DODGE RAM 1999 Service Repair Manual

required because the part in question is no longer providing the
function for which it is intended, does not meet a vehicle
manufacturer's design specification or is missing.
Example:
An exhaust pipe has corroded severely and has a hole in it
through which exhaust gases are leaking. Replacement of the
exhaust pipe in this case is required due to functional
failure.
Example:
A brake rotor has been worn to the point where it measures
less than the vehicle manufacturer's discard specifications.
Replacement of the rotor is required because it does not meet
design specifications.
Some conditions indicate that a service or part replacement
is suggested because the part is close to the end of its useful life
or addresses a customer's need, convenience or request. If a
customer's vehicle has one of these conditions, the procedure may be
only to suggest service.
Example:
An exhaust pipe is rusted, corroded or weak, but no leaks are
present. In this case, the exhaust pipe has not failed.
However, there is evidence that the pipe may need replacement
in the near future. Replacement of the pipe may be suggested
for the customer's convenience in avoiding a future problem.
Example:
The customer desires improved ride and/or handling,
but the vehicle's shocks or struts have not failed. In this
case, replacement may be suggested to satisfy the customer's
wishes. In this case, replacement of the shocks or struts may
not be sold as a requirement.
A customer, of course, has the choice of whether or not a
shop will service his or her vehicle. He or she may decide not to
follow some of your suggestions. When a repair is required, a MAP shop
must refuse partial service on that system if, in the judgment of the
service provider, proceeding with the work could create or continue an
unsafe condition. When a procedure states that required or suggested
repair or replacement is recommended, the customer must be informed of
the generally acceptable repair/replacement options whether or not
performed by the shop.
When presenting suggested repairs to the customer, you must
present the facts, allowing the customer to draw their own conclusions
and make an informed decision about how to proceed.
The following reasons may be used for required and suggested
services. These codes are shown in the "Code" column of the MAP
Uniform Inspection & Communications Standards that follow:
Reasons to Require Repair or Replacement
A - Part no longer performs intended purpose
B - Part does not meet a design specification (regardless of
performance)
C - Part is missing
NOTE: When a repair is required, the shop must refuse partial
service to the system in question, if the repair creates
or continues an unsafe condition.
Reasons to Suggest Repair or Replacement

1 - Part is close to the end of its useful life (just above
discard specifications, or weak; failure likely to occur
soon, etc.)
2 - To address a customer need, convenience, or request (to
stiffen ride, enhance performance, eliminate noise,
etc.)
3 - To comply with maintenance recommended by the vehicle's
Original Equipment Manufacturer (OEM)
4 - Technician's recommendation based on substantial and
informed experience
NOTE: Suggested services are always optional. When presenting
suggested repairs to the customer, you must present
the facts, allowing the customer to draw their own
conclusions and make an informed decision about how to
proceed.
EXHAUST
SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER
VEHICLE OPERATION
WARNING: Federal EPA rules prohibit altering an exhaust system in
any way that defeats the emission reduction components of a
vehicle. Be sure to review and adhere to EPA policy on
removing and replacing catalytic converters. Where state or
local laws are stricter, they take precedence over these
guidelines.
NOTE: Some exhaust systems are of a welded design. It is not
required that the entire system be replaced. Determine the
need to replace individual components based on conditions of
component.
CATALYTIC CONVERTERS
CAUTION: Before working on an exhaust system, review EPA
regulations on removing and replacing catalytic converters.
NOTE: Any time a converter has failed, further diagnosis is
required to determine the reason(s) for converter failure.
CATALYTIC CONVERTER INSPECTION









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Condition Code Procedure
Air injection tube
broken ................. A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Air injection tube
burnt .................. A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Air injection tube
leaking ................ A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Air injection tube

loose .................. A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Air injection tube
restricted ............. A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Air injection tube
threads damaged ........ A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Air injection tube
threads stripped
(threads missing) ...... A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Body cracked ............ B .. Require repair or replacement.
Converter empty ......... A .. Require repair or replacement.
Converter fill plug
missing ................ C .. Require repair or replacement.
Converter missing ....... C ............ Require replacement.
Exhaust gases leaking ... A .. Require repair or replacement.
Flanges leaking ......... A ... Require repair or replacement
of flanges.
Inlet pipes cracked ..... B .. Require repair or replacement.
Internal rattle (except
pellet-type) ........... 2 .......... (1) Further inspection
required.
Mounting brackets that
are part of converter
broken ................. A .. Require repair or replacement.
Obvious overheating ..... .. ......... ( 2) Require testing of
converter.
Outlet pipes cracked .... B .. Require repair or replacement.
Pieces of catalyst
material found
downstream ............. 1 ............ Suggest replacement.
Plugged ................. A ........ ( 3) Require replacement.
Testing has determined
that existing converter
has been lead-poisoned,
contaminated, or failed
testing ................ A .. Require repair or replacement.
( 1) - If the converter is breaking up, suggest converter
replacement. If an object has fallen into the converter,
remove the object.
( 2) - Overheating is caused by something other than the
converter. Further diagnosis is required to determine
the cause of the overheating.
( 3) - Determine cause and correct to ensure that new converter
will not become plugged.









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EXHAUST AND TAIL PIPES
NOTE: For pipes with resonators, also see MUFFLERS AND RESONATORS.
EXHAUST AND TAIL PIPE INSPECTION

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Condition Code Procedure
Bracket broken .......... A .. Require repair or replacement.
Pipe bent out of
position ............... B .. Require repair or replacement.
Pipe broken ............. A .. Require repair or replacement.
Pipe cracked ............ B .. Require repair or replacement.
Pipe leaking ............ A ............ Require replacement.
Pipe missing ............ C ............ Require replacement.
Pipe plugged ............ A ............ Require replacement.
Pipe weak due to
corrosion, but no leaks
present ................ 1 ............ Suggest replacement.
Weld broken ............. A .. Require repair or replacement.









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EXHAUST CONNECTIONS
EXHAUST CONNECTION INSPECTION








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Condition Code Procedure
Attaching hardware
incorrect .............. B ......... Require replacement of
hardware.
Clamp broken ............ A ........... Require replacement.
Clamp loose ............. A . Require repair or replacement.
Clamp missing ........... C ........... Require replacement.
Corroded, affecting
structural integrity ... 1 ........... Suggest replacement.
Incorrect type (i.e.
flange, ball & socket
etc.) .................. B ........... Require replacement.
Leaking ................. A ................ Require repair.
Loose ................... A ................ Require repair.









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HANGERS
HANGER INSPECTION








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Condition Code Procedure
Broken .................. A ............ Require replacement.
Corroded, affecting
structural integrity ... 1 ............ Suggest replacement.
Incorrect type .......... B ............ Require replacement.
Loose ................... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Out of position ......... B .. Require repair or replacement.
Rubber deteriorated ..... 1 ............ Suggest replacement.









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HEAT RISERS (MECHANICAL EFE DEVICES)
HEAT RISER (MECHANICAL EFE DEVICE) INSPECTION








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Condition Code Procedure
Broken .................. A .......... Require replacement of
affected parts.
Diaphragm inoperative ... A ........ ( 1) Require replacement.

Leaking ................. A .. Require repair or replacement.
Noisy ................... 2 ... Suggest repair or replacement
of affected parts.
Seized .................. A ... Require repair or replacement
of affected parts.
Spring broken ........... B .......... Require replacement of
spring(s).
Spring inoperative ...... A .......... Require replacement of
spring(s).
(1) - If the inoperative diaphragm is separate from the heat
riser, then require replacement of the inoperative
diaphragm. If the inoperative diaphragm is part of the
heat riser, then replace the heat riser.









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HEAT SHIELDS
HEAT SHIELD INSPECTION








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Condition Code Procedure
Bent .................... B .. Require repair or replacement.
Broken .................. A ............ Require replacement.
Corroded, affecting
structural integrity ... 1 ............ Suggest replacement.
Loose ................... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.









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MANIFOLDS (CAST AND TUBE TYPE)
MANIFOLD (CAST AND TUBE TYPE) INSPECTION








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Condition Code Procedure
Air injection tube in
manifold broken ........ A ... Require repair or replacement
of injection tube or
replacement of manifold.
Air injection tube in
manifold corroded,
affecting structural
integrity .............. 1 ......... Suggest replacement of
injection tube or manifold.
Air injection tube in
manifold leaking ....... A ... Require repair or replacement
of injection tube or
replacement of manifold.
Air injection tube in
manifold loose ......... A ................. Require repair.
Air injection tube in
manifold restricted .... A .......... Require replacement of
injection tube or manifold.
Air injection tube in
manifold threads
damaged ................ A ..... Require repair of injection
tube or manifold.
Air injection tube in
manifold threads stripped
(threads missing) ...... A .......... Require replacement of
injection tube or manifold.
Bolt broken ............. A ... Require replacement of bolts.

Bolt loose .............. A ........... Require tightening or
replacement of bolts.
Bolt missing ............ C ... Require replacement of bolts.
Corroded, affecting
sealability ............ A .. Require repair or replacement.
Cylinder head threads
stripped ............... A ... Require repair or replacement
of cylinder head.
Gasket leaking .......... A ........... Require tightening or
replacement of gasket.
Heat stove bent ......... B ........... (1) Require repair or
replacement of stove.
Heat stove broken ....... A ......... ( 1) Require replacement
of stove.
Heat stove corroded,
affecting structural
integrity .............. 1 ......... ( 1) Suggest replacement
of stove.
Heat stove missing ...... C ......... ( 1) Require replacement
of stove.
Manifold broken ......... A .. Require repair or replacement.
Manifold cracked ........ B .. Require repair or replacement.
Manifold warped ......... A .. Require repair or replacement.
Out of specification .... B .. Require repair or replacement.
Stud broken ............. A .... Require replacement of stud.
Stud missing ............ C .... Require replacement of stud.
Stud threads damaged .... A ... Require repair or replacement
of stud.
Stud threads stripped
(threads missing) ...... A .... Require replacement of stud.
( 1) - Stove may not be available separately; this may require
replacement of manifold.









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MECHANICAL EFE DEVICES
See HEAT RISERS (MECHANICAL EFE DEVICES) .
MUFFLERS AND RESONATORS
MUFFLER AND RESONATOR INSPECTION








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Condition Code Procedure
Body shell distorted,
affecting performance or
structural integrity ... A ............ Require replacement.
Corrosion hole .......... A ............ Require replacement.
Missing ................. C ............ Require replacement.
Mounting bracket broken . A .. Require repair or replacement.
Mounting bracket
cracked ................ B .. Require repair or replacement.
Nipple cracked .......... A .. Require repair or replacement.
Nipple loose ............ B ............ Require replacement.
Outer wrap peeling
(exhaust not leaking) .. 1 ............ Suggest replacement.
Plugged ................. A ............ Require replacement.
Puncture (other than a
drain hole) ............ A ............ Require replacement.
Rattling or knocking noise
from inside muffler .... B ............ Require replacement.
Seam open (exhaust

leaking) ............... A ............ Require replacement.
Sound quality
unsatisfactory ......... 2 .. Suggest replacement to address
customer need and/or request.
Split (exhaust leaking) . A ............ Require replacement.
Weak due to corrosion, but
no leaks present ....... 1 ............ Suggest replacement.









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GEA R T O OTH C O NTA C T P A TTE R NS
1999 Dodge Pickup R1500
GENERAL INFORMATION
Gear Tooth Contact Patterns
* PLEASE READ THIS FIRST *
The following article is for GENERAL INFORMATION purposes
only. Information does not SPECIFICALLY apply to all years, makes and
models, but is to be used as a general reference guide.
INSPECTION
PRELIMINARY INSPECTION
Wipe lubricant from internal parts. Rotate gears and inspect
for wear or damage. Mount dial indicator to housing, and check
backlash at several points around ring gear. Backlash must be within
specifications at all points. If no defects are found, check gear
tooth contact pattern.
GEAR TOOTH CONTACT PATTERN
NOTE: Drive pattern should be well centered on ring gear teeth.
Coast pattern should be centered, but may be slightly toward
toe of ring gear teeth.
1) Paint ring gear teeth with marking compound. Wrap cloth or
rope around drive pinion flange to act as brake. Rotate ring gear
until clear tooth contact pattern is obtained.
2) Contact pattern will indicate whether correct pinion
bearing mounting shim has been installed and if drive gear backlash
has been set properly. Backlash between drive gear and pinion must be
maintained within specified limits, until correct tooth pattern is
obtained.

Fig. 1: Drive Axle Gear Tooth Patterns
ADJUSTMENTS
GEAR BACKLASH & PINION SHIM CHANGES
NOTE: Backlash is adjusted by either moving shims from one side of
differential case to the other or by turning adjusting nuts
on which side bearing races ride. Changing of pinion shims
alters the distance from face of pinion of centerline of
ring gear.
1) With no change in backlash, moving pinion further from
ring gear moves drive pattern toward heel and top of tooth, and moves
coast pattern toward toe and top of tooth.
2) With no change in backlash, moving pinion closer to ring
gear moves drive pattern toward toe and bottom of tooth, and moves
coast pattern toward heel and bottom of tooth.
3) With no change in pinion shim thickness, an increase in
backlash moves ring gear further from pinion. Drive pattern moves
toward heel and top of tooth, and coast pattern moves toward heel and
top of tooth.

GEN ER AL C O OLIN G S YSTE M S ER VIC IN G
1999 D odge P ic ku p R 1500
GENERAL INFORMATION
General Cooling System Servicing
* PLEASE READ THIS FIRST *
The following article is for general information only.
Information may not apply to all years, makes and models. See specific
article in the ENGINE COOLING section.
DESCRIPTION
The basic liquid cooling system consists of a radiator, water
pump, thermostat, electric or belt-driven cooling fan, pressure cap,
heater, and various connecting hoses and cooling passages in the block
and cylinder head.
MAINTENANCE
DRAINING
Remove radiator cap and open heater control valve to maximum
heat position. Open drain cocks or remove plugs in bottom of radiator
and engine block. In-line engines usually have one plug or drain cock,
while "V" type engines will have 2, one in each bank of cylinders.
CLEANING
A good cleaning compound removes most rust and scale. Follow
manufacturer's instructions in the use of cleaner. If considerable
rust and scale has to be removed, cooling system should be flushed.
Clean radiator air passages with compressed air.
FLUSHING
CAUTION: Some manufacturers use an aluminum and plastic radiator.
Flushing solution must be compatible with aluminum.
Back Flushing
Back flushing is an effective means of removing cooling
system rust and scale. The radiator, engine and heater core should be
flushed separately.
Radiator
To flush radiator, connect flushing gun to water outlet of
radiator and disconnect water inlet hose. To prevent flooding engine,
use a hose connected to radiator inlet. Use air in short bursts to
prevent damage to radiator. Continue flushing until water runs clear.
Engine
To flush engine, remove thermostat and replace housing.
Connect flushing gun to water outlet of engine. Flush using short air
bursts until water runs clean.
Heater Core
Flush heater core as described for radiator. Ensure heater
control valve is set to maximum heat position before flushing heater.