting to Power SECTION 7 Fuse # Description Fuse Size Fuse Type 2003-2005 Yellow Constant Wire 45 Horn Relay 20 Amp Mini Red Switched Wire 27 Heated Mirror 10 Amp Mini Orange Headlight Switched Wire 32 Park/Turn Signal Lamp 10 Amp Mini 2006-2009 Yellow Constant Wire 31 Powertrain Control Module 10 Amp Mini Red Switched Wire 33 Heating and A/C 10 Amp Mini Orange Headlight Switched Wire 16 Right Front Park/ Turn Lamp 15 Amp Mini 2003-2005 Fuse Box 2006-2009 Fuse Box

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