GLOW SHIFT Diesel Gauge Package Compatible with Dodge Ram Cummins 2500 3500 2003-2009 Installation Guide

GLOW SHIFT Diesel Gauge Package Compatible with Dodge Ram Cummins 2500

3500 2003-2009 Installation Guide

TOOLS & ACCESSORIES

•  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
•  Pen Magnet
•  Panel Pop Tool
•  Cutting Oil
•  Pick Tool
•  Zip Ties
• Grommet
•  Drain Pan
•  Teflon Tape
•  Wire Connectors
•  Anti-Seize
•  Transmission Fluid

OPTIONAL ADD-ONS AND ADAPTERS

•  3 Gauge Wiring Kit
•  Boost Bolt Adapter
•  Banjo Bolt/Snubber Valve
•  1/2″ Transmission T-Fitting
•  Transmission Test Port Adapter
•  Mini-Expandable Circuits
•  1/8-27 NPT Drill and Tap set

Preparing The Installation

1.  Open the hood and locate the truck’s two batteries. Disconnect the negative terminal of each battery using a 13mm wrench to ensure there is no power running through the truck during the installation. When it comes time to wire and connect the gauges to their power source, we will reconnect power to the negative terminals of the batteries.

2.  To remove the factory A-pillar trim, use a Flathead Screwdriver to remove the cover tabs and a 10mm Socket to remove the A-pillar bolts. The triple
   pillar gauge pod you will be installing is a complete replacement. Be sure to store the factory A-pillar trim in a safe location.

3.  Now that you have the power disconnected from your truck and your factory A-pillar has been removed, you can proceed with the installation.

Boost Gauge Installation

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 1: BOOST BOLT INSTALLATION

1.  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.
2.  Locate and remove the front inner intake heater grid bolt using a 10mm Socket.
3.  Thread the boost bolt adapter where you removed the front inner intake heater grid bolt and tighten using a 5/8” Wrench. Note: Torque to 12ft lbs using a Torque Wrench.
4.  Prepare the boost hose for installation by installing the compression nut and ferrule fitting over the boost hose. Note: Wrap Teflon tape clockwise on the male threads.
5.  Install the compression adapter into the boost bolt adapter using an 11mm Wrench. Using a 3/8” Wrench, tighten the compression nut until the boost hose is snug. Note: Do not overtighten.
6.  Route the boost hose up to the firewall to the driver side of the engine bay and use zip ties to secure the boost hose to ensure there is no contact with any direct heat source or moving parts of the truck.

BOOST BOLT ADAPTER

Option 2: DRILLING AND TAPPING THE INTAKE MANIFOLD

1.  The boost gauge can also be installed by drilling and tapping the intake manifold horn to 1/8-27 NPT. First, mark the drilling location on the intake manifold horn using a Marker and a Center Punch.
2.  Remove the intake manifold horn 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 horn. Clean the manifold horn with a Vacuum to remove all shavings.
5. Prepare the boost hose for installation by installing the compression nut and ferrule fitting over the boost hose. Tip: Wrap Teflon tape clockwise on all male threads.
6.  Install the compression adapter into the 1/8-27 NPT hole you tapped using an 11mm Wrench. Using a 3/8” Wrench, tighten the compression nut onto the fitting until the boost hose is snug. 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 boost hose to ensure there is no contact with any direct heat source or moving parts of the truck.

Pyrometer EGT Gauge Installation

1.  Make sure the exhaust is cooled off during this process.
2.  We are going to be 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. Optional: To install the EGT probe, we are going to use GlowShift’s Drill and Tap Kit.
3.  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.
4.  Starting with a 1/8” Drill Bit, drill your pilot hole into the manifold and gradually step up in drill bit size until you reach the size R drill bit. Note: Clean the manifold with a Pen Magnet and Vacuum to ensure no shavings are present in the manifold.
5.  Take the 1/8-27 NPT Tap and slowly tap the size R hole in the manifold using cutting oil. Again, clean the manifold with a Pen Magnet and Vacuum to remove all shavings.
6.  We recommend using anti-seize on all EGT probe threads. Using a 14mm Wrench, slowly thread the ferrule fitting adapter into the 1/8-27 NPT hole you just tapped and tighten until snug. Note: Do not overtighten the ferrule fitting.
7.  Slide the EGT probe into the ferrule fitting adapter and tighten until snug using a 14mm Wrench. Note: Probe depth should be in the center of the manifold.
8.  Now that the EGT probe is installed, run the lead wires up to the firewall to the driver side of the engine bay and secure the wires using zip ties to ensure there is no contact with any direct heat source or moving parts of the truck.

Transmission Temperature Gauge Installation

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.

TEST PORT EXTENDER

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 Flathead 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 line fitting 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.

Fuel Pressure Gauge Installation

1.  The fuel pressure gauge will be installed to the fuel filter housing using a snubber valve and banjo bolt 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. 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: Have a drain pan available for any remaining fuel that will leak from the housing and make sure to remove both crush washers from the line and/or fuel filter housing.
4.  Before installing the fuel pressure sensor to the fuel filter housing, be sure to wrap Teflon Tape or thread sealant on the snubber valve male threads. Thread the fuel pressure sensor into the snubber valve. Thread the snubber valve into the banjo bolt adapter. Note: Tighten until snug to avoid any fuel leaks.
5.  Place a new copper crush washer on the banjo bolt adapter. Slide the banjo bolt adapter into the banjo fitting and then place the second copper crush washer on the bolt, 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.
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.

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 pre- fuel filter application. A Big Line Kit can be used with a T-Fitting to install the sensor for Pre-Fuel Filter applications.

Wiring The Gauges

1.  You can now mount the gauges into the pillar pod. For this installation, we used three gauges in a triple pillar pod. There is no specific order to mount the gauges in the pod, it’s all personal preference. You can also reconnect the negative terminals of the two batteries to prepare power for the gauges.

2.  Now that all of your gauges are mounted, sensors and fittings are installed to their sources and the secured sensor wires are run to the driver side of the engine bay, we can now route the wires through the firewall and into the cab of the truck. You can remove the dash side cover to gain more access by unclipping the spring tabs using a Flathead Screwdriver. 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.

3.  Connect the appropriate wiring harnesses to the back of each gauge in the sensor location.
   A: 2003-2005 Fuse Box

4.  We are going to wire the gauges using GlowShift’s 3 Gauge
   Wiring Kit (Optional):

5. A. Connect all of the yellow wires together. This will be the color memory wire that connects to a constant 12v source. Locate and remove fuse 45 (20amp Fuse) from the fuse panel. Using GlowShift’s mini expandable circuit (Optional), crimp the yellow wires to the expandable circuit and insert the circuit into the empty fuse 45 slot.

6. A. Connect all of the red wires together. This will be connected to a switched 12v source. Locate and remove fuse 27 (10amp Fuse) from the fuse panel. Using GlowShift’s mini expandable circuit (Optional), crimp the red wires to the expandable circuit and insert the circuit into the empty fuse 27 slot.

7. A. Connect all of the orange wires together. This enables the dimming function that will lower the brightness of your gauges 30% for easier viewing when driving at night. The orange wire will connect to the headlight switch source. Locate and remove fuse 32
   (10amp Fuse) from the fuse panel. Using GlowShift’s mini expandable circuit (Optional), crimp the orange wires to the expandable circuit and insert the circuit into the empty fuse 32 slot.

8. b: 2006-2009 Fuse Box

9. B. We are going to wire the gauges using GlowShift’s 3
   Gauge Wiring Kit (Optional):

10. B. Connect all of the yellow wires together. This will be the color memory wire that connects to a constant 12v source. Locate and remove fuse 31 (10amp Fuse) from the fuse panel. Using GlowShift’s mini expandable circuit (Optional), crimp the yellow wires to the expandable circuit and insert the circuit into the empty fuse 31 slot.

11. B. Connect all of the red wires together. This will be connected to a switched 12v source. Locate and remove fuse 33 (10amp Fuse) from the fuse panel. Using GlowShift’s mini expandable circuit (Optional), crimp the red wires to the expandable circuit and insert the circuit into the empty fuse 33 slot.

12. B. Connect all of the orange wires together. This enables the dimming function that will lower the brightness of your gauges 30% for easier viewing when driving at night. The orange wire will connect to the headlight switch source. Locate and remove fuse 16 (15amp Fuse) from the fuse panel. Using GlowShift’s mini expandable circuit (Optional), crimp the orange wires to the expandable circuit and insert the circuit into the empty fuse 16 slot.
    All years Continued

13.  Connect all of the black wires together. This will be connected to any bare metal grounding location. If the black wires are not connected to a bare metal grounding location, then your gauges will not power on. Tip: Remove all rust and paint from the grounding location for a better connection.

14. Secure any excess wiring with Zip ties.

15. Wrap Teflon Tape counter-clockwise on the fitting located on the back of the boost gauge. This will ensure a leak-free connection. You can now route the boost hose to the back of the gauge and tighten until snug using a 3/8” Wrench. Note: Do not overtighten the fitting on the back of the gauge.

16. Route the EGT probe harness and connect to the back of the pyrometer EGT gauge.

17. Route the transmission temperature sensor harness and connect to the back of the transmission temperature gauge.

18. Route the fuel pressure sensor harness and connect to the back of the fuel pressure gauge.

19. Reinstall the dash side cover.

Installing The Pillar Pod

1.  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. Note: Do not overtighten the bolt because it will cause the pod to bow. If the pod is bowed out, loosen the bolt to refit the pod and tighten the bolt when the pod is properly aligned.
2.  Power the truck on to see if the gauges are functioning properly and check for any leaks or loose sensor connections.

References

• 1.888.GS
• GLOWSHIFT.COM
• GUIDEGlowShift.com
• GLOWSHIFT.COM

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