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Power Wagon FAQ's - just the FAQ's! PLEASE READ FIRST!

Postby Cactus Red » Mon May 21, 2012 6:45 pm

This FAQ's/MOD's post is a list of the most common modifications, questions and answers specific to PW that frequently get asked.

The information in this post is a collection of everyone’s efforts to provide accurate and detailed information, but the website cannot be held responsible for mistakes. In compiling this, I have not made proper attribution to the original authors when I copy text verbatim, but you know who you are, and we all thank you.

Much of it is located on the DodgeTalk forum. When possible, I've pulled the tech out of the original post, but most topics are multi-page or have photos. Again, I have made no attempt to quote the original author or date the material. We as a group built the original FAQ's page, so I don't feel bad at all about relocating what I can :mrgreen:

If you find false information and have good proof stating so, please contact the person that posted it so it can get corrected and will not mislead other people. Remember keeping the accuracy of this FAQ is a group effort.

Please be concise, accurate, and spell check your information.

Here are the FAQ's Rules:

The information in this post is a collection of everyone’s efforts to provide accurate and detailed information, but the website cannot be held responsible for mistakes. All of us can post to this when you find good information, but,

IT IS NOT AN AREA FOR DISCUSSION OR QUESTIONS. IF YOU HAVE A QUESTION OR WISH TO DISCUSS SOMETHING, START A NEW THREAD ON THE TOPIC OR ADD A POST TO AN EXISTING POST.

If you find false information and have good proof stating so, please contact the person that posted it so it can get corrected and will not mislead other people. Remember keeping the accuracy of this FAQ is a group effort.

Please be concise, accurate, and spell check your information.


So, to start with, please register your Power Wagon @ http://powerwagonregistry.org/

There is a lot of info there to start with when researching your truck!

Thanks,

Mark
Last edited by Cactus Red on Wed May 23, 2012 7:14 am, edited 1 time in total.
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Locker Bypass w/o harness:

Postby Cactus Red » Mon May 21, 2012 6:50 pm

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Winch Thermal Protection Switch Mod:

Postby Cactus Red » Mon May 21, 2012 6:55 pm

http://www.dodgetalk.com/forums/showpos ... ostcount=7

After troubleshooting using the Chrysler Winch Service Manual (provided courtesy of Warn also attached here), I finally figured out that it wasn't my solenoids or my motor that had gone bad (as previously diagosed by the stealership), but rather the stupid thermal protector that had gone bad again (I had previously had the motor replaced for this).

This time I wasn't so quick to spend a few hundred dollars on a motor etc, so I set about trying to figure out if anyone else was having the same issue. After looking around on the internet it appeared that there were a few other folks were having the same issue even though they hardly used their winch's (I have only used mine for any real purpose, once to pull a car out of ditch a few years ago, other then that just to test that it works or not.)

After reading a few posts I decided to take a trip to my local NAPA auto parts to see if I could put together a bypass that looked pretty good and didn't cost an arm and a leg. I purchased item number 755-1598 a 2-Flat Electrical Connector - 12" Loop ($1.99) (similar to the connector that goes from the solenoids to the thermal protection switch) a few crimp ends and had some electical tape laying around the house. (All told less then $3.00)

Here are the pictures and instructions to detail what i did to put it together.

Instructions:

1. Cut the 2-Flat Electrical Connector in half and leave about 2 inches of wire on both ends.

2. Strip all 4 wires leaving the bare copper ends

3. Twist the ends of the black and white wires together

4. Use a 14-20 gauge crimp ends and crimp them onto the ends of the combined wires.

5. Finish with electrical tape to make more water resistant and a nicer finish.

6. Separate the two ends on the winch

7. Plug the newly created bypasses onto each end (you likely don't need the end from the side going to the winch motor but I don't like to leave empty wires hanging.)

8. Enjoy the fact that your winch is working again without having to replace the motor. (Just to verify the fact that there wasn't anything wrong with the motor I did take it apart and it looked good as new).
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Fender Liners

Postby Cactus Red » Mon May 21, 2012 6:57 pm

Dodge PN 82207367AB Liner Kit, Wheel - as of Aug 2009 cost was $120.00
The kit above is for rear fender well liners. The plastic liners provided by the factory offer scanty protection from mud and rocks. I had to trim the new liners to clear 315/70-17 MT\R Kevlars at full stuff.
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Postby Cactus Red » Mon May 21, 2012 6:58 pm

Light Bar for PW: http://www.randyellisdesign.com/

Synthetic Replacement Winch Rope: http://www.vikingoffroad.com/

Front and rear Diff Guards: http://purplecranium.com/
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Flashing Rear Locker Switch

Postby Cactus Red » Mon May 21, 2012 7:01 pm

Flashing Rear Locker Switch

http://www.dodgetalk.com/forums/show...84#post3181684

Many of the folks experiencing this problem put silicone grease around the connectors to help seal out water and reported back that it made a big difference.

I unplugged the connections outside of the housings and greased them up. and I did the smart bar connection too, at the sway bar. You might want to take off your diff covers, and clean (wipe off) the sensor in there.
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J10 windshield Wiper Motor Recall

Postby Cactus Red » Mon May 21, 2012 7:02 pm

J10 windshield Wiper Motor Recall

Vehicle Make / Model: Model Year(s):
DODGE / RAM 2008-2009

Manufacturer: CHRYSLER LLC Mfr's Report Date: MAR 09, 2009
NHTSA CAMPAIGN ID Number: 09V084000 N/A
NHTSA Action Number: N/A

Component: VISIBILITY:WINDSHIELD WIPER/WASHER:MOTOR
Potential Number of Units Affected: 72136
Summary:
CHRYSLER IS RECALLING 72,136 MY 2008-2009 LIGHT AND HEAVY DUTY RAM PICKUP TRUCKS. THE WINDSHIELD WIPER MODULE MOTOR ASSEMBLY MAY BE SUSCEPTIBLE TO WATER INTRUSION THAT COULD RESULT IN PARTIAL OR COMPLETE LOSS OF WINDSHIELD WIPING CAPABILITY.
Consequence:
WHEN THE WIPER SYSTEM FAILS, THE OPERATOR WILL HAVE REDUCED VISIBILITY WHICH COULD RESULT IN A CRASH.
Remedy:
DEALERS WILL REPLACE THE WIPER MODULE ASSEMBLIES WITH VENTED WIPER MOTOR HOUSINGS FREE OF CHARGE. THE MANUFACTURER HAS NOT YET PROVIDED AN OWNER NOTIFICATION SCHEDULE. OWNERS MAY CONTACT CHRYSLER AT 1-800-853-1403.
Notes:
CHRYSLER RECALL NO. J10. OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO SAFERCAR.GOV .
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H46 Steering Recall

Postby Cactus Red » Mon May 21, 2012 9:46 pm

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Recirculation Door Repair Video

Postby Cactus Red » Mon May 21, 2012 9:47 pm

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Grease fitting on front d'shaft

Postby Cactus Red » Mon May 21, 2012 9:59 pm

Grease fitting on front d'shaft

http://powerwagonregistry.org/faq.php

Greasing Front Drive Shaft

If there's one maintenance piece that is tough to find, it's this. Unique to Power Wagons, many dealerships will argue that it just doesn't exist. Well, here it is, how to find it and what needle fitting you'll need.

First, jack the driver side front up so that you can spin the tire. Slowly turn it until you get the grease fitting into view. If your u-joints are dirty, this will be hard to see so you might want something to clean around in there. After you grease it up, you might want to use a Q-tip to clean up overspill so it doesn't collect more dirt and will be easier to find in the future. Some folks have even used nail polish to mark arrows on the u-joint to make it way easier to find.

Grease gun needle fitting:

http://www.tractorsupply.com/vehicle-ma ... ct-3952769
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Winch Cable Maintenance

Postby Cactus Red » Mon May 21, 2012 10:01 pm

Winch Cable Maintenance

Warn says a a thin coat of light oil is the only thing you can do for the cable. If you live in a dry dusty climate I would skip the oil because if will only collect dust most of the time. I could spray it down with some dry lube but the cable looks good and rust free after 2 years so it's low on the list of things to do.

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http://www.dodgetalk.com/forums/showthread.php?t=239734
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Fuel Filter Replacement - or lack there of...

Postby Cactus Red » Mon May 21, 2012 10:03 pm

Fuel Filter Replacement - or lack there of...

The fuel filter is in the tank and is not serviceable.
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Oil or Grease on winch, is it a problem?

Postby Cactus Red » Mon May 21, 2012 10:10 pm

Oil or Grease on winch, is it a problem?

http://www.dodgetalk.com/forums/showthread.php?t=245223

It's common for the seals to weep. Unless it's excessive, wipe it down if needed. The winch does not contain oil, only grease.
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Mud or water in the air box

Postby Cactus Red » Tue May 22, 2012 8:49 pm

Mud or water in the air box

http://www.dodgetalk.com/forums/showthread.php?t=211638

This is for those who are thinking about CAI's and mud running. Think again. Here's a couple of pictures of under the hood on my truck after a small mud puddle. Last picture is the air box. You can see the dry mud in it. This is with the stock air box. Hate to think how much mud would be on a CAI. Was thinking about getting a CAI. Don't think so now. Had mud on the filter, and it was still wet. So I changed it out to a K&N. That's the only filter I could get right NOW.
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Bigger or Longer Oil Filter- '08 and newer PW

Postby Cactus Red » Tue May 22, 2012 8:59 pm

Bigger or Longer Oil Filter- '08 and newer PW
and


The '08's have a 22mm screw on thread. The '07's and earlier ones have the 3/4 screw on thread. There is no longer filter available.
_________________

What is the proper filter for '08 and up Hemi's?

TSB NUMBER: 09-006-07
GROUP: Engine
DATE: October 23, 2007

SUBJECT:
Oil Filter Change For Some 2008 Vehicles
OVERVIEW:
This bulletin describes proper oil filter usage for 2008 vehicles with engines listed below.

NOTE: This bulletin applies to the above listed vehicles equipped with the following
engines:
• 2.4L - Turbo Only (sales code ED4)
• 2.7L - (sales code EER) - (JS) Changed after 2008 production began,
see chart below.
• 3.5L - (sales codes EGF & EGG) (JS) Changed after 2008 production
began, see chart below.
• 4.7L - (sales code EVE)
• 5.7L - (sales code EZB)
• 5.7L - (sales code EZA)
• 6.1L - (sales code ESF)
NUMBER: 09-006-07
GROUP: Engine
DATE: October 23, 2007
DISCUSSION:
When performing scheduled maintenance, it is critical to use the correct oil filter to prevent
engine damage. The oil filter on the 2008 vehicle with the engines listed above now have a
M22 x 1.5 METRIC thread in place of the traditional 3/4” SAE thread.
NOTE: The new filter part number is 04884899AB.
Ensure that any personnel performing oil change maintenance service and parts personnel
are informed of this change.
POLICY:
Information Only
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Warn Winch Wireless Remote

Postby Cactus Red » Tue May 22, 2012 9:10 pm

Warn Winch Wireless Remote

http://www.warn.com/truck/accessories/w ... trol.shtml

When out and got the Warn wireless remote. Not hard to do at all. One end of the wiring harnless plugs into the winch, and the other end plugs into the control box. No slicing wires or anything like that. Just made sure that you use dielectrical grease on the plugs. Hardest part of the whole job is finding a good location for the control box. Warn says to mount it away from the exhaust, and battery. Temps should be below 200f. So I mounted mine on the back side of the air box. Here's some pictures of the install. Enjoy.
___________

I have one on Cactus Red, and it's worth it's weight in silver (yeah, yeah). It offers the operator the freedom to move anywhere the line will reach, and to do it safely. It's especially helpful in setting up rigging since you can either release or tighten the rope.
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Deluxe Model Winch Thermal Protection Switch

Postby Cactus Red » Tue May 22, 2012 9:12 pm

Deluxe Model Winch Thermal Protection Switch

Hey Guys i've been contemplating this for awhile. I know that many of you are considering only installing the bypass for the thermal only once in awhile but leaving it out untill the winch cuts out. Well here's a different way of going about it. Here's sort of a step by step of how you can make good use of that thermal switch. This allows you to use the TBS but still have the peace of mind of knowing how hot the winch is. Using the existing switch I have created the WHITE. Winch Hot Indicating Thermal Exceeded. This is the luxury model of the bypass. IMO anyway. This system only works when the truck key is in the aux postion or running that way there is no drain on the batt. The line runs through the existing sensor but when it gets too hot and trips the relay trips the LED on so you know when the Factory systems would cut the winch for being too hot. Kinda step by step pics. I'm going to install it soon in the truck but figured i'd show you guys the build first. BTW I can make a few for ppl if they really want. It didn't take long. Here's pics. Tell me what you think

http://www.dodgetalk.com/forums/showthread.php?t=265326
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Changing Fluid's in Diff's, Tranny

Postby Cactus Red » Tue May 22, 2012 9:13 pm

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Replacement Battery discussion

Postby Cactus Red » Tue May 22, 2012 9:17 pm

Replacement Battery discussion

http://www.dodgetalk.com/forums/showthread.php?t=255087

Sears DieHard Platinum for 08'....

Ready to pull the trigger and get one. What size fits the 08 ? Do I need to do any trimming of battery edges or truck to get it to fit properly ? Will the stock holddowns work with this battery ? I want the biggest one I can fit. Oh yeah, will the stock battery shelf be up to the task of a 75# battery ?
Thanks for any info guys.
______________

The DieHard Platinum G65 is a direct replacement, and it's a great upgrade to the stock battery.
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Noisy fan, or no to low AC air flow - Recirculation door rem

Postby Cactus Red » Tue May 22, 2012 9:19 pm

Noisy fan, or no to low AC air flow - Recirculation door removal

http://www.dodgetalk.com/forums/showthread.php?t=256941

My ac was not blowing very hard and was making noise.
I removed the 3 bolts (8MM with short extension)on the blower unit on the passenger side floorboard. You can unclip the elect. plug if you need more room.
The the recirculating door was sitting in the opening. I simply turned the door and removed it from the opening.
Took 10 mins.
Everything else works fine ,defrost and all the optional settings. Blows hard again.

The only thing I am missing is to recycle the air(setting) within the cab. Works perfect even in the Texas heat!!!
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Factory PW Rock Rails are NOT available from Dealers

Postby Cactus Red » Tue May 22, 2012 9:21 pm

Factory PW Rock Rails are NOT available from Dealers

Factory rock rails have been discontinued, and the dealers are out of stock.

Search Craigslist nation wide, post a wanted add here, or having a set custom built are the only options. Finding a set of factory rails is damn near impossible as of this date, 22 May 2012. I haven't seen a set for sale in a couple years.
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High End Performance Suspension

Postby Cactus Red » Tue May 22, 2012 9:22 pm

High End Performance Suspension

These are not your typical lift kits - all are race inspired, go fast type setups, but they do offer upgrades from stock.

No recommendations - I'd have to try each one to form an opinion, so here are the companies I know of in alphabetical order:

BDS: http://www.bds-suspension.com/

Carli: http://www.thecarlisuspension.com/

KORE: http://koreperformance.com/

Lorenz: http://www.lorenzindustries.com/

Spirson: http://spirsonoffroad.com/

Thuren: http://thurenfabrication.com/
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Is ABS turned off when 4x4 is engaged?

Postby Cactus Red » Tue May 22, 2012 9:25 pm

Is ABS turned off when 4x4 is engaged?

"Dodge engineers recalibrated the ABS for 4LO operation so that the pedal isn’t taken away from the driver in extreme situations when some lockup is preferred."
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Can you run 37's with Glassworks fenders and no lift?

Postby Cactus Red » Tue May 22, 2012 9:26 pm

Can you run 37's with Glassworks fenders and no lift?

Short answer is no.

http://www.dodgetalk.com/forums/showthread.php?t=149959
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Exhaust Tip Mod

Postby Cactus Red » Fri May 25, 2012 9:09 pm

Exhaust Tip Mod

Some of you may have found this out already but if not keep this in mind. The stock exhaust pipe tip is pretty low and near the rear tire. Watch out if you get stuck in a hole with the back right tire as if you bounce through it in reverse you may find your exhaust bent with the tip way inside under the axle and rubbing the tire. This happened to me and i have now cut the exhaust off just above the axle. No more issue. just a heads up.
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