DODGE RAM 1999 Service Repair Manual

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application INCH Lbs. (N.m)\
Air Bag Retaining Nuts ................................ 90-97 (9-11)\
Ignition Switch Mounting Screw ..................... 22-30 (2.5-3.5)\
Multifunction Switch Connector Screw ........................ 17 (2)\
Multifunction Switch Mounting Screw ......................... 17 (2)\
Steering Column Cover Screw ................................. 17 (2)\









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WIRING DIAGRAMS
Fig. 9: Horn System Wiring Diagram (Dakota)

Fig. 10: Horn System Wiring Diagram (Durango)

Fig. 11: Horn System Wiring Diagram (Ram Pickup)


STE ER IN G K NUCKLE S - 4 W D

1999 D odge P ic ku p R 1500
1998-99 DRIVE AXLES
CHRY - 4WD Steering Knuckles
Ram Pickup
DESCRIPTION
Open type steering knuckles are used on all models. Open type
knuckles provide sharper turning angle, decreasing turning radius.
Axle shafts are free floating. Steering knuckles are attached to axle
housing by ball joints.
REMOVAL & INSTALLATION
REMOVAL
1) Raise and support vehicle. Remove wheels. Remove brake
caliper, and support aside. DO NOT allow caliper to hang by brake
hose. On one ton models, remove adapter hub bolts and hub from rotor
and hub assembly. On all models, remove cotter pin from rotor and hub
nut.
2) Remove rotor and hub nut. Remove bolts securing rotor and
hub assembly to steering knuckle. Bolts are accessible from inboard
side of steering knuckle. Remove rotor and hub assembly. Remove hub
spacer from steering knuckle. Note spacer position for installation
reference.
3) Disconnect tie rod end and drag link studs. Remove anti-
lock brake sensor from steering knuckle. Remove ball joint cotter pins
and nuts. Discard lower nut. Using a soft-face hammer, tap steering
knuckle to free it from ball joints.
4) Clean all components with solvent, and dry with compressed
air. Inspect all parts for burrs, chips, wear, flat spots or cracks.
Replace all damaged or worn parts.
INSTALLATION
NOTE: When aligning upper ball joint nut to install cotter pin,
always tighten nut to align holes. Never loosen nut to align
holes.
1) Position steering knuckle on ball joints, and install NEW
lower ball joint nut. Tighten nut to specification. See TORQUE
SPECIFICATIONS. Install upper ball joint nut, and tighten to
specification. Tighten, DO NOT loosen, nut to install NEW cotter pin.
2) Install hub bearing and axle shaft. Connect drag link stud
to steering knuckle arm. Install retaining nut, and tighten to
specification. Install NEW cotter pin. Connect tie rod end stud to
steering knuckle arm. Install retaining nut and tighten to
specification. Install NEW cotter pin. Install anti-lock brake sensor
to steering knuckle.
3) Apply anti-seize compound to splines of front drive axle.
Inspect hub grease seal and wheel bearing. Replace as necessary. From
rear of steering knuckle, install 2 rearward rotor and hub assembly
bolts in steering knuckle.
4) Apply chassis grease to hub spacer to secure on steering
knuckle. Position spacer on rotor and hub assembly bolts. Ensure
spacer is installed with flat edge toward rear of vehicle. Apply
Loctite to rotor and hub assembly bolt threads. Install rotor and hub

assembly to steering knuckle. Finger tighten bolts. Install 2
remaining rotor and hub assembly bolts. Tighten all bolts to
specification.
5) Install rotor and hub nut. Tighten nut to specification.
See TORQUE SPECIFICATIONS. Install cotter pin. On one ton models,
install adapter hub bolts and hub to rotor and hub assembly. Install
brake caliper, and tighten bolts to specification. Install wheels, and
tighten lug nuts to specification.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application (1) Ft. Lbs. (N.m)
ABS Sensor Bolt ............................................ 15 (11)\
Brake Caliper Bolt ......................................... 38 (52)\
Drag Link Nut .............................................. 65 (88)\
Hub-To-Steering Knuckle Bolt ..................... 125-160 (170-217)\
Lower Ball Joint Nut
216 FBI ................................................. 80 (108)\
248 FBI ........................................ 140-160 (190-217)\
Rotor & Hub Nut .................................. 160-200 (217-271)\
Shock Absorber Lower Bolt ................................ 100 (136)\
Stabilizer Bar Bolt ........................................ 27 (37)\
Tie Rod-To-Steering Knuckle Nut ............................ 65 (88)\
Upper Ball Joint Nut
216 FBI ................................................. 75 (102)\
248 FBI .................................................. 70 (94)\
Wheel Lug Nuts .................................... 95-145 (130-195)\
( 1) - Front axles can be identified by differential cover. The 216 FBI
has rounded edges, the 248 FBI has flat angled edges.









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STE ER IN G S YSTE M - P O W ER R EC IR CULA TIN G B ALL

1999 D odge P ic ku p R 1500
1998-99 STEERING
CHRY - Power Recirculating Ball - RWD Trucks
Dakota 4WD, Ram Pickup, Ram Van/Wagon
DESCRIPTION & OPERATION
The recirculating ball power steering system consists of
steering gear, steering linkage, pressure and return fluid hoses and
fittings, and a hydraulic steering pump with fluid reservoir.
The steering gear is a power assisted recirculating-ball type
that acts as a rolling thread between worm shaft and rack piston. See
Fig. 1 . When worm shaft is turned, the rack piston moves and piston
teeth mesh with sector shaft teeth, turning pitman arm, which turns
steering linkage.
The steering linkage consists of pitman arm, idler arm(s),
tie rods, center link and drag link (if equipped).
The power steering pump is a constant flow rate and
displacement, vane-type pump. Pump is connected to steering gear by
pressure and return hoses. On gasoline models, pump shaft has pressed
on belt-driven pulley.
On diesel models, power steering pump is bolted onto rear of
vacuum pump and is driven by a common shaft.
Fig. 1: Exploded View Of Saginaw Rotary Valve Power Steering Gear
Courtesy of Chrysler Corp.
TESTING

NOTE: Before testing, check fluid level, belt tension, pump pulley,
tire pressure and engine idle speed.
HYDRAULIC SYSTEM PRESSURE TEST
NOTE: Replacement fittings are required on Pressure Test Gauge(C
-3309E) for adapting to "O" ring type hose tube ends.
Idle Pressure Test
1) Remove high pressure hose at steering pump and connect a
spare hose to pump fitting. Connect opposite end of spare hose to
Pressure Test Gauge (C-3309E). Connect pressure hose from valve side
of steering gear to valve side of gauge. Valve must be installed on
outlet side of gauge. See Fig. 2.
2) Fully open shutoff valve on test gauge. With a thermometer
in fluid reservoir, start engine and warm fluid to 150-170
F (66-
77C). Turning wheels from stop-to-stop will aid in warming fluid. DO
NOT hold wheels against stop.
3) With engine at idle and gauge valve open, check initial
pressure. See POWER STEERING PUMP PRESSURE TEST SPECIFICATIONS table.
If pressure is greater than 125 psi (8.8 kg/cm

), check for restricted
hoses or crimped lines.
Fig. 2: Installing Pressure Gauge
Courtesy of Chrysler Corp.
POWER STEERING PUMP PRESSURE TEST SPECIFICATIONS
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Application psi (kg/cm
FD)
Idle Pressure ...................................... 50-80 (3.5-5.6)\
Relief Pressure
Dakota (4WD) ........................................ 1450 (101.9\
)
Ram Pickup .......................................... 1450 (101.9)\
Ram Van/Wagon ........................................ 1400 (98.4)\
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CAUTION: DO NOT leave shutoff valve closed more than 5 seconds, or
pump damage could result.

Relief Pressure Test
1) Close gauge shutoff valve completely 3 times. Record
highest pressure attained each time. All 3 readings must be greater
than specifications and within 50 psi (3.5 kg/cm

) of each other. See
POWER STEERING PUMP PRESSURE TEST SPECIFICATIONS table. If pressures
are not as specified, replace pump. See POWER STEERING PUMP (GASOLINE)\
or VACUUM/POWER STEERING PUMP (DIESEL) under REMOVAL & INSTALLATION.
CAUTION: DO NOT hold steering wheel against stops more than 4 seconds,
or pump damage may result.
2) Open test valve and turn steering wheel to left and right
stops. Record highest pressure attained at each stop. If output
pressures are not equal against each stop, gear is leaking internally
and must be replaced. See STEERING GEAR under REMOVAL & INSTALLATION.
Shut off engine, remove test gauge, and connect pressure hose.
LUBRICATION
CAPACITY
CAPACITY\
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Models Pts. (L)\
Dakota (4WD) ............................................. 2.5 (1.2\
)
Ram Pickup & Ram Van/Wagon ............................... 2.7 (1.3)\
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FLUID TYPE
CAUTION: DO NOT use Automatic Transmission Fluid (ATF).
Use Mopar Power Steering Fluid (4318055).
FLUID LEVEL CHECK
Check fluid level with engine cold and not running. Remove
fluid level dipstick on pump reservoir. Dipstick should indicate FULL
COLD with fluid temperature of 70-80
F (21-27C). If needed, add fluid
through dipstick opening, and recheck. DO NOT overfill.
HYDRAULIC SYSTEM BLEEDING
Fill power steering pump reservoir to specified level. Start
engine and slowly turn steering wheel to left and right, but DO NOT
contact steering stops in either direction. Stop engine. Inspect
reservoir fluid level and add fluid if necessary. Bleeding process may
have to be repeated several times to completely purge all air from
system.
ADJUSTMENTS
POWER STEERING PUMP BELT
Vehicles are equipped with dynamic tensioner. No adjustment
is required.
POWER STEERING PUMP PULLEY

After pulley installation, run the engine until warm. See
PUMP PULLEY under REMOVAL & INSTALLATION. If drive belt chirps, move
pulley outward approximately .020" (0.5 mm). If noise increases, press\
pulley inward .040" (1.0 mm). Ensure pulley does not contact mounting
bolts.
THRUST BEARING PRELOAD
NOTE: Manufacturer recommends removing steering gear from vehicle
before performing any adjustments.
1) Remove steering gear from vehicle. See STEERING GEAR under
REMOVAL & INSTALLATION. Ensure steering gear is empty of hydraulic
fluid. Rotate steering from stop-to-stop several times to drain fluid.
Loosen lock nut on adjuster plug. See Fig. 3. Using spanner wrench,
rotate adjuster plug clockwise until plug is seated in housing. Torque
will be approximately 20 ft. lbs. (27 N.m).
Fig. 3: Measuring Thrust Bearing Preload
Courtesy of Chrysler Corp.
2) Place reference mark on steering gear housing adjacent to
one hole in adjuster plug. Measure counterclockwise about 1/2" (13 mm)\

from reference mark and place a second reference mark on steering gear
housing.
3) Rotate adjuster plug counterclockwise until hole in
adjuster plug aligns with second mark on steering gear housing.
Tighten lock nut on adjuster plug to 80 ft. lbs. (108 N.m). Ensure
adjuster plug does not move while tightening lock nut.
OVER-CENTER PRELOAD
CAUTION: Thrust bearing preload must be adjusted before adjusting
over-center preload.
1) Loosen lock nut on sector shaft adjuster screw. See Fig. 4
. Rotate stub shaft and count turns required to go from stop-to-stop.
Turn stub shaft back 1/2 number of turns to center steering gear.
Fig. 4: Adjusting Over-Center Preload
Courtesy of Chrysler Corp.
2) Rotate sector shaft adjuster screw counterclockwise until
fully extended, then turn clockwise one full turn. Attach INCH-lb.
torque wrench to end of stub shaft. Position torque wrench handle in a
vertical position. Rotate stub shaft 45 degrees from vertical position
in each direction, and record highest reading. See Fig. 4.
3) Turn adjuster in until torque required to turn stub shaft
is 6-10 INCH lbs. (0.7-1.1 N.m) more than reading in step 2). Hold
adjuster screw, and tighten lock nut to 20 ft. lbs. (27 N.m).