brakes DODGE RAM 1999 Service Repair Manual

HEATER HOSES
HIGH PRESSURE RELIEF VALVES (HPRV)
IDLERS
IN-LINE FILTERS
METAL FITTINGS
METAL LINES
MIX AND AIR CONTROL DOORS (BLEND DOORS)
O-RINGS
ORIFICE TUBES
PILOT-OPERATED ABSOLUTES (POAS)
PLENUMS
PRESSURE CONTROL VALVES
PRESSURE SENSORS
PULLEYS
RADIATORS
RECEIVER-DRIERS
REFRIGERANT
REFRIGERANT OIL
RELAYS
SEALS
SERVICE PORTS
SPRING LOCK COUPLINGS
SUCTION THROTTLING VALVES (STVS)
SWITCHES (ELECTRICAL)
TENSIONERS
THERMISTORS AND PRESSURE SENSORS
THERMOSTATS AND HOUSINGS
VACUUM HOSES AND TUBES
VACUUM RESERVOIRS
VACUUM TUBES
VALVES IN RECEIVER (VIRS)
WATER PUMPS (ELECTRIC AUXILIARY)
WIRING HARNESSES AND CONNECTORS
MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
(1) a Pledge of Assurance to their Customers and (2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards

AN TI- L O CK B RAK E S A FE TY P R EC AU TIO NS

1999 D odge P ic ku p R 1500
GENERAL INFORMATION
Anti-Lock Brake Safety Precautions
* PLEASE READ THIS FIRST *
This article is intended for general information purposes
only. This information may not apply to all makes and models. If
vehicle is equipped with Anti-Lock Brake System (ABS), refer to
appropriate ANTI-LOCK BRAKE SYSTEM article in the BRAKES section for
description, operation, depressurizing, testing, system bleeding,
trouble shooting and servicing of specific system.
WARNING: Failure to depressurize ABS could lead to physical injury.
ANTI-LOCK BRAKE SAFETY PRECAUTIONS
WARNING: Failure to depressurize ABS could lead to physical injury.
* NEVER open a bleeder valve or loosen a hydraulic line
while ABS is pressurized.
* NEVER disconnect or reconnect any electrical connectors
while ignition is on. Damage to ABS control unit may result.
* DO NOT attempt to bleed hyudarulic system without first
referring to the appropriate ANTI-LOCK BRAKE SYSTEM article
in the BRAKES section.
* Only use specially designed brake hoses/lines on ABS equipped
vehicles.
* DO NOT tap on speed sensor components (sensor, sensor rings).
Sensor rings must be pressed into hubs, NOT hammered into
hubs. Striking these components can cause demagnetization or
a loss of polarization, affecting the accuracy of the speed
signal returning to the ABS control unit.
* DO NOT mix tire sizes. Increasing the width, as long as tires
remain close to the original diameter, is acceptable. Rolling
diameter must be identical for all 4 tires. Some
manufacturers recommend tires of the same brand, style and
type. Failure to follow this precaution may cause inaccurate
wheel speed readings.
* DO NOT contaminate speed sensor components with grease. Only
use recommended coating, when system calls for an
anti-corrosion coating.
* When speed sensor components have been removed, ALWAYS check
sensor-to-ring air gaps when applicable. These specifications
can be found in each appropriate article.
* ONLY use rocommended brake fluids. DO NOT use silicone brake
fluids in an ABS equipped vehicle.
* When instlling transmittion devices (CB's, telephones, etc.)
on ABS equipped vehicles, DO NOT locate the antenna near the
ABS control unit (or any control unit).
* Disconnect all on-board computers, when using electric
welding equipment.
* DO NOT expose the ABS control unit to prolonged periods of
high heat (185
F/85C for 2 hours is generally considered a
maximum limit).

problem is found, measure resistance between output speed sensor
terminals. If resistance is 300-1200 ohms, go to next step. If
resistance is not as specified, replace output speed sensor.
7) Reconnect output speed sensor. Measure resistance between
ground and output speed sensor ground circuit at PCM harness
connector. If resistance is greater than 5 ohms, go to next step. If
resistance is not as specified, repair output speed sensor ground
circuit for a short to ground.
8) Measure resistance between ground and output speed sensor
signal circuit at PCM harness connector. If resistance is less than 5
ohms, repair output speed sensor signal circuit for a short to ground.
If resistance is not as specified, go to next step.
9) Measure resistance between output speed sensor signal
circuit and ground circuit at PCM harness connector. If resistance is
300-1200 ohms, replace PCM. If resistance is not as specified, go to
next step.
10) Disconnect output speed sensor harness connector. Measure
resistance of output speed sensor signal circuit between output speed
sensor harness connector and PCM harness connector. If resistance is
greater than 5 ohms, repair open in output speed sensor signal
circuit. If resistance is not as specified, repair open in output
speed sensor ground circuit.
11) Turn ignition on. Measure voltage between ground and
speed sensor ground circuit at PCM harness connector. Place gearshift
lever in each gear position and record voltage at each position. If
voltage is greater than one volt in any gear position, repair speed
sensor ground circuit for a short to power. If voltage is not as
specified, go to next step.
12) Raise and support vehicle. Start engine. Place gearshift
lever in "OD" position. Release brakes and allow wheels to rotate.
Using scan tool, monitor output speed sensor. While monitoring output
speed sensor, wiggle harness between output speed sensor and PCM. If
reading dropped towards zero while wiggling harness, repair
intermittent short or open in harness. If reading does not drop
towards zero while wiggling harness, problem is intermittent. See
INACTIVE DTC CONDITION under SELF-DIAGNOSTIC SYSTEM. Testing is
complete.
DTC P0740: TORQ CONV CLU, NO RPM DROP AT LOCKUP
Circuit Description
Circuit is monitored continuously while key is on, and gear
selector is not in Park or Neutral. Code sets if Torque Converter
Clutch (TCC) does not achieve desired drop in RPM when TCC solenoid is\
near maximum duty cycle. A bad test 3 consecutive times is required to
set code.
Possible Causes
* Misfire trouble code set.
* Vehicle stalls (faulty TCC solenoid).
* TCC shaft seal/seal defective.
* Transmission fluid contaminated.
* TCC solenoid wiring harness defective.
* TCC defective.
* TCC hydraulic circuit damaged.
Diagnostic Procedure
1) Using scan tool, read DTCs. On all bodies except AB and WJ
bodies, go to next step. On AB and WJ bodies, if DTC SPECIFIC GOOD
TRIPS counter is not displayed or displayed count is not "0", go to
step 10). If DTC SPECIFIC GOOD TRIPS counter is displayed and
displayed count is "0", indicating DTC still exists, go to next step.

SHOE HARDWARE
SHOES
SOCKETS
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)
STEEL BRAKE LINES
STOPLIGHT SWITCHES
SWITCHES
TIRES
TOOTHED RINGS (TONE WHEEL)
VACUUM BOOSTERS
VACUUM HOSES
VALVES
WHEEL ATTACHING HARDWARE
WHEEL BEARINGS, RACES AND SEALS
WHEEL CYLINDERS
WIRING HARNESSES
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt:\
1) a Pledge of Assurance to their Customers and
2) the Motorist Assurance Program Standards of Service.
All participating service providers have agreed to subscribe
to this Pledge and to adhere to the promulgated Standards of Service
demonstrating to their customers that they are serious about customer
satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards
are continually re-published. In addition to these, standards for
Drive Train and Transmissions have recently been promulgated.
Participating shops utilize these Uniform Inspection & Communication
Standards as part of the inspection process and for communicating
their findings to their customers.
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
(and their representatives), concerned with auto repair and/or
consumer protection, are conducted. Feedback from these sessions is
brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not

and make an informed decision about how to proceed.
BRAKES
SERVICE PROCEDURES REQUIRED & SUGGESTED FOR PROPER
VEHICLE OPERATION
Some states may have specifications that differ from OEM.
Check your local/state regulations. Where state or local laws are
stricter, they take precedence over these guidelines.
ACCELEROMETERS (G SENSOR OR LATERAL)
ACCELEROMETER INSPECTION








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Condition Code Procedure
Broken .................. A ............ Require replacement.
Connector loose ......... A .. Require repair or replacement.
Loose ................... B .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Out of position ......... B ....... Require re-positioning to
vehicle manufacturer's
specifications.
Output signal incorrect . B ............ Require replacement.









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ACCUMULATORS
ACCUMULATOR INSPECTION








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Condition Code Procedure
Leaking ................. B ............ Require replacement.
Missing ................. C ............ Require replacement.
Pre-charge incorrect .... B ............ Require replacement.









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ANCHOR PINS
See BACKING PLATES .
ANTI-LOCK BRAKE SYSTEMS
NOTE: Anti-lock brakes are an integral part of the brake system. It
is essential that the anti-lock brakes function properly when
brake service is performed.
Anti-lock brake systems are commonly referred to as "ABS" and
will be referred to as "ABS" throughout these guidelines. Some ABS
components also function as part of a traction control system (TCS).
WARNING: When diagnosing and servicing high pressure components,
observe safety procedures and equipment requirements
established by the vehicle manufacturer to reduce the
possibility of serious personal injury.
NOTE: Intermittent electrical conditions are often caused by a loss
of ground, poor connection, or water intrusion into the
wiring harness.

(1) - This condition may be normal on some vehicles equipped with
anti-lock brakes.
( 2) - Refer to OEM procedures for adjusting low fluid level.
Inspect for brake hydraulic system leaks and friction
material wear.
( 3) - This condition may indicate contaminated brake fluid.
See BRAKE FLUID .









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MODULATORS
See HYDRAULIC MODULATORS .
MOTORS
See ELECTRICAL PUMPS AND MOTORS .
PARKING BRAKE SWITCHES
See SWITCHES.
PARKING BRAKE SYSTEMS
NOTE: The parking brake is an integral part of the brake
system. It is important that the parking brake function
properly when brake service is performed.
PARKING BRAKE SYSTEM INSPECTION









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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Cable improperly
adjusted ............... B ....... Require cable adjustment.
Cable or individual
wires in the cable
are broken ............. A .... Require replacement of cable
assembly.
Cable sticking .......... A ...... Require cable lubrication.
Cable stuck inside conduit
and cannot be lubricated
so that parking brake
functions properly ..... A .... Require replacement of cable
assembly.
Inoperative ( 1) ......... A .......... Require replacement of
inoperative parts.
Parking brake
parts bent ............. B ... Require repair or replacement
of bent parts.
Parking brake
parts broken ........... A ... Require replacement of broken
parts.
Parking brake parts

BRAK E S YSTE M
1999 D odge P ic ku p R 1500
1998-99 BRAKES
CHRY - Disc & Drum - Trucks & Vans - Except FWD
Dakota, Ram Pickup, Ram Van
DESCRIPTION & OPERATION
All models are equipped with single-piston, sliding-caliper
front disc brakes with ventilated rotors. All models utilize self-
adjusting rear drum brakes. Rear Wheel Anti-Lock (RWAL) brake system
is standard on all models. Optional 4-wheel Anti-Lock (4WAL) brake
system is available on all models.
System also includes power brake booster, dual-reservoir
master cylinder and combination valve. Combination valve consists of
metering valve and pressure differential switch.
Models with diesel engine include a gear-driven vacuum pump.
Depending on speed of engine, pump produces 8-25 in. Hg. Models
without full-floating rear axle use 9", 10" or 11" single-anchor rear
brakes. Models with full-floating rear axle use 12" or 13" single-
anchor rear brakes.
NOTE: For information on Anti-Lock Brake Systems (ABS), see
appropriate ANTI-LOCK article.
BLEEDING BRAKE SYSTEM
BLEEDING PROCEDURES
Complete Brake System
Before bleeding system, exhaust all vacuum from power unit by
depressing brake pedal several times. Bleed master cylinder using
bleeder screws (if equipped). Bleed wheel cylinders and calipers in
sequence. See BLEEDING SEQUENCE table.
BLEEDING SEQUENCE









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Application Sequence
1999 Dakota & Ram Van .......... Master Cylinder, Combination Valve,
RR, LR, RF & LF
All Other Models ............... Master Cylinder, Combination Valve,
Rear Anti-Lock Valve, RR, LR, RF & LF









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Master Cylinder (Bench Bleeding)
1) Bench bleed master cylinder before installation. Place
master cylinder in soft-jaw vise. Install bleeder tubes in both
outlets of master cylinder. See Fig. 1.
2) Fill master cylinder with clean brake fluid. Ensure ends
of bleeder tubes are submerged in brake fluid.
3) Using a wood dowel, apply and release master cylinder
until no air bubbles exist in brake fluid flow. Leave bleeder tubes
installed on master cylinder during installation. Install master
cylinder. Remove bleeder tubes, and connect brakelines. Bleed brake
system if necessary.

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Application psi (kg/cm)
All Models ....................................... 10-15 (1.06-1.41)\









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NOTE: When bleeding disc brakes, air may tend to cling to caliper
walls. Lightly tap caliper while bleeding to aid in removal
of air.
Manual Bleeding
1) Fill master cylinder. Install bleeder hose on first
bleeder valve to be serviced. See BLEEDING SEQUENCE table. Submerge
other end of hose in clean glass jar partially filled with clean brake
fluid.
NOTE: When bleeding brake system manually, ensure bleeder valve is
closed when brake pedal is released.
2) Open bleeder valve 3/4-1 turn. Depress brake pedal slowly
through full travel. Close bleeder valve. Release pedal. Repeat
procedure until fluid flow is free of air bubbles.
ADJUSTMENTS
PARKING BRAKE
1) Release parking brake, and loosen cable adjusting nut to
allow slack in cable. Adjust rear brakes. Tighten cable adjusting nut
until a slight drag is felt while rotating rear wheels.
2) Loosen cable adjusting nut until both rear wheels can be
rotated freely. Back off adjusting nut an additional 2 turns. Apply
and release parking brake several times, checking for free rotation at
rear wheels.
REAR BRAKE SHOES
1) Raise and support vehicle. Ensure parking brake lever is
fully released. Back off parking brake cable adjustment to ensure
cable has slack. Remove adjusting hole cover.
2) Using a brake adjuster, expand brake shoes until slight
drag is felt when wheel assembly is rotated. Using thin screwdriver,
hold automatic adjusting lever away from adjustment star wheel.
3) Back off adjustment star wheel until wheel assembly
rotates freely and brake shoe drag is eliminated. Repeat adjustment
for remaining wheels. Adjustment must be equal at all wheels. Replace
adjusting hole covers. Adjust parking brake. See PARKING BRAKE.
STOPLIGHT SWITCH
Stoplight switch is attached to brake pedal support. Push
stoplight switch through clip in mounting bracket until switch seats
in bracket. Pull brake pedal backward as far as pedal will travel.
Brake pedal will ratchet stoplight switch to correct position. Verify
full brake pedal return, and that stoplights glow when brake pedal is
applied.
TESTING
POWER BRAKE BOOSTER FUNCTIONAL TEST

1) Start engine, and check booster vacuum hose connections. A
hissing noise indicates a vacuum leak. Repair any vacuum leaks before
proceeding. Stop engine, and shift transmission into Neutral. Pump
brake pedal until all vacuum reserve in booster is depleted.
2) Hold brake pedal under light pressure. If pedal does not
hold firm and falls away, master cylinder may be faulty. Bleed system
using appropriate method, and repeat step 1). See BLEEDING PROCEDURES
under BLEEDING BRAKE SYSTEM.
3) If pedal still does not hold firm, master cylinder is
faulty. If pedal holds firm, start engine and observe pedal height. If
pedal height change is not apparent, power booster or vacuum check
valve is faulty. Install good check valve, and repeat steps 1) and 2).\
If pedal falls away slightly under light pressure and then holds firm,
go to next step .
4) Start engine. Release brake pedal. Increase engine speed
to 1500 RPM. Close throttle and immediately turn off ignition. Wait at
least 90 seconds, and try brake action again. Booster should provide 2
or more vacuum assisted pedal applications. If vacuum assist is not
provided, perform booster and check valve vacuum tests.
POWER BRAKE BOOSTER VACUUM TEST
Connect vacuum gauge to booster check valve using "T"
fitting. Start engine, and run at idle speed for one minute. Clamp
hose shut between vacuum source and check valve. Stop engine, and
observe vacuum gauge. If vacuum drops more than one in. Hg within 15
seconds, booster diaphragm or check valve is faulty.
POWER BRAKE BOOSTER CHECK VALVE TEST
Disconnect vacuum hose from check valve. Remove check valve
and valve seal from booster. Use a hand-operated vacuum pump for
testing. Apply 15-20 in. Hg at large end of check valve. Vacuum should
hold steady. If gauge on pump indicates vacuum loss, check valve is
faulty and should be replaced.
COMBINATION VALVE METERING VALVE TEST
Metering valve operation can be checked visually with aid of
an assistant. While an assistant applies and releases brake pedal,
observe metering valve stem. If valve is operating correctly, stem
will extend slightly when brakes are applied, and contract when brakes
are released. If valve is faulty, replace combination valve assembly.
COMBINATION VALVE PRESSURE DIFFERENTIAL SWITCH TEST
1) Using an assistant, apply brake pedal. Observe brake
warning light. Raise and support vehicle, and connect a bleed hose to
one rear wheel cylinder. Submerge other end of hose into container
partially filled with brake fluid. Have assistant press and hold brake
pedal down while observing brake warning light. Open bleeder screw. If
warning light glows, switch is operating properly.
2) If warning light fails to glow, check circuit fuse, bulb
and wiring. Repair as necessary. Repeat step 1). If warning light
fails to glow, check brakelight, parking brake switches and related
wiring. Repair as necessary. Repeat step 1). If warning light fails to
glow, pressure differential switch is faulty. Replace combination
valve assembly, and bleed brake system. Verify proper valve operation.
REMOVAL & INSTALLATION

first with coil on opposite side of adjusting lever. Install lever
spring and adjusting lever over pivot pin.
5) Slide lever rearward to lock in position. Thread adjuster
cable over guide, and hook end of cable in lever. Verify adjuster
operation. Pull adjuster cable upward. Cable should lift lever and
rotate star wheel. Ensure adjuster lever properly engages star wheel
teeth. Adjust brakes. See REAR BRAKE SHOES under ADJUSTMENTS.
Removal (Ram Pickup)
1) Remove drum. See AXLE BEARING & SEAL (FULL FLOATING AXLE)\
.
Disconnect adjusting lever from cable. Disconnect adjusting lever
return spring from lever. Remove lever, and return spring from pivot
pin. Remove upper shoe-to-shoe spring.
2) Disconnect and remove shoe retainers, springs and hold-
down pins. Disconnect parking brake cable from lever. Remove both
brake shoes, lower shoe-to-shoe spring and adjustment star wheel as an
assembly. See Fig. 4. Remove lower shoe-to-shoe spring.
Fig. 4: Exploded View Of Typical Rear Drum Brake Assembly (Ram
Pickup)
Courtesy of Chrysler Corp.
NOTE: Adjustment star wheel on left brake assembly has left-hand