shock DODGE RAM 1999 Service Owner's Manual

(1) - Require replacement of units where dents restrict shock
or strut piston rod movement. If dents don't restrict
movement, no service is suggested or required. Especially
critical on mono-tube shocks.
( 2) - This condition can lead to damage of the piston rod,
which, in turn, causes premature piston rod seal wear.
( 3) - Only required if replacing cartridge.
( 4) - CAUTION: If the strut cartridge has been replaced previously,
the oil on the strut housing may be filler oil. The
technician must identify the source of the oil.
( 5) - If noise is isolated to shock or strut, suggest
replacement.
( 6) - Although shocks or struts may have contributed to tire
cupping, an inspection is needed of the entire suspension
system. If the shock or strut is found to be contributing
to the tire cupping, require replacement.









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SPINDLES
SPINDLE INSPECTION








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Condition Code Procedure
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.
Bent .................... B ............ Require replacement.
Broken .................. A ............ Require replacement.
Race seat area
undersized ............. B ............ Require replacement.
Scored .................. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.









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SPRINGS - COIL, LEAF AND TORSION BAR
When springs are replaced, it is suggested, but not required,
that both springs on an axle be replaced to maintain equal height from
side to side and to provide a balanced ride and proper handling.
When variable rate springs are installed in place of
conventional coil springs, they must be installed in axle sets to
ensure proper handling, uniform ride, and proper chassis height.
Erroneous height measurements may result from: improper tire
inflation, non-standard tire or wheel size, and heavy load in vehicle
or trunk.
SPRING (COIL, LEAF AND TORSION BAR) INSPECTION


SU SPEN SIO N - F R O NT - 2 W D C O IL S PR IN G
1999 D odge P ic ku p R 1500
1998-99 SUSPENSION
CHRY - Front - 2WD Coil Spring
Ram Pickup
DESCRIPTION
All models are equipped with independent front suspension,
consisting of upper and lower control arms, steering knuckles, coil
springs and shock absorbers. See Fig. 1. Upper control arms are
mounted to frame side rails. Lower control arms are mounted to
crossmember. Steering knuckles are mounted between upper and lower
control arms by conventional ball joints. Coil springs are mounted
between seat in frame and lower control arm.
Fig. 1: Exploded View Of Front Suspension
Courtesy of Chrysler Corp.
ADJUSTMENTS & INSPECTION

WHEEL ALIGNMENT
NOTE: See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL
ALIGNMENT.
WHEEL BEARING ADJUSTMENT
1) Tighten wheel bearing adjusting nut to 30-40 ft. lbs. (41-\
54 N.m) while rotating wheel. Stop rotation, and back off adjusting
nut to release all preload. Retighten nut finger tight.
2) Ensure bearing end play is .001-.003" (.025-.076 mm).
Install nut lock and cotter pin. Coat grease cap inside lightly with
grease, and install cap.
BALL JOINT CHECKING
Ball joints are preloaded. Replace lower ball joint if
vertical movement exceeds .03" (.8 mm). Replace upper ball joint if
movement exceeds .03" (.8 mm).
REMOVAL & INSTALLATION
COIL SPRING
Removal
1) Raise vehicle, and position safety stands under frame.
Remove wheels. Remove brake caliper retainer and brake caliper (if
necessary). Support caliper aside. Disconnect tie rod from steering
knuckle.
2) Disconnect stabilizer bar link from lower control arm. See
Fig. 1 . Support lower suspension arm outboard end with jack. Place
jack under arm in front of shock mount. Remove cotter pin and nut from
lower ball joint stud. Using Ball Joint Breaker (C-4150A), separate
ball joint from steering knuckle.
3) Remove lower shock bolt from suspension arm. Lower jack
and suspension arm until spring tension is relieved. Remove spring and
rubber isolator.
Installation
1) Install rubber isolator on top of spring. Position spring
between upper spring seat and lower suspension arm. Raise suspension
arm with jack, and position shock into suspension arm mount.
2) Install shock bolt and tighten to specification. See
TORQUE SPECIFICATIONS table. Install steering knuckle on lower ball
joint stud. Install lower ball joint stud nut and tighten. See TORQUE
SPECIFICATIONS table. Replace cotter pin, and remove jack. Install
stabilizer bar link on lower suspension arm. Install grommet, retainer
and nut.
3) Install tie rod on steering knuckle, and tighten nut to 65
ft. lbs. (88 N.m). Install brake caliper assembly and rotor. Install
tire and wheel assembly. Remove support, and lower vehicle.
STEERING KNUCKLE
Removal & Installation
1) Raise and support vehicle. Remove wheel and tire assembly.
Remove brake caliper. Remove wheel hub and bearing assembly from
spindle.
2) Remove cotter pin and nut from tie-rod end, and disconnect
tie rod. Remove cotter pins and nut from upper and lower ball joint

stud. Separate upper ball joint stud from knuckle with Ball Joint
Breaker (MB-990635).
3) Separate lower ball stud with Ball Joint Breaker (C-
4150A). Remove knuckle. To install, reverse removal procedure. Tighten
all nuts and bolts to specification. See TORQUE SPECIFICATIONS table.
LOWER CONTROL ARM & BALL JOINT
Removal
1) Raise and support vehicle. Remove wheel. Support lower
control arm.
CAUTION: DO NOT remove shock until lower control arm is supported.
Shock holds lower control arm and spring in position.
2) Remove shock absorber and coil spring. See COIL SPRING.
Remove bolts mounting lower control arm to crossmember. Remove lower
control arm.
Bushing Replacement
If bushings are worn, use a sleeve and press to remove and
replace bushings.
Installation
To install, reverse removal procedure. Tighten all nuts and
bolts to specification. See TORQUE SPECIFICATIONS table.
STABILIZER BAR
Removal & Installation
Raise and support vehicle. Remove link rod retaining nut at
each end of stabilizer bar. Remove outer retainers and rubber bushings
from link rods. Remove stabilizer bar clamps from frame rails. Remove
stabilizer bar from vehicle. To install, reverse removal procedure.
Ensure stabilizer bar is centered in chassis. Tighten all nuts and
bolts to specifications.
UPPER CONTROL ARM & BALL JOINT
Removal
1) Raise vehicle, and position safety stands under frame.
Remove wheel. Support upper control arm.
2) Disconnect upper ball joint. Refer to step 2) under LOWER
CONTROL ARM & BALL JOINT. Remove pivot bolts and control arm.
Bushing Replacement
If bushings are worn, use a sleeve and press to remove and
replace bushings.
Installation
To install, reverse removal procedure. Ensure ball joint is
fully seated against control arm. With vehicle at normal operating
height, tighten all retaining nuts and bolts to specifications. See
TORQUE SPECIFICATIONS table.
WHEEL BEARINGS
Removal
1) Raise and support vehicle. Remove wheel. Remove brake
caliper, and support it aside. Remove inboard brake pad (if
necessary). Remove grease cap, cotter pin, nut, washer and outer wheel
bearing.

CAUTION: To avoid damage to threads, bearing and seal, DO NOT allow
inner bearing and seal to contact spindle threads during
removal.
2) Carefully slide rotor from steering knuckle. Remove oil
seal and inner bearing.
Installation
Clean and inspect bearings. Pack or replace bearings as
required. Install inner bearing and oil seal. Carefully install rotor
and outer bearing, washer, and nut. Adjust wheel bearings. See WHEEL
BEARING ADJUSTMENT under ADJUSTMENTS & INSPECTION. To install
remaining components, reverse removal procedure.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Ball Joint Nuts
Lower
Light Duty ............................................. 95 (129)\
Heavy Duty ............................................ 110 (149)\
Upper .................................................... 60 (81)\
Lower Control Arm-To-Crossmember Bolt .................... 145 (196)\
Lower Shock Absorber Mounting Bolt
1998 Models ............................................ 100 (135)\
1999 Models ........................................... 105 (142))\
Stabilizer Bar Bolts/Nuts
Frame End ................................................ 40 (54)\
Link End ................................................. 25 (34)\
Tie Rod End Nut ............................................ 40 (54)\
Upper Ball Joint-To-Control Arm .......................... 125 (169)\
Upper Control Arm Eccentric Cam Bolt ....................... 70 (95)\
Upper Control Arm Pivot Bar To Frame ..................... 150 (203)\
Upper Shock Absorber Mounting Bolt
1998 Models .............................................. 35 (47)\
1999 Models .............................................. 40 (54)\
Wheel Lug Nuts
Tapered (Coned)
1/2"-20 ............................................... 105 (142)\
5/8"-18 ............................................... 200 (271)\
Flat (Flanged) (5/8"-18) ............................... 325 (4\
40)









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SU SPEN SIO N - F R O NT - L IN K/C O IL S PR IN G

1999 D odge P ic ku p R 1500
1998-99 SUSPENSION
CHRY - Front - Link/Coil Spring
Ram Pickup
DESCRIPTION
Link/coil front suspension uses upper and lower suspension
arms attached to frame and drive axle (4WD) or tube axle (2WD). Shoc\
k
absorbers are mounted inside the coil springs, and attached at top to
a bracket with grommets. These brackets are bolted onto the frame with
3 studs on a ring. The shock is mounted at bottom of axle below the
spring seat. See Fig. 1.
A track bar is used, and is attached to a frame rail bracket
with a ball stud. The track bar is isolated with a bushing at the axle
bracket. Other components of the link/coil spring suspension system
are a stabilizer bar, links, upper and lower suspension arms, bushings
and ball joints.
Fig. 1: Exploded View Of Front Suspension Assembly
Courtesy of Chrysler Corp.
ADJUSTMENTS & INSPECTION
WHEEL ALIGNMENT
NOTE: See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL
ALIGNMENT.

WHEEL BEARING & HUB
Wheel bearing and hub assembly is not serviceable, and is
replaced as an assembly only.
REMOVAL & INSTALLATION
COIL SPRING
Removal & Installation
1) Raise and support vehicle. Position jack under axle for
added support. Scribe alignment marks on lower control arm cam
adjusters and axle bracket for installation reference.
2) Remove upper control arm. See UPPER CONTROL ARM. Loosen
lower control arm bolts. See Fig. 1. On 4WD models, scribe marks on
front drive shaft for installation reference. Disconnect front drive
shaft from axle. On all models, disconnect track bar from frame rail
bracket. See TRACK BAR. Disconnect drag link from pitman arm.
3) Disconnect stabilizer bar link and shock absorber from
axle. Lower axle until spring is free from upper mount. Remove coil
spring. To install, reverse removal procedure. Tighten nuts and bolts
to specification. See TORQUE SPECIFICATIONS table.
LOWER CONTROL ARM
Removal & Installation
1) Raise and support vehicle. Scribe alignment marks on cam
adjusters and suspension arm for installation reference. Remove lower
control arm nut, cam and cam bolt from axle. See Fig. 1.
2) Remove nut and bolt from frame rail bracket. Remove lower
control arm. To install, reverse removal procedure. Tighten nuts and
bolts to specification. See TORQUE SPECIFICATIONS table.
UPPER CONTROL ARM
Removal & Installation
1) Raise and support vehicle. Remove upper control arm nut
and bolt at axle bracket. See Fig. 1. Remove nut and bolt at front
rail and remove upper control arm assembly.
2) To install, reverse removal procedure. Tighten nuts and
bolts to specification. See TORQUE SPECIFICATIONS table.
SHOCK ABSORBER
Removal & Installation
1) Remove nut, retainer and grommet from upper stud in engine
compartment. See Fig. 2. Remove 3 nuts from upper shock bracket.
Remove lower bolt from axle bracket. Remove shock absorber from engine
compartment.
2) To install, reverse removal procedure. Tighten nuts and
bolts to specification. See TORQUE SPECIFICATIONS table.

Fig. 2: Removing Front Shock Absorber Assembly
Courtesy of Chrysler Corp.
STABILIZER BAR

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