INSTALLATION GUIDE 94-97 DODGE RAM 12V CUMMINS 1994-1997
1994-1997 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 12V CUMMINS TABLE OF CONTENTS SECTION 1 Boost Gauge Installation 1 SECTION 2 Pyrometer EGT Gauge Installation 2 SECTION 3 Transmission Temp Gauge Installation 3 SECTION 4 Fuel Pressure Gauge Installation 4 SECTION 5 Preparing The Pillar Pod 5 SECTION 6 Mounting the Pillar Pod 6 SECTION 7 Connecting To Power 7 CHECK OUT THE FULL INSTALL VIDEO FOR THIS CUMMINS: GLOWSHIFT.COM/9497RAM 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. TOOLS & ACCESSORIES NOT INCLUDED OPTIONAL ADD-ONS AND ADAPTERS SOLD SEPARATELY AT GLOWSHIFT.COM • Safety Glasses & Gloves • Assorted Wrenches • Socket Set • Flat Head Screwdriver • Phillips Head Screwdriver • Center Punch • Drill & Drill Bits • Tap Handle • Multi-Meter/Test Light • Wire Strippers & Crimper • Shop Vacuum • Pen Magnet • Panel Pop Tool • Cutting Oil • Pick Tool • Zip Ties • Grommet • Drain Pan • Teflon Tape • Wire Connectors • Anti-Seize • Transmission Fluid • 3 Gauge Wiring Kit • Splice Connectors • 2 Mini Expandable Circuits • 1/8-27 NPT Drill and Tap Set • Transmission Test Port Extender • 12 Valve Banjo Bolt • Snubber Valve • 12 Valve Banjo Bolt and Snubber Valve Combo • Rail Pressure Harness • 45 Degree Thread Adapter (MaxTow only) 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 1994-1997 Dodge Ram 2500 & 3500 with a 12v 5.9L Cummins. Before getting started, confirm you have the tools and accessories below and let’s get to work.
1994-1997 INSTALLATION GUIDE 1 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 12V 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. 1. Using an 11mm wrench, remove the intake plug located under the intake horn. 2. Wrap Te on tape around the 1/8-27 NPT male threads of the boost line fitting. 3. Thread and tighten the male end of the boost line fitting into the intake port using an 11mm wrench. 4. Insert the boost line fitting cap on the boost line followed by the ferrule. 5. Insert the boost line into the boost line fitting and tighten the cap with a 3/8” wrench. Note: Do not over tighten the ferrule fitting. 6. Route the boost line 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 of the truck. 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. An additional 45° fitting will be needed. 1. 3. 5. PROPER ORIENTATION Note
1994-1997 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 12V CUMMINS 2 Pyrometer EGT Gauge Installation SECTION 2 Warning: Make sure the exhaust is cooled off before starting 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 to any other location can cause significantly inaccurate readings. 2. 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. 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. 6.
1994-1997 INSTALLATION GUIDE 3 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 12V CUMMINS 1. 3. Transmission Temp Gauge Installation SECTION 3 Warning : Be sure that the transmission is cool before removing the transmission cooler line. Note: If you are installing a MaxTow Transmission Temperature Gauge, the connectors are already connected to the Transmission Temperature Sensor Harness and can simply be plugged into the Transmission Temperature Sensor before routing the wire to the firewall. 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 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 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.
1994-1997 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 12V CUMMINS 4 Fuel Pressure Gauge Installation Optional: Remove the intercooler pipe to have a clearer path to the injection pump using an 11mm socket. 1. Remove the injection pump feed line banjo bolt using a 19mm shallow socket, 3” extension, and a ratchet. Have a catch pan ready for the diesel fuel that will come out. Make sure to remove both crush washers or gaskets from the banjo fitting. 2. Before installing the Fuel Pressure Sensor on the truck, make sure to use Teflon tape on the male threads of the Snubber Valve. Thread the Fuel Pressure Sensor into the Snubber Valve, and tighten using a 22mm wrench and an 18mm wrench. Note: If the 12 valve Banjo Bolt & Snubber Valve Combo is used to thread the Fuel Pressure Sensor into the adapter, tighten using a 22mm wrench and a 19mm wrench and then skip to step 4. 3. Then thread the Snubber into the Banjo Bolt and tighten using an 18mm wrench and a 19mm wrench. 4. Install the new Banjo Bolt into the banjo fitting, making sure to install 2 new crush washers, and thread into the injection pump. Tighten with a 19mm wrench. 5. Plug the Fuel Pressure Sensor Harness into the Fuel Pressure Sensor. Optional: Reinstall the intercooler pipe if it was removed. 6. Route the Fuel Pressure 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 of the truck. SECTION 4 Note 1. 4.
1994-1997 INSTALLATION GUIDE 5 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 12V CUMMINS Preparing The Pillar Pod SECTION 5 1. Carefully remove the factory trim from the truck by pulling and releasing the spring clips. Note: This gauge pod mounts directly on top of your truck’s A-pillar using the supplied push-in clips and is not a complete replacement. 2. Place the triple pillar pod overtop of the removed factory trim. 3. Mark and drill (4) 7/32” holes and secure with the flush mount fasteners. 4. Mark and drill 3 holes using a step bit for the wiring to pass through the factory trim. 5. 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. 6. Feed the wires from each gauge into the pillar pod. 7. Insert each gauge into the pod. 8. If using a 3 Gauge Wiring Harness, attach all of the wires. 9. Connect all of the yellow wires together using a splice connector. 10. Connect all of the red wires together using a splice connector. 11. Connect all of the orange wires together using a splice connector. 12. Connect all of the black wires together using a splice connector. 13. Secure all wires with Zip Ties. 1. 2. 9.
1994-1997 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 12V CUMMINS 6 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 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. 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 white signal wire from the sensor. (If used) 8. Mount the pillar pod and factory trim assembly to the truck cab A-pillar, securing it with the factory spring clips. Mounting the Pillar Pod SECTION 6 2. 3. 4. PROPER ORIENTATION
1994-1997 INSTALLATION GUIDE 7 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 12V 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. Attach expandable circuits to both the yellow wire and the red wire. 2. Remove the fuse from fuse location 18 for the park lamp circuit. Plug the fuse into the open section of the expandable circuit for the yellow wire and install in the fuse box. 3. Remove the fuse from fuse location 7 for the radio circuit. Plug the fuse into the open section of the expandable circuit for the red wire and install 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. Splice into the black wire with a yellow stripe to obtain the correct voltage for the dimming feature of the gauges. 6. Secure any excess wiring with Zip Ties. 7. Reinstall the headlight switch and dash trim. 8. Connect the black wire to a reliable, clean and unpainted ground source. Connecting to Power SECTION 7 1 2 R1 R2 CB2 CB1 22 21 R3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2.-3. 5. 8. Continued on Next Page 2.-3.
1994-1997 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved DODGE RAM 12V CUMMINS 8 9. Reinstall the lower dash trim. 10. Reconnect the negative cables of both batteries. 11. Power up the truck to confirm 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. 12. Press the Color Changing Button on the gauges to ensure they are working correctly. 13. Test drive your vehicle to ensure all gauges are functioning properly. Note: The Boost Gauge will only read while driving. 9. 10. 11. Continued From Previous Page
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