Dodge Durango (HB). Manual - part 552

The airbag cushion, housing (5), and inflator (3) are
secured within an integral receptacle molded into the
back of the trim cover (4). The four vertical walls of
this receptacle have a total of twelve small windows
with blocking tabs that are engaged by twelve hook
formations around the perimeter of the airbag housing.
Each hook is inserted through one of the windows and
the blocking tab in each window keeps the hook prop-
erly engaged with the trim cover, locking the trim
cover securely into place on the airbag housing.

The resistive membrane-type horn switch is secured
with heat stakes to the inside surface of the driver air-
bag trim cover, between the trim cover and the folded
airbag cushion. The horn switch ground pigtail wire (2)
has an eyelet terminal connector that is captured
beneath a flanged nut on the upper right inflator
mounting stud on the back of the housing. The horn
switch feed pigtail wire has a black, molded plastic
insulator (1) that is secured by an integral retainer in a
locator hole near the upper right corner of the airbag housing and is connected to the vehicle electrical system
through a dedicated take out and connector of the steering wheel wire harness. Both horn switch wires are routed
through an integral notch in the center of the upper edge of the airbag housing stamping.

The airbag used in this model is a multistage, Next Generation-type that complies with revised federal airbag stan-
dards to deploy with less force than those used in some prior models. A 71 centimeter (28 inch) diameter, radial
deploying fabric cushion with internal tethers is used. The airbag inflator is a dual-initiator, non-azide, pyrotechnic-
type unit with four mounting studs and is secured to the stamped metal airbag housing by four flanged hex nuts.
Two keyed and color-coded connector receptacles on the driver airbag inflator connect the two inflator initiators to
the vehicle electrical system through two yellow-jacketed, two-wire pigtail harnesses of the clockspring.

The driver airbag unit cannot be repaired, and must be replaced if deployed or in any way damaged. The driver
airbag trim cover and horn switch unit may be disassembled from the driver airbag unit, and is available for sepa-
rate service replacement.

OPERATION

The multistage driver airbag is deployed by electrical signals generated by the Occupant Restraint Controller (ORC)
through the driver airbag squib 1 and squib 2 circuits to the two initiators in the airbag inflator. By using two initi-
ators, the airbag can be deployed at multiple levels of force. The force level is controlled by the ORC to suit the
monitored impact conditions by providing one of three delay intervals between the electrical signals provided to the
two initiators. The longer the delay between these signals, the less forcefully the airbag will deploy.

When the ORC sends the proper electrical signals to each initiator, the electrical energy generates enough heat to
initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these
chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the back of the
airbag housing and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion
to inflate. As the cushion inflates, the driver airbag trim cover will split at predetermined breakout lines, then fold
back out of the way along with the horn switch unit. Following an airbag deployment, the airbag cushion quickly
deflates by venting the inert gas towards the instrument panel through vent holes within the fabric used to construct
the back (steering wheel side) panel of the airbag cushion.

Some of the chemicals used to create the inert gas may be considered hazardous while in their solid state before
they are burned, but they are securely sealed within the airbag inflator. Typically, both initiators are used and all
potentially hazardous chemicals are burned during an airbag deployment event. However, it is possible for only one
initiator to be used during a deployment due to an airbag system fault; therefore, it is necessary to always confirm
that both initiators have been used in order to avoid the improper disposal of potentially live pyrotechnic or hazard-
ous materials. (Refer to 8 - ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE - SERVICE AFTER A SUP-
PLEMENTAL RESTRAINT DEPLOYMENT).

The inert gas that is produced when the chemicals are burned is harmless. However, a small amount of residue
from the burned chemicals may cause some temporary discomfort if it contacts the skin, eyes, or breathing pas-
sages. If skin or eye irritation is noted, rinse the affected area with plenty of cool, clean water. If breathing passages

RESTRAINTS - SERVICE INFORMATION

8O - 477

are irritated, move to another area where there is plenty of clean, fresh air to breath. If the irritation is not alleviated
by these actions, contact a physician.

REMOVAL

WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental
restraint system before attempting any steering wheel, steering column, airbag, occupant classification sys-
tem, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect
and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge
before performing further diagnosis or service. This is the only sure way to disable the supplemental
restraint system. Failure to take the proper precautions could result in accidental airbag deployment.

WARNING: To avoid personal injury or death, when removing a deployed airbag, rubber gloves, eye protec-
tion, and a long-sleeved shirt should be worn. There may be deposits on the airbag cushion and other inte-
rior surfaces. In large doses, these deposits may cause irritation to the skin and eyes.

NOTE: The following procedure is for replacement of a faulty or damaged driver airbag. If the airbag is
faulty or damaged, but not deployed, review the recommended procedures for handling non-deployed sup-
plemental restraints. (Refer to 8 - ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE - HANDLING NON-
DEPLOYED

SUPPLEMENTAL

RESTRAINTS).

the

driver

airbag

has

been

deployed,

review

the

recommended procedures for service after a supplemental restraint deployment before removing the airbag
from the vehicle. (Refer to 8 - ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE - SERVICE AFTER A
SUPPLEMENTAL RESTRAINT DEPLOYMENT).

1. Disconnect and isolate the battery negative cable.

Wait two minutes for the system capacitor to dis-
charge before further service.

2. From the underside of the steering wheel, remove

the two screws (3) that secure the driver airbag (1)
to the steering wheel armature (2).

8O - 478

RESTRAINTS - SERVICE INFORMATION

CAUTION: Do not pull on the horn switch feed pig-
tail wire to disengage the connector from the
driver airbag housing or to disconnect the horn
switch to steering wheel wire harness connection.
Improper pulling on this pigtail wire or connection
can result in damage to the horn switch mem-
brane or feed circuit.

3. Pull the driver airbag (1) away from the steering

wheel far enough to access the three electrical
connections on the back of the airbag housing.

4. Disconnect the steering wheel wire harness con-

nector for the horn switch (2) from the horn switch
feed pigtail wire connector (4), which is located on
the back of the driver airbag housing.

CAUTION: Do not pull on the clockspring pigtail
wires or pry on the connector insulator to disen-
gage the connector from the driver airbag inflator
connector receptacle. Improper removal of these
pigtail wires and their connector insulators can
result in damage to the airbag circuits or connec-
tor insulators.

5. The clockspring driver airbag pigtail wire connectors (3) are secured by integral latches to the airbag inflator

connector receptacles, which are located on the back of the driver airbag housing. Depress the latches on each
side of the connector insulator and pull the insulators straight out from the airbag inflator to disconnect them from
the connector receptacles.

6. Remove the driver airbag from the steering wheel.

7. If the driver airbag has been deployed, the clockspring must be replaced. (Refer to 8 - ELECTRICAL/RE-

STRAINTS/CLOCKSPRING - REMOVAL).

DISASSEMBLY

WARNING: To avoid personal injury or death, service of this unit should be performed only by Daimler-
Chrysler-trained and authorized dealer service technicians. Failure to take the proper precautions or to fol-
low the proper procedures could result in accidental, incomplete, or improper airbag deployment and
possible occupant injuries.

WARNING: To avoid personal injury or death, use extreme care to prevent any foreign material from enter-
ing the driver airbag, or becoming entrapped between the driver airbag cushion and the driver airbag trim
cover. Failure to observe this warning could result in occupant injuries upon airbag deployment.

WARNING: To avoid personal injury or death, the driver airbag trim cover must never be painted. Replace-
ment trim covers are serviced in the original colors. Paint may change the way in which the material of the
trim cover responds to an airbag deployment. Failure to observe this warning could result in occupant inju-
ries upon airbag deployment.

RESTRAINTS - SERVICE INFORMATION

8O - 479

NOTE: The following procedures can be used to replace the driver airbag trim cover and horn switch unit
for service. If the driver airbag is faulty or deployed, the entire driver airbag, trim cover and horn switch
must be replaced as a unit.

1. Disconnect and isolate the battery negative cable.

Wait two minutes for the system capacitor to dis-
charge before further service.

2. Remove the driver airbag from the steering wheel

(Refer to 8 - ELECTRICAL/RESTRAINTS/DRIVER
AIRBAG - REMOVAL).

3. Place the driver airbag on a suitable clean and dry

work surface with the trim cover facing down. If the
trim cover will be reused, be certain to take the
proper precautions to prevent the trim cover from
receiving cosmetic damage during the following
procedures.

4. Carefully pry the horn switch feed pigtail wire con-

nector (1) away from the back of the driver airbag
housing (3) far enough to disengage the integral
connector retainer from the locator hole just above
the upper right inflator mounting stud.

5. Remove the nut that secures the horn switch

ground pigtail wire eyelet terminal (2) to the upper right inflator stud on the back of the driver airbag housing.

6. Remove the horn switch ground pigtail wire eyelet terminal from the upper right inflator stud on the back of the

driver airbag housing.

7. Disengage each of the twelve hooks (5 and 6) of the airbag housing from the twelve windows in the vertical walls

of the trim cover (4), one wall at a time. Start by disengaging the upper wall, then do each of the two side walls,
and finish with the lower wall. To disengage the hooks, use hand pressure to push the adjacent edge of the
airbag housing firmly and evenly downward into the trim cover receptacle, while at the same time pushing out-
ward on the upper edge of the receptacle wall.

8. With all of the hooks disengaged, lift the housing, inflator, and cushion as a unit from the receptacle on the back

of the driver airbag trim cover.

ASSEMBLY

8O - 480

RESTRAINTS - SERVICE INFORMATION

Content .. 550 551 552 553 ..