Alignment DODGE RAM 1500 1998 2.G Owners Manual

FRONT AIR DAM
REMOVAL
(1) Remove the two outboard screws.
(2) Remove the three middle screws and remove
the air dam.
INSTALLATION
(1) Position the air dam onto the bumper and seat
the carrot type fasteners fully.
(2) Starting at the center screw install the three
middle screws.
(3) Install the two outboard screws.
FRONT BUMPER
REMOVAL
(1) Using a grease pencil or equivalent, mark the
position of the bumper on the frame rail tip to aid
installation.
(2) Disconnect the fog lamp electrical connector at
the left frame rail.
(3) Support the bumper with a suitable lifting
device.
(4) Remove the center bracket nuts and bolts and
remove bumper. (Fig. 1)
INSTALLATION
(1) Install the bumper onto the frame rails and
position the wheelhouse splash shield into the sup-
port brackets.
(2) Install the bolts and nuts.
(3) Line up the bumper with the marks made pre-
viously and tighten the bolts and nuts to 95 N´m (70
ft. lbs.).
(4) Check and adjust the bumper alignment as
necessary. (Refer to 23 - BODY/BODY STRUCTURE/
GAP AND FLUSH - SPECIFICATIONS)
FRONT FASCIA
REMOVAL
ST/SLT/SLT+ - FASCIA REMOVAL
(1) Remove the two screws at each trailing edge of
the fascia. (Fig. 2)
(2) Remove the four push pin fasteners from the
upper edge of the close out panel.
(3) Using a trim stick C-4755 or equivalent, care-
fully release the six lower clips and remove the close
out panel.
(4) Using a trim stick C-4755 or equivalent, care-
fully remove the step pad.
(5) Remove and discard the four push pin fasten-
ers and remove the fascia.
Fig. 1 BUMPER SUPPORT BRACKET - TYPICAL
1 - FASCIA - SPORT MODEL
2 - SUPPORT BRACKET
3 - FASCIA SUPPORT BRACKET
4 - WHEELHOUSE SPLASH SHIELD SUPPORT BRACKET
5 - BUMPER CENTER BRACKET
6 - NUTS (4 PER SIDE)
7 - FRAME RAIL TIP
8 - CENTER BRACKET NUTS (2 PER SIDE)
9 - CENTER BRACKET BOLTS ASSEMBLY (1 PER SIDE)
10 - FOG LAMPFig. 2 UPPER FASCIA - ST/SLT/SLT+
1 - STEP PAD
2 - UPPER FASCIA (ST/SLT/SLT+ MODEL ONLY)
3 - INBOARD BUMPER BRACKET ATTACHMENTS
4 - SCREWS (4)
5 - PUSH PIN FASTENERS (4)
13 - 2 FRAMES & BUMPERSDR

(14) Dress the cut edge of the existing frame in
preparation for the new rail tip.
(a) Drill four 13 mm (0.5 in.) diameter holes in
the new tip and four more in the existing frame to
accommodate ring-fillet welds. Center these holes
19 mm (0.75 in.) from the cut face of the rail and
38 mm (1.5 in.) from the top and bottom of the rail.
(Fig. 7)
(b) Bevel the edges of the new tip, existing
frame, and ring-fillet holes 25É - 30É. Scribing a
line 2 mm from the cut edge and then grinding
back to the mark will simplify the bevel creation
process and accuracy. (Fig. 8)
(c) Remove any burrs at the holes and beveled
edges.
(15) Dry fit the new rail to ensure alignment and
fit and make any adjustments as necessary.(16) Remove all internal and external OEM e-coat
within 51 mm (2.0 in.) of the weld joint on the
replacement tip and the existing frame rail.
NOTE: Any burned surface coatings will need to be
removed prior to application of corrosion preventa-
tive coatings.
CAUTION: Shield the surrounding area and compo-
nents from exposure to the welding spatter and
heat.
Fig. 7 REPAIR SLEEVE INSTALLATION (TYPICAL)
1 - REPLACEMENT FRAME TIP
2 - FRAME RAIL
3 - SERVICE SLEEVE
4 - CENTER LINE
5 - LOCATOR LINES (2)
6 - HORIZONTAL WELD HOLE LOCATION - 38 mm (1.5 in.)(BOTH
FRAME SECTIONS)
7 - LOCATOR LINE DIMENSION-2mm(0.08 in.)
8 - VERTICAL WELD HOLE LOCATION - 19 mm (0.75 in.)(BOTH
FRAME SECTIONS)
9 - RING FILLET WELD HOLES
Fig. 8 WELD DIMENSIONS
1 - FRAME REPLACEMENT TIP
2 - FRAME RAIL
3 - FRAME DRESS ANGLE 25É-30É
4 - ROOT PASS
5 - COVER PASS
6 - SERVICE SLEEVE
7 - WELD ROOT GAP 4 mm-6mm(0.16 in. - 0.24 in.)
8 - SERVICE SLEEVE
13 - 6 FRAMES & BUMPERSDR
FRAME (Continued)

(25) Confirm alignment of the replacement frame
rail tip. (Fig. 14)
(26) Final welding should be performed in a skip
(stitch) type method to minimize the heat buildup
and frame distortion, utilizing the Weld Process
Specifications at the end of this section. The pre-
ferred method is GMAW (MIG). (Refer to 13 -
FRAME & BUMPERS/FRAME - SPECIFICATIONS -
WELDING)
(a) Apply root pass welds to the root joint one
quadrant at a time, switching to the opposite side
of the frame for each quadrant. (Fig. 8)
(b) Clean the welds of any flux and other impu-
rities before proceeding with the cover pass welds.
(c) Apply the cover pass welds in the same man-
ner as described above.
(27) Confirm alignment of the replacement frame
rail tip. (Fig. 14)
NOTE: Any burned surface coatings will need to be
removed prior to application of corrosion preventa-
tive coatings.
(28) Dress the welded area and apply corrosion
resistant coatings inside and out.
(a) Apply etch-primer to the inside of the frame
rail repair area.
(b) Inside the rail, inject a creeping wax based
rust inhibitor compound through the existing holes
in the frame ensuring 100% coverage including the
space between the original frame rail and the rein-
forcing sleeve.
(c) Apply a durable top coat to the outside of the
repair area.
(29) Tighten the front cab mounting bolt to the
FESM bracket to 81 N´m (60 ft. lbs.).(30) Install the stabilizer bar. (Refer to 2 - SUS-
PENSION/FRONT/STABILIZER BAR - INSTALLA-
TION)
(31) Install the front bumper. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/FRONT BUMPER
- INSTALLATION)
(32) Install the wire harness and ground strap if
previously removed and install the bolt.
(a) If necessary, re-drill and tap the ground
strap mounting hole
(33) Install the front wheelhouse splash shield.
(Refer to 23 - BODY/EXTERIOR/FRONT WHEEL-
HOUSE SPLASH SHIELD - INSTALLATION)
Fig. 13 RING FILLET WELD
1 - WELD START LOCATION
2 - WELD END LOCATION
3 - RING-FILLET WELD
Fig. 14 FRAME TIP DIMENSIONS
1 - PLP POINT
2 - FRAME
3 - PLP POINT
4 - REPLACEMENT FRAME TIP
DRFRAMES & BUMPERS 13 - 9
FRAME (Continued)

REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING THE FUEL PUMP MODULE,
THE FUEL SYSTEM PRESSURE MUST BE
RELEASED.
(1) Drain and remove fuel tank. Refer to Fuel
Tank Removal/Installation.
(2) The plastic fuel pump module locknut (Fig. 15)
is threaded onto fuel tank. Install Special Tool 6856
to locknut and remove locknut (Fig. 16). The fuel
pump module will spring up slightly when locknut is
removed.
(3) Remove module from fuel tank.
INSTALLATION
CAUTION: Whenever the fuel pump module is ser-
viced, the rubber gasket must be replaced.
(1) Using a new gasket, position fuel pump module
into opening in fuel tank.
(2) Position locknut over top of fuel pump module.
Install locknut finger tight.
(3) Rotate module until embossed alignment arrow
(Fig. 15) points to center alignment mark. This step
must be performed to prevent float from contactingside of fuel tank. Also be sure fitting on fuel filter/
fuel pressure regulator is pointed to drivers side of
vehicle.
(4) Install Special Tool 6856 (Fig. 16) to locknut.
(5) Tighten locknut. Refer to Torque Specifications.
(6) Install fuel tank. Refer to Fuel Tank Removal/
Installation.
FUEL RAIL
DESCRIPTION
The fuel injector rail is used to mount the fuel
injectors to the engine.
OPERATION
High pressure from the fuel pump is routed to the
fuel rail. The fuel rail then supplies the necessary
fuel to each individual fuel injector.
A quick-connect fitting with a safety latch clip is
used to attach the fuel line to the fuel rail.
The fuel rail is not repairable.
CAUTION: The left and right sections of the fuel rail
are connected with either a flexible connecting
hose, or joints. Do not attempt to separate the rail
halves at these connecting hose or joints. Due to
the design of the connecting hose or joint, it does
not use any clamps. Never attempt to install a
clamping device of any kind to the hose or joint.
When removing the fuel rail assembly for any rea-
son, be careful not to bend or kink the connecting
hose or joint.
Fig. 15 FUEL PUMP MODULE (TOP)
1 - FUEL FILTER / FUEL PRESSURE REGULATOR
2 - ALIGNMENT ARROW
3 - TOP OF PUMP MODULE
4 - LOCKNUT
5 - ALIGNMENT MARKS
Fig. 16 LOCKNUT REMOVAL/INSTALLATION -
TYPICAL
1 - SPECIAL TOOL 6856
2 - LOCKNUT
14 - 12 FUEL DELIVERY - GASDR
FUEL PUMP MODULE (Continued)

INSTALLATION - EXCEPT DIESEL
(1) If fuel tank is to be replaced, install fuel pump
module into tank. Refer to Fuel Pump Module
Removal/Installation procedures.
(2) Disconnect clamps and remove rubber fuel fill
hose and fuel vent hose at fuel fill tube. Install these
2 hoses to 2 fuel tank fittings. Rotate hoses until
paint marks on hoses line up with alignment marks
(Fig. 26). Tighten both clamps.
(3) Position fuel tank to hydraulic jack.
(4) Raise tank until positioned near body.
(5) Connect EVAP line at tank (Fig. 1).
(6) Connect fuel pump module electrical connector
(Fig. 25) at top of tank.
(7) Connect fuel line quick-connect fitting to fuel
filter / fuel pressure regulator (Fig. 1) or (Fig. 25).
(8) Continue raising tank until positioned snug to
body.(9) Install and position both tank support straps.
Install 2 fuel tank strap nuts (Fig. 24) and tighten.
Tighten rear strap nut first.Refer to Torque Spec-
ifications.
(10) Connect rubber fill and vent hoses to fuel fill
tube and tighten clamps.
(11) Lower vehicle.
(12) Fill fuel tank with fuel.
(13) Start engine and check for fuel leaks near top
of module.
Fig. 24 FUEL TANK MOUNTING
1 - FUEL TANK
2 - STRAP MOUNTING STUDS
3 - VEHICLE FRAME4 - MOUNTING STRAPS
5 - STRAP NUTS
DRFUEL DELIVERY - GAS 14 - 19
FUEL TANK (Continued)

INLET FILTER
REMOVAL
The fuel pump inlet filter (strainer) is located on
the bottom of the fuel pump module (Fig. 27). The
fuel pump module is located inside of fuel tank.
(1) Remove fuel tank. Refer to Fuel Tank Removal/
Installation.
(2) Remove fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(3) Remove filter by carefully prying 2 lock tabs at
bottom of module with 2 screwdrivers. Filter is
snapped to module.
(4) Clean bottom of pump module.
INSTALLATION
The fuel pump inlet filter (strainer) is located on
the bottom of the fuel pump module (Fig. 27). The
fuel pump module is located inside of fuel tank.
(1) Snap new filter to bottom of module. Be sure
o-ring is in correct position.
(2) Install fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(3) Install fuel tank. Refer to Fuel Tank Removal/
Installation.
Fig. 25 FUEL PUMP MODULE CONNECTIONS
1 - TOP OF FUEL TANK
2 - FUEL PUMP MODULE
3 - FUEL FILTER / FUEL PRESSURE REGULATOR
4 - ELEC. CONNECT.
Fig. 26 HOSE ALIGNMENT MARKS
1 - ALIGNMENT MARKS (MARK FOR FILL HOSE IS LOCATED
ON FUEL TANK - MARK FOR VENT HOSE IS LOCATED ON
FITTING)
2 - PAINT MARKS ON RUBBER HOSES
Fig. 27 FUEL PUMP INLET FILTER
1 - FUEL PUMP INLET FILTER
2 - LOCK TABS (2)
3 - FUEL PUMP MODULE (BOTTOM)
14 - 20 FUEL DELIVERY - GASDR
FUEL TANK (Continued)

4.7L V-8
(1) Clean throttle body-to-intake manifold o-ring.(2) Clean mating surfaces of throttle body and
intake manifold.
(3) Install throttle body to intake manifold by posi-
tioning throttle body to manifold alignment pins.
(4) Install three mounting bolts. Tighten bolts to
12 N´m (105 in. lbs.) torque.
(5) Install control cables.
(6) Install vacuum line to throttle body.
(7) Install electrical connectors.
(8) Install air plenum.
5.7L V-8
CAUTION: Do not use spray (carb) cleaners on any
part of the throttle body. Do not apply silicone lubri-
cants to any part of the throttle body.
(1) Clean and check condition of throttle body-to-
intake manifold o-ring.
(2) Clean mating surfaces of throttle body and
intake manifold.
(3) Install throttle body to intake manifold by posi-
tioning throttle body to manifold alignment pins.
(4) Install 4 mounting bolts. Refer to Torque Spec-
ifications.
(5) Install electrical connector.
(6) Install air plenum.
(7)If the throttle body has been changed, the
following procedure must be performed:
(a) Disconnect negative battery cable from bat-
tery. Leave cable disconnected for approximately 90
seconds.
(b) Reconnect cable to battery.
(c) Turn ignition switch ON, but do not crank
engine.
(d) Leave ignition switch ON for a minimum of
10 seconds. This will allow PCM to learn throttle
body electrical parameters.
THROTTLE CONTROL CABLE
REMOVAL
3.7L V-6
CAUTION: Be careful not to damage or kink cable
core wire (within cable sheathing) while servicing
accelerator pedal or throttle cable.
(1) From inside vehicle, hold up accelerator pedal.
Remove plastic cable retainer (clip) and throttle cable
core wire from upper end of pedal arm (Fig. 1). Plas-
tic cable retainer snaps into top of pedal arm.
(2) Remove cable core wire at pedal arm.
(3) From inside vehicle, remove metal clip holding
cable to dashpanel (Fig. 1).
Fig. 31 5.7L V-8 THROTTLE BODY
1 - THROTTLE BODY
2 - ELECTRICAL CONNECTOR
3 - SILICONE SEAL
4 - MOUNTING BOLTS (4)
Fig. 32 5.7L V-8 THROTTLE BODY O-RING
1 - INTAKE MANIFOLD
2 - THROTTLE BODY O-RING
14 - 38 FUEL INJECTION - GASDR
THROTTLE BODY (Continued)

BINDING AND STICKING
CONDITION POSSIBLE CAUSE CORRECTION
DIFFICULT TO TURN WHEEL
STICKS OR BINDS1. Low fluid level. 1. Fill to proper level.
2. Tire pressure. 2. Adjust tire pressure.
3. Steering components (ball
joints/tie rod ends).3 Inspect and repair as necessary.
4. Loose belt. 4. Adjust or replace.
5. Low pump pressure. 5. Pressure test and replace if
necessary.
6. Column shaft coupler binding. 6. Replace coupler.
7. Steering gear worn. 7. Replace gear.
8. Pump seized / Stuck valve 8. Replace pump.
INSUFFICIENT ASST. OR POOR RETURN TO CENTER
CONDITION POSSIBLE CAUSE CORRECTION
HARD TURNING OR MOMENTARY
INCREASE IN TURNING EFFORT1. Tire pressure. 1. Adjust tire pressure.
2. Low fluid level. 2. Fill to proper level.
3. Loose belt. 3. Adjust or replace.
4. Low pump pressure. 4. Pressure test and repair as
necessary.
5. Internal gear leak. 5. Replace gear.
STEERING WHEEL DOES NOT
WANT TO RETURN TO CENTER
POSITION1. Tire pressure. 1. Adjust tire pressure.
2. Wheel alignment. 2. Align front end.
3. Lack of lubrication. 3. Inspect and lubricate suspension
compnents.
4. High friction in steering gear. 4. Replace gear.
LOOSE STEERING AND VEHICLE LEAD
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE PLAY IN STEERING
WHEEL1. Worn or loose suspension or
steering components.1. Inspect and repair as necessary.
2. Worn or loose wheel bearings. 2. Inspect and repair or adjust
bearings.
3. Steering gear mounting. 3. Tighten gear mounting bolts to
specification.
4. Gear out of adjustment. 4. Replace gear.
5. Worn or loose steering coupler. 5. Inspect and replace as
necessary.
VEHICLE PULLS OR LEADS TO
ONE SIDE.1. Tire Pressure. 1. Adjust tire pressure.
2. Radial tire lead. 2. Rotate tires.
3. Brakes dragging. 3. Repair as necessary.
4. Wheel alignment. 4. Align front end.
DRSTEERING 19 - 3
STEERING (Continued)

INSTALLATION
NOTE: Before installing gear inspect bushings and
replace if worn or damaged.
NOTE: In the frame there is two holes for the
mounting of the steering gear one is slotted and
one is round, When tightening the gear to specifi-
cations make sure to tighten the mounting bolt with
the hole first to avoided movement of the steering
gear.
(1) Install the gear on the front crossmember and
tighten the mounting bolts to 319 N´m (235 ft. lbs.).
(Fig. 4) & (Fig. 3).
(2) Slide the shaft coupler onto the gear. Install
newpinch bolt and tighten to 49 N´m (36 ft. lbs.).
(3) Clean and dry the tie rod end studs and the
knuckle tapers.
(4) Install the tie rod ends into the steering knuck-
les and tighten the nuts to 61 N´m (45 ft. lbs.) thenan additional 90É. (Refer to 19 - STEERING/LINK-
AGE/TIE ROD END - INSTALLATION).
(5) Install the pressure power steering hose to the
steering gear and tighten to 32 N´m (23 ft. lbs.).
(Refer to 19 - STEERING/PUMP/HOSES - INSTAL-
LATION).
(6) Install the return power steering hose to the
steering gear and tighten to 71 N´m (52 ft. lbs.).
(Refer to 19 - STEERING/PUMP/HOSES - INSTAL-
LATION).
(7) Install the front skid plate (Refer to 13 -
FRAME & BUMPERS/FRAME/FRONT SKID PLATE
- INSTALLATION).
(8) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(9) Remove the support and lower the vehicle.
(10) Fill the system with fluid, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
(11) Adjust the toe position. (Refer to 2 - SUSPEN-
SION/WHEEL ALIGNMENT - STANDARD PROCE-
DURE).
Fig. 3 STEERING GEAR 4X2
1-SWAYBAR
2 - STEERING GEAR
3 - LEFT OUTER TIE ROD END
4 - LOWER CONTROL ARMS
5 - LEFT INNER & RIGHT OUTER (TIE ROD ENDS)
Fig. 4 STEERING GEAR 4X4
1 - FRONT AXLE
2 - STEERING GEAR MOUNTING NUTS & BUSHINGS
19 - 18 GEAR - INDEPENDENT FRONT SUSPENSIONDR
GEAR - INDEPENDENT FRONT SUSPENSION (Continued)

SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Rack and Pinion Steering
Gear
Gear to Frame Bolts319 235 Ð
Rack and Pinion Steering
Gear
Coupler Bolt49 36 Ð
Tie Rod End
Knuckle Nut61
Then tighten an additional
90É45
Then tighten an additional
90ÉÐ
Tie Rod End
Jam Nut75 55 Ð
Power Steering Line
Pressure Line32 23 Ð
Power Steering Line
Return Line71 52 Ð
Power Steering Line
Pressure Line To Pump37 27 Ð
BUSHING
REMOVAL
(1) Remove the steering gear (Refer to 19 -
STEERING/GEAR - REMOVAL).
CAUTION: Do not overtighten the vise on the gear
case.
(2) Mount the steering gear in a soft jawed vise.
NOTE: If the bushings are seized a brass punch can
be used to remove the bushings from the gear
using care not to strike the gear.
(3) Remove the front mounting bushings.
(4) Remove the rear mounting bushings.
(5) Remove the steering gear from the vise and
place it on the bench.
INSTALLATION
NOTE: Coat all bushings with a thin rubber lubri-
cate oil prior to installation.
NOTE: A rubber mallet can be used to assist in the
installation of the bushings once lubricated.
(1) Coat the rear bushings with a thin rubber
lubricate oil then install the rear bushings using a
rubber mallet to seat the bushings in the gear.
(2) Coat the front bushings with a thin rubber
lubricate oil then install the front bushings using a
rubber mallet to seat the bushings in the gear.
(3) Install the steering gear (Refer to 19 - STEER-
ING/GEAR - INSTALLATION).
(4) Adjust the toe position (if necessary) (Refer to 2
- SUSPENSION/WHEEL ALIGNMENT - STAN-
DARD PROCEDURE).
DRGEAR - INDEPENDENT FRONT SUSPENSION 19 - 19
GEAR - INDEPENDENT FRONT SUSPENSION (Continued)