Dodge finds flexibility
Nov 1, 2007 12:00 PM, By Rick Weber
For manual-transmission vehicles: the vehicle must come equipped with cruise switches in order to have “idle-up” control capability; a clutch up-stop switch is required and will be available through a Dodge dealer (part number 05026273AB); and the vehicle must be taken to a Dodge dealership and have the “PTO and idle-up” feature enabled.
The 4500 and 5500 chassis cabs will be built at Chrysler Group's Saltillo Assembly Plant in Coahuila, Mexico. One of the company's most flexible plants, the Saltillo Plant — which also produces the all-new Dodge Ram 3500 chassis cab, Dodge Ram Mega Cab, Dodge Ram Power Wagon, and Dodge Ram Heavy Duty 2500 and 3500 models — takes on production of the Ram 4500 and 5500 chassis cabs as part of the company's Flexible Manufacturing Strategy (FMS).
The FMS approach allows the company to not only balance production with demand, but to also efficiently build low-volume vehicles that take advantage of market niches, and to quickly shift production volumes between different models within a single plant or among multiple plants.
For production of the Dodge Ram 4500 and 5500 chassis cabs, Chrysler Group recently invested an additional $48 million into the plant, which follows a $210 million investment in 2005 for production of the all-new 2006 Dodge Ram Mega Cab. Enlarging the facility by 120,000 square feet enables the plant to produce commercial vehicles and accommodate new frame configurations. In addition, the expansion increases production capacity and enables the plant to manage the added complexity of the Dodge Ram 4500/5500's all-new commercial-grade chassis and suspensions, including two cab-axle lengths, regular and quad cab versions, 4×2 and 4×4 variants, and single- and dual-rear-wheel models.
Sprinter update
Walther Bloch of the Sprinter engineering and compliance support team said a new generation of regulator is used in the new Sprinter. The alternator regulator is equipped with a Local Interface Network (LIN).
He said the characteristics of the LIN alternators are fixed in the engine-control unit. For this reason, aftermarket alternators can't be retrofitted and a Sprinter should be ordered with the correct alternator from the factory.
The standard equipment for the Sprinter is 180A and an optional 200A alternator (code BAJ) is available. No D+ (engine running positive signal) output is available at the alternator with the LIN bus technology. Only the upfitter connector EK1 under the driver seat should be used.
He said the alternator power supply cable is fused with a 300A fuse integrated in the wiring harness. The fuse location is in the rear of the engine at the bell housing. He said if a short occurs and the fuse blows, then the alternator cable harness has to be completely replaced.
He said that for electrical aftermarket equipment with an amp draw of more than 25A, it is necessary to use the optional auxiliary battery 12V/100Ah lead antimony, deep-cycle strength (option BC1). That option is retrofitable, but for cost and practical reasons Dodge recommends that this option be ordered directly from the plant.
He said that on the Sprinter OM642 diesel engine, it is possible to attach an additional compressor or auxiliary alternator located next to the oil pan. An A/C compressor bracket can be retrofitted by exchanging the existing casting. The compressor pulley and the cooling fan are connected with the crankshaft pulley via a serpentine belt.
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