DODGE RAM 1999 Service Repair Manual

threads. Right side assembly has right-hand threads.
Installation
1) Lubricate and assemble adjustment star wheel. Apply thin
film of multipurpose grease to shoe contact pads on support plate.
Assemble lower shoe-to-shoe spring, adjustment star wheel and both
shoes. Position shoe assembly on support plate.
2) Attach parking brake cable to lever using NEW "U" clip or
"E" clip. Install shoe hold-down pins, springs and retainers. Install
upper shoe-to-shoe spring. Position adjusting lever return spring on
pivot. Install adjusting lever. Route cable, and connect it to
adjuster. Install drum assembly and wheel. Adjust brakes. See REAR
BRAKE SHOES under ADJUSTMENTS.
WHEEL CYLINDERS
Removal & Installation
1) Remove wheel, drum and brake shoes. Inspect boots for
damage and signs of leakage. Disconnect and plug hydraulic brakeline
from wheel cylinder. Remove attaching bolts, and remove cylinder. See
Fig. 5 .
2) Apply silicone sealant to cylinder mounting surface, and
position cylinder on support plate. Start brakeline fitting in wheel
cylinder. Install and tighten mounting bolts. Tighten brakeline
fitting. To complete installation, reverse removal procedure. Fill
brake fluid reservoir, and bleed hydraulic system. See BLEEDING
PROCEDURES under BLEEDING BRAKE SYSTEM.
Fig. 5: Exploded View Of Rear Wheel Cylinder (Typical)
Courtesy of Chrysler Corp.
MASTER CYLINDER & RESERVOIR
NOTE: Manufacturer does not recommend overhaul of master cylinder.
Removal and replacement of reservoir and grommets are the
only recommended service procedures. Replace master cylinder
if faulty.

Removal & Installation
1) Disconnect and plug primary and secondary brakelines from
master cylinder. Remove master cylinder-to-power brake booster nuts.
Slide master cylinder straight out and away from power brake booster
unit.
2) Ensure reservoir is empty. Install master cylinder in
soft-jaw vise. Pry gently upward between reservoir ports while working
reservoir side to side. Remove reservoir and grommets. See Fig. 6.
3) Install NEW grommets in master cylinder ports. Lubricate
grommets with brake fluid. Firmly and evenly, press reservoir into
grommets by hand.
4) To complete installation, position master cylinder over
studs of power brake booster. Align power cylinder brake push rod with
cylinder piston. Install master cylinder nuts, and tighten to
specification. See TORQUE SPECIFICATIONS table. Connect both
brakelines. Bleed system. See BLEEDING BRAKE SYSTEM.
Fig. 6: Exploded View Of Master Cylinder (Ram Pickup)
Courtesy of Chrysler Corp.
POWER BRAKE BOOSTER
Removal
1) Disconnect vacuum hose from booster check valve. Remove
nuts attaching master cylinder, and move cylinder away from booster.
Inside vehicle, remove booster push rod-to-brake pedal clip. Pry clip
off pedal pivot pin.
2) Remove lock nuts from booster mounting studs. Slide
booster away from dash and out of engine compartment. If booster is

being replaced, remove booster check valve and seal.
Installation
1) If new booster is being installed, install check valve and
seal. Position booster on dash, and install lock nuts on booster
mounting studs finger tight. Install booster push rod on brake pedal
pin, and secure rod with NEW retaining clip.
2) Tighten booster lock nuts to specification. Install master
cylinder on booster, and tighten mounting nuts to specification. See
TORQUE SPECIFICATIONS table. Connect vacuum hose to booster check
valve. Start vehicle and check booster operation.
COMBINATION VALVE
Removal & Installation
Raise and support vehicle. Mark brakelines for assembly
reference. Disconnect parking brake cable from clip on valve, if
necessary. Disconnect brake warning light connection at switch.
Disconnect all brake hydraulic lines at valve. Cap brakelines to
prevent dirt from entering system. Remove valve. To install, reverse
removal procedures. Bleed brake system. See BLEEDING PROCEDURES under
BLEEDING BRAKE SYSTEM.
AXLE BEARING & SEAL (FULL FLOATING AXLE)
Removal & Installation (Ram Pickup With 12" & 13" Drums)
1) Raise and support vehicle. Remove wheel. Remove axle shaft
nuts and washers. Strike center of axle flange to free cones. Remove
axle shaft and gasket.
2) Straighten and remove nut lock. Remove adjustment nut and
outer bearing. Remove drum assembly. Remove seal and inner bearing
from drum assembly.
3) Pack inner bearing, and install inner bearing and seal in
drum. Install drum assembly, outer bearing and adjustment nut. While
rotating drum, tighten adjustment nut to specification. See TORQUE
SPECIFICATIONS table.
4) Back off adjustment nut 1/8 turn to obtain .001-.010" (0.
025-0.254 mm) end play. Bend nut lock into spindle keyway. Install
gasket and axle shaft. Install wheel, and lower vehicle. See TORQUE
SPECIFICATIONS table.
OVERHAUL
NOTE: Use illustrations when overhauling components. See
Figs. 2-6.
DISC BRAKE SPECIFICATIONS
DISC BRAKE SPECIFICATIONS








\









\









\









\









\









\









\







Application In. (mm)\
Disc Diameter
Dakota ............................................... 11.30 (287)\
Ram Pickup
1/2 Ton ............................................. 11.57 (294)\
3/4 & 1 Ton ......................................... 12.50 (318)\
Ram Van
1/2 & 3/4 Ton ....................................... 11.75 (299)\
1 Ton ............................................... 12.82 (326)\
Lateral Runout

Dakota & Ram Van ..................................... .004 (.102)\
Ram Pickup ........................................... .005 (.127)\
Parallelism
Dakota & Ram Van .................................... .0005 (.013)\
Ram Pickup ........................................... .001 (.025)\
Original Thickness
Dakota & Ram Van ............................................. (1)
Ram Pickup
1/2 Ton ............................................... 1.26 (32)\
3/4 & 1 Ton ........................................... 1.50 (38)\
Minimum Refinish Thickness ..................................... ( 1)
Dakota ............................................... .890 (22.6)\
Ram Van ................................................ 1.18 (30)\
Ram Pickup
1/2 Ton ............................................ 1.22 (31.00)\
3/4 Ton ............................................ 1.27 (32.26)\
1 Ton .............................................. 1.52 (38.61)\
Discard Thickness .............................................. ( 2)
( 1) - Information is not available from manufacturer.
( 2) - Discard thickness is marked on rotor hub.









\









\









\









\









\









\









\







DRUM BRAKE SPECIFICATIONS
DRUM BRAKE SPECIFICATIONS








\









\









\









\









\









\









\







Application In. (mm)\
9" Drum
Drum Width ........................................... 2.50 (63.5)\
Maximum Allowable Diameter ........................ 9.060 (230.12)\
Wheel Cylinder Diameter ............................. .750 (19.05)\
10" Drum
Drum Width ........................................... 2.50 (63.5)\
Maximum Allowable Diameter ....................... 10.060 (255.52)\
Wheel Cylinder Diameter ............................. .810 (20.57)\
11" Drum
Drum Width
Ram Pickup (1/2 Ton) ................................ 2.00 (51.0\
)
Ram Van (1/2 & 3/4 Ton) ............................ 2.25 (57.15\
)
Maximum Allowable Diameter ....................... 11.060 (280.92)\
Wheel Cylinder Diameter ............................. .940 (23.88)\
12" Drum
Drum Width
Ram Van (1 Ton) ..................................... 3.50 (88.9\
)
Maximum Allowable Diameter ....................... 12.060 (306.32)\
Wheel Cylinder Diameter
Ram Van
3/4 Ton .......................................... .940 (23.88)\
1 Ton ........................................... 1.060 (27.00)\
13" Drum
Drum Width
Ram Pickup
3/4 Ton ........................................... 2.50 (63.5)\
1 Ton ............................................. 3.50 (89.0)\
Maximum Allowable Diameter ....................... 13.060 (331.72)\
Wheel Cylinder Diameter
Ram Pickup
3/4 Ton .......................................... .940 (23.88)\
1 Ton ............................................. 1.06 (27.0)\









\









\









\









\









\









\









\

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








\









\









\









\









\









\









\







Application Ft. Lbs. (N.m)\
Axle Adjustment Nut .............................. 120-140 (163-190)\
Axle Shaft Flange Or Support Plate Mounting Nuts
Dakota .................................................. 47 (64)\
Ram Pickup ........................................ 35-50 (48-68)\
Ram Van ................................................ 85 (115)\
Bearing/Hub Assembly Mounting Bolts ...................... 125 (170)\
Brake Booster Mounting Nuts
Dakota & Ram Pickup ...................................... 21 (29)\
Ram Van .................................................. 13 (18)\
Brake Hose Front Bolt (Dakota) ............................. 21 (29\
)
Brake Hose Front Fitting (Dakota) .......................... 12 (16\
)
Brake Hose Rear Fitting (Dakota) ........................... 14 (19\
)
Brakeline Fittings Combination Valve
Dakota ................................................... 14 (19)\
Ram Pickup ......................................... 14-17 (19-23)\
Brakeline Fittings Master Cylinder
Dakota ................................................... 14 (19)\
Ram Pickup ......................................... 14-17 (19-23)\
Brakeline Fittings Wheel Cylinder
Dakota ................................................... 12 (16)\
Ram Pickup ............................................... 10 (14)\
Brake Pedal Shaft Nut (Ram Van) ............................ 40 (54\
)
Caliper Adapter Bolts (Ram Van)
1/2 Ton ................................................ 130 (176)\
3/4 & 1 Ton ............................................ 210 (285)\
Caliper Mounting Bolts
Dakota (Guide Pins) ...................................... 22 (30\
)
Ram Pickup ............................................... 38 (52)\
Ram Van .................................................. 24 (33)\
Combination Valve Mounting Bolt (Ram Pickup) ............... 17 (23\
)
Diesel Hydraulic Booster Hoses (Ram Pickup) ................ 23 (31\
)
Diesel Hydraulic Booster Lines (Ram Pickup) ................ 21 (29\
)
Diesel Hydraulic Booster Mounting Bolts (Ram Pickup) ....... 21 (29\
)
Drive Flange Lock Nuts (4WD) ............................... 65 (88\
)
Master Cylinder Nuts
Dakota
1998 .................................................... 21 (29)\
1999 .................................................... 13 (18)\
Ram Pickup ............................................... 21 (29)\
Ram Van .................................................. 17 (23)\
Park Brake Pedal Assembly Mounting Bolts/Nuts
Ram Pickup ............................................... 21 (29)\
Ram Van .................................................. 40 (54)\
Pivot Pin .................................................. 30 (41)\
Power Booster Lock Nuts
Dakota & Ram Pickup ...................................... 21 (29)\
Ram Van .................................................. 13 (18)\
Proportioning Valve Brake Hose (Ram Pickup) ................ 23 (31\
)
Proportioning Valve Brakelines (Ram Pickup) .......... 14-17 (19-23\
)
Proportioning Valve Mounting Nuts (Ram Pickup) ............. 25 (34\
)
Wheel Bearing Outer Lock Nut (4WD) ......................... 65 (88\
)
Wheel Cylinder Mounting Bolts
1/4" Bolts (Dakota) ...................................... 11 (15\
)
5/16" Bolts (Dakota) ..................................... 16 (22\
)
Ram Pickup & Ram Van ..................................... 15 (20)\

Wheel Lug Nuts
Dakota .......................................... 85-115 (115-156)\
Ram Pickup
5-Stud Wheel ........................................... 95 (129)\
8-Stud Wheel
Single Wheel ........................................ 135 (183)\
Dual Wheel .......................................... 145 (197)\
Ram Van
15" Wheel (5 Stud) ............................. 80-110 (109-149\
)
16" Wheel (8 Stud) ............................ 120-150 (163-203\
)
INCH Lbs. (N.m)
Locking Hub Allen Screws ........................... 35-45 (4.0-5.0)\









\









\









\









\









\









\









\

CLU TC H
1999 D odge P ic ku p R 1500
1998-99 CLUTCHES
CHRY - RWD - Trucks
Dakota, Ram Pickup
DESCRIPTION
Clutches on all models are dry, single-disc design.
Adjustment for wear is not possible. Clutch pedal is connected to
release fork through a hydraulic master cylinder and slave cylinder
and is not adjustable. Pre-lubricated clutch bearing is constant
running type. External adjustments cannot be made.
All models are equipped with a clutch pedal position switch.
The switch completes the circuit to the starter relay and is mounted
on clutch master cylinder push rod. The position switch is an integral
part of clutch master cylinder push rod and cannot be serviced
separately.
TRANSMISSION/TRANSFER CASE APPLICATION









\









\









\









\









\









\









\







Transmission Transfer Case
Dakota
AX15, NV1500 & NV3500 .............................. NV231 & NV242
Ram Pickup
NV3500, NV4500, NV4500HD & NV5600 ..... NV231HD, NV241LD & NV241HD









\









\









\









\









\









\









\







ADJUSTMENTS
CLUTCH PEDAL FREE PLAY
NOTE: Clutches are a single, dry disc type. Adjustment for wear is
not possible. Clutch is actuated through hydraulic master
cylinder and slave cylinder, and is self-adjusting.
SHIFT LINKAGE ADJUSTMENT
NV231 (Dakota)
1) Shift transfer case into 4H position, and secure shift
lever in shift gate. See Fig. 1. Raise and support vehicle. Loosen
shift rod lock bolt at swivel. Ensure shift rod slides freely in
adjusting swivel.
2) Ensure transfer case range lever is in 4H position. Slide
adjusting swivel forward until shift rod contacts shift gate
crossover, then slide adjusting swivel back, allowing a .11-.20" (3-5
mm) gap between shift lever and shift gate.
3) Center pin on adjusting swivel in shift arm and tighten
lock bolt to 90 INCH lbs. (10 N.m.). Lower vehicle, making sure all
wheels are off floor. Start engine. Shift transfer case through all
ranges to verify correct adjustment.
NV231HD, NV241LD & NV241HD (Ram Pickup)
1) Place shift lever into 2H position. Raise and support
vehicle. Loosen shift rod lock bolt at swivel. See Fig. 2. Ensure
shift rod fits in swivel and does not bind.
2) Ensure transfer case shift lever is in 2H position. Lower
vehicle. Position shift lever in cab so distance between instrument

panel and 2H position dot in shift lever insert is 5.75" (14.6 cm).
Make measurement parallel to floor of vehicle.
3) Tighten shift rod lock bolt to 90 INCH lbs. (10 N.m).
Start engine. Shift transfer case through all ranges to verify proper
operation.
NV242 (Dakota)
1) Put shift lever into 4FT position and secure. Raise
vehicle. Loosen shift rod lock bolt at swivel. See Fig. 1. Ensure
shift rod slides freely in adjusting swivel.
2) Ensure transfer case shift lever is in 4FT position. Slide
adjusting swivel forward until shift lever contacts shifter gate
crossover then slide adjusting swivel back, allowing a 0.11-0.20" (3-5
mm) gap between shift lever and shift gate.
3) Center pin on adjusting swivel in shift arm and tighten
lock bolt to 90 INCH lbs. (10 N.m). Lower vehicle, making sure wheels
are off floor. Start engine. Shift transfer case through all ranges to
verify correct adjustment.
Fig. 1: Adjusting Transfer Case Shift Linkage (Dakota)
Courtesy of Chrysler Corp.

Fig. 2: Adjusting Transfer Case Shift Linkage (Ram Pickup)
Courtesy of Chrysler Corp.
TROUBLE SHOOTING
NOTE: For trouble shooting not covered in this article, see
appropriate table in TROUBLE SHOOTING article in GENERAL
INFORMATION.
Hydraulic system should not require addition of fluid under
normal circumstances. Reservoir fluid level will increase as normal
clutch wear occurs. Avoid overfilling or removing fluid from
reservoir. This will cause clutch release problems.
TESTING
CLUTCH PEDAL POSITION SWITCH
NOTE: The position switch is an integral part of clutch master
cylinder push rod and cannot be serviced separately.
Disconnect clutch pedal position switch electrical connector.
Depress switch. Using a DVOM, measure continuity between clutch pedal
position switch terminals No. 1 (Yellow/Red wire) and No. 2 (Dark
Blue/Yellow wire). If continuity exists, switch is okay. If continuity
does not exist, replace clutch master cylinder. See CLUTCH MASTER
CYLINDER under REMOVAL & INSTALLATION.

CLUTCH HOUSING (RAM PICKUP)
NOTE: Only NV4500 clutch housing can be checked using the following
bore and face runout procedures. The NV1500, NV3500 and
NV5600 clutch housings are an integral part of transmission
front case and can only be checked off vehicle.
Clutch Housing Bore Runout (NV4500)
1) Remove clutch housing. Remove clutch cover and disc. See
CLUTCH ASSEMBLY under REMOVAL & INSTALLATION. Replace one flywheel
bolt with a threaded rod. See Fig. 2. Remove release fork from clutch
housing. Reinstall clutch housing. Tighten housing bolts nearest
alignment dowels first. Mount dial indicator on threaded rod and
position indicator plunger on surface of clutch housing bore. See
Fig. 4 .
2) Rotate crankshaft until indicator plunger is at top center
of housing bore. Zero dial indicator. Rotate crankshaft and record
indicator readings at 8 points, 45 degrees apart, around bore. See
Fig. 5 .
3) Repeat measurement at least twice. Subtract each reading
from one 180 degrees opposite to determine magnitude and direction of
runout. For example: 0.000" minus (-0.007") = 0.007", 0.002" minus (-\
0.010") = 0.01", 0.004" minus (-0.005") = 0.009" or -0.001" minus (0\
.
001") = -0.002" which will be 0.002". In this example, largest
difference is 0.012" (total indicator reading). This means housing
bore is offset from crankshaft centerline by 0.006" (1/2 of 0.012").
4) On gas engines, acceptable total indicator reading is 0.
010". If measured total indicator reading is more than 0.010", bore
runout will have to be corrected using offset dowels. Offset dowels
are available in 0.007", 0.014" and 0.021". See DOWEL SELECTION table.
If total indicator reading is 0.053" or greater, replace clutch
housing. If dial indicator reads positive when plunger moves inward
(toward indicator) and negative when moves outward away from
indicator), lowest or most negative reading determines direction of
housing bore offset (runout).
5) On diesel engines, offset dowels are not available to
correct runout. If total indicator reading exceeds bore runout of 0.
015", replace either clutch housing, or transmission adapter plate. On
gas engines, if bore is offset, remove housing and original dowels,
install new offset dowels in direction need to center bore with
crankshaft centerline. Install new dowels with slotted side facing
out. Using a screwdriver, rotate dowels until total indicator reading
is less than 0.010". Ensure clutch housing face runout is within
specification.
DOWEL SELECTION









\









\









\









\









\









\









\







Application - In. (mm) Offset Dowel - In. (mm\
)
0.011-0.021 (0.2794-0.5334) ......................... 0.007 (0.1778\
)
0.022-0.035 (0.5588-0.8890) ......................... 0.014 (0.3556\
)
0.036-0.052 (0.9144-1.3208) ......................... 0.021 (0.5334\
)









\









\









\









\









\









\









\







Fig. 3: Manufactured Stud Or Threaded Rod
Courtesy of Chrysler Corp.