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Old 01-05-2011, 02:06 PM
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Default How to Fix Dodge '94-'98 Cruise Control

I took my cruise control vacuum actuator apart and found out why the cruise control speeds up and does all the other stuff it likes to do to drive you nuts. The video is a little different since I don't have a battery in the way, you will have to remove some things to get to the cruise control unit.

Inside the unit is 3 actuators with rubber seals (orange things) that end up not being able to seal because the plungers rust out and they become hard to move. The electromagnet (coils) do not have the power to overcome the rust and stuff in there so you end up with a weak seal. I don't think the rust helps the coils move the plungers either.

There are 2 fixes, cleaning the rust or getting a new plunger. The plunger cap (things that fall out of the bottom first that were bigger diameter but shorter) also rusts but I was able to polish it right up. The plunger itself could possibly be fixable with polish but mine was too far past that point and had lots of pitting. It seemed that one side had a perfect plunger and the other had the rusty one so you can go to any junkyard and just take the good plunger out of a truck and replace that with the rusty one in yours.

Just cleaning the rust out of the bore and getting the majority of it off the plunger will fix the issue as that rust just makes it hard to slide and any resistance will keep it from sealing very good. I had to push that plunger out with a screwdriver when I initially took it apart.. All I did was polish the plunger and clean the bore and my problems were solved.

Make sure to lube it to prevent further rust using penetrating oil or something that will just coat it and lube it. Gun oil might work good too.


Here is right after I took them all out.


Here is after I cleaned the rusty set up. Not too shiny but still fixed the issue.
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1997-12V-NV4500-Dana 80/3.54/2wd-350k---21-27mpg
Removed AFC--No Plate--13.5* timing--BHAF--5" Exhaust--Valair Clutch
1994-Jeep Cherokee-5spd-3.07-4wd-202k---16-19mpg
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Old 01-05-2011, 03:06 PM
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Excellent job SIR!!! Thank you!!
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1996 RAM "Custom Ground" 100 plate 3/4 forward, 300 injectors, 16.5 timing, Goerends Auto = 365HP, 833TQ Third Gen Rims, Aluminum Headache Rack
Duct Tape can't fix stupid, BUT it can muffle the sound
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Old 01-05-2011, 07:59 PM
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Let me know if this fixes yours..
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1997-12V-NV4500-Dana 80/3.54/2wd-350k---21-27mpg
Removed AFC--No Plate--13.5* timing--BHAF--5" Exhaust--Valair Clutch
1994-Jeep Cherokee-5spd-3.07-4wd-202k---16-19mpg
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Old 01-05-2011, 09:02 PM
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We're going to take a look at mine on Thursday (hopefully)
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Old 01-05-2011, 09:14 PM
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THanks for posting this, it is great info!!!!!
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O.O., 01.5, Dodge, 2500, High Output (H.O.) Cummins Turbo Diesel (245/505), Quad Cab Long Bed (QCLB), 4x4, Sport, Original Bosch VP 44 Injection Pump, 6 Speed/NV5600 Transmission, 3.55 Gears, 105k, currently stock engine, Fram Air Filter, 285/75R16s, Glow Shift Gauges: Fuel Pressure (FP), Boost, Exhaust Gas Temperature (EGT), Oil Temperature, SMARTY@1, Airtex lift pump 19 psi @ idle, 14 psi @ WOT, Propane Injection, 2 Stroke Oil, Intake Air Temperature (IAT) Fooler = Better MPG, Bed Lined, Chrome Nerf Bars, more to come!!

Toys:
'79 CJ5, 258ci, 3" lift, 33x12.50x15, Stock Engine and 3 Speed Tranny
'05 Suzuki, GSX1300R, Hayabusa, All Stock, #3('00 blown engine, '00 stolen, & '05)
The complete live & learn and pass it on by H. Jackson Brown, Jr.
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Old 01-06-2011, 08:20 PM
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Quote:
Originally Posted by NikkiMn View Post
We're going to take a look at mine on Thursday (hopefully)
Looks like Saturday now....... I really want to tear into it and see if it looks the same.
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1996 RAM "Custom Ground" 100 plate 3/4 forward, 300 injectors, 16.5 timing, Goerends Auto = 365HP, 833TQ Third Gen Rims, Aluminum Headache Rack
Duct Tape can't fix stupid, BUT it can muffle the sound
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Old 01-06-2011, 08:33 PM
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I just tore into a 94, they are a little different design. His was spotless somehow, even after being a hard core mudrunner. I have twice as many miles as him though. He converted it from auto to manual and did something and it didn't work so I stole his shiny plungers and got rid of my rust bucket
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1997-12V-NV4500-Dana 80/3.54/2wd-350k---21-27mpg
Removed AFC--No Plate--13.5* timing--BHAF--5" Exhaust--Valair Clutch
1994-Jeep Cherokee-5spd-3.07-4wd-202k---16-19mpg
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Old 01-06-2011, 09:17 PM
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That's cheating!
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1996 RAM "Custom Ground" 100 plate 3/4 forward, 300 injectors, 16.5 timing, Goerends Auto = 365HP, 833TQ Third Gen Rims, Aluminum Headache Rack
Duct Tape can't fix stupid, BUT it can muffle the sound
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Old 01-06-2011, 09:27 PM
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That is creative engineering!!
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O.O., 01.5, Dodge, 2500, High Output (H.O.) Cummins Turbo Diesel (245/505), Quad Cab Long Bed (QCLB), 4x4, Sport, Original Bosch VP 44 Injection Pump, 6 Speed/NV5600 Transmission, 3.55 Gears, 105k, currently stock engine, Fram Air Filter, 285/75R16s, Glow Shift Gauges: Fuel Pressure (FP), Boost, Exhaust Gas Temperature (EGT), Oil Temperature, SMARTY@1, Airtex lift pump 19 psi @ idle, 14 psi @ WOT, Propane Injection, 2 Stroke Oil, Intake Air Temperature (IAT) Fooler = Better MPG, Bed Lined, Chrome Nerf Bars, more to come!!

Toys:
'79 CJ5, 258ci, 3" lift, 33x12.50x15, Stock Engine and 3 Speed Tranny
'05 Suzuki, GSX1300R, Hayabusa, All Stock, #3('00 blown engine, '00 stolen, & '05)
The complete live & learn and pass it on by H. Jackson Brown, Jr.
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Old 04-25-2011, 07:57 AM
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(Looking for a Thank You Button)

Nice Job ISX...
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2002 Dodge Ram 2500, 5.9L Cummins Turbo Diesel, 5 Speed NV4500 transmission, 4x4, 3.55 Gears, AirDog 150 fuel pump with 1/2" Big Line Kit, Stock Bosch VP44 Injection Pump, Bosch RV275 Injectors +40HP, Edge Comp Performance Box, BHAF (Big Honkin' Air Filter), Stock Holset HX35W Turbo, Straight 3" Pipe Exhaust, Crankcase Vent Mod, High Idle Mod, MPG / IAT fooler Mod, ScanGauge II, 25% Tinted Windows, DiPricol Gauges (Fuel pressure, Boost, Pyrometer), 235/85 R16 tires mounted on 16x7 Aluminum mags (weighing 62#), Custom Fog Lights, Custom Backup lights, Silverstar Headlights, 23-24 MPG

1996 Dodge Ram 1500, 5.9L Magnum V8 Gasoline Engine, 46RE Automatic Transmission, 4WD with CAD axle with 3.55 Gears, Mopar Performance PCM, Gutted Kitty, ScanGauge II, 35% Tinted Windows, 16-17 MPG

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