engine DODGE RAM 1999 Service Repair Manual

TESTING
NOTE: Trac-Lok differential can be tested without removing
differential case from axle housing.
1) Place blocks under both front wheels. Ensure engine is off
and transmission is in Neutral. Release parking brake. Raise one rear
wheel until it is completely clear of the floor. Remove wheel. Install
Adapter (6790) to wheel studs and tighten securely.
2) Using torque wrench on adapter, rotate axle and record
torque required. Repeat procedure for remaining rear wheel position.
If rotational torque for either rear wheel is less than 30 ft. lbs.
(40.1 N.m) or greater than 200 ft. lbs. (271 N.m), Trac-Lok unit mus\
t
be replaced or repaired.
REMOVAL & INSTALLATION
Servicing procedure is same as that used for standard
differential. See RBI FULL FLOATING AXLES article for servicing
procedures.
OVERHAUL
DIFFERENTIAL CARRIER
Disassembly
1) Place appropriate side gear holding tool in soft-jaw vise.
Position differential carrier on holding tool. Remove ring gear, if
necessary. Ring gear removal is only necessary when ring gear is being
replaced.
2) Remove roll pin holding pinion mate shaft into housing.
Remove pinion gear mate shaft. A drift and hammer can be used if
necessary. See Fig. 1.
3) Install appropriate Step Plate on lower side gear. Install
appropriate threaded forcing screw into upper side gear. See Fig. 2.
4) Thread Forcing Screw into threaded adapter disc until
forcing screw is centered in threaded adapter disc. Perform STEP 1
shown in illustration. See Fig. 2.
5) Place small screwdriver in slot of threaded adapter disc
to prevent disc from rotating. Tighten forcing screw to relieve
tension from clutch pack.
6) Remove pinion gear thrust washers. Loosen forcing screw to
release pressure from clutch pack. Install appropriate turning bar in
hole on side of differential case. Perform STEP 2 shown in
illustration. See Fig. 2.
7) Using turning bar, rotate differential case until pinion
gears can be removed. Remove pinion gears. Remove turning bar, forcing
screw, step plate, and threaded adapter disc from differential case.
8) Remove upper side gear and clutch pack. See Fig. 1. Remove
differential case from axle shaft. Remove remaining side gear and
clutch pack from differential case.
CAUTION: Mark clutch pack location for reassembly reference. Note
position of clutch pack components before removing clutch
pack retainers. Clutch packs must be assembled in correct
order and installed in original location.
9) Remove clutch pack retainers from clutch pack. Keeping
clutch pack components in correct order, disassemble clutch pack.

Apply multipurpose lubricant (NLGI grade 2 EP) to "U" joints
and slip joint fittings.
INSPECTION
Abnormal vibration and noise can come from many driveline
sources. Drive shaft vibration/noise increases with vehicle speed
(MPH). A vibration that occurs within a specific speed is not caused
by drive shaft imbalance. Before overhauling driveline, check for
other causes/sources of possible vibration/noise.
TIRES & WHEELS
Check tire inflation and wheel balance. Check for foreign
objects in tread, damaged tread, mismatched tread patterns or
incorrect tire sizes. Check for bent wheels.
CENTER BEARING
Tighten drive shaft center bearing mounting bolts. If bearing
insulator is deteriorated or oil-soaked, or drive shaft can be moved
up/down in support, replace center bearing support assembly.
ENGINE & TRANSMISSION MOUNTS
Tighten mounting bolts. If rubber mounts are deteriorated or
broken, replace as needed.
DRIVE SHAFT(S)
Check drive shaft(s) for missing weights, broken welds, or
for dents affecting balance. Check for undercoating, mud, snow/ice on
drive shaft(s). Clean shafts thoroughly and test drive.
"U" JOINTS
Check for foreign material lodged in joints and flange/yokes.
Check for loose "U" joint-to-flange mounting bolts. Check for worn "U"
joint needle bearings. Check for Reddish-Brown rust-dust around "U"
joint caps. Replace "U" joints if necessary.
ADJUSTMENTS
CHECKING DRIVE SHAFT PHASING
One-Piece Drive Shafts
1) Ensure "U" joint flanges on either end of drive shaft are
in same plane. See Fig. 2. Drive shafts with slip joints between yokes
often have arrows to aid in alignment. If yokes are not in same plane,
disassemble slip joint from drive shaft splines. Install slip joint
back onto drive shaft splines, aligning "U" joint yokes. Test drive.
2) Single tube type drive shaft has slip joint on outside of
"U" joint yoke (at transmission end). If one-piece tube type drive
shaft yokes are out of alignment, the drive shaft is torque-twisted.
Drive shaft must be replaced.

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.

perpendicular to each other in vertical plane. See Fig. 6. With non-
parallel or broken-back type installation, working angles of "U"
joints of given drive shaft must be equal (angle "A" = angle "B").
Fig. 6: Identifying Broken-Back Type Drive Shaft
Courtesy of Chrysler Corp.
2) Calculate by subtracting angle of output shaft center line
from angle of drive shaft. Difference should be equal to front shaft
angle subtracted from rear shaft angle.
2-Piece Drive Shafts (Except Broken-Back Type)
1) All yokes must be perpendicular in both vertical and
horizontal planes to engine crankshaft. Using Inclinometer (C-4224),
measure drive shaft vertical angles.
2) Raise and support vehicle so rear wheels can be rotated.
Rotate drive shaft so a pinion flange bearing cap faces downward.
Attach inclinometer magnet to bearing cap, and note angle. See Fig. 4.
Remove inclinometer.
3) Rotate drive shaft 90 degrees until drive shaft rear yoke
bearing cap faces downward. Attach inclinometer magnet to bearing cap,
and note angle. Difference between 2 measured angles is drive shaft
rear angle. See Fig. 5. Remove inclinometer.
4) 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. Difference between 2 measured
angles is drive shaft front angle. See Fig. 5. Remove inclinometer.
5) Rotate drive shaft until front yoke of rear shaft faces
downward. Attach inclinometer magnet to bearing cap, and note angle.
Rotate drive shaft until rear yoke of front drive shaft faces
downward. Attach inclinometer magnet to bearing cap, and note angle.
Remove inclinometer.
6) Difference between 2 measured angles is drive shaft center
angle. Compare front, center and rear angles. Vertical alignment of 2
piece drive shafts at yokes should be greater than 1/2 degree and must
be retained as close to one degree as possible. See Fig. 7. If
difference of angles is greater than specified, adjustment is
necessary. See ADJUSTING VERTICAL ANGLE.


* 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

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

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

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.
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.

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








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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.









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DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES
NOTE: Does not include half shafts.
DIFFERENTIAL AND FINAL DRIVE ASSEMBLY INSPECTION









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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.









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MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES
MANUAL TRANSMISSION/TRANSAXLE ASSEMBLY INSPECTION








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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,

Torn .................... A ............ Require replacement.








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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








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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.









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FLANGES
See COMPANION FLANGES .
FLEX PLATES
FLEX PLATE INSPECTION








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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