dimensions DODGE RAM 1500 1998 2.G User Guide

After removing the boring bar, use a honing stone
to chamfer the corner of the repair sleeve(s).
SLEEVE MACHINING DIMENSIONS CHART
ITEM MEASUREMENT
SLEEVE PROTRUSION MIN. - FLUSH WITH
BLOCK
MAX. - 0.050 mm
(0.0019 in.)
SLEEVE DIAMETER 101.956 mm (4.014 in.)
SLEEVE CHAMFER APPROX. 1.25 mm
(0.049 in.) by 15É
A correctly honed surface will have a crosshatch
appearance with the lines at 15É to 25É angles with
the top of the cylinder block. For the rough hone, use
80 grit honing stones. To finish hone, use 280 grit
honing stones.
Finished bore inside dimension is 102.020  0.020
mm (4.0165  0.0008 inch).
A maximum of 1.2 micrometer (48 microinch) sur-
face finish must be obtained.
After finish honing is complete, immediately clean
the cylinder bores with a strong solution of laundry
detergent and hot water.
After rinsing, blow the block dry with compressed
air.
Wipe the bore with a white, lint-free, lightly oiled
cloth. Make sure there is no grit residue present.
Apply a rust-preventing compound if the block will
not be used immediately.
A standard diameter piston and a piston ring set
must be used with a sleeved cylinder bore.
STANDARD PROCEDUREÐCAM BORE REPAIR
For standard bushings, not oversized, maximum
front and rear cam bushing bore diameter is 59.248
mm. (2.3326 in.). DO NOT bore the intermediate cam
bore to the front cam bore oversize dimensions. Max-
imum front and rear camshaft bushing installed
diameter is 54.147 mm. (2.1318 in.). Minimum
installed diameter is 54.083 mm. (2.1293 in.). Maxi-
mum intermediate camshaft bore diameter is 54.164
mm. (2.1324 in.).
A surface finish of 2.3 micrometers (92 microinch)
must be maintained. Not more than 20% of an area
of any one bore may be 3.2 micrometers (126 micro-
inch).
Camshaft bores can be repaired individually. It is
not necessary to repair undamaged cam bores in
order to repair individually damaged cam bores. The
standard front bushing cannot be used to repair
intermediate bores.Install all cam bushings flush or below the front
and rear cam bore surface. The front camshaft bush-
ing should be installed flush with front face of block.
The rear camshaft bushing should be installed flush
with rear face of block. The oil hole must align to
allow a 3.2 mm (0.125 inch) rod to pass through
freely (Fig. 52).
INSPECTION
Measure the combustion deck face using a straight
edge and a feeler gauge (Fig. 53). Cylinder block flat-
ness: End-to-end 0.076 mm ( .003 in.). Maximum
variation side-to-side 0.051 mm (.002 in.).
Inspect for any localized dips or imperfections.
If the surface exceeds the limit, (Refer to 9 -
ENGINE/ENGINE BLOCK - STANDARD PROCE-
DURE).
Fig. 52 Oil Hole Alignment
1 - CAMSHAFT BUSHING
Fig. 53 Combustion Deck Face Measurement
1 - STRAIGHT EDGE
2 - FEELER GAUGE
DRENGINE 5.9L DIESEL 9 - 267
ENGINE BLOCK (Continued)

INSPECTION
Camshaft
(1) Inspect the valve lobes and bearing journals for
cracks, pitting, scoring, or generally excessive wear.
Replace any camshaft that exceeds the allowable lim-
its.
(2) Measure the bearing journals and lobes (Fig.
58).
CAUTION: If Camshaft lobes are worn, requiring
camshaft replacement, it is necessary to replace the
tappets also. (Refer to 9 - ENGINE/ENGINE BLOCK/
SOLID LIFTERS - REMOVAL).
CAMSHAFT DIMENSIONS
CAMSHAFT DIMENSIONS
Journal diameter (No.1 and No.7)
Min. 54.028 mm.
(2.127 in.)
Max. 54.048 mm.
(2.128 in.)
Journal diameter (No.2 through
No.6)
Min. 53.962 mm.
(2.1245 in.)
Max. 54.013 mm.
(2.1265 in.)
Diameter of peak of lobe
Intake
Min. 47.175 mm
(1.857 in.)
Max 47.855 mm.
Exhaust
Min. 45.632 mm.
(1.797 in.)
Max. 46.312 mm.
(1.823 in.)
Camshaft Bushing/Bores
Camshaft bores No. 2±6do notuse a bushing.
(1) Inspect the camshaft bushing and bores for
signs of excessive wear.
(2) Measure the camshaft bushing and bores (Fig.
59) with a telescoping bore gauge and micrometer. If
out of specification, (Refer to 9 - ENGINE/ENGINE
BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) -
REMOVAL).
Fig. 59 Measuring Camshaft Bushing and Bores
Fig. 58 Measuring
1 - VALVE LOBE
2 - CAMSHAFT JOURNAL
9 - 270 ENGINE 5.9L DIESELDR
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

FRAMES & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE...............1
FRONT AIR DAM
REMOVAL.............................2
INSTALLATION..........................2
FRONT BUMPER
REMOVAL.............................2
INSTALLATION..........................2
FRONT FASCIA
REMOVAL.............................2
INSTALLATION..........................3
REAR BUMPER
REMOVAL.............................3
INSTALLATION..........................4
FRAME
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 4
STANDARD PROCEDURE
STANDARD PROCEDURE - LIGHT DUTY
FRONT FRAME RAIL TIP REPLACEMENT....4
STANDARD PROCEDURE - HYDROFORM
FENDER RAIL REPAIR.................11
STANDARD PROCEDURE - REAR FRAME
H-SECTION REPLACEMENT.............13SPECIFICATIONS
SPECIFICATIONS - WELD PROCESS......15
SPECIFICATIONS - FRAME DIMENSIONS . . . 16
SPECIFICATIONS - TORQUE............22
FRONT CROSSMEMBER
REMOVAL.............................22
INSTALLATION.........................22
FRONT SKID PLATE
REMOVAL.............................23
INSTALLATION.........................23
FRONT TOW HOOK ASSEMBLY
REMOVAL.............................23
INSTALLATION.........................23
TRANSMISSION CROSSMEMBER
REMOVAL.............................24
INSTALLATION.........................24
TRAILER HITCH
REMOVAL.............................25
INSTALLATION.........................25
TRANSFER CASE SKID PLATE
REMOVAL.............................26
INSTALLATION.........................26
BUMPERS
SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front bumper center bracket nuts 95 70 Ð
Front bumper stud plate nuts 95 70 Ð
License plate hitch reinforcement bolts 54 40 Ð
Rear bumper support bracket stud plate nuts 54 40 Ð
Rear bumper support bracket to hitch bolts 54 40 Ð
Rear bumper to hitch bolts 54 40 Ð
DRFRAMES & BUMPERS 13 - 1

(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)

(9) Remove the clip and remove the spare tire
winch tube. (Fig. 21)
(10) Remove the bolts and remove the spare tire
winch. (Fig. 22)
(11) Position the wire harness forward of the work
area.
CAUTION: Do not use any flame or plasma cutting
equipment to cut the frame in this procedure. The
inaccurate and high temperatures achieved during
flame or plasma cutting will change the metal char-
acteristics and may weaken the frame and/or repair
location.(12) Carefully remove the H-section welds using a
grinder or equivalent tool.
(13) Remove the H-section and clean any remain-
ing welds from the frame.
(14) Trial fit the replacement part.
(15) Remove all e-coat from within 25 mm (1.0 in.)
of the weld area.
(16) Using the appropriate measuring equipment,
position the replacement part and verify correct posi-
tioning in all three (X,Y, and Z) planes of space.
(Refer to 13 - FRAME & BUMPERS/FRAME - SPEC-
IFICATIONS - FRAME DIMENSIONS)
CAUTION: Shield the surrounding area and compo-
nents from exposure to the welding spatter and
heat.
(17) Weld the replacement H-section into position.
The welding should be performed in a skip (stitch)
type method to minimize the heat buildup following
I-CAR or the American Welding Society welding pro-
cedures and utilizing the process specifications at the
end of this section. (Refer to 13 - FRAME &
BUMPERS/FRAME - SPECIFICATIONS - WELD-
ING)
(18) Dress the welded area and apply corrosion
resistant coatings inside and out.
(a) Inside the rail, inject a creeping wax based
rust inhibitor compound through the existing holes
in the frame ensuring 100% coverage including the
mating face between the frame and replacement
H-section.
(b) Apply a durable top coat to the outside of the
repair area.
(19) Position the wiring harness back.
CAUTION: Inspect the tire winch assembly for dam-
age. If any one or more of the following are evident,
replace the winch assembly.
²Indications of cracked or bulging plastic.
²Housing flanges are bent or cracked.
²If winch was loose before repair.
(20) Install the spare tire winch and install the
bolts. (Fig. 22)
(21) Tighten the bolts to 41 N´m (30 ft. lbs.).
(22) Install the spare tire winch tube and install
the clip. (Fig. 21)
(23) Install the spare tire.
CAUTION: Check operation of the spare tire winch
by manipulating it up and down. If the winch binds
or jambs, replace the winch assembly.
(24) Lift the axle into position and install the rear
shackle bolts. (Fig. 20)
(25) Tighten the bolts to 163 N´m (120 ft. lbs.).
Fig. 21 SPARE TIRE WINCH TUBE
1 - SPARE TIRE WINCH ASSEMBLY
2 - HAIR PIN CLIP
3 - WINCH TUBE
4 - H-SECTION/SPARE WHEEL SUPPORT
Fig. 22 SPARE TIRE WINCH ASSEMBLY
1 - SPARE TIRE WINCH ASSEMBLY
2 - BOLTS
3 - RETAINER BRACKET
4 - H-SECTION/SPARE WHEEL SUPPORT
13 - 14 FRAMES & BUMPERSDR
FRAME (Continued)

SPECIFICATIONS - FRAME DIMENSIONS
NOTE: Frame dimensions are listed in metric scale.
All dimensions are from center to center of Princi-
pal Locating Point (PLP), or from center to center of
PLP and fastener location.
VEHICLE PREPARATION
Position the vehicle on a level work surface. Using
screw or bottle jacks, adjust the vehicle PLP heights
to the specified dimension above a level work surface.
Vertical dimensions can be taken from the work sur-
face to the locations indicated were applicable.
INDEX
DESCRIPTION FIGURE
Frame Dimensional Graphics, Side
And Top View23
140.5 In Wheelbase - Heavy Duty -
2 Wheel Drive24
140.5 In Wheelbase - Heavy Duty -
4 Wheel Drive25
160.5 In Wheelbase - Heavy Duty -
2 Wheel Drive26
160.5 In Wheelbase - Heavy Duty -
4 Wheel Drive27
13 - 16 FRAMES & BUMPERSDR
FRAME (Continued)

Fig. 23 FRAME DIMENSIONS
DRFRAMES & BUMPERS 13 - 17
FRAME (Continued)

SPECIFICATIONS
TRANSMISSION
GENERAL
Component Metric Inch
Planetary end play 0.150-1.22
mm0.006-0.048
in.
Input shaft end play 0.86-2.13
mm0.034-0.084
in.
Clutch pack clearance/
Front.2.5-4.09
mm0.098-0.161
in.
Clutch pack clearance/
Rear.0.635-0.914
mm0.025-0.036
in.
Front clutch 5 discs
Rear clutch 4 discs
Overdrive clutch 5(STD) OR 6(Diesel HO)
discs
Direct clutch 23 Single Sided discs
Band adjustment from
72 in. lbs.
Front band Back off 1 3/4 turns
Rear band Back off 3 turns
Recommended fluid MoparTAT F + 4GEAR RATIOS
1ST GEAR 2.45:1
2ND GEAR 1.45:1
3RD GEAR 1.0:1
4TH GEAR 0.69:1
REVERSE 2.20:1
THRUST WASHER/SPACER/SNAP-RING DIMENSIONS
Component Metric Inch
Front clutch thrust washer (reaction shaft support hub) 1.55 mm 0.061 in.
2.15 mm 0.084 in.
2.59 mm 0.102 in.
Rear clutch thrust washer (clutch retainer) 1.55 mm 0.061 in.
Intermediate shaft thrust plate (shaft hub pilot) 1.5-1.6 mm 0.060-0.063 in.
Output shaft thrust washer (rear clutch hub) 1.3-1.4 mm 0.052-0.054 in.
1.75-1.8 mm 0.068-0.070 in.
2.1-2.2 mm 0.083-0.085 in.
Rear clutch pack snap-ring 1.5-1.6 mm 0.060-0.062 in.
1.9-1.95 mm 0.074-0.076 in.
Planetary geartrain snap-ring (at front of output shaft) 1.4-1.5 mm 0.055-0.059 in.
1.6-1.7 mm 0.062-0.066 in.
Overdrive piston thrust plate Thrust plate and
spacer are select fit.
Refer to size charts
and selection
procedures in
Overdrive Unit D&A
procedures Intermediate shaft spacer
DRAUTOMATIC TRANSMISSION - 48RE 21 - 189
AUTOMATIC TRANSMISSION - 48RE (Continued)

BODY STRUCTURE
TABLE OF CONTENTS
page page
GAP AND FLUSH
SPECIFICATIONS.......................95
OPENING DIMENSIONS
SPECIFICATIONS - BODY OPENING
DIMENSIONS.........................99
SEALER LOCATIONS
SPECIFICATIONS......................102STRUCTURAL ADHESIVE LOCATIONS
SPECIFICATIONS......................112
WELD LOCATIONS
SPECIFICATIONS......................120
GAP AND FLUSH
SPECIFICATIONS
GAP & FLUSH DIMENSIONS INDEX
DESCRIPTION FIGURE
STANDARD CAB 1
QUAD CAB 2
PICKUP BOX 3
DRBODY STRUCTURE 23 - 95