sensor DODGE RAM 1999 Service Repair Manual


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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* S TE ER IN G U NIF O RM IN SPEC TIO N G UID ELIN ES *

1 999 D odge P ic ku p R 1500
GENERAL INFORMATION
Steering, Suspension, Wheel Alignment, Wheels and Tires
Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Steering and Suspension
AIR RIDE SUSPENSION
AIR RIDE SUSPENSION - AIR SHOCKS AND AIR STRUTS
AIR RIDE SUSPENSION - AIR SPRING VALVES
AIR RIDE SUSPENSION - AIR SPRINGS
AIR RIDE SUSPENSION - COMPRESSORS
AIR RIDE SUSPENSION - HEIGHT SENSORS
AIR RIDE SUSPENSION - MODULES
AIR RIDE SUSPENSION - RELAYS (COMPRESSOR)
AIR RIDE SUSPENSION - SWITCHES (ON/OFF)
AIR RIDE SUSPENSION - TORSION SPRINGS (COUNTER BALANCING)
AIR RIDE SUSPENSION - TUBING
AIR RIDE SUSPENSION - WARNING LAMPS
AIR RIDE SUSPENSION - WIRING HARNESSES
BALL JOINTS
BUSHINGS
CENTER LINKS
CONTROL ARM SHAFTS
CONTROL ARMS
DRAG LINKS
ELECTRONIC RIDE CONTROL SHOCKS AND STRUTS
IDLER ARMS
KING PINS
PITMAN ARMS
POWER STEERING HOSES
POWER STEERING (HYDRAULIC) PUMPS
RADIUS ARMS
RELAY RODS
SHOCK ABSORBERS, STRUT CARTRIDGES AND STRUT ASSEMBLIES
SPINDLES
SPRINGS - COIL, LEAF AND TORSION BAR
STEEL POWER STEERING LINES
STEERING ARMS
STEERING DAMPERS
STEERING GEARS (EXCEPT RACK AND PINION)
STEERING GEARS - RACK AND PINION
STEERING KNUCKLES
STRIKE OUT BUMPERS
STRUT RODS
STRUT UPPER BEARING PLATE ASSEMBLIES
SWAY BAR LINKS
SWAY BARS

AIR RIDE SUSPENSION - COMPRESSORS
AIR RIDE SUSPENSION - COMPRESSOR INSPECTION








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Condition Code Procedure
Attaching hardware bent . B ... Require repair or replacement
of bent part.
Attaching hardware
broken ................. A ... Require replacement of broken
part.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part.
Attaching hardware
missing ................ C .. Require replacement of missing
part.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Connector bent .......... A .. Require repair or replacement.
Connector broken ........ A ............ Require replacement.
Connector loose ......... A .. Require repair or replacement.
Does not build pressure . A .......... ( 1) Further inspection
required.
Excessive run time ...... B .......... ( 2) Further inspection
required.
Inoperative ............. A ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
( 1) - If failure to build pressure is traced to the
compressor, require replacement.
( 2) - If excessive run time is traced to the compressor,
require replacement.









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AIR RIDE SUSPENSION - HEIGHT SENSORS
AIR RIDE SUSPENSION - HEIGHT SENSOR INSPECTION








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Condition Code Procedure
Attaching hardware bent . B ... Require repair or replacement
of bent part.
Attaching hardware
broken ................. A ... Require replacement of broken
part.
Attaching hardware
corroded, affecting
structural integrity .... A .......... Require replacement of
corroded part.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part.
Attaching hardware
missing ................ C .. Require replacement of missing
part.
Attaching hardware

threads damaged ........ A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Dust boot missing ....... 2 ........ (1) Suggest replacement.
Dust boot split ......... 2 ........ ( 1) Suggest replacement.
Dust boot torn .......... 2 ........ ( 1) Suggest replacement.
Housing cracked ......... A ............ Require replacement.
Lead routing incorrect .. B .. Require rerouting according to
vehicle manufacturer's
specifications.
Loose ................... B ... Require adjustment to vehicle
manufacturer's specifications.
Missing ................. C ............ Require replacement.
Output signal incorrect . A .. Require repair or replacement.
Wire lead damaged ....... A .. Require repair or replacement.
( 1) - This condition can lead to damage of the sliding magnet,
which, in turn, causes premature sensor failure.









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AIR RIDE SUSPENSION - MODULES
AIR RIDE SUSPENSION - MODULE INSPECTION








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Condition Code Procedure
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part.
Attaching hardware
missing ................ C .. Require replacement of missing
part.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Housing cracked ......... 2 .. Suggest repair or replacement.
Inoperative ............. A ............ Require replacement.
Missing ................. C ............ Require replacement.









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AIR RIDE SUSPENSION - RELAYS (COMPRESSOR)
AIR RIDE SUSPENSION - RELAY (COMPRESSOR) INSPECTION








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Condition Code Procedure
Housing cracked ......... 2 ........ ( 1) Suggest replacement.
Intermittent ............ A ............ Require replacement.
Missing ................. C ............ Require replacement.
Output signal incorrect . A ............ Require replacement.
( 1) - If moisture enters the relay, it can reduce life
expectancy or impair function.









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AIR RIDE SUSPENSION - SWITCHES (ON/OFF)

Removal & Installation
Raise and support vehicle. Disconnect stabilizer bar links
from axle brackets. See Fig. 3. Disconnect stabilizer bar from links.
Disconnect stabilizer bar clamps from frame rails. Remove stabilizer
bar. To install, reverse removal procedure. Tighten nuts and bolts to
specification. See TORQUE SPECIFICATIONS table.
Fig. 3: Removing Stabilizer Bar Assembly
Courtesy of Chrysler Corp.
STEERING KNUCKLE
Removal & Installation
1) Raise and support vehicle. Remove wheel and tire assembly.
Remove tie-rod or drag link end from steering knuckle arm. Remove ABS
sensor wire and bracket from knuckle.
2) Remove cotter pin and nut from upper and lower ball joint
stud. Strike steering knuckle with brass hammer to loosen. Remove
knuckle. To install, reverse removal procedure. Tighten nuts and bolts
to specification. See TORQUE SPECIFICATIONS table.
TRACK BAR
Removal & Installation

1) Raise and support vehicle. Remove cotter pin and nut from
ball joint stud at end of frame rail bracket. See Fig. 4. Remove ball
stud from bracket with Puller C-4150A.
2) Remove bolt and flag nut from axle bracket. Remove track
bar. To install, reverse removal procedure. Tighten nuts and bolts to
specification. See TORQUE SPECIFICATIONS table.
Fig. 4: Removing Track Bar Assembly
Courtesy of Chrysler Corp.
WHEEL BEARINGS & HUB ASSEMBLY (5 STUDS)
Removal & Installation
1) Raise and support vehicle. Remove wheel. Remove caliper
and rotor. Remove ABS sensor (if equipped). Remove cotter pin and axle\
hub nut.
2) Remove wheel bearing and hub assembly hub-to-knuckle
bolts. Remove wheel bearing and hub assembly from steering knuckle and
axle shaft. Remove brake dust shield and spacer. To install, reverse
removal procedure. Tighten retaining nuts and bolts to specification.
See TORQUE SPECIFICATIONS table.
WHEEL BEARINGS & HUB ASSEMBLY (8 STUDS)
Removal & Installation
1) Raise and support vehicle. Remove wheel. Remove caliper
and rotor. Remove hub extension mounting nuts and remove extension
rotor (if equipped).

2) Remove brake caliper. Remove cotter pin and axle hub nut.
3) Disconnect ABS speed sensor wire. Remove sensor wire from
frame and steering knuckle (if equipped).
4) Remove wheel bearing and hub assembly hub-to-knuckle
bolts. Remove wheel bearing and hub assembly from steering knuckle and
axle shaft. Remove brake dust shield and spacer.
5) Press out wheel studs/hub extension studs and separate
rotor from hub. Remove wheel speed sensor from hub bearing (if
equipped). To install, reverse removal procedure. Tighten retaining
nuts and bolts to specification. See TORQUE SPECIFICATIONS table.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Anti-Rattle Springs & Clips ................................ 15 (20)\
Axle Nut ................................................. 175 (237)\
Ball Joint Nut
Model 44
Lower .................................................. 80 (108)\
Upper .................................................. 75 (102)\
Model 60
Lower ......................................... 140-160 (190-217)\
Upper ................................................... 70 (95)\
Cam Adjustment Nut ....................................... 170 (230)\
Control Arm
Lower
At Axle Bracket ........................................ 95 (129)\
At Frame Bracket ...................................... 125 (169)\
Upper
At Axle Bracket ........................................ 89 (121)\
At Frame Bracket ....................................... 80 (108)\
Drag Link-To-Pitman Arm .................................... 65 (88)\
Shock Absorber
Bracket Nut .............................................. 55 (75)\
Lower Mounting Bolt .................................... 100 (135)\
Upper Mounting Nuts ...................................... 35 (47)\
Stabilizer Bar
Bar-To-Link .............................................. 50 (68)\
Link-To-Axle Nut (1988 Models) ........................... 27 (37\
)
Link-To-Axle Nut (1999 Models) ........................... 35 (47\
)
Frame Bracket ............................................ 40 (54)\
Steering Knuckle Arm Nut ................................... 55 (75)\
Track Bar
Axle End ............................................... 130 (176)\
Frame End ................................................ 70 (95)\
Wheel Bearing & Hub Assembly-To-Knuckle Bolt ............. 125 (169)\
Wheel Lug Nuts
5 Stud Wheel
1998 Models ............................................ 95 (129)\
1999 Models .................................... 80-110 (108-149)\
8 Stud Wheel
1998 Models ........................................... 135 (183)\
1999 Models ................................... 120-150 (163-203)\
8 Stud Dual Wheel ...................................... 145 (196)\









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* S U SPEN SIO N U NIF O RM IN SPEC TIO N G UID ELIN ES *

1 999 D odge P ic ku p R 1500
GENERAL INFORMATION
Steering, Suspension, Wheel Alignment, Wheels and Tires
Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Steering and Suspension
AIR RIDE SUSPENSION
AIR RIDE SUSPENSION - AIR SHOCKS AND AIR STRUTS
AIR RIDE SUSPENSION - AIR SPRING VALVES
AIR RIDE SUSPENSION - AIR SPRINGS
AIR RIDE SUSPENSION - COMPRESSORS
AIR RIDE SUSPENSION - HEIGHT SENSORS
AIR RIDE SUSPENSION - MODULES
AIR RIDE SUSPENSION - RELAYS (COMPRESSOR)
AIR RIDE SUSPENSION - SWITCHES (ON/OFF)
AIR RIDE SUSPENSION - TORSION SPRINGS (COUNTER BALANCING)
AIR RIDE SUSPENSION - TUBING
AIR RIDE SUSPENSION - WARNING LAMPS
AIR RIDE SUSPENSION - WIRING HARNESSES
BALL JOINTS
BUSHINGS
CENTER LINKS
CONTROL ARM SHAFTS
CONTROL ARMS
DRAG LINKS
ELECTRONIC RIDE CONTROL SHOCKS AND STRUTS
IDLER ARMS
KING PINS
PITMAN ARMS
POWER STEERING HOSES
POWER STEERING (HYDRAULIC) PUMPS
RADIUS ARMS
RELAY RODS
SHOCK ABSORBERS, STRUT CARTRIDGES AND STRUT ASSEMBLIES
SPINDLES
SPRINGS - COIL, LEAF AND TORSION BAR
STEEL POWER STEERING LINES
STEERING ARMS
STEERING DAMPERS
STEERING GEARS (EXCEPT RACK AND PINION)
STEERING GEARS - RACK AND PINION
STEERING KNUCKLES
STRIKE OUT BUMPERS
STRUT RODS
STRUT UPPER BEARING PLATE ASSEMBLIES
SWAY BAR LINKS
SWAY BARS

AIR RIDE SUSPENSION - COMPRESSORS
AIR RIDE SUSPENSION - COMPRESSOR INSPECTION








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Condition Code Procedure
Attaching hardware bent . B ... Require repair or replacement
of bent part.
Attaching hardware
broken ................. A ... Require replacement of broken
part.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part.
Attaching hardware
missing ................ C .. Require replacement of missing
part.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Connector bent .......... A .. Require repair or replacement.
Connector broken ........ A ............ Require replacement.
Connector loose ......... A .. Require repair or replacement.
Does not build pressure . A .......... ( 1) Further inspection
required.
Excessive run time ...... B .......... ( 2) Further inspection
required.
Inoperative ............. A ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
( 1) - If failure to build pressure is traced to the
compressor, require replacement.
( 2) - If excessive run time is traced to the compressor,
require replacement.









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AIR RIDE SUSPENSION - HEIGHT SENSORS
AIR RIDE SUSPENSION - HEIGHT SENSOR INSPECTION








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Condition Code Procedure
Attaching hardware bent . B ... Require repair or replacement
of bent part.
Attaching hardware
broken ................. A ... Require replacement of broken
part.
Attaching hardware
corroded, affecting
structural integrity .... A .......... Require replacement of
corroded part.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part.
Attaching hardware
missing ................ C .. Require replacement of missing
part.
Attaching hardware