tow DODGE RAM 1999 Service Repair Manual


H - T E STS W /O C O DES - G ASO LIN E
1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Trouble Shooting - No Codes - Gasoline
Avenger, Breeze, Caravan, Cirrus, Concorde, Dakota, Durango,
Intrepid, LHS, Neon, Ram Pickup, Ram Van, Ram Wagon,
Stratus, Town & Country, Sebring Convertible, Sebring
Coupe, Voyager, 300M
INTRODUCTION
Before diagnosing symptoms or intermittent faults, perform
basic diagnostic procedures in the appropriate BASIC DIAGNOSTIC
PROCEDURES article and applicable self-diagnostic tests in the
appropriate SELF-DIAGNOSTICS article. Use this article to diagnose
driveability problems existing when a hard fault code is not present.
NOTE: Some driveability problems may have been corrected by
manufacturer with a revised Powertrain Control Module (PCM).
Check with manufacturer for latest PCM application.
Symptom checks direct the technician to malfunctioning
component(s) for further diagnosis. A symptom should lead to a
specific component, system test or adjustment.
Use intermittent test procedures to locate driveability
problems that do not occur when the vehicle is being tested. These
problems may cause a noticeable driveability problem or cause the
Malfunction Indicator Light (MIL) to illuminate on some vehicles.
These test procedures should also be used if a soft (intermittent)
trouble code is present, but no problem is found during self-
diagnostic testing.
NOTE: For specific testing procedures, see appropriate SELF
-DIAGNOSTICS article. For specifications, see appropriate ON
-VEHICLE ADJUSTMENTS and SERVICE & ADJUSTMENT SPECIFICATIONS
articles.
SYMPTOMS
SYMPTOM DIAGNOSIS
Symptom checks cannot be used properly unless the problem
occurs while the vehicle is being tested. To reduce diagnostic time,
ensure basic diagnostic procedures and self-diagnostic were performed
before diagnosing a symptom. Symptoms available for diagnosis are as
follows:
* Hard Start
* Starts But Stalls
* Hesitation Or Stumble
* Surging
* Lack Of Power
* Knocking
* Engine Misfire
* Backfire
* Rough Or Erratic Idle
* Poor Fuel Economy
HARD START

Fig. 2: Identifying Oil Pan Gasket (36RH, 46RE & 47RE)
LUBRICATION
SERVICE INTERVALS
Transmission
Check transmission fluid level when performing other
underhood services. Under normal service conditions or severe service
conditions change transmission fluid, adjust bands and replace
transmission filter at specified interval. See TRANSMISSION SERVICING
INTERVALS table. Severe service conditions are conditions such as long
periods of engine idling, trailer towing, off-highway operation, snow
removal, or operating in dusty or excessively hot conditions.
TRANSMISSION SERVICING INTERVALS









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Application Months Miles
Dakota & Durango
Normal Service ........................ 30 .............. 37,500
Severe Service ........................ ( 1) ............. 12,000

Ram Pickup
Gasoline Models
Light-Duty (2)
Normal Service ..................... 30 .............. 37,500
Severe Service ..................... ( 1) ............. 12,000
Medium-Duty & Heavy-Duty
Normal Service ..................... 24 .............. 24,000
Severe Service ..................... ( 1) ............. 12,000
Diesel Models
Normal Service ....................... 24 .............. 24,000
Severe Service ....................... ( 1) ............. 12,000
Ram Van/Wagon
Normal Service ........................ ( 3) ................ ( 3)
Severe Service ........................ ( 1) ............. 12,000
( 1) - Monthly interval is not available from manufacturer.
( 2) - Light-duty applies to all 1500 models and 2500 models except
5.9L diesel or 8.0L engines. Medium-duty applies to 2500 and
3500 California models with 8.0L engine. Heavy-duty applies to
2500 and 3500 Federal models with 8.0L engine and all 3500
models with 5.9L gasoline engine.
( 3) - Normal service interval is not available from manufacturer.









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Transfer Case
Check transfer case fluid level when performing other
underhood services. Under normal service conditions or severe service
conditions change transfer case fluid at specified interval. See
TRANSFER CASE SERVICING INTERVALS table. Severe service conditions are
conditions such as long periods of engine idling, trailer towing, off-
highway operation, snow removal, or operating in dusty or excessively
hot conditions.
TRANSFER CASE SERVICING INTERVALS









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Application Months Miles
Dakota
Normal Service ....................... 30 ............... 37,500
Severe Service ....................... ( 1) .............. 36,000
Ram Pickup
Gasoline Models
Light-Duty ( 2)
Normal Service .................... 30 ............... 37,500
Severe Service .................... ( 1) .............. 36,000
Medium-Duty & Heavy-Duty
Normal Service .................... 36 ............... 36,000
Severe Service .................... ( 1) .............. 36,000
Diesel Models
Normal Service ...................... 36 ............... 36,000
Severe Service ...................... ( 1) .............. 36,000
( 1) - Monthly interval is not available from manufacturer.
( 2) - Light-duty applies to all 1500 models and 2500 models except
5.9L diesel or 8.0L engines. Medium-duty applies to 2500 and
3500 California models with 8.0L engine. Heavy-duty applies to
2500 and 3500 Federal models with 8.0L engine and all 3500
models with 5.9L gasoline engine.









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Power Take-Off (PTO) Adapter (Ram Pickup 2WD 2500 & 3500)
Check PTO adapter fluid level when performing other underhood
services. Service interval is not available from manufacturer.

Dakota & Durango
1) Raise and support vehicle. Ensure shift lever is in Park.
Release shift cable adjuster lock. Shift cable adjuster lock is
located on shift cable, just below brake booster.
2) Disconnect shift cable from transmission shift lever on
transmission. Ensure transmission is still in Park by rotating
transmission shift lever fully toward rear of vehicle to Park detent.
3) Verify parking sprag on transmission is engaged by
attempting to rotate drive shaft. Install shift cable on transmission
shift lever. Lock shift cable in place by pressing shift cable
adjuster lock downward until it snaps into place.
4) To verify proper adjustment, check that engine only starts
with shift lever in Park and Neutral. If engine starts in any other
gears except Park or Neutral, shift cable may be improperly adjusted
or park/neutral position switch may be defective.
Ram Van/Wagon
1) Raise and support vehicle. Ensure shift lever is in Park.
Unsnap shift cable from ball at transmission shift lever on
transmission. See Fig. 6.
2) Check that transmission is still in Park by rotating
transmission shift lever fully toward rear of vehicle to Park detent
position. Release cable adjuster at transmission end of shift cable to
unlock shift cable. See Fig. 6. Snap shift cable back on ball at
transmission shift lever. Press cable lock inward to secure shift
cable.
3) To verify proper adjustment, ensure engine only starts
with shift lever in Park and Neutral. Shift lever should not move from
Park when ignition switch is in LOCK position. Shift lever should move
from Park when ignition switch is in any position except LOCK
position.
Fig. 6: Locating Cable Adjuster (Ram Van/Wagon)
Courtesy of Chrysler Corp.
SHIFT LINKAGE

Ram Pickup
1) Raise and support vehicle. Inspect shift linkage for worn
components. Replace any damaged or worn grommets or shift linkage
components before adjusting.
2) Ensure shift lever is in Park. Loosen lock bolt on
adjusting swivel. See Fig. 7. Ensure shift rod slides freely in
adjusting swivel. If shift rod fails to slide freely in adjusting
swivel, lubricate shift rod as necessary.
3) Rotate transmission shift lever fully toward rear of
vehicle to the Park detent position. Position adjusting swivel so it
is centered in grommet on torque shaft arm. See Fig. 7. Tighten lock
bolt on adjusting swivel. Check that engine only starts with shift
lever in Park and Neutral. If engine starts in any other gears except
Park and Neutral, shift linkage adjustment is incorrect or
park/neutral position switch is defective.
Fig. 7: Identifying Typical Shift Linkage Components
Courtesy of Chrysler Corp.
THROTTLE VALVE CABLE
1) Ensure shift lever is in Park and ignition is off. Remove
air cleaner. Disconnect throttle valve cable from stud on throttle
lever at throttle body.
2) Ensure throttle lever on throttle body is in idle position
and throttle valve lever on transmission is in idle (fully forward)
position.
3) Using small screwdriver, remove retaining clip from
throttle valve cable. Center end of throttle valve cable with stud on
throttle lever at throttle body within .039" (1.00 mm), and install
retaining clip. Install throttle valve cable on throttle lever.
4) To verify proper adjustment, ensure throttle valve lever
on throttle body and throttle lever on transmission move

Transmission (Dakota)
Check transmission fluid level when performing other
underhood services. Under normal service conditions, change
transmission fluid at 30 months or 37,500 miles. Under severe service
conditions, change transmission fluid at 18,000 miles. Severe service
are conditions such as long periods of engine idling, trailer towing,
off-highway operation, snow removal, or operating in dusty or
excessively hot conditions.
Transmission (Ram Pickup)
Check transmission fluid level when performing other
underhood services. Fluid change service interval information is not
available from manufacturer.
Transfer Case
Check transfer case fluid level when performing other
underhood services. On Dakota and Light-Duty Pickup, change transfer
case fluid at 37,500 miles or 30 months. On Medium-Duty and Heavy-Duty
Pickup, change transfer case fluid at 36,000 miles or 36 months.
CHECKING FLUID LEVEL
Transmission (Dakota)
1) Park vehicle on level surface. Remove transmission fill
plug from side of transmission. On AX-15 transmission, transmission
fill plug is located on driver's side of transmission. On NV3500
transmission, transmission fill plug is located near front of
transmission on passenger's side of transmission.
2) On all transmissions, fluid level should even with bottom
of fill plug hole on side of transmission. Add appropriate type of
transmission fluid if necessary. See RECOMMENDED FLUID. Install and
tighten transaxle fill plug to specification. See TORQUE
SPECIFICATIONS.
Transmission (Ram Pickup)
1) Park vehicle on level surface. Remove transmission fill
plug from side of transmission. On NV3500 transmissions, transmission
fill plug is located near front of transmission on passenger's side of
transmission. On NV4500 transmissions, transmission fill plug is
located near rear of transmission on passenger's side of transmission.
2) On all transmissions, fluid level should even with bottom
of fill plug hole on side of transmission. Add appropriate type of
transmission fluid if necessary. See RECOMMENDED FLUID. Install and
tighten transaxle fill plug to specification. See TORQUE
SPECIFICATIONS.
Transfer Case
Park vehicle on level surface. Remove transfer case fill plug
from rear of transfer case. Fluid level should even with bottom of
transfer case fill plug hole on rear of transfer case. Add appropriate
type of transfer case fluid if necessary. See RECOMMENDED FLUID.
Install and tighten transfer case fill plug to specification. See
TORQUE SPECIFICATIONS.
RECOMMENDED FLUID
Transmission (Dakota)
On AX-15 transmissions, use API 75W-90 GL-3 gear oil. On
NV1500 and NV3500 transmissions, use ONLY Mopar M/T Lube Part No.
4761526.
Transmission (Ram Pickup)


M - V A C UUM D IA G RAM S
1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Vacuum Diagrams - Trucks
Caravan, Dakota, Durango, Ram Pickup, Ram Van, Ram Wagon,
Town & Country, Voyager
INTRODUCTION
This article contains underhood views or schematics of vacuum
hose routing. Use these vacuum diagrams during the visual inspection
in appropriate BASIC DIAGNOSTIC PROCEDURES article. This will assist
in identifying improperly routed vacuum hoses, which may cause
driveability and/or computer-indicated malfunctions.
VACUUM DIAGRAMS
NOTE: References to California models apply to California emission
vehicles, which may be verified by underhood Emission Control
label. California emissions may be available in other
states.
NOTE: Vacuum diagrams for applications not shown were not available
at time of publication. See underhood Emission Control
label.
Fig. 1: Vacuum Hose Diagram (Caravan & Voyager - 2.4L - Calif.)
Courtesy of Chrysler Corp.

Fig. 2: Vacuum Hose Diagram (Caravan & Voyager - 2.4L - Except
Calif.)
Courtesy of Chrysler Corp.
Fig. 3: Vacuum Hose Diagram (Caravan, Town & Country, & Voyager -
3.3L & 3.8L - Calif.)
Courtesy of Chrysler Corp.

Fig. 4: Vacuum Hose Diagram (Caravan, Town & Country, & Voyager -
3.3L & 3.8L - Except Calif.)
Courtesy of Chrysler Corp.
Fig. 5: Vacuum Hose Diagram (Dakota - 2.5L - Calif.)
Courtesy of Chrysler Corp.

3800 engines were suffering from exactly this. The point is that a
lack of detail could cause misdiagnosis.
As you might have guessed, a lab scope would not miss this.
RELATIONSHIP BETWEEN DWELL & DUTY CYCLE READINGS TABLE (1)









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Dwell Meter (2) Duty Cycle Meter
1
.................................................... 1%
15 .................................................. 25%
30 .................................................. 50%
45 .................................................. 75%
60 ................................................. 100%
( 1) - These are just some examples for your understanding.
It is okay to fill in the gaps.
( 2) - Dwell meter on the six-cylinder scale.









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THE TWO TYPES OF INJECTOR DRIVERS
OVERVIEW
There are two types of transistor driver circuits used to
operate electric fuel injectors: voltage controlled and current
controlled. The voltage controlled type is sometimes called a
"saturated switch" driver, while the current controlled type is
sometimes known as a "peak and hold" driver.
The basic difference between the two is the total resistance
of the injector circuit. Roughly speaking, if a particular leg in an
injector circuit has total resistance of 12 or more ohms, a voltage
control driver is used. If less than 12 ohms, a current control driver
is used.
It is a question of what is going to do the job of limiting
the current flow in the injector circuit; the inherent "high"
resistance in the injector circuit, or the transistor driver. Without
some form of control, the current flow through the injector would
cause the solenoid coil to overheat and result in a damaged injector.
VOLTAGE CONTROLLED CIRCUIT ("SATURATED SWITCH")
The voltage controlled driver inside the computer operates
much like a simple switch because it does not need to worry about
limiting current flow. Recall, this driver typically requires injector
circuits with a total leg resistance of 12 or more ohms.
The driver is either ON, closing/completing the circuit
(eliminating the voltage-drop), or OFF, opening the circuit (causing \
a
total voltage drop).
Some manufacturers call it a "saturated switch" driver. This
is because when switched ON, the driver allows the magnetic field in
the injector to build to saturation. This is the same "saturation"
property that you are familiar with for an ignition coil.
There are two ways "high" resistance can be built into an
injector circuit to limit current flow. One method uses an external
solenoid resistor and a low resistance injector, while the other uses
a high resistance injector without the solenoid resistor. See the left
side of Fig. 1.
In terms of injection opening time, the external resistor
voltage controlled circuit is somewhat faster than the voltage
controlled high resistance injector circuit. The trend, however, seems
to be moving toward use of this latter type of circuit due to its
lower cost and reliability. The ECU can compensate for slower opening