DODGE RAM 1999 Service Repair Manual

REMOVAL & INSTALLATION
CAUTION: When battery is disconnected, vehicle computer and memory
systems may lose memory data. Driveability problems may exist
until computer systems have completed a relearn cycle. See
the COMPUTER RELEARN PROCEDURES article in GENERAL
INFORMATION before disconnecting battery.
POWER STEERING PUMP (GASOLINE)
WARNING: DO NOT attempt to remove power steering pump without removing
power steering pump belt. Personal injury or pulley damage
could result.
Removal
1) Disconnect and isolate negative battery cable. To remove
serpentine belt, rotate tensioner clockwise and hold in place, slide
belt from tensioner pulley. Place drain pan under pump. Disconnect and
cap hoses.
2) Remove bracket-to-engine block bolts. Remove pump, pulley
and mounting bracket as an assembly. To allow access to pump screws,
remove pump pulley. See PUMP PULLEY. Remove bracket-to-pump screws.
Installation
To install pump, reverse removal procedure. Fill and bleed
system. See HYDRAULIC SYSTEM BLEEDING under LUBRICATION.
VACUUM/POWER STEERING PUMP (DIESEL)
Removal
1) Disconnect negative battery cable. Place drip pan under
vacuum/power steering pump. Disconnect and cap power brake booster
hose at vacuum pump and hydraulic lines at power steering pump.
Disconnect oil pressure sending unit electrical connector. Remove
sending unit from engine block and plug hole in block. Disconnect and
cap oil feed line from bottom of vacuum pump.
2) Remove vacuum/power steering pump-to-engine block nuts and
bolts, and mounting bracket. Remove upper pump bolt and remove pump.
Drain fluid from steering pump reservoir. Remove gaskets from mounting
surfaces.
CAUTION: DO NOT damage internal vacuum pump oil seal when separating
steering pump from vacuum pump. See Fig. 5.
3) Remove steering pump-to-vacuum pump bracket bolts.
Carefully slide steering pump from bracket. Remove 2 pump body
spacers. See Fig. 5.
NOTE: Steering pump housing and spacers must mate completely with
vacuum pump bracket.
Installation
1) Install 2 pump body spacers and rotate drive gear until
steering pump and vacuum pump drive splines align. See Fig. 5.
Carefully install steering pump on vacuum pump bracket to prevent
damaging oil seal.

Fig. 5: Installing Power Steering Pump (Diesel)
Courtesy of Chrysler Corp.
2) Install 3 vacuum pump bracket-to-steering pump nuts and
tighten to 18 ft. lbs. (24 N.m). Using silicone sealer if needed,
position NEW gaskets on mounting surfaces.
3) Ensuring steering pump stud is inserted into block
bracket, align and install pump assembly. Tighten pump assembly-to-
engine block bolts to 57 ft. lbs. (77 N.m). Install steering pump-to-
bracket nut. Tighten nut to 18 ft. lbs. (24 N.m).
4) Remove plug from engine block and install oil sending
unit. Tighten sending unit to 60 INCH lbs. (7 N.m) and install
electrical connector. Install oil feed line to vacuum pump and tighten
to 60 INCH lbs. (7 N.m). To complete installation, reverse removal
procedure. Fill and bleed system. See HYDRAULIC SYSTEM BLEEDING under
LUBRICATION. Start engine. Ensure brakes are operating properly.
PUMP PULLEY
CAUTION: Examine exposed end of rotor drive shaft before removal. If
it is corroded, clean surface with crocus cloth to prevent
damage to shaft bushing during removal.
Removal & Installation (Gasoline)
Remove power steering pump from vehicle if necessary. See
POWER STEERING PUMP (GASOLINE). Using Puller (C-4333), remove pump
pulley. See Fig. 6. Replace pulley if bent, cracked or loose. Using
Installer (C-4063-B), press pulley until flush with end of shaft. If
drive belt chirps after engine starts, see POWER STEERING PUMP PULLEY

under ADJUSTMENTS.
Fig. 6: Removing & Installing Pump Pulley (Gasoline)
Courtesy of Chrysler Corp.
PUMP RESERVOIR
Removal
1) Remove pump from vehicle. See POWER STEERING PUMP. Remove
filler cap and drain oil from reservoir before removing parts. Remove
2 studs and fitting from back of pump. See Fig. 7.
2) Rock reservoir by hand or tap with soft-face mallet to
remove. Remove "O" ring from housing and reservoir. Remove flow
control valve and spring from rear of pump housing. See Fig. 8. Clean
all parts.
NOTE: If expansion plug is deformed or dislodged, DO NOT remove.
Replace pump housing.
Installation
To install, reverse removal procedure. Use NEW "O" ring and

seals. Apply power steering fluid to NEW seals. Install flow control
valve. Tighten flow control valve fitting to 55 ft. lbs. (75 N.m).
Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS.
Add power steering fluid. DO NOT use ATF. Bleed hydraulic system. See
HYDRAULIC SYSTEM BLEEDING under LUBRICATION.
Fig. 7: Exploded View Of Power Steering Pump
Courtesy of Chrysler Corp.
Fig. 8: Removing Flow Control Valve
Courtesy of Chrysler Corp.
STEERING GEAR

Removal
1) Place wheels in straight-ahead position. Place drain pan
under steering gear assembly. Disconnect and cap pressure and return
hoses from steering gear. Disconnect steering column shaft coupling
from steering gear stub shaft.
2) Raise and support vehicle. Disconnect steering linkage
(center link) from pitman arm. See Fig. 9. Disconnect stabilizer bar
(if necessary). Place reference mark on pitman arm and sector shaft.
Remove nut and pitman arm from sector shaft. Remove steering gear-to-
frame bolts. Remove steering gear.
Installation
1) Install steering gear with bolts finger tight. Center
steering gear and align stub shaft with steering column. Install
steering column shaft coupling bolt and tighten to specification. See
TORQUE SPECIFICATIONS.
CAUTION: Stake pitman arm nut against pitman arm to ensure proper
retention.
2) Reposition steering gear to eliminate binding, and tighten
bolts to specification. Install pitman arm on sector shaft with
reference marks aligned. Install lock washer and nut. Tighten nut to
specification.
3) To install remaining components, reverse removal
procedure. Fill pump reservoir. Bleed air from hydraulic system. See
HYDRAULIC SYSTEM BLEEDING under LUBRICATION.
SECTOR SHAFT OIL SEAL
Removal
1) Raise and support vehicle. Place wheels in straight-ahead
position. Disconnect steering linkage (center link) from pitman arm.
Disconnect stabilizer bar (if necessary).
2) Place reference mark on pitman arm and sector shaft.
Remove nut and pitman arm from sector shaft. Place drain pan under
steering gear. Remove retaining ring and steel washer. See Fig. 1.
CAUTION: DO NOT hold steering wheel in left-turn position for more
than 2 seconds.
3) Start engine and momentarily hold steering wheel in
extreme left-turn position. When pressure develops, this should force
upper oil seal, steel washer and lower oil seal from steering gear
housing. Stop engine and remove seals.
Installation
1) Ensure seal bore of steering gear is free of burrs and
sector shaft is free of pitting or roughness. Lubricate replacement
seals and steel washers with power steering fluid.
2) Wrap sector shaft with plastic tape or .005" (.13 mm)
thick shim stock. Install upper oil seal (single lip seal) and steel
washer first. Oil seal must be installed only deep enough to allow for
remaining oil seal, steel washer and retaining ring.
CAUTION: DO NOT install upper oil seal against inner bore surface of
steering gear housing. Oil seals must be installed so each
oil seal is separately seated in shaft bore.
3) Install lower oil seal (double lip seal) and steel washer\
.
Oil seal must be installed only deep enough to allow for steel washer
and retaining ring. Remove tape or shim stock and install retaining
ring.

CAUTION: Stake pitman arm nut against pitman arm to ensure proper
retention.
4) Install pitman arm on sector shaft with reference marks
aligned. Install lock washer and nut. Tighten nut to specification.
See TORQUE SPECIFICATIONS.
5) To install remaining components, reverse removal
procedure. Fill pump reservoir. Allow engine to idle for at least 3
minutes. DO NOT turn wheels during this time. Rotate wheels both
directions and check for leaks. Refill pump reservoir.
CENTER LINK
Removal & Installation
Separate tie rods, idler arm, steering and drag link (if
equipped) from center link. Remove center link. To install, reverse
removal procedure. Tighten nuts to specification.
Fig. 9: Exploded View Of Steering Linkage
Courtesy of Chrysler Corp.
DRAG LINK
Removal & Installation
Remove cotter pins and drag link nuts. Using Separator (C-
4150), separate drag link from steering knuckle or center link and

pitman arm. Remove drag link. To install, reverse removal procedure.
Tighten nuts to specification. See TORQUE SPECIFICATIONS. Install
cotter pins.
IDLER ARM
Removal & Installation
Remove cotter pin and nut from idler arm. Separate idler arm
from center link. Remove idler arm bolts. Remove idler arm. To
install, reverse removal procedure. Tighten bolts to specification.
See TORQUE SPECIFICATIONS. Install NEW cotter pin.
PITMAN ARM
Removal & Installation
1) Remove cotter pin and nut at pitman arm-to-center link or
drag link. Separate pitman arm from center link or drag link. Mark
location of pitman arm on steering gear shaft. Remove pitman arm-to-
steering gear shaft nut. Separate pitman arm from steering gear.
CAUTION: Stake pitman arm nut against steering gear shaft to ensure
proper retention.
2) To install, reverse removal procedure. Ensure reference
marks are aligned. Tighten bolts and nuts to specification. Install
NEW cotter pin.
TIE ROD END
Removal
Remove cotter pin and nut from tie rod end. Using Tie Rod End
Puller (C-3894-A), remove tie rod end from steering knuckle or center
link. Loosen lock nut or clamp bolt. Remove tie rod end. Note number
of turns required for removal.
NOTE: Use Tie Rod End Puller (C-3894-A) to prevent tie rod end seal\
damage.
Installation
1) To install, reverse removal procedure. Ensure tie rod end
is installed at same location. Position clamp sleeve with bolt located
on bottom. Clamp opening should be aligned with slot in sleeve.
2) Tighten the tie rod end nut to specification. Install a
NEW cotter pin. Check and adjust toe-in. See appropriate
SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT. Tighten clamp
bolt to specification. See TORQUE SPECIFICATIONS.
OVERHAUL
POWER STEERING PUMP OVERHAUL
Only fluid reservoirs, caps, pulleys, "O" rings, seals and
flow control valve are replaceable on pump. See Figs. 7 and 8.
Internal components are non-serviceable. If internal components fail,
replace pump. Replace reservoir, or "O" ring and seals if damaged.
NOTE: If expansion plug is deformed or dislodged, DO NOT remove it.
Replace pump housing.
STEERING GEAR OVERHAUL

NOTE: Manufacturer does not recommend overhaul of steering. If
faulty, replace steering gear as an assembly.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS\
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Application Ft. Lbs. (N.m)\
Center Link-To-Pitman Arm Nut .............................. 65 (88)\
Drag Link Nut .............................................. 65 (88)\
Flow Control Valve Fitting ................................. 55 (75)\
Idler Arm-To-Center Link Nut
Dakota (4WD) & Ram Pickup ................................ 65 (88\
)
Ram Van/Wagon ............................................ 47 (64)\
Idler Arm-To-Frame Bolt
Dakota (4WD)
Standard Duty ........................................... 50 (68)\
Heavy Duty ............................................ 195 (264)\
Ram Pickup ............................................... 50 (68)\
Ram Van/Wagon .......................................... 115 (156)\
Mounting Studs ............................................. 35 (47)\
Pitman Arm Nut ( 1) ....................................... 185 (251)
Sector Shaft Adjuster Screw Lock Nut ....................... 20 (27)\
Dakota (4WD) & Ram Van/Wagon ............................. 20 (27\
)
Ram Pickup ............................................... 43 (58)\
Steering Gear Housing-To-Frame Bolt
Dakota (4WD) ............................................. 65 (88\
)
Ram Pickup ............................................. 140 (190)\
Ram Van/Wagon
Steering Gear-To-Bracket .............................. 105 (142)\
Bracket-To-Frame ...................................... 100 (136)\
Tie Rod Clamp Bolt
Dakota (4WD) ............................................. 56 (75\
)
Ram Pickup
Standard Duty ........................................... 45 (61)\
Heavy Duty .............................................. 60 (81)\
Ram Van/Wagon
Standard Duty (9/16" Nut) ............................... 16 (22\
)
Heavy Duty (5/8" Nut) ................................... 26 (35\
)
Tie Rod Nut
Dakota (4WD) & Ram Pickup ................................ 65 (88\
)
Ram Van/Wagon
9/16" ................................................... 55 (75)\
5/8" ................................................... 75 (102)\
Vacuum/Power Steering Pump Assembly-To-Engine Bolts ........ 57 (77)\
Vacuum Pump-To-Power Steering Pump Nuts .................... 18 (24)\
( 1) - Nut must be staked against pitman arm threads.
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* S TE ER IN G U NIF O RM IN SPEC TIO N G UID ELIN ES *

1 999 D odge P ic ku p R 1500
GENERAL INFORMATION
Steering, Suspension, Wheel Alignment, Wheels and Tires
Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Steering and Suspension
AIR RIDE SUSPENSION
AIR RIDE SUSPENSION - AIR SHOCKS AND AIR STRUTS
AIR RIDE SUSPENSION - AIR SPRING VALVES
AIR RIDE SUSPENSION - AIR SPRINGS
AIR RIDE SUSPENSION - COMPRESSORS
AIR RIDE SUSPENSION - HEIGHT SENSORS
AIR RIDE SUSPENSION - MODULES
AIR RIDE SUSPENSION - RELAYS (COMPRESSOR)
AIR RIDE SUSPENSION - SWITCHES (ON/OFF)
AIR RIDE SUSPENSION - TORSION SPRINGS (COUNTER BALANCING)
AIR RIDE SUSPENSION - TUBING
AIR RIDE SUSPENSION - WARNING LAMPS
AIR RIDE SUSPENSION - WIRING HARNESSES
BALL JOINTS
BUSHINGS
CENTER LINKS
CONTROL ARM SHAFTS
CONTROL ARMS
DRAG LINKS
ELECTRONIC RIDE CONTROL SHOCKS AND STRUTS
IDLER ARMS
KING PINS
PITMAN ARMS
POWER STEERING HOSES
POWER STEERING (HYDRAULIC) PUMPS
RADIUS ARMS
RELAY RODS
SHOCK ABSORBERS, STRUT CARTRIDGES AND STRUT ASSEMBLIES
SPINDLES
SPRINGS - COIL, LEAF AND TORSION BAR
STEEL POWER STEERING LINES
STEERING ARMS
STEERING DAMPERS
STEERING GEARS (EXCEPT RACK AND PINION)
STEERING GEARS - RACK AND PINION
STEERING KNUCKLES
STRIKE OUT BUMPERS
STRUT RODS
STRUT UPPER BEARING PLATE ASSEMBLIES
SWAY BAR LINKS
SWAY BARS

TIE ROD ENDS (INNER AND OUTER)
TRACK BARS
TRAILING ARMS
WHEEL BEARINGS, RACES AND SEALS
Wheel Alignment
WHEEL ALIGNMENT
Wheels and Tires
TIRES
VALVE STEMS
WHEEL ATTACHMENT HARDWARE
WHEELS (RIMS)
MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW
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 communication standards
are continually re-published. 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-