DODGE RAM 1999 Service Repair Manual
Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
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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
has been incorporated which includes the "mystery shopping" of
outlets.
We welcome you to join us as we continue our outreach... with
your support, both the automotive repair industry and your customers
will reap the benefits. Please visit MAP at our Internet site www.
motorist.org or contact us at:
1444 I Street, NW Suite 700
Washington, DC 20005
Phone (202) 712-9042 Fax (202) 216-9646
January 1999
MAP UNIFORM INSPECTION GENERAL GUIDELINES
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
It is MAP policy that all exhaust, brake, steering,
suspension, wheel alignment, drive-line, engine performance and
maintenance, and heating, ventilation and air conditioning, and
electrical services be offered and performed under the standards and
procedures specified in these sections.
Before any service is performed on a vehicle, an inspection
of the appropriate system must be performed. The results of this
inspection must be explained to the customer and documented on an
inspection form. The condition of the vehicle and its components will
indicate what services/part replacements may be "Required" or
"Suggested". In addition, suggestions may be made to satisfy the
requests expressed by the customer.
When a component is suggested or required to be repaired or
replaced, the decision to repair or replace must be made in the
customer's best interest, and at his or her choice given the options
available.
This section lists the various parts and conditions that
indicate a required or suggested service or part replacement.
Although this list is extensive, it is not fully inclusive. In
addition to this list, a technician may make a suggestion. However,
any suggestions must be based on substantial and informed experience,
or the vehicle manufacturer's recommended service interval and must be
documented.
Some conditions indicate that service or part replacement is
required because the part in question is no longer providing the
function for which it is intended, does not meet a vehicle
manufacturer's design specification or is missing.
Example:
An exhaust pipe has corroded severely and has a hole in it
through which exhaust gases are leaking. Replacement of the
exhaust pipe in this case is required due to functional
failure.
Example:
A brake rotor has been worn to the point where it measures
less than the vehicle manufacturer's discard specifications.
Replacement of the rotor is required because it does not meet
design specifications.
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Some conditions indicate that a service or part replacement
is suggested because the part is close to the end of its useful life
or addresses a customer's need, convenience or request. If a
customer's vehicle has one of these conditions, the procedure may be
only to suggest service.
Example:
An exhaust pipe is rusted, corroded or weak, but no leaks are
present. In this case, the exhaust pipe has not failed.
However, there is evidence that the pipe may need replacement
in the near future. Replacement of the pipe may be suggested
for the customer's convenience in avoiding a future problem.
Example:
The customer desires improved ride and/or handling, but the
vehicle's shocks or struts have not failed. In this case,
replacement may be suggested to satisfy the customer's
wishes. In this case, replacement of the shocks or struts may
not be sold as a requirement.
A customer, of course, has the choice of whether or not a
shop will service his or her vehicle. He or she may decide not to
follow some of your suggestions. When a repair is required, a MAP shop
must refuse partial service on that system if, in the judgment of the
service provider, proceeding with the work could create or continue an
unsafe condition. When a procedure states that required or suggested
repair or replacement is recommended, the customer must be informed of
the generally acceptable repair/replacement options whether or not
performed by the shop.
When presenting suggested repairs to the customer, you must
present the facts, allowing the customer to draw their own conclusions
and make an informed decision about how to proceed.
The following reasons may be used for required and suggested
services. These codes are shown in the "Code" column of the MAP
Uniform Inspection & Communications Standards that follow:
Reasons to Require Repair or Replacement
A - Part no longer performs intended purpose
B - Part does not meet a design specification (regardless of
performance)
C - Part is missing
NOTE: When a repair is required, the shop must refuse partial
service to the system in question, if the repair creates
or continues an unsafe condition.
Reasons to Suggest Repair or Replacement
1 - Part is close to the end of its useful life (just above
discard specifications, or weak; failure likely to occur
soon, etc.)
2 - To address a customer need, convenience, or request (to
stiffen ride, enhance performance, eliminate noise,
etc.)
3 - To comply with maintenance recommended by the vehicle's
Original Equipment Manufacturer (OEM)
4 - Technician's recommendation based on substantial and
informed experience
NOTE: Suggested services are always optional. When presenting
suggested repairs to the customer, you must present
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the facts, allowing the customer to draw their own
conclusions and make an informed decision about how to
proceed.
STEERING AND SUSPENSION
SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER VEHICLE
OPERATION
Steering and suspension are complex systems made up of a
variety of interdependent components. For proper vehicle handling,
ride, and tire wear, a thorough inspection is required whenever
suspension work is being performed.
Conditions listed assume that the problem has been isolated
to the specific component by proper testing procedures.
NOTE: When replacing steering and/or suspension components which
may affect an alignment angle, you are required to check
and adjust alignment as needed. Refer to the OEM
specifications.
CAUTION: DO NOT use ride height altering or load compensating
components, such as variable rate springs and coil over
shocks, on vehicles with height or load sensing
proportioning valve-equipped braking systems, unless
these components are original equipment.
AIR RIDE SUSPENSION
NOTE: Depending on the air suspension design, there are some
aftermarket products available to eliminate the air ride
suspension on certain vehicles. If the system has been
eliminated with one of these products, then no service is
suggested or required.
AIR RIDE SUSPENSION - AIR SHOCKS AND AIR STRUTS
NOTE: This section covers the air spring portion of the
air shock or strut. For damping portion of shock
or strut conditions and procedures, refer to the
SHOCK ABSORBERS, STRUT CARTRIDGES AND STRUT ASSEMBLIES
section.
AIR RIDE SUSPENSION - AIR SHOCK AND AIR STRUT INSPECTION
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Condition Code Procedure
Inner fabric of air bag
damaged ................ A ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Outer covering of air bag
is cracked to the extent
that inner fabric of air
bag is visible ......... 1 ............ Suggest replacement.
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AIR RIDE SUSPENSION - AIR SPRING VALVES
AIR RIDE SUSPENSION - AIR SPRING VALVE INSPECTION \
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Condition Code Procedure
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Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part.
Attaching hardware
missing ................ C .. Require replacement of missing
part.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Blocked ................. A .. Require repair or replacement.
Connector bent .......... A .. Require repair or replacement.
Connector broken ........ A ............ Require replacement.
Connector loose ......... A .. Require repair or replacement.
Inoperative ............. A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Restricted .............. A .. Require repair or replacement.
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AIR RIDE SUSPENSION - AIR SPRINGS
AIR RIDE SUSPENSION - AIR SPRING INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require replacement of broken
part.
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part.
Attaching hardware
missing ................ C .. Require replacement of missing
part
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Collar cracked .......... A ............ Require replacement.
End cap cracked ......... A ............ Require replacement.
Inner fabric of bag
damaged ................ A ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Outer covering of air bag
is cracked to the extent
that inner fabric of air
bag is visible ......... 1 ............ Suggest replacement.
Piston cracked .......... A ............ Require replacement.
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![DODGE RAM 1999 Service Repair Manual AIR RIDE SUSPENSION - COMPRESSORS
AIR RIDE SUSPENSION - COMPRESSOR INSPECTION \
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AIR RIDE SUSPENSION - COMPRESSORS
AIR RIDE SUSPENSION - COMPRESSOR INSPECTION \
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Condition Code Procedure
Attaching hardware bent . B ... Require repair or replacement
of bent part.
Attaching hardware
broken ................. A ... Require replacement of broken
part.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part.
Attaching hardware
missing ................ C .. Require replacement of missing
part.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Connector bent .......... A .. Require repair or replacement.
Connector broken ........ A ............ Require replacement.
Connector loose ......... A .. Require repair or replacement.
Does not build pressure . A .......... ( 1) Further inspection
required.
Excessive run time ...... B .......... ( 2) Further inspection
required.
Inoperative ............. A ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
( 1) - If failure to build pressure is traced to the
compressor, require replacement.
( 2) - If excessive run time is traced to the compressor,
require replacement.
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AIR RIDE SUSPENSION - HEIGHT SENSORS
AIR RIDE SUSPENSION - HEIGHT SENSOR INSPECTION \
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Condition Code Procedure
Attaching hardware bent . B ... Require repair or replacement
of bent part.
Attaching hardware
broken ................. A ... Require replacement of broken
part.
Attaching hardware
corroded, affecting
structural integrity .... A .......... Require replacement of
corroded part.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part.
Attaching hardware
missing ................ C .. Require replacement of missing
part.
Attaching hardware
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threads damaged ........ A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Dust boot missing ....... 2 ........ (1) Suggest replacement.
Dust boot split ......... 2 ........ ( 1) Suggest replacement.
Dust boot torn .......... 2 ........ ( 1) Suggest replacement.
Housing cracked ......... A ............ Require replacement.
Lead routing incorrect .. B .. Require rerouting according to
vehicle manufacturer's
specifications.
Loose ................... B ... Require adjustment to vehicle
manufacturer's specifications.
Missing ................. C ............ Require replacement.
Output signal incorrect . A .. Require repair or replacement.
Wire lead damaged ....... A .. Require repair or replacement.
( 1) - This condition can lead to damage of the sliding magnet,
which, in turn, causes premature sensor failure.
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AIR RIDE SUSPENSION - MODULES
AIR RIDE SUSPENSION - MODULE INSPECTION \
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Condition Code Procedure
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part.
Attaching hardware
missing ................ C .. Require replacement of missing
part.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Housing cracked ......... 2 .. Suggest repair or replacement.
Inoperative ............. A ............ Require replacement.
Missing ................. C ............ Require replacement.
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AIR RIDE SUSPENSION - RELAYS (COMPRESSOR)
AIR RIDE SUSPENSION - RELAY (COMPRESSOR) INSPECTION \
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Condition Code Procedure
Housing cracked ......... 2 ........ ( 1) Suggest replacement.
Intermittent ............ A ............ Require replacement.
Missing ................. C ............ Require replacement.
Output signal incorrect . A ............ Require replacement.
( 1) - If moisture enters the relay, it can reduce life
expectancy or impair function.
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AIR RIDE SUSPENSION - SWITCHES (ON/OFF)
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![DODGE RAM 1999 Service Repair Manual AIR RIDE SUSPENSION - SWITCH (ON/OFF) INSPECTION \
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AIR RIDE SUSPENSION - SWITCH (ON/OFF) INSPECTION \
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Condition Code Procedure
Broken .................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
Output signal incorrect . A ............ Require replacement.
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AIR RIDE SUSPENSION - TORSION SPRINGS (COUNTER BALANCING)
AIR RIDE SUSPENSION - TORSION SPRING (COUNTER BALANCING) INSPECTION \
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Condition Code Procedure
Attaching hardware bent . B ... Require repair or replacement
of bent part.
Attaching hardware
broken ................. A ... Require replacement of broken
part.
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part.
Attaching hardware
missing ................ C .. Require replacement of missing
part.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Broken .................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
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AIR RIDE SUSPENSION - TUBING
AIR RIDE SUSPENSION - TUBING INSPECTION \
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Condition Code Procedure
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part.
Attaching hardware
missing ................ C .. Require replacement of missing
part.
Blocked ................. A .. Require repair or replacement.
Fitting incorrect ....... B ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Line type incorrect ..... B ............ Require replacement.
Missing ................. C ............ Require replacement.
Restricted .............. A .. Require repair or replacement.
Routed incorrectly ...... B ..... Require routing correction.
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AIR RIDE SUSPENSION - WARNING LAMPS
AIR RIDE SU](/img/12/56915/w960_56915-1327.png "DODGE RAM 1999 Service Repair Manual \
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AIR RIDE SUSPENSION - WARNING LAMPS
AIR RIDE SU")
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AIR RIDE SUSPENSION - WARNING LAMPS
AIR RIDE SUSPENSION - WARNING LAMP INSPECTION \
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Condition Code Procedure
Bulb burned out ......... A ............ Require replacement.
Warning light does
not come on during
bulb check ............. .. . Further inspection required to
determine cause.
Warning light flashes ... .. . Further inspection required to
determine cause.
Warning light is
intermittent ........... .. . Further inspection required to
determine cause.
Warning light stays
on after initial
bulb check ............. .. . Further inspection required to
determine cause.
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AIR RIDE SUSPENSION - WIRING HARNESSES
AIR RIDE SUSPENSION - WIRING HARNESS INSPECTION \
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Condition Code Procedure
Connector bent .......... A .. Require repair or replacement.
Connector broken ........ A .. Require repair or replacement.
Connector loose ......... A .. Require repair or replacement.
Damaged (cut, burned, or
chafed) ................ A .. Require repair or replacement.
Excessive resistance .... B .. Require repair or replacement.
Fuse blown .............. A ............ Require replacement.
Fusible link blown ...... A ............ Require replacement.
Open .................... A .. Require repair or replacement.
Poor ground ............. A .. Require repair or replacement.
Routed incorrectly ...... B .. Require rerouting according to
vehicle manufacturer's
specifications.
Shorted ................. A .. Require repair or replacement.
Terminal bent ........... A .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal corroded ....... A .. Require repair or replacement.
Terminal loose .......... A .. Require repair or replacement.
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BALL JOINTS
Before requiring or suggesting ball joint replacement, the
approved OEM procedure must be used to measure ball joint wear. The
measurement(s) obtained, along with the vehicle manufacturer's
specifications, must be noted on the inspection report. Some states
require that these measurements also appear on the invoice.
NOTE: The term "perceptible movement," defined as any visible
movement in any direction, has been the industry standard
for determining the need for replacement of follower ball
joints. Some vehicle manufacturers are now publishing
specifications for follower ball joints that were
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previously diagnosed by the "perceptible movement"
standard. Before requiring or suggesting any parts be
replaced based on "perceptible movement," consult your
repair manual to determine if OEM specifications exist.
You are not required to replace ball joints in axle sets.
However, when replacing a ball joint due to wear exceeding
manufacturer's specification, you may suggest replacement of the other
ball joint if its measurement shows it is close to the end of its
useful life, for preventive maintenance.
BALL JOINT INSPECTION
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Condition Code Procedure
Attaching hardware bent . B ... Require repair or replacement
of bent part if available;
otherwise, replace ball joint.
Attaching hardware
broken ................. A ... Require replacement of broken
part if available; otherwise,
replace ball joint.
Attaching hardware
corroded, affecting
structural integrity ... A . Require replacement of corroded
part if available; otherwise,
replace ball joint.
Attaching hardware
incorrect ............... A .......... Require replacement of
incorrect part if available;
otherwise, replace ball joint.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part if available;
otherwise, replace ball joint.
Attaching hardware
missing ................ C .. Require replacement of missing
part if available; otherwise,
replace ball joint.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads if
available; otherwise, replace
ball joint.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads if
available; otherwise, replace
ball joint.
Binding ................. A .......... (1) Further inspection
required.
Grease boot cracked ..... 2 ........ ( 2) Suggest replacement.
Grease boot missing ..... 2 ........ ( 3) Suggest replacement.
Grease boot torn ........ 2 ........ ( 4) Suggest replacement.
Grease fitting broken ... A ... Require replacement of grease
fitting.
Grease fitting missing .. C ... Require replacement of grease
fitting.
Grease fitting
won't seal ............. A ... Require replacement of grease
fitting.
Greaseable ball joint will
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not take grease ........ 2 ...... (5) Suggest replacement of
grease fitting.
Nut on ball joint loose . A ........... ( 6) Require repair or
replacement.
Pre-load adjustment
incorrect .............. B .. Require repair or replacement.
Seized .................. A ............ Require replacement.
Stud bent ............... B ........ ( 7) Require replacement.
Stud broken ............. A ........ ( 7) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ........ ( 7) Require replacement.
Wear exceeds
manufacturer's
specifications ......... B ............ Require replacement.
( 1) - If greaseable, grease ball joint. If problem persists
or joint is non-greaseable, require replacement.
( 2) - Cracked grease boot will allow contaminants to enter
the ball joint and will accelerate wear.
( 3) - Lack of grease boot will allow contaminants to enter
the ball joint and will accelerate wear.
( 4) - Torn grease boot will allow contaminants to enter the
ball joint and will accelerate wear.
( 5) - If the greaseable ball joint still will not take grease
after replacing the grease fitting, suggest replacement
of ball joint.
( 6) - Check for bent stud or damaged taper hole.
( 7) - Check for damaged taper hole.
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BUSHINGS
BUSHING INSPECTION \
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Condition Code Procedure
Attaching hardware bent . B ... Require repair or replacement
of bent part if available;
otherwise, replace bushing.
Attaching hardware
broken ................. A ... Require replacement of broken
part if available; otherwise,
replace bushing.
Attaching hardware
corroded, affecting
structural integrity ... A . Require replacement of corroded
part if available; otherwise,
replace bushing.
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part if available;
otherwise, replace bushing.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part if available;
otherwise, replace bushing.
Attaching hardware
missing ................ C .. Require replacement of missing
part if available; otherwise,
replace bushing.
Attaching hardware
threads damaged ........ A ... Require repair or replacement