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Engine/Transmission (1998.5 - 2002) 2001.5 Cruise Control Issues

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99 idle only

A short piece of pipe

Shelby Griggs

TDR MEMBER
My cruise control has been acting up intermittently. It will sometimes cut out, sometimes seems to want accelerate beyond set point when trying to set, other times it works fine. It also seems affected somewhat by temperature, not sure if cabin temperature, outside temperature or engine temperature AND at least some times seems related to bumps in the road.

I haven't found too many old threads dealing with issues with the ALL electronic CC on the late 2nd gen trucks with manual transmission.

As I understand, all electronic with these inputs: wheel speed (ABS) sensor on rear differential, the steering wheel switches and the stop lamp switch. Am I missing any other controls?

I replaced the speed sensor on the rear differential housing with a Dorman aftermarket from Geno's (it had been replaced once before by a shop for ABS light on, also likely also aftermarket). I replaced the stop lamp switch with one from NAPA (and have an OEM on on backorder from Geno's). I have a set of used switches for the steering wheel, but haven't tackled that yet. Can't seem to find a new set of switches anywhere. At least this used set looks like way less miles than mine, all the lettering is still in like new condition.

Today I drove some short trips in the AM, about 50F outside and then around noon about an hour drive, all worked fine. Stopped for lunch for about an hour, then another hour home, after lunch it never did work correctly. Generally I have noticed first trip of day seems to work ok. Sometimes later in day works too. At first I though ABS sensor heating up or engine ECM, however these would be up to temperature way before things start acting up, so now leaning toward outside temperatures or cabin temperatures being warmer, today was around 80F after lunch.

Not always, BUT the cutting out or stuttering when hitting a bump leads me to believe something like the stop lamp switch and the peddle vibrating causing stop lamp switch movement, but with a new switch??? I had read someplace that ONLY the OEM switches worked reliably, but find it hard to believe an Echlin brand switch from NAPA wouldn't be up to spec.

Other theory's are intermittent wiring in the tilt column or a bad clock spring (it was replaced as a recall years ago, but still old now). I have 330K miles, BUT I never tilt the wheel unless I need to work on something in/on the dash, it probably hasn't had more than 100 cycles in 22 years, so I can't imagine wiring would have a break, but anything is possible.

No codes are set in the odometer, haven't hooked a scan tool to the OBD2 port. Would need to borrow one or take it to a shop.

I can continue throwing stuff at it, BUT any input appreciated, maybe there are other controlling inputs I am missing? There is the clutch switch, but I am unclear if that is an input or not, pushing the clutch (normally I think) disengages cruise, BUT I think that is due to rapid increase in engine RPM, not the switch? That switch normally doesn't engage and let starter operate until clutch is fully depressed.

This has me kind of baffled.
 
Thanks for link. I have FSM so had read all that. No taps or anything like that. I think I did read about checking grounds somewhere, so maybe I will start with battery terminals although visually they look good. I know the stop lamp switch seems to fix for some folks, but there apparently isn't a single point of failure causing the symptoms.
 
I am the original owner of an '02 truck (manual 6 spd) with 368,000 miles logged. So far, my cruise control problems (3 times now) have all been broken wire(s) in the tilt area of the steering wheel. In my case, each time a DTC was set.

The brake switch on your vehicle may be suspect. You mentioned that it has been replaced. Years ago I noticed that my stop lights would be on occasionally after I exited the truck. I modified and made an adjustment on the OEM brake light switch. It hasn't failed since. The FSM mentions that a misadjusted brake light switch could cause an intermittent cruise control problem.

From the FSM:

A misadjusted brake (stop) lamp switch. This
could also cause an intermittent problem.


- John
 
Maybe I need to look at the switch again, I just put it in last week, but if the mounting bracket is out of whack it still may cause issues. It occurs to me maybe the brake peddle isn't coming back up as high as it once did and that could cause an issue?

How did you modify yours?
 
When I had the problem with brake lights occasionally staying, I read the FSM regarding brake switch replacement. The following Step (4) always puzzled me. Why would a brake switch have only a one time adjustment? Makes no sense to me.

(4) Release brake pedal. With out moving the
pedal, move the lever so that it is parallel with the
connector. The switch is now adjusted and can not be
adjusted again.


Anyway, I removed the switch and studied its operation. I am sorry, but I cannot recall exactly what I did to make it adjustable. It seems that either I filed something or removed something to make it adjustable. I do remember that it wasn't hard to to.

- John
 
I had read that thread before. I have the Denso alternator, it was replaced once by the dealer, no idea if it was new or rebuilt, it doesn't say rebuilt on the sticker. I guess I could do the voltage check, I do have a decent Fluke meter.

Today I pulled all four battery cables, cleaned them and reinstalled. I run AGM batteries, so not much in typical battery crud, but the terminals and posts were pretty oxidized. (As an aside these two Optima Yellow Tops will be 12 years old in December, can't complain about that) I also poked around for loose grounds, nothing obvious. I also pulled the engine harness plug from the PDC and reseated. The bolt in the center wasn't exactly tight, although it doesn't seem that you can get it real tight without the captured nut/insert spinning.

Took it for a spin, worked fine, temps about 75F. Ran it out 10 miles, stopped and shut down, waited about 15 minutes, fired up and 10 miles back, stopped for fuel with a shut down and then home a couple miles. All three segments of the 20 or so miles it worked fine, bumps and all and shutting CC off and on, tapping brakes, etc. all the normal actions.

Did I fix it? Not claiming that yet, but happy with the short test run.
 
Just wanted to update for future readers. My CC has been working fine since removing all four battery cables and cleaning and reinstallation. As mentioned, they were not grungy at all, but oxidized a bit. It was either that or the big engine control harness connection in the fuse box. I reseated that at same time.

Granted I initially thought this was ambient temperature related and it has been much cooler temperatures since I cleaned the terminals, but it was intermittent enough to think it probably was one of those two things since it has been working perfect in hundreds of miles now.
 
My guess would be a programming glitch in the ECM/PCM - often, totally disconnecting all power for a few minutes, then reconnecting, will "reset" the ECM/PCM, and all will be well - had much the same issue with wifes '05 Ford Escape, disconnecting battery and reconnecting cleared the issue. Random "spikes" during engine starts, headlights and other current surges sometimes cause computer glitches easily corrected just by removing all power for a short period of time, then reconnecting. Just remember to also "reset" the accellerator peddle travel after reconnecting batteries.
 
Gary, you could be correct, whatever the cause it seems to have gone away with pulling the battery terminals, cleaning and retightening along with reseating the engine harness in the PDC. Probably 2000 miles now with no further issues. The occasional failure when hitting a road bump leads me to believe it was a mechanical connection issue, but of course it seemed ambient temperature related too, so maybe both were taking me down wrong path?

I guess maybe I need to do APPS recalibration, I did not do that after pulling power, BUT in 2000 miles or so I haven't noticed an issues either...
 
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