DODGE RAM 1999 Service Repair Manual

1) Locate low pressure cut-out switch located on suction
line, near firewall. Ensure system pressure is correct. See
A/C SYSTEM PERFORMANCE test. Disconnect negative battery cable.
Disconnect low pressure cut-out switch connector.
2) Place a jumper wire across terminals of low pressure cut-
out switch harness connector. Connect negative battery cable. Connect
manifold gauge set. Set A/C-heater controls to A/C. Start and operate
engine at idle speed.
3) Using an ohmmeter, check for continuity between switch
terminals. Continuity should exist when suction pressure reading is
between 13-27 psi (.9-1.9 kg/cm
). Continuity should not exist when
suction pressure reading is 10 psi (.7 kg/cm) or lower. If switch is
okay, repair open or short in Brown wire between low pressure cut-out
switch and PCM. If switch is not okay, replace faulty low pressure
cut-out switch.
REMOVAL & INSTALLATION
* PLEASE READ THIS FIRST *
WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all SERVICE PRECAUTIONS and DISABLING &
ACTIVATING AIR BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY
article.
A/C-HEATER ASSEMBLY
Removal (Dakota & Durango - Front)
1) Disconnect negative battery cable. Drain cooling system.
Discharge A/C system, using approved refrigerant recovery/recycling
equipment. Disconnect refrigerant lines from evaporator and plug or
cover all openings in A/C system. Remove instrument panel. See
INSTRUMENT PANEL .
2) In engine compartment, disconnect heater hoses. Remove 4
A/C-heater assembly nuts from engine compartment firewall. Inside
vehicle, remove A/C-heater assembly support brace screw, and swing
support brace out of way. Move passenger seat rearward.
3) Carefully pull A/C-heater assembly rearward until studs
and heater core tubes clear firewall. Lower A/C-heater assembly and
rotate assembly until studs are facing downward. Remove A/C-heater
assembly from vehicle. See Fig. 4.
4) Place A/C-heater assembly on work bench with assembly
housing cover facing down. Remove 2 screws securing A/C-heater
assembly housing cover to blower motor housing cover. Unplug vacuum
harness connector from panel/defrost door actuator.
5) Remove floor duct from A/C-heater assembly housing. Remove
2 screws securing A/C-heater assembly housing cover to lower housing
near floor outlet. Turn assembly over. Disengage vacuum harness
retainer and vacuum harness. Remove 13 screws securing housing cover.
6) Remove blend-air door lever. Gently pry panel-defrost door
lever off. Pull up on A/C-heater assembly housing cover far enough to
separate cover sealant and remove cover.
Installation
Ensure blower motor housing cover sealant is in place and in
good condition. To complete installation, reverse removal procedure.

Fig. 4: A/C-Heater Housing Removal/Installation (Dakota & Durango -
Front)
Courtesy of Chrysler Corp.

Fig. 5: Exploded View Of A/C-Heater Assembly (Ram Pickup)
Courtesy of Chrysler Corp.
Removal & Installation (Durango - Rear)
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Remove
headliner from passenger compartment of vehicle. Remove sun visors and
sun visor arm supports.
2) Remove coat hooks, overhead assist handle and dome light.
If equipped, remove overhead console. Remove air outlet bezel from
rear A/C-heater assembly. Remove rear blower motor switch. Remove
upper liftgate opening trim. Disengage "A", "B", "C", and "D" pillar
trim as necessary to prevent trim panel interference.
3) Move second and third row seats to cargo position. Move
front seats to full recline position. Remove headliner fasteners.
Carefully bow headliner and remove through lift gate opening.
4) Disconnect "B" pillar drain hoses from "Y" fittings.
Disconnect "B" pillar refrigerant lines and plug or cover all openings
in A/C system. Disconnect rear A/C-heater assembly harness connector.
Loosen but DO NOT remove screws securing left end of rear A/C-heater
assembly. Support right end of rear A/C-heater assembly. Remove screws
from right side of rear A/C-heater assembly. Slide rear A/C-heater

assembly towards right side of vehicle and remove rear A/C-heater
assembly.
5) To install, reverse removal procedure. Ensure all wiring
and hoses are clear and not pinched. Tighten bolts and nuts to
specification. See TORQUE SPECIFICATIONS .
Removal (Ram Pickup - Front)
1) Disconnect negative battery cable. Drain cooling system.
In engine compartment, remove coolant hoses from heater core tubes.
Remove coolant overflow bottle.
2) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Disconnect refrigerant lines from
evaporator and plug or cover all openings in A/C system. Remove
instrument panel. See INSTRUMENT PANEL. Remove Powertrain Control
Module (PCM) and position aside. DO NOT disconnect 60-pin connector
from PCM.
3) Remove attaching nuts from studs on engine compartment
side of dash panel. Remove defrost duct. Disconnect electrical
connectors. Remove attaching nuts from studs in passenger compartment
side of dash panel. Remove A/C-heater assembly from vehicle. See
Fig. 5 .
4) Place A/C-heater assembly upside-down on work bench.
Remove screw securing floor duct to bottom of A/C-heater assembly and
slide floor duct off of center heat duct adapter. Unsnap center heat
duct adapter from bottom of A/C-heater assembly housing. Remove screw
hidden behind adapter. Remove remaining screws and separate A/C-heater
assembly.
Installation
Ensure mode door pivot pins are properly inserted in holes.
To complete installation, reverse removal procedure.
A/C-HEATER CONTROL PANEL R & I
Removal & Installation (Dakota & Durango)
1) Disconnect negative battery cable. On models equipped with
A/T, unlock ignition switch. Set parking brake and place gear selector
lever in "L" position. If equipped, set tilt steering column in lowest
position.
2) On all models, carefully pry bezel away from instrument
panel to disengage clips. Unplug connectors from cigarette lighter and
auxiliary power outlet. Disconnect fog light switch (if equipped).
Remove A/C-heater control panel screws.
3) Pull control panel outward enough to disconnect wiring
connector, vacuum harness, and temperature control cable. Remove A/C-
heater control panel. To install, reverse removal procedure. Adjust
temperature control cable. See TEMPERATURE CONTROL CABLE ADJUSTMENT .
Removal & Installation (Ram Pickup)
1) Disconnect negative battery cable. Reach under driver's
side of instrument panel, near transmission tunnel and unplug A/C-
heater control panel to A/C-heater assembly vacuum harness connector.
Disconnect vacuum harness from center air duct.
2) On models equipped with A/T, unlock ignition switch. Set
parking brake and place gear selector lever in "L" position. If
equipped, set tilt steering column in lowest position.
3) On all models, remove screw securing cluster bezel to
instrument panel. See Fig. 6. Carefully pry bezel away from instrument
panel to disengage clips. Unplug connectors from cigarette lighter and
auxiliary power outlet.
4) Remove 4 screws attaching A/C-heater control panel. Pull
control panel outward enough to disconnect wiring connector, vacuum
harness and temperature control cable. Remove A/C-heater control

panel. To install, reverse removal procedure.
Fig. 6: Removing Cluster Bezel (Ram Pickup)
Courtesy of Chrysler Corp.
ACCUMULATOR
Removal & Installation
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
clutch cycling pressure switch connector.
2) On Dakota, remove nuts securing cruise control servo
mounting bracket to studs on cowl plenum panel (if equipped). Move
servo far enough to access accumulator refrigerant lines.
3) On all models, disconnect refrigerant lines from A/C
compressor and evaporator. Plug or cover all openings in A/C system.
Loosen support bracket screw. Remove accumulator.
4) To install, reverse removal procedure. Install new "O"
rings. Evacuate and charge A/C system.
BLOWER MOTOR
Removal (Dakota & Durango - Front)
1) Disconnect negative battery cable. Remove and disassemble
A/C-heater assembly. See A/C-HEATER ASSEMBLY. Disconnect blower motor
lead at bottom of housing. Remove 6 screws and blower motor housing
cover.
2) Remove 3 screws and blower motor and fan assembly. Place
reference marks on blower motor and fan for reassembly reference.
Remove blower fan retainer clip. Pull blower motor fan off blower
motor shaft.
Installation
Align reference marks. Press blower fan hub onto blower motor
shaft. Ensure retainer clip ears are indexed over flats of blower
motor shaft and fan hub. To complete installation, reverse removal

procedure.
NOTE: On Durango rear A/C-heater assembly, blower motor and fan are
serviced as an assembly.
Removal (Durango - Rear)
1) Disconnect negative battery cable. Remove headliner from
passenger compartment of vehicle. Remove sun visors and sun visor arm
supports.
2) Remove coat hooks, overhead assist handle and dome light.
If equipped, remove overhead console. Remove air outlet bezel from
rear A/C-assembly. Remove rear blower motor switch. Remove upper
liftgate opening trim. Disengage "A", "B", "C", and "D" pillar trim as
necessary to prevent trim panel interference.
3) Move second and third row seats to cargo position. Move
front seats to full recline position. Remove headliner fasteners.
Carefully bow headliner and remove through lift gate opening.
4) Disconnect "B" pillar drain hoses from "Y" fittings.
Remove lower A/C-heater assembly cover. Disconnect blower motor
harness connector. Remove blower motor and fan assembly. To install,
reverse removal procedure.
Removal (Ram Pickup - Front)
1) Disconnect negative battery cable. Disconnect blower motor
cooling tube. Remove blower motor electrical connector from retainer.
Disconnect electrical connector. See Fig. 5.
2) Remove blower motor and fan assembly mounting screws.
Remove blower motor and fan assembly. Place reference marks on blower
motor and fan for reassembly reference. Remove blower motor fan
retainer clip. Pull blower motor fan off blower motor shaft.
Installation
Align reference marks made during removal. Press blower fan
hub onto blower motor shaft. Ensure retainer clip ears are indexed
over flats of blower motor shaft and fan hub. Ensure blower motor seal
is installed on housing. To complete installation, reverse removal
procedure.
BLOWER MOTOR RESISTOR
Removal & Installation (Dakota & Durango - Front)
Blower motor resistor is located in engine compartment, under
upper right corner of dash panel. Disconnect negative battery cable.
Remove cowl plenum cover to access resistor. Remove blower motor
resistor connector. Remove resistor retaining screws. Remove blower
motor resistor. To install, reverse removal procedure.
Removal & Installation (Durango - Rear)
1) Rear blower motor resistor is located in A/C-heater
assembly. Disconnect negative battery cable. Remove headliner from
passenger compartment of vehicle. Remove sun visors and sun visor arm
supports.
2) Remove coat hooks, overhead assist handle and dome light.
If equipped, remove overhead console. Remove air outlet bezel from
rear A/C-assembly. Remove rear blower motor switch. Remove upper
liftgate opening trim. Disengage "A", "B", "C", and "D" pillar trim as
necessary to prevent trim panel interference.
3) Move second and third row seats to cargo position. Move
front seats to full recline position. Remove headliner fasteners.
Carefully bow headliner and remove through lift gate opening.
4) Disconnect "B" pillar drain hoses from "Y" fittings.
Remove lower A/C-heater assembly cover. Disconnect rear blower motor
resistor connector. Remove screw and rear blower motor resistor. To

install, reverse removal procedure.
Removal & Installation (Ram Pickup - Front)
Blower motor resistor is located under glove box, attached to
blower motor housing. See Fig. 5. Disconnect negative battery cable.
Remove blower motor resistor connector. Remove resistor retaining
screws. Remove blower motor resistor. To install, reverse removal
procedure.
BLOWER MOTOR SWITCH (REAR)
Removal & Installation (Durango)
Disconnect negative battery cable. Pry above indentations at
outer perimeter of rear blower motor switch. Pull rear blower motor
switch and disconnect electrical connector. Remove rear blower motor
switch. To install, reverse removal procedure.
COMPRESSOR
Removal & Installation
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
refrigerant lines and plug or cover all openings in A/C system.
2) Remove drive belt. Disconnect compressor electrical leads.
Remove compressor mounting nuts and bolts. Remove compressor. Drain
oil from compressor, and record amount of oil drained.
3) To install, reverse removal procedure. Using new
refrigerant oil, add to compressor the same amount of oil drained from
it. Evacuate and charge A/C system.
CONDENSER
NOTE: Before removing condenser, note location of radiator and
condenser air seals. If air seals are not installed properly,
A/C and engine cooling systems will not perform properly.
Removal
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
A/C fittings at inlet and outlet of condenser. Plug or cover all
openings in A/C system.
2) On Dakota, remove bolts securing radiator and fan shroud
to inside of upper radiator crossmember. Remove top mounting bolts
securing condenser to upper crossmember. Tilt top of radiator and fan
shroud toward engine.
3) On Ram Pickup (gasoline engine), remove bolts securing
condenser upper mounting brackets to outside of upper radiator
crossmember. Tilt condenser away from engine compartment far enough to
grasp top of condenser with both hands. On Ram Pickup (diesel engine),\
remove bolts securing condenser to charge air cooler. On all models,
lift condenser assembly from vehicle.
Installation
To install, reverse removal procedure. Install new "O" rings
to fittings. Fill cooling system. Evacuate and charge A/C system.
EVAPORATOR CORE & HEATER CORE
Removal & Installation (Dakota & Durango - Front)
Remove instrument panel. See INSTRUMENT PANEL. Remove A/C-
heater assembly. See A/C-HEATER ASSEMBLY. With A/C-heater housing
removed, remove housing cover. Remove evaporator core or heater core

from housing. To install, reverse removal procedure. Install new "O"
rings to A/C fittings. Evacuate and charge A/C system.
Removal & Installation (Durango - Rear Evaporator Core)
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Remove
headliner from passenger compartment of vehicle. Remove sun visors and
sun visor arm supports.
2) Remove coat hooks, overhead assist handle and dome light.
If equipped, remove overhead console. Remove air outlet bezel from
rear A/C-heater assembly. Remove rear blower motor switch. Remove
upper liftgate opening trim. Disengage "A", "B", "C", and "D" pillar
trim as necessary to prevent trim panel interference.
3) Move second and third row seats to cargo position. Move
front seats to full recline position. Remove headliner fasteners.
Carefully bow headliner and remove through lift gate opening.
4) Disconnect "B" pillar drain hoses from "Y" fittings.
Disconnect "B" pillar refrigerant lines and plug or cover all openings
in A/C system. Remove lower A/C-heater assembly cover. Remove screws
securing refrigerant tube and retaining strap to right side of upper
housing cover. Remove evaporator core. To install, reverse removal
procedure. Install new "O" rings to A/C fittings. Evacuate and charge
A/C system.
Removal & Installation (Ram Pickup - Front)
1) Remove and disassemble A/C-heater housing. See
A/C-HEATER ASSEMBLY . Separate halves of A/C-heater housing and remove
top half. Remove evaporator or heater core from housing.
2) To install, reverse removal procedure. Install new "O"
rings to A/C fittings. Evacuate and charge A/C system. Fill cooling
system. On 5.9L diesel engine, engine is equipped with a one-way check
valve. DO NOT run engine while filling cooling system. Fill engine
with engine turned off.
INSTRUMENT PANEL
Removal & Installation (Dakota & Durango)
1) Disconnect negative battery cable. Disable air bag system.
See AIR BAG SYSTEM SAFETY article. Place front wheels in straight-
ahead position. Remove sill trim from both doorways. Remove kick panel
covers from both sides of vehicle. Remove mounting screws for hood
release handle.
2) Remove steering column trim panel and support bracket.
Remove tilt steering column lever (if equipped). Remove upper and
lower shrouds from steering column. Unplug driver's side air bag
module. Loosen multifunction switch wiring harness connector screw and
disconnect from switch. Screw will remain in connector.
3) Disconnect PRNDL cable. Disconnect shift cable from
steering column. Remove steering coupler lock pin. Remove toe plate
retaining screws. Remove steering column mounting bolts and remove
steering column from vehicle.
4) Remove screw from bulkhead wiring harness connector and
disconnect. Disconnect 2 body wiring harness connectors located next
to bulkhead connector. Disconnect 3 wiring harness connectors, from
junction block, located nearest to dash panel. Disconnect brake light
switch connector. Disconnect Rear Wheel Anti-Lock (RWAL) brake module
(if equipped), located near steering column support brackets.
5) Disconnect plastic retainer clip from parking brake
linkage rod, located at back of parking brake release handle. Remove
rod end from parking brake handle. Remove instrument panel center
support bracket. Unplug vacuum harness connector located at left end
of A/C-heater housing. Disconnect Air Bag Control Module (ACM)
connector.

6) Remove glove box. Reach through glove box opening and
disconnect antenna coaxial cable connector. Disconnect blower motor
connector located above glove box opening, near support brace for A/C-
heater housing. Disconnect radio ground strap. Loosen instrument panel
roll down bracket bolts about 2 turns, located at lower corners on
both sides of instrument panel. Remove 5 screws across top of dash
panel at base of windshield, removing center screw last.
7) Roll down instrument panel and install a temporary support
hook that is about 18" (457 mm) in length. Install hook from center
hole in instrument panel to center hole of dash panel. Pull lower
instrument panel outward until both roll down bracket bolts are in
slotted roll down position. Instrument panel should now be supported
and away from firewall.
8) Disconnect 2 door harness connectors, located on a bracket
near right end of instrument panel. Disconnect blower motor resistor.
Disconnect temperature control cable from A/C-heater housing and
remove from housing. See Fig. 5. Disconnect demister duct flexible
hose from A/C-heater housing.
9) Ensure instrument panel is free and clear for removal.
With the aid of an assistant, remove temporary support hook. Lift
instrument panel off of roll down bracket bolts and remove from
vehicle.
10) To install, reverse removal procedure. Ensure all wiring
and hoses are clear and not pinched. Tighten bolts and nuts to
specification. See TORQUE SPECIFICATIONS . Enable air bag system. See
AIR BAG SYSTEM SAFETY article.
Removal & Installation (Ram Pickup)
1) Disable air bag system. See AIR BAG SYSTEM SAFETY article.
Disconnect negative battery cable. Drain cooling system. Remove left
and right kick panel trim. Remove 5 screws and knee bolster/steering
column cover. Remove hood release and parking brake release handle
screws from lower instrument panel support. Remove 6 screws and
instrument panel support. Disconnect air bag connector at lower left
corner of instrument panel.
2) Pull PRNDL cable and twist to remove from position arm.
Push tab on bottom of cable retainer upward, then squeeze sides to
remove retainer from column. Remove tilt lever (tilt column only).
Remove both upper and lower shrouds from column. Remove lower fixed
column shroud. Loosen multifunction switch connector screw. Screw will
remain in connector.
3) Remove remaining steering column electrical connectors.
Remove air bag wiring harness from steering column wiring trough.
Remove wiring trough from steering column. Remove 3 toe plate nuts and
washers.
4) Remove 2 nuts and washers attaching steering column
bracket to instrument panel steering column support bracket. Allow
column to lower and rest on seat. Remove 2 screws from bottom of Air
Bag Control Module (ACM) cover. Remove 4 screws holding ACM to
transmission tunnel.
5) Disconnect wiring at ACM. Disconnect instrument panel left
side wiring connectors. Remove screw holding brake release to bottom
of instrument panel. Disconnect instrument panel right side wiring
connectors, which includes 2 connectors attached to A/C-heater
assembly housing, courtesy light connector, antenna cable and 2 body
connectors. Disconnect vacuum harness from A/C-heater system.
6) Remove 5 screws holding instrument panel to dash. Loosen
lower instrument panel pivot bolts. Roll instrument panel downward.
Remove instrument panel from vehicle.
7) To install, reverse removal procedure. Ensure all wiring
and hoses are clear and not pinched. Tighten bolts and nuts to
specification. See TORQUE SPECIFICATIONS . Enable air bag system. See
AIR BAG SYSTEM SAFETY article.

TEMPERATURE CONTROL CABLE R & I
Removal (Dakota & Durango)
Disconnect negative battery cable. Disconnect but DO NOT
remove instrument panel. See INSTRUMENT PANEL. Disconnect temperature
control cable from A/C-heater control panel. Disconnect temperature
control cable from flag retainer located at top of A/C-heater assembly
housing. See Fig. 7. Remove temperature control cable self-adjuster
clip and temperature control cable.
Installation
1) Before installing temperature control cable, ensure that
self-adjuster clip is positioned as indicated. See Fig. 8.
Measurements must be made with cable end bottomed against flag
retainer on A/C-heater control panel end of cable housing.
2) Measure distance between center of self-adjusting clip and
end of cable flag retainer. If distance is not as specified, adjust
self-adjuster clip. To complete installation, reverse removal
procedure.
Fig. 7: Removing Control Cable Flag From Receiver (Typical)
Courtesy of Chrysler Corp.
Fig. 8: Adjusting Temperature Control Cable (Dakota & Durango)
Courtesy of Chrysler Corp.