Ignition System Cross Fire/Secondary Ignition Wire Induction
Note: this page is for the V8 repair. The V6
repair is on another page.
Date: December 30, 1998
Models: 1994-1999 BR/BE Ram
Note: applies to vehicles with 3.9L, 5.2L and 5.9L engines (gas)
1994 - 1999 (AN) Dakota
1994 - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
1995 - 1999 (XJ) Cherokee
1994 - 1999 (ZJ) Grand Cherokee
Symptoms: some vehicles may exhibit
one or more of these symptoms:
spark knock complaints with vehicle under load
various single cylinder misfire (1, 3, 7,) ad especially 5 and/or
surge in 4th gear with the Electronically Modulated Converter Clutch
(EMCC) engaged (around 45MPH).
Perceived torque converter EMCC engagement/ disengagement around 45 MPH.
Using the Mopar Diagnostic System (MDS/MDS2) or the Diagnostic
Scan Tool (DRB III), verify that all engine/transmission
systems are functioning as designed. If other DTC's are present, repair
as necessary before proceeding with this bulletin. If no other
DTC's are present and the above symptoms have been reported by the customer,
perform the repair procedure.
NOTE: This rerouting procedure should be performed before any other
misfire, surge, or spark knock repairs are attempted.
3 56028186 Clip, single wire
2 06503441 Clip, wire to hose (5.2L,
1 04364375 Convolute, 10 ft
The repair procedure involves rerouting the coil wires and/or the plug
wires to minimize induction effects.
NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST
CROSS AT A RIGHT ANGLE.
5.2L and 5.9L ENGINE PROCEDURE
A - Coil Wire Routing (Fig 1 & Fig 2).
Route the coil wire starting from the ignition coil and working toward
the distributor. Any excess wire should end up at the distributor end.
Install the coil wire into the one wire clips. This may be easier to perform
while the coil wire is loose from the valve cover and before the one-wire
clips are attached to the valve cover studs.
Cut the ignition wire convolute into three lengths 8", 4", and 3.25"
(203 mm, 101.5 mm, 82.5 mm).
Slit and install the three sections of convolute onto the coil wire between
the clips. Install the 3.25" section at the front of the right valve cover.
Install the 8" and the 4" sections along the top side of the right valve
cover. This may be easier to perform while the coil wire is loose from
the valve cover and before the one-wire clips are attached to the valve
Route the distributor end of the coil wire down and behind the intake manifold
in front of the oil pressure switch.
Remove coil wire from distributor cap tower terminal.
Remove coil wire from the rear five-wire clip, the center three-wire clip,
and the front one-wire clip along the lower side of the right valve cover.
Install 3 one wire clips along the top and front of the valve cover. Use
the valve cover retaining bolt studs (Fig 1).
Route the distributor end of the coil wire up the side of the distributor
cap and onto the coil tower terminal.
Use the original piece of coil wire convolute to protect the wire against
chafing by components at the rear of the engine.
B - Number 8 Cylinder Plug Wire Routing (Fig 3).
NOTE: The coil wire must be a minimum of 1" away from any other ignition
wires. This may require the coil wire to be routed under the vacuum and/or
wire harnesses in the right rear corner of the intake manifold.
Reposition the original piece of plug wire convolute to prevent the wire
from chafing at the right valve cover and with other engine components.
Secure the #8 plug wire and convolute in place with the hose to wire clip.
The small end of the clip supports the convolute. The large end of the
clip attaches to the heater hose.
Remove the #8 plug wire from the distributor tower terminal.
Remove the #8 plug wire from the five-wire clip at the lower rear of the
Route the #8 plug wire over the rear quarter of the right valve cover (Fig
Install the #8 plug wire into its distributor cap terminal.
C - Number 4 Plug Wire Rerouting (Fig 4 & Fig 5).
NOTE: Make sure the #8 plug wire is secure and away from the #4 plug
wire. Make certain it will not fall to contact the cylinder head or exhaust
Remove the #4 cylinder plug wire from the distributor cap terminal.
At the center of the lower side of the right valve cover is three-wire
clip. Keep the #2 and #4 plug wires from crossing each other at this clip.
Position the #2 plug wire in the top wire slot and the #4 wire in the bottom
wire slot. Leave the middle slot empty (Fig 5).
Keep the plug wires from crossing and chafing each other at the five-wire
clip found at the right rear lower side of the valve cover. Position the
#4 plug wire in a slot that will space it farthest away from the #8 plug
wire (Fig 6). Remove any slack in the #4 plug wire between the three-wire
and the five-wire clips.
Route the #4 plug wire behind the transmission dipstick tube and heater
NOTE: Earlier model five-wire clips look slightly different but the
same wiring layout applies.
Install the #4 Plug wire to its distributor cap terminal (Fig 7).
D - Number 7 Plug Wire Rerouting (Fig 8 & Fig 9)
NOTE: Make sure that the #4 plug wire is at least one inch away from
the #8 wire.
For 1999 models, the #7 plug wire was shortened. Reroute the #7 wire so
that it crosses the distributor cap and leaves the cap between the #6 and
#5 tower terminals (Fig 9).
Verify that the #7 plug wire crosses over the distributor cap and leaves
the distributor cap between the #3 and the #6 tower terminals (Fig 8).
This is the original wire routing on 1998 and earlier models.
E - Number 5 Plug Wire Rerouting (Fig 10)
NOTE: Make sure the #7 plug wire is at least one inch away from the
Remove the #5 plug wire from the distributor cap terminal.
Remove the #5 plug wire from the five-wire clip found at the lower rear
of the left valve cover.
Route the #5 plug wire over the left valve cover and in front of the breather
Position the original convolute from the #5 wire to prevent chafing against
the valve cover and any engine components. Secure the small end of the
hose to wire clip over the convolute. Secure the large end of the hose
to wire clip to the breather hose.
NOTE: Make sure the #5 plug wire is secure and away from the #7 plug
wire. Make certain it will not fall down and contact the cylinder head
and/or exhaust components.
Policy: Reimbursable within the terms of the warranty.
Labor charge: V6 ...... 0.2 Hrs.
V8 ...... 0.4 Hrs.
Thanks to Bob Bergevin for supplying the TSB information