transmission DODGE RAM 1999 Service Repair Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 460 of 1691
1) On drive shafts greater than 30" in length, measure runout
3" from transmission flange/yoke, center bearing yoke and pinion
flange using dial indicator. Maximum runout for Ram Pickup is .030" (.
76 mm) at front and rear end of drive shaft and .035" (.89 mm) at
center of drive shaft. Maximum runout for all other models is .010" (.
25 mm) at front and rear end of drive shaft and .015" (.38 mm) at
center of drive shaft.
2) For drive shafts less than 30" in length, maximum runout
for Pickup is .030" (.76 mm). Maximum runout for all other models is .\
020" (.51 mm). Replace drive shaft if maximum runout is exceeded.
BALANCING DRIVE SHAFT
1) Perform following procedure only after inspecting all
other possible causes of vibration. See INSPECTION. Drive shaft
imbalance may often be cured by disconnecting shaft, rotating it 180
degrees and reconnecting shaft to flange. Test drive to check results.
NOTE: DO NOT run engine for prolonged periods without forced
airflow across radiator. Engine or transmission may
overheat.
2) To balance drive shaft(s), begin by raising rear wheels
off ground and turning drive shaft with engine. Balance testing may be
done by marking drive shaft in 4 positions, 90 degrees apart around
shaft. Place marks about 6" forward of rear flange/yoke weld. Number
marks 1-4.
3) Install large diameter screw-type hose clamp around drive
shaft so clamp's head is in No. 1 position. Spin drive shaft with
engine and note vibrations. If there is little or no change in
vibration intensity, move clamp head to No. 2 position, and repeat
test.
4) Continue procedure until vibration is at lowest level. If
no difference is noted with clamp head moved to all 4 positions,
vibrations may not be due to drive shaft imbalance.
5) If vibration decreases but is not completely eliminated,
place a second clamp at same position, and repeat test. Combined
weight of both clamps in one position may increase vibration. If so,
rotate clamps 1/2" apart, above and below lowest vibration level
position, and repeat test.
6) Continue to rotate clamps, as necessary, until vibration
is at lowest point. If vibration can be eliminated or reduced to
acceptable level, bend back slack end of clamp so screw cannot loosen.
If vibration level is still unacceptable, leave rear clamp(s) in
place, and repeat procedure at front end of drive shaft. Road test
vehicle. On 4WD models, perform procedure on each shaft.
CHECKING VERTICAL ANGLE
One-Piece Drive Shafts
1) Raise and support vehicle so rear wheels can be rotated.
Rotate drive shaft so a pinion flange bearing cap faces downward.
Attach Inclinometer (C-4224) magnet to bearing cap, and measure drive
shaft vertical angle. See Fig. 4. Remove inclinometer.
2) Rotate drive shaft 90 degrees until drive shaft rear yoke
bearing cap faces downward. Attach inclinometer magnet to bearing cap,
and measure drive shaft vertical angle. Difference between 2 measured
angles is drive shaft rear angle. See Fig. 5. Remove inclinometer.
3) Rotate drive shaft until a slip joint yoke bearing cap
faces downward. Attach inclinometer magnet to bearing cap, and note
angle. Remove inclinometer. Rotate drive shaft 90 degrees until drive
shaft front yoke bearing cap faces downward. Attach inclinometer
magnet to bearing cap, and note angle. Remove inclinometer.
Page 464 of 1691
Fig. 8: Identifying Horizontal Misalignment Of Drive Shaft
Courtesy of Chrysler Corp.
Fig. 9: Checking Horizontal Alignment
Courtesy of Chrysler Corp.
3) To make horizontal alignment checks, set up straightedges
as shown. See Fig. 9. Set transmission output flange/yoke
Page 465 of 1691
horizontally, and clamp straightedge to yoke in a horizontal plane.
Repeat procedure with drive pinion flange. Ensure flange/yokes are
horizontal by checking angle of straightedge using a machinist spirit
level.
4) Measure distance "X" at each side. See Fig. 9. If
measurements are not within 1/16" (1.6 mm) of each other, transmission\
flange is horizontally misaligned.
5) Measure distance "Y" (edge of straightedge to axle shaft
center line) at each side. If measurements are not within 1/8" (3.2
mm) of each other, axle housing is misaligned. Measure distance "W" at
each side. If measurements are not within 1/16" (1.6 mm) of each
other, pinion flange is horizontally misaligned.
ADJUSTING HORIZONTAL ALIGNMENT
NOTE: Excessive difference in measurements may indicate frame
damage. DO NOT attempt to use following correction procedure
if more than slight horizontal misalignment exists.
Minor adjustment of drive shaft horizontal alignment may be
made by loosening axle housing "U" bolts and moving either side of
axle housing forward or backward. If frame is not bent, slight axle
movement should make "W" measurements equal. See Fig. 9.
REMOVAL & INSTALLATION
CENTER BEARING SUPPORT ASSEMBLY
Removal
1) With transmission in neutral and parking brake off, raise
vehicle. Scribe alignment marks on all flange/yokes and slip joints to
be disassembled or disconnected. Remove drive shaft from pinion
flange/yoke.
2) Slide rear drive shaft slip joint from front drive shaft
splines. See Fig. 10. Support drive shaft(s) while removing center
bearing support bracket mounting bolts. Pull to remove front drive
shaft slip joint from transmission extension housing shaft.
Fig. 10: Identifying Center Bearing Support Assembly Components
Courtesy of Chrysler Corp.
CAUTION: DO NOT clamp drive shaft tube or slip joint tube in a vise.
Clamp only forged portion of each yoke in vise. To avoid
Page 470 of 1691
* D RIV ETR AIN S YSTE M S U NIF O RM IN SPEC TIO N G UID ELIN ES *
1 999 D odge P ic ku p R 1500
GENERAL INFORMATION
Drivetrain/Transmission Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Drive/Power Train Assemblies
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLIES
DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES
MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES
TRANSFER CASE ASSEMBLIES
Drive/Power Train Components
ACTUATORS (ELECTRICAL)
ACTUATORS (VACUUM)
AXLES
BEARINGS AND RACES
BELL CRANKS
BELL HOUSINGS
BUSHINGS (EXTERNAL)
CABLES (SPEEDOMETER)
CABLES (TV, DETENT AND SHIFT)
CARRIER BEARINGS
CLUTCH CABLES AND CABLE HOUSINGS
CLUTCH DISCS (MANUAL TRANSMISSION)
CLUTCH FORKS
CLUTCH LINKAGES (MECHANICAL)
CLUTCH MASTER CYLINDERS
CLUTCH PEDALS
CLUTCH PIVOTS
CLUTCH PRESSURE PLATES
CLUTCH RELEASE BEARINGS
CLUTCH SLAVE CYLINDERS (CONCENTRIC)
CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)
COMPANION FLANGES
CONNECTORS
COOLER BYPASS VALVES
COOLER LINES
COOLERS
CV JOINTS
DIP STICK TUBES
DIP STICKS (FLUID LEVEL INDICATORS)
DOWEL PINS, GUIDES AND PILOT HOLES
DRIVE SHAFT FLANGES
DRIVE SHAFTS AND HALF SHAFTS
DUST BOOTS
ENGINE MOUNTS
EXCITER RINGS
FILLER TUBES
FILTERS AND SCREENS
Page 471 of 1691
FLANGES
FLEX PLATES
FLUID LEVEL INDICATORS
FLUIDS AND LUBRICANTS
FLYWHEELS
FORCE MOTORS
GUIDES
HALF SHAFTS
HOSES, LINES AND TUBES
HOUSINGS (BELL, CASE, TAIL (EXTENSION) AND AUXILIARY)
INTERMEDIATE SHAFT SUPPORT BEARINGS
KEY INTERLOCK SYSTEMS
LIMITED SLIPS
LINES
LINKAGES (EXTERNAL)
LOCKING HUB ASSEMBLIES
LOCKING HUB CONTROL KNOBS
LUBRICANTS
METAL-CLAD SEALS
METALASTIC JOINTS
MODULATOR PINS
MODULATORS
MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION)
ODOMETER DRIVES (MECHANICAL)
ODOMETER HEADS (MECHANICAL)
OIL PANS
PANS
PILOT HOLES
PRESSURE PLATES
PRESSURE SWITCHES
RACES
RUBBER JOINTS (METALASTIC)
SCREENS
SEALS
SEALS (METAL-CLAD)
SELECTOR INTERLOCK SYSTEMS
SERVOS
SHIFT INTERLOCK SYSTEMS (SELECTOR AND KEY INTERLOCK SYSTEMS)
SENSORS
SIDE COVERS
SLIP YOKES
SOLENOIDS
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)
SPEEDOMETER-DRIVEN GEAR HOUSINGS
SPEEDOMETER/ODOMETER DRIVES (MECHANICAL)
SPEEDOMETER/ODOMETER HEADS (MECHANICAL)
SPEEDOMETERS AND ODOMETERS (ELECTRONIC)
SWITCHES
TONE WHEELS
TOOTHED RINGS (TONE WHEELS)
TORQUE CONVERTERS
TRANSAXLE MOUNTS
TRANSDUCERS (TRANSMISSION)
TRANSMISSION COOLERS
TRANSMISSION MOUNTS
TRANSMISSION PANS
TRANSMISSION RANGE INDICATORS (PRNDL)
TUBES
UNIVERSAL JOINTS (CARDON OR CROSS TYPE)
VACUUM CONTROLS
VACUUM HOSES
VACUUM MOTORS
VACUUM-OPERATED SWITCHES
Page 472 of 1691
VEHICLE SPEED SENSORS
VENTS
VIBRATION DAMPERS
WHEEL ATTACHMENT HARDWARE
WHEEL SPEED SENSORS
WIRING HARNESSES AND CONNECTORS
YOKES AND SLIP YOKES
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 were recently published.
Further, revisions to all of these inspection communication standards
are continually republished. 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
satisfied with a repair transaction, the Motorist Assurance Program
offers mediation and arbitration through MAP/BBB-CARE and other non-
profit organizations. MAP conducted pilot programs in twelve states
before announcing the program nationally in October, 1998. During the
pilots, participating repair shops demonstrated their adherence to the
Pledge and Standards and agreed to follow the UICS in communicating
the results of their inspection to their customers. To put some
"teeth" in the program, an accreditation requirement for shops was
initiated. The requirements are stringent, and a self-policing method
Page 475 of 1691
NOTE: Whenever transmission or drivetrain service is performed
that affects the suspension alignment, for example,
removing the engine cradle, it is required that the
alignment be checked and corrected if necessary.
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLIES
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLY INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Any internal component
failure that requires
removal of the assembly
from the vehicle for
service. ( 1) ........... A ........... ( 2) Require repair or
replacement of the automatic
transmission/transaxle
assembly.
( 1) - It is Required that the torque converter and all other
failure related components be inspected for cause and
condition.
( 2) - For components not requiring removal of the assembly,
refer to the component listing in this document.
\
\
\
\
\
\
\
DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES
NOTE: Does not include half shafts.
DIFFERENTIAL AND FINAL DRIVE ASSEMBLY INSPECTION
\
\
\
\
\
\
\
Condition Code Procedure
Any internal component
failure that requires
removal of the assembly
from the vehicle for
service. ( 1) ........... A ... Require repair or replacement
of the differential assembly.
( 1) - For components not requiring removal of the assembly,
refer to the component listing in this document.
\
\
\
\
\
\
\
MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES
MANUAL TRANSMISSION/TRANSAXLE ASSEMBLY INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Any internal component
failure that requires
removal of the assembly
from the vehicle for
service. ( 1) ........... A ... Require repair or replacement
of the manual
transmission/transaxle
assembly.
( 1) - For components not requiring removal of the assembly,
Page 483 of 1691
![DODGE RAM 1999 Service Repair Manual CLUTCH DISCS (MANUAL TRANSMISSION)
CLUTCH DISC (MANUAL TRANSMISSION) INSPECTION \
\
\
\
\](/img/12/56915/w960_56915-482.png "DODGE RAM 1999 Service Repair Manual CLUTCH DISCS (MANUAL TRANSMISSION)
CLUTCH DISC (MANUAL TRANSMISSION) INSPECTION \
\
\
\
\")
CLUTCH DISCS (MANUAL TRANSMISSION)
CLUTCH DISC (MANUAL TRANSMISSION) INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Backing plate cracked ... A ............ Require replacement.
Broken .................. A ............ Require replacement.
Contaminated with oil ... A ............ Require replacement.
Damper cushion broken ... A ............ Require replacement.
Damper cushion
collapsed .............. A ............ Require replacement.
Damper spring collapsed . A ............ Require replacement.
Damper spring missing .. C ........ ( 1) Require replacement.
Friction material cracked
through ................ B ............ Require replacement.
Friction material flaking
or chunking ............ B ............ Require replacement.
Friction material surface
cracking ............... B ......... No service suggested or
required.
Grooved ................. B ......... No service suggested or
required unless the pressure
plate or flywheel is being
resurfaced or replaced. In this
case, replacement of clutch
disc is required.
Ridged .................. B ......... No service suggested or
required unless the pressure
plate or flywheel is being
resurfaced or replaced. In this
case, replacement of clutch
disc is required.
Splines worn, affecting
performance ............ A ............ Require replacement.
Warped .................. A ............ Require replacement.
Wear exceeds
specifications (where
applicable) ............ B ............ Require replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.
( 1) - Not all clutch discs have springs in all spring
chambers on the disc.
\
\
\
\
\
\
\
CLUTCH FORKS
CLUTCH FORK INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Bent .................... B ............ Require replacement.
Broken .................. A .. Require repair or replacement.
Cracked ................. B .. Require repair or replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.
\
\
\
\
\
\
\
Page 487 of 1691
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Clamp corroded, not
reusable ............... 1 ............ Suggest replacement.
Connected incorrectly ... A ................. Require repair.
Corroded, affecting
structural integrity ... A ............ Require replacement.
Corroded, not affecting
structural integrity ... .. ........ No service suggested or
required.
Cracked ................. A .. Require repair or replacement.
Fitting type incorrect
(such as compression
fitting) ............... B ............ Require replacement.
Flange leaking .......... A .. Require repair or replacement.
Insufficient clamping
force, allowing hose to
leak ................... A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Melted .................. 1 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Outer covering damaged to
the extent that the inner
fabric is visible ...... A ............ Require replacement.
Protective sleeves
damaged ................ 2 . Suggest replacement of sleeves.
Protective sleeves
missing ................ C . Require replacement of sleeves.
Restricted, affecting
performance ............ A .. Require repair or replacement.
Routed incorrectly ...... 2 ................. Require repair.
Swollen ................. 1 ............ Suggest replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Type incorrect .......... 1 .. Suggest repair or replacement.
\
\
\
\
\
\
\
COOLERS
See TRANSMISSION COOLERS .
CV JOINTS
CV JOINT INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Bearing, bushing or seal
surface worn, affecting
performance ............ A .. Require repair or replacement.
Boot clamp broken ....... A ... Require repair or replacement
of clamp.
Boot clamp loose ........ A ... Require repair or replacement
of clamp.
Boot clamp missing ...... C ... Require repair or replacement
of clamp.
Boot leaking ............ A . Require replacement of CV boot.
Boot surface cracked,
Page 490 of 1691
![DODGE RAM 1999 Service Repair Manual Torn .................... A ............ Require replacement. \
\
\
\
\
\](/img/12/56915/w960_56915-489.png "DODGE RAM 1999 Service Repair Manual Torn .................... A ............ Require replacement. \
\
\
\
\
\")
Torn .................... A ............ Require replacement. \
\
\
\
\
\
\
ENGINE MOUNTS
See MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION) .
EXCITER RINGS
See TOOTHED RINGS (TONE WHEELS) .
FILLER TUBES
See DIP STICK TUBES .
FILTERS AND SCREENS
FILTER AND SCREEN INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
At service interval ..... 3 ............ Suggest replacement.
Bent .................... A .. Require repair or replacement.
Exceeding service
interval ............... 3 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
Near service interval ... 3 ............ Suggest replacement.
Restricted .............. A ........... ( 1) Require repair or
replacement.
Torn .................... A ............ Require replacement.
Worn, affecting
performance (metal or
nylon screen type) ..... A .. Require repair or replacement.
( 1) - Further inspection may be required to determine the
source of restriction or contamination.
\
\
\
\
\
\
\
FLANGES
See COMPANION FLANGES .
FLEX PLATES
FLEX PLATE INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Bent, affecting
performance ............ A ............ Require replacement.
Bent, not affecting
performance ............ .. ........ No service suggested or
required.
Bolt or stud holes
elongated .............. B ............ Require replacement.
Broken .................. A ............ Require replacement.
Cracked ................. A ............ Require replacement.
Ring gear worn close
to the end of its
useful life ............ 1 ............ Suggest replacement.
Ring gear worn to the
extent that it no longer