4X4 DODGE RAM 1500 1998 2.G Service Manual

Position both the left and right side engine mount
brackets and install the through bolts and nuts.
Tighten nuts to4X2 vehicles95 N´m (70 ft. lbs.).
4X4 vehicles102 N´m (75 ft. lbs.).
(2)4X4 vehiclesInstall locknuts onto the engine
mount brackets. Tighten locknuts to 41 N´m (30 ft.
lbs.).
(3) Remove jack from under the transmission.
(4) Remove Engine Lifting Fixture Special Tool
8347 (Fig. 4).
(5) Remove Special Tools 8400 Lifting Studs.
(6) Position generator wiring behind the oil dip-
stick tube, then install the oil dipstick tube upper
mounting bolt.
(7) Connect both left and right side body ground
straps.
(8) Install power steering pump.
(9) Connect fuel supply line quick connect fitting
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
QUICK CONNECT FITTING - STANDARD PROCE-
DURE).
(10) Connect the vacuum lines at the throttle body
and intake manifold.
(11) Connect engine harness at the following
points (Fig. 3):
²Intake Air Temperature (IAT) Sensor
²Idle Air Control (IAC) Motor
²Fuel Injectors
²Throttle Position (TPS) Switch
²Engine Oil Pressure Switch
²Engine Coolant Temperature (ECT) Sensor
²Manifold Absolute Pressure (MAP) Sensor
²Camshaft Position (CMP) Sensor
²Coil Over Plugs
(12) Position and install heater hoses and tubes
onto intake manifold.
(13) Install the heater hoses onto the heater core
and the engine front cover.
(14) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(15) Install A/C condenser (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/A/C CON-
DENSER - INSTALLATION), radiator (Refer to 7 -
COOLING/ENGINE/RADIATOR - INSTALLATION)
and transmission oil cooler.
(16) Connect radiator upper and lower hoses.
(17) Connect the transmission oil cooler lines to
the radiator.
(18) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -INSTALLATION), fan assembly and shroud (Refer to
7 - COOLING/ENGINE/FAN DRIVE VISCOUS
CLUTCH - INSTALLATION).
(19) Install A/C compressor (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - INSTALLATION).
(20) Install both breathers. Connect tube to both
crankcase breathers (Fig. 2).
(21) Connect throttle and speed control cables.
(22) Install throttle body resonator assembly and
air inlet hose. Tighten clamps 4 N´m (35 in. lbs.).
(23) Raise vehicle.
(24) Install transmission to engine mounting bolts.
Tighten the bolts to 41 N´m (30 ft. lbs.).
(25) Install torque converter bolts (Automatic
Transmission Only).
(26) Connect crankshaft position sensor (Fig. 1).
(27)4X4 vehiclesPosition and install the axle
isolator bracket onto the axle, transmission and
engine block. Tighten bolts to specification (Refer to 9
- ENGINE - SPECIFICATIONS).
(28) Install starter (Refer to 8 - ELECTRICAL/
STARTING/STARTER MOTOR - INSTALLATION).
CAUTION: The structural cover requires a specific
torque sequence. Failure to follow this sequence
may cause severe damage to the cover.
(29) Install structural cover (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION).
(30) Install exhaust crossover pipe.
(31) Install engine block heater power cable, If
equipped.
(32)4X4 vehiclesConnect axle vent tube to left
side engine mount.
(33) Lower vehicle.
(34) Check and fill engine oil.
(35) Recharge the A/C system (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/REFRIG-
ERANT - STANDARD PROCEDURE).
(36) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(37) Install the battery tray and battery.
(38) Connect the battery positive and negative
cables.
(39) Start the engine and check for leaks.
9 - 98 ENGINE - 4.7LDR
ENGINE - 4.7L (Continued)

(14) Raise the engine far enough to be able to
remove the left (Fig. 89) and right (Fig. 88) engine
mounts.
(15) Remove the engine mounts.
INSTALLATION
2WD
NOTE: For mount to engine block and left engine
bracket to front axle bolts, apply MoparTLock and
Seal Adhesive, Medium Strength Threadlocker.
(1) Install the right and left side engine mounts to
the engine block with (8) bolts. Torque bolts to 54
N´m (40 ft. lbs.).
(2) Insert the (2) through bolts into the right and
left side engine mounts and loose assemble the two
nuts onto the through bolts.
(3) Lower the engine until the through bolts rest
onto the slots in the frame brackets.
(4) Tighten the through bolt nuts to 94 N´m (70 ft.
lbs.).
(5) Install the oil drain trough.
(6) Install the engine oil filter.
Fig. 87 ENGINE INSULATOR MOUNTS 4X4
1 - RH INSULATOR TO AXLE BOLT
2 - NUT
3 - PINION SUPPORT MOUNT
4 - LH INSULATOR MOUNT5 - LH INSULATOR TO AXLE BOLT
6 - FRONT AXLE
7 - NUT
8 - RH INSULATOR MOUNT
Fig. 88 ENGINE MOUNT SUPPORT BRACKET RH
1 - BOLT
2 - ENGINE MOUNT SUPPORT BRACKET
DRENGINE - 4.7L 9 - 147
FRONT MOUNT (Continued)

(7) Lower the vehicle.
(8) Install the viscous fan (Refer to 7 - COOLING/
ENGINE/FAN DRIVE VISCOUS CLUTCH -
REMOVAL).
(9) Reconnect the negative battery cable.
4WD
NOTE: For mount to engine block and left engine
bracket to front axle bolts, apply MoparTLock and
Seal Adhesive, Medium Strength Threadlocker.
(1) Install the right and left side engine mounts to
the front axle. Torque nuts to 94 N´m (70 ft. lbs.).
(2) Raise the front axle into the frame and install
the left and right side through bolts. Torque nuts to
94 N´m (70 ft. lbs.).
(3) Insert the two upper through bolts into the
right and left side engine mounts and loose assemble
the two nuts onto the through bolts.
(4) Lower the engine until the left and right side
engine brackets rest on the through bolts, and the
lower engine bracket through holes align with the
engine mounts, and the left engine bracket holes
align with the front axle slots (Fig. 90).
(5) Loose assemble the (3) bolts that attach the
front axle to the left engine bracket.
(6) Loose assemble the lower through bolts.
Fig. 89 ENGINE MOUNT SUPPORT BRACKET
1 - BOLT
2 - ENGINE MOUNT SUPPORT BRACKET
3 - BOLT
Fig. 90 ENGINE INSULATOR MOUNTS 4X4
1 - RH INSULATOR TO AXLE BOLT
2 - NUT
3 - PINION SUPPORT MOUNT
4 - LH INSULATOR MOUNT5 - LH INSULATOR TO AXLE BOLT
6 - FRONT AXLE
7 - NUT
8 - RH INSULATOR MOUNT
9 - 148 ENGINE - 4.7LDR
FRONT MOUNT (Continued)

(6) Support the engine using engine support fix-
ture, special tool # 8534.
(7) Support the front axle with a suitable jack.
(8) Remove the (4) bolts that attach the engine
mounts to the front axle (Fig. 23).
(9) Remove the (3) bolts that attach the front axle
to the left engine bracket.
(10) Lower the front axle.
(11) Remove the (6) through bolts
(12) Raise the engine far enough to be able to
remove the left and right engine mounts.
(13) Remove the engine mounts.
INSTALLATION
2WD
(1) Install insulator on the engine (Fig. 24).
NOTE: For mount to engine block and left engine
bracket to front axle bolts, apply MoparTLock and
Seal Adhesive, Medium Strength Threadlocker.
(2) Install upper and lower mount mounting bolts.
Tighten bolts to 61 N´m (45 ft. lbs.).
(3) Lower the engine using engine support fixture
special tool # 8534.
Fig. 22 LH INSULATOR
1 - BOLT
2 - INSULATOR
Fig. 23 ENGINE INSULATOR MOUNTS 4X4
1 - RH INSULATOR TO AXLE BOLT
2 - NUT
3 - PINION SUPPORT MOUNT
4 - LH INSULATOR MOUNT5 - LH INSULATOR TO AXLE BOLT
6 - FRONT AXLE
7 - NUT
8 - RH INSULATOR MOUNT
9 - 218 ENGINE - 5.7LDR
FRONT MOUNT (Continued)

(4) Install mount through bolts.
(5) Tighten through bolts on both sides to 61 N´m
(45 ft. lbs.).
(6) Lower vehicle.(7) Connect negative battery cable.
4WD
NOTE: For mount to engine block and left engine
bracket to front axle bolts, apply MoparTLock and
Seal Adhesive, Medium Strength Threadlocker.
(1) Install the right and left side engine mounts to
the front axle. Torque nuts to 94 N´m (70 ft. lbs.).
(2) Raise the front axle into the frame and install
the left and right side through bolts. Torque nuts to
94 N´m (70 ft. lbs.).
(3) Insert the two upper through bolts into the
right and left side engine mounts and loose assemble
the two nuts onto the through bolts.
(4) Lower the engine using engine support fixture
special tool # 8534, until the left and right side
engine brackets rest on the through bolts, and the
lower engine bracket through holes align with the
engine mounts, and the left engine bracket holes
align with the front axle slots (Fig. 25).
(5) Loose assemble the (3) bolts that attach the
front axle to the left engine bracket.
(6) Loose assemble the lower through bolts.
(7) Torque the nuts for the (4) through bolts to 101
N´m (75 ft. lbs.).
Fig. 24 RH INSULATOR
1 - BOLT
2 - INSULATOR
Fig. 25 ENGINE INSULATOR MOUNTS 4X4
1 - RH INSULATOR TO AXLE BOLT
2 - NUT
3 - PINION SUPPORT MOUNT
4 - LH INSULATOR MOUNT5 - LH INSULATOR TO AXLE BOLT
6 - FRONT AXLE
7 - NUT
8 - RH INSULATOR MOUNT
DRENGINE - 5.7L 9 - 219
FRONT MOUNT (Continued)

INSTALLATION
(1) Align the holes in the bumpers to the trailer
hitch pins and install the bumper.
(2) Install the support bracket to the hitch bolts,
loosely.
(3) Install the front upper edge to the trailer hitch
bolts and tighten to 54 N´m (40 ft. lbs.).
(4) Install the license plate reinforcement to hitch
bolts and tighten to 54 N´m (40 ft. lbs.).
(5) Tighten the left bumper bracket bolts to 54
N´m (40 ft. lbs.).
(6) Tighten the right bumper bracket bolts to 54
N´m (40 ft. lbs.).
(7) Connect the trailer light connector electrical
connection, if equipped.
(8) Connect the license plate light electrical con-
nectors.
(9) Install the license plate.
FRAME
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT.
²BEFORE PROCEEDING WITH FRAME REPAIR
INVOLVING GRINDING OR WELDING, VERIFY THAT
VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN
CONTACT WITH REPAIR AREA, PERSONAL INJURY
CAN RESULT.
²DO NOT ALLOW OPEN FLAME OR HEAT AND
METAL SPATTER FROM ARC WELDING, TO CON-
TACT PLASTIC BODY PANELS. FIRE OR EXPLO-
SION CAN RESULT.
²WHEN WELDED FRAME COMPONENTS ARE
REPLACED, ENSURE COMPLETE PENETRATION
WELD IS ACHIEVED DURING INSTALLATION. IF
NOT, DANGEROUS OPERATING CONDITIONS CAN
RESULT.
²STAND CLEAR OF CABLES OR CHAINS ON
PULLING EQUIPMENT DURING FRAME STRAIGHT-
ENING OPERATIONS, PERSONAL INJURY CAN
RESULT.
²DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT SUPPORTED ON SAFETY
STANDS, PERSONAL INJURY CAN RESULT.
CAUTION: 1500 series Dodge Ram Trucks (2002 and
later) are not designed for snow plow equipment.The front collision repair tips must not be installed
on any truck equipped with a snow plow, or even
intended to be equipped with a snow plow.
CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect. Failure to use only pro-
duction fasteners or fasteners of equivalent hard-
ness can result in loosening or failure. Do not drill
any holes in the frame that are not specifically out-
lined in this or other, DaimlerChrysler procedure as
frame rail failure can result. When using heat to
straighten frame components do not exceed 566ÉC
(1050ÉF), metal fatigue can result.
STANDARD PROCEDURE
STANDARD PROCEDURE - LIGHT DUTY FRONT
FRAME RAIL TIP REPLACEMENT
CAUTION: This procedure is designed to replace
the front frame rail tips that have been damaged in
the crush initiator zones. Prior to any cutting, the
vehicle must be mounted on the appropriate frame
repair equipment (ªframe rackº), checked with three
dimensional measuring equipment, and the neces-
sary pull corrections made. If damage remains in
the frame beyond the area covered by this service
part after the pull, the frame must be replaced in its
entirety.
NOTE: Procedures for 4X2 and 4X4 are common
except as noted in this procedure.
(1) Before proceding with this repair procedure
review the required service warnings and precau-
tions. (Refer to 13 - FRAME & BUMPERS/FRAME -
WARNING)
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the front wheelhouse splash shield.
(Refer to 23 - BODY/EXTERIOR/FRONT WHEEL-
HOUSE SPLASH SHIELD - REMOVAL)
(4) Remove the bolts and position aside the wire
harness and grounds, if required.
(5) Remove the front bumper. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/FRONT BUMPER
- REMOVAL)
(6) Loosen and lower the stabilizer bar mount and
bar. (Refer to 2 - SUSPENSION/FRONT/STABI-
LIZER BAR - REMOVAL)
13 - 4 FRAMES & BUMPERSDR
REAR BUMPER (Continued)

(17) On 4X4 models use the service sleeve as a
template to drill a hole in the frame tip to accommo-
date the sway bar mounting bolt. (Fig. 11)
(18) Slide the service sleeve into the replacement
frame tip and align to the 2 mm (0.08 in.) off center
line made previously during the sleeve assembly and
tack the ring fillet welds to hold them in place. (Fig.
9) (Fig. 10) (Fig. 11) (Fig. 12)
(19) On 4X4 models, install the sway bar tapping
plate and secure with tack welds. (Fig. 11) (Fig. 12)
Fig. 9 4X2 SLEEVE INSTALLATION
1 - REPLACEMENT FRAME TIP
2 - FRAME RAIL
3 - SERVICE SLEEVE
4 - PLP
5 - SWAY BAR MOUNTING BRACKET
6 - TAPPING PLATE
7 - ROOT WELD GAPFig. 10 4X2 SLEEVE INSTALLATION
1 - REPLACEMENT FRAME TIP
2 - ROOT WELD GAP
3 - SERVICE SLEEVE
4 - SWAY BAR MOUNTING BRACKET
5 - TAPPING PLATE
DRFRAMES & BUMPERS 13 - 7
FRAME (Continued)

(20) Apply ring-fillet welds into the ring-fillet weld
holes on the replacement frame tip (Fig. 13). (Refer
to 13 - FRAME & BUMPERS/FRAME - SPECIFICA-
TIONS - WELDING)
(21) Install the upper FESM insulator onto the
replacement tip and position the service sleeve/re-
placement tip into the existing frame rail.
(22) Loosely install the lower FESM insulator and
cab mounting bolt.
(23) Using the appropriate measuring equipment,
verify the front end sheet metal bracket's location in
all three (X,Y, and Z) planes of space, and adjust if
required. (Fig. 14)
CAUTION: Shield the surrounding area and compo-
nents from exposure to the welding spatter and
heat.(24) When correctly fitted and a weld root gap of 4
mm minimum to 6 mm maximum (0.16 in - 0.24 in)
is established, tack the ring fillet welds to hold the
tip in position, then complete the ring fillet welds.
NOTE: Ring-fillet welds may be filled in with weld
material if an improved cosmetic appearance is
desired.
Fig. 11 4X4 TAPPING PLATE/SLEEVE
INSTALLATION
1 - REPLACEMENT FRAME TIP
2 - FRAME RAIL
3 - SERVICE SLEEVE
4 - PLP
5 - SWAY BAR MOUNTING BRACKET
6 - TAPPING PLATE
7 - ROOT WELD GAP
8 - SLEEVE TAB
Fig. 12 4X4 TAPPING PLATE/SLEEVE
INSTALLATION
1 - REPLACEMENT FRAME TIP
2 - ROOT WELD GAP
3 - SERVICE SLEEVE
4 - SWAY BAR MOUNTING BRACKET
5 - TAPPING PLATE
6 - SLEEVE TAB
13 - 8 FRAMES & BUMPERSDR
FRAME (Continued)

SERVICE SLEEVE ASSEMBLY
NOTE: Two sleeve halves are included with each
kit. Modifications as follow, are necessary to create
the correct sleeve assembly for each application.
(1) On 4X2 models, the9lower9sleeve is made by
cutting off the tab and cutting out a notch in the bot-
tom sleeve portion. Round the corners of the cut out
to keep stress cracks from forming. On 4X4 models
the9lower9sleeve is used as provided. (Fig. 15)
(2) On both 4X2 and 4X4 models cut off the front
tab on the upper sleeve portion. (Fig. 16)(3) The sleeve halves are shipped slightly over-
sized to allow custom fitting to each replacement
frame rail tip. It is necessary to grind the mating
surfaces to achieve the desired snug fit into the
replacement tip (rail tube has increasing height rear-
ward of the cut line). Once the two sleeve halves are
fitted, bevel the edges 25É - 30É.
NOTE: Scribing a line 2 mm from the cut edge and
then grinding back to the mark will simplify the
bevel creation process and accuracy.
(4) Remove any burrs at the beveled edges.
(5) Using the Weld Process Specifications table
(Refer to 13 - FRAME & BUMPERS/FRAME - SPEC-
IFICATIONS - WELDING), weld the two halves of
the repair sleeve together. (Fig. 17)
(6) Clean the welds of any flux and other impuri-
ties and grind smooth before proceeding with the
installation of the sleeve.
(7) Find the centerline of the sleeve and scribe a
centerline mark. Mark two additional lines 2 mm
(0.08 in.) on either side of the centerline mark to help
ensure the required 4 mm-6mm(0.16 in. - 0.24 in.)
weld root gap. (Fig. 17)
Fig. 15 4X2 LOWER SLEEVE CUT LOCATION
1 - SERVICE SLEEVE LOWER HALF
2 - CUT DIMENSION 27 mm (1.06 in.)
3 - CUT DIMENSION 36.1 mm (1.42 in)
4 - 4X2 CUTOUT
5 - FRONT TAB CUT LINE (4X2 ONLY)
Fig. 16 UPPER SLEEVE CUT LOCATION
1 - SERVICE SLEEVE UPPER HALF
2 - CUT LOCATION
Fig. 17 SERVICE SLEEVE ASSEMBLY
1 - CENTERLINE SCRIBE MARK
2 - WELD SEAM
3 - REAR TAB (4X4 ONLY)
4 - SCRIBE LINE LOCATION 2 mm (0.08 in.)
5 - FRONT TAB (4X4 ONLY)
13 - 10 FRAMES & BUMPERSDR
FRAME (Continued)

COLUMN
TABLE OF CONTENTS
page page
COLUMN
DESCRIPTION..........................6
DIAGNOSIS AND TESTING - STEERING
COLUMN.............................7
REMOVAL.............................7
INSTALLATION..........................9
IGNITION SWITCH
DESCRIPTION..........................9
OPERATION............................9
DIAGNOSIS AND TESTING - IGNITION
SWITCH.............................9
REMOVAL.............................10
INSTALLATION.........................11
KEY-IN IGNITION SWITCH
DESCRIPTION.........................11
DIAGNOSIS AND TESTING - IGNITION
SWITCH AND KEY LOCK CYLINDER.......11
KEY CYLINDER
REMOVAL.............................12
INSTALLATION.........................12GEAR SHIFT LEVER
REMOVAL.............................12
INSTALLATION.........................12
UPPER STEERING COUPLING
REMOVAL.............................13
INSTALLATION.........................13
LOWER STEERING COUPLING
REMOVAL
REMOVAL - ALL LD & HD EXCEPT 4X4 HD . 14
REMOVAL - 4X4 HD...................14
INSTALLATION
INSTALLATION - ALL LD & HD EXCEPT 4X4
HD.................................14
INSTALLATION - 4X4 HD................15
STEERING WHEEL
REMOVAL.............................15
INSTALLATION.........................15
TILT LEVER KNOB RELEASE
REMOVAL.............................16
INSTALLATION.........................16
COLUMN
DESCRIPTION
NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth-
ods of locking the steering wheel for service will
have to be used.
The tilt and standard column (Fig. 1) has been
designed to be serviced as an assembly; less wiring,
switches, shrouds, steering wheel, etc. Most steering
column components can be serviced without remov-
ing the steering column from the vehicle.
To service the steering wheel, switches or airbag,
refer to Restraints and follow all WARNINGS and
CAUTIONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT INACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
CAUTION: Do not hammer on steering column
shaft. This may cause damage to the shaft or bear-
ing.
CAUTION: Do not attempt to remove the pivot bolts
to disassemble the tilting mechanism. Do not
remove shaft lock plate or plate retainer. This will
damage the column.
CAUTION: Do not attempt to remove or modify the
park lock slider or link.
19 - 6 COLUMNDR