Fuse Box - Interior

This procedure covers removal and replacement of the interior fuse box (Integrated Power Module) on a 1994-2007 Dodge Ram 2500 with the 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Interior fuse box assembly (Integrated Power Module) × 1 — Use OEM specification
• Fuse box cover — Usually reused unless damaged

Preparation

1. Park vehicle on level surface and set parking brake
2. Turn ignition and all accessories OFF
3. Open driver's door and leave open throughout procedure
4. Photograph or document the existing fuse layout before removal
5. Gather all tools and new parts within reach

Procedure

1. 1

   Disconnect battery system
   Open hood and disconnect both negative battery terminals first, then both positive terminals. Wait minimum 5 minutes for airbag SRS capacitors to discharge. On Cummins diesel models, there are two batteries, one on each side of the engine bay.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
2. 2

   Remove fuse box cover
   Locate the interior fuse box on the driver's side lower dash panel, left of the steering column. Pull the fuse box cover straight out to release the retaining clips. Remove the cover completely and set aside.
3. 3

   Document fuse and relay positions
   Take detailed photographs of all fuse and relay positions. Use masking tape to label any aftermarket circuits or non-standard fuses. This is critical for proper reinstallation and troubleshooting.
4. 4

   Remove lower dash panel
   Remove the lower dash trim panel below the steering column. Remove 4-6 screws securing the panel (locations vary by year). Gently pull panel away from dash and disconnect any electrical connectors for lights or switches. Set panel aside.
5. 5

   Disconnect electrical connectors from fuse box
   Working from underneath the dash, identify all electrical connectors plugged into the back of the fuse box. There are typically 3-5 large multi-pin connectors. Press release tabs and carefully pull connectors straight out. Label each connector position with tape if needed.
   ⚠Do not pull on wires - grip the connector body only to avoid damaging pins or wiring
6. 6

   Remove ground strap connections
   Locate ground strap(s) connected to the fuse box mounting area or bracket. Remove ground strap bolts and clean contact surfaces with wire brush or contact cleaner to ensure good electrical connection during reassembly.
   Torque spec

   Ground Strap Bolts12 Nm (9 lb-ft)
7. 7

   Remove fuse box mounting fasteners
   Remove the mounting bolts securing the fuse box to the dash structure. Typically 3-4 bolts around the perimeter of the unit. Support the fuse box with one hand while removing the final bolt.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
8. 8

   Remove fuse box assembly
   Carefully maneuver the fuse box out from under the dash. May need to tilt or rotate the unit to clear surrounding components. Inspect the mounting bracket and dash structure for any damage or corrosion.
9. 9

   Transfer fuses and relays to new box
   If installing a new fuse box, carefully transfer all fuses and relays from the old unit to the new unit, matching positions exactly as documented. Inspect each fuse and relay for damage or corrosion. Replace any blown fuses or corroded relays.
10. 10

    Install new fuse box assembly
    Position the new or serviced fuse box into the mounting location. Align mounting holes with dash structure. Start all mounting bolts by hand before tightening any of them to ensure proper alignment.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
11. 11

    Reconnect ground straps
    Install ground strap(s) to fuse box bracket or mounting location. Ensure contact surfaces are clean and free of paint or corrosion. Torque ground strap bolts to specification.
    Torque spec

    Ground Strap Bolts12 Nm (9 lb-ft)
12. 12

    Reconnect electrical connectors
    Reconnect all electrical connectors to the back of the fuse box. Push each connector firmly until the locking tab clicks into place. Verify each connector is fully seated and locked.
13. 13

    Reinstall lower dash panel
    Reconnect any electrical connectors to the lower dash panel. Position panel and secure with all screws. Ensure panel fits flush and does not interfere with steering column operation.
14. 14

    Reinstall fuse box cover
    Align fuse box cover with mounting clips and press firmly until it clicks into place. Verify cover is secure and properly seated.
15. 15

    Reconnect batteries
    Reconnect positive battery terminals first, then negative terminals on both batteries. Torque battery terminal bolts to specification - do not overtighten as this can damage terminals.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Ensure all electrical connectors are fully seated with locking tabs engaged
2. Verify all mounting bolts are torqued to specification
3. Confirm ground connections are clean and tight
4. Double-check that fuse and relay positions match documentation

Verification

• Turn ignition to ON position (do not start) and verify dash lights illuminate normally
• Check for any warning lights or abnormal indicators on instrument cluster
• Start engine and verify all electrical systems function properly: lights, wipers, HVAC, power windows, radio
• Test turn signals, brake lights, and hazard lights with helper
• Verify no blown fuses and all relays are clicking when activated
• Check for any electrical odors or signs of heat at fuse box
• Reset clock and radio presets as needed

Related trouble codes on this vehicle

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