light DODGE RAM 1999 Service Repair Manual


SC HED ULE D S ER VIC ES - S EVER E S ER VIC E ( G AS)

1 999 D odge P ic ku p R 1500
1997-99 MAINTENANCE
Chrysler Maintenance & Service Intervals
Gasoline Engines
Severe Service/Light Duty Trucks
DODGE; RAM PICKUP 1500: 3.9L VIN [X]
DODGE; RAM PICKUP 1500/2500: 5.2L VIN [Y]
DODGE; RAM PICKUP 1500/2500: 5.2L VIN [T]
DODGE; RAM PICKUP 1500/2500: 5.9L VIN [Z]
* READ THIS FIRST *
Before preforming maintenance on vehicle, ensure that all
cautions and warnings have been observed to prevent vehicle damage or
personal injury. See CAUTIONS & WARNINGS in MAINTENANCE INFORMATION
article in this section.
Introduction
The frequency of scheduled inspection and maintenance
services in this article are based on Severe Duty vehicle usage ONLY.
Severe Duty vehicle usage is defined as any one of the following
conditions:
* Frequent short driving less than 5 Miles (8 16 Km).
* Frequent driving in dusty conditions.
* Frequent trailer towing.
* Extensive idling.
* More than 50% of your driving is at sustained high speeds
during hot weather, above 90
F (32C).
If none of these conditions apply, this Severe service
schedule article is excessive. DO NOT USE. Instead, use the Normal
service schedule: See appropriate
SCHEDULED SERVICE - NORMAL SERVICE (GAS) article.
3,000 MILE (5,000 KM) SEVERE DUTY SERVICE
3,000 MILE (5,000 KM) SEVERE DUTY SERVICE
\
\
\
\
\
\
\
 
INSPECT 

\b\
\
\
\
\
\
\


 Exhaust System 


\
\
\
\
\
\
\


 Brake Hoses 


\
\
\
\
\
\
\


 Engine Coolant Level, Hoses & Clamps 

\
\
\
\
\
\
\



SERVICE 

\b\
\
\
\
\
\
\


 Rotate Tires 


\
\
\
\
\
\
\


 Lubricate Steering Linkage 

\
\
\
\
\
\
\



REPLACE 

\b\
\
\
\
\
\
\


 Engine Oil 


\
\
\
\
\
\
\


 Engine Oil Filter (
1) 

\
\
\
\
\
\
\


\
\
\
\
\
\
\


(
1) - SAE 10W-30 engine oil is preferred. Use only API approved 

oil with Starburst Symbol. 

\
\
\
\
\
\
\



FLUID CAPACITIES 

\
\b\
\
\
\b\
\
\



Item  Condition  Specification (1) 

\

\
\
\

\
\
\


Engine Oil  5.9L: Drained, W/New Filter  5 Qts. (4.7L) 


\
\
\

\
\


 8.0L: Drained, W/New Filter  5 Qts. (4.7L) 


\
\
\

\
\


 5.9L: Drained  4.5 Qts. (4.2L) 

\

\
\
\

\
\
\


Engine  5.9L: Drained  20 Qts. (19L) 

Coolant 
\
\
\

\
\


 8.0L: Drained  24 Qts. (22.7L) 

\
\
\
\
\
\
\


(
1) - Capacities are recommended or calculated levels. Always use 

dipstick (if available) to measure level. 
\f
\
\
\
\
\
\
\


82,500 MILE (132,000 KM)/82 MONTH NORMAL SERVICE
82,500 MILE (132,000 KM)/82 MONTH NORMAL SERVICE
\
\
\
\
\
\
\
 
VERIFY 

\b\
\
\
\
\
\
\



Last Major Service Was Performed. 

\
\
\
\
\
\
\



REPLACE 

\b\
\
\
\
\
\
\


 Oxygen Sensor (5.9L Only) (
1) 

\
\
\
\
\
\
\


(
1)  Requires service reminder indicator light. If so equipped, 

these parts are to be replaced at the indicated mileage 

when the service reminder indicator light remains on 

continuosly with the key in the "ON" position, which occurs 

first. 
\f
\
\
\
\
\
\
\


84,000 MILE (134,000 KM) SEVERE DUTY SERVICE
84,000 MILE (134,000 KM) SEVERE DUTY SERVICE
\
\
\
\
\
\
\


VERIFY 

\b\
\
\
\
\
\
\



Last Major Service Was Performed. 

\
\
\
\
\
\
\



INSPECT 

\b\
\
\
\
\
\
\


 Exhaust System 


\
\
\
\
\
\
\


 Brake Hoses 


\
\
\
\
\
\
\


 Engine Coolant Level, Hoses & Clamps 


\
\
\
\
\
\
\


 Engine Air Cleaner & Air Pump Filters 


\
\
\
\
\
\
\


 Brake Linings 

\
\
\
\
\
\
\



SERVICE 

 \
\
\

\
\


 Model 286 (4WD)  10.1 Pts. (4.8L) 

\

\
\
\

\
\
\


Rear Axle  Model 248 (2WD)  6.3 Pts. (3L) 

Limited Slip 
\
\
\

\
\


Differential  Model 248 (4WD)  7.3 Pts. (3.4L) 


\
\
\

\
\


 Model 267 (2WD)  7 Pts. (3.3L) 


\
\
\

\
\


 Model 267 (4WD)  7.8 Pts. (3.6L) 


\
\
\

\
\


 Model 286 (2WD)  6.8 Pts. (3.2L) 


\
\
\

\
\


 Model 286 (4WD)  10.1 Pts. (4.8L) 

\

\
\
\

\
\
\


Front Axle  Model 216  6.8 Pts. (3.6L) 

Lubricant 
\
\
\

\
\


 Model 248  7.6 Pts. (3.6L) 

\

\
\
\

\
\
\


Transfer Case NV241  5 Pts. (2.7L) 

Fluid 
\
\
\

\
\


 NV241 HD  6.5 Pts. (3.5L) 


\
\
\

\
\


 NV241 HD W/PTO  9 Pts. (4.9L) 

\

\
\
\

\
\
\


Power Take  NV021  4.6 Pts. (2.1L) 

Off Adapter   

\

\
\
\

\
\
\


Power  Drained  2.7 Pts. (1.3L) 

Steering   

Fluid   

\

\
\
\

\
\
\


A/C  Charge Capacity  32 Oz. (.9Kg) 

Refrigerant   

  

\

\
\
\

\
\
\


Refrigerant  A/C System Capacity  7.75 Oz. (230ML) 

Oil   

\

\
\
\

\
\
\


Fuel Tank 119" & 139" Wheelbase Vehicles 26 Gal. (98L) 


\
\
\

\
\


 All Others  35 Gal. (132L) 

\
\
\
\
\
\
\


(
1) - Capacities are recommended or calculated levels. Always use 

dipstick (if available) to measure level. 
\f
\
\
\
\
\
\
\


MISCELLANEOUS NOTES
* Once a month, check tire pressure and look for unusual wear
or damage.
* Once a month, Inspect battery and clean and tighten
terminals as required.
* Once a month, check fluid levels of coolant reservoir,
brake master cylinder, power steering & transmission.
Add fluids as required.
* Once a month, check all lights and all other electrical items
for correct operation
* Once a month, Inspect and clean wiper blades as required.
* Twice a year, lubricate the external lock cylinders.

Air Filter
Normal Service .......................... 24 ............ 30,000
Severe Service ......................... (2) ........ ( 3) 15,000
Coolant .................................. ( 4) ............... ( 4)
Engine Oil
Normal Service .......................... 6 ............... 7500
Severe Service ......................... ( 2) .............. 3000
Engine Oil Filter
Normal Service .......................... 12 ............ 15,000
Severe Service ......................... ( 2) .............. 6000
PCV Valve ( 5)
Normal Service .......................... 48 ............ 60,000
Severe Service ......................... ( 2) ............ 30,000
Spark Plugs
Normal Service .......................... 24 ............ 30,000
Severe Service ......................... ( 2) ............ 30,000
Spark Plug Wires
Normal Service .......................... 48 ............ 60,000
Severe Service ......................... ( 2) ............ 60,000
Automatic Transmission Fluid,
Filter & Band Adjustment
Normal Service .......................... 30 ............ 37,500
Severe Service ......................... ( 2) ............ 12,000
Transfer Case Fluid (4WD)
Normal Service .......................... 30 ............ 37,500
Severe Service ......................... ( 2) ............ 36,000
Front Differential Fluid (4WD) ( 6)
Severe Service ......................... ( 2) ............ 12,000
Rear Differential Fluid ( 6)
Severe Service ......................... ( 2) ............ 12,000
Repack Front Wheel Bearings
Normal Service .......................... 18 ............ 22,500
Severe Service ......................... ( 2) ............ 21,000
( 1) - Different interval may be required for normal and severe
service. Severe service is described as long periods of engine
idling, frequent short trip operation of less than 5 miles,
trailer towing, off-highway operation, snow removal operation,
or operating in dusty or excessively hot conditions.
( 2) - Monthly interval is not available from manufacturer.
( 3) - Inspect air filter every 15,000 miles and replace as necessary.
Replace at 30,000 miles unless previously replaced during
inspection.
( 4) - Replace coolant at 45,000 miles or 36 months whichever occurs
first. Replace coolant at 36 months regardless of mileage. After
first coolant change, replace coolant every 24 months or 30,000
miles thereafter.
( 5) - Inspect at scheduled interval and replace as necessary.
( 6) - Normal service interval is not available from manufacturer.
Manufacturer lists service schedule only under severe service
conditions.









\









\









\









\









\









\









\







REPLACEMENT INTERVALS (RAM PICKUP - LIGHT-DUTY) ( 1)( 2)








\









\









\









\









\









\









\







Component Months Miles
Air Filter
Normal Service ......................... 24 ............. 30,000
Severe Service ......................... ( 3) ........ ( 4) 15,000
Coolant .................................. ( 5) ............... ( 5)
Engine Oil

Normal Service .......................... 6 ............... 7500
Severe Service ......................... (3) .............. 3000
Engine Oil Filter
Normal Service .......................... 12 ............ 15,000
Severe Service ......................... ( 3) .............. 6000
PCV Valve ( 6)
Normal Service .......................... 48 ............ 60,000
Severe Service ......................... ( 3) ............ 30,000
Spark Plugs
Normal Service .......................... 24 ............ 30,000
Severe Service ......................... ( 3) ............ 30,000
Spark Plug Wires
Normal Service .......................... 48 ............ 60,000
Severe Service ......................... ( 3) ............ 60,000
Automatic Transmission Fluid,
Filter & Band Adjustment
Normal Service .......................... 30 ............ 37,500
Severe Service ......................... ( 3) ............ 12,000
Manual Transmission Fluid ................ ( 7) ............... ( 7)
Transfer Case Fluid (4WD)
Normal Service .......................... 30 ............ 37,500
Severe Service ......................... ( 3) ............ 36,000
Front Differential Fluid (4WD) ( 8)
Severe Service ......................... ( 3) ............ 12,000
Rear Differential Fluid ( 8)
Severe Service ......................... ( 3) ............ 12,000
Repack Front Wheel Bearings (2WD)
Normal Service .......................... 18 ............ 22,500
Severe Service ......................... ( 3) ............ 21,000
( 1) - Light-duty vehicles apply to all 1500 models and 2500 except
5.9L diesel or 8.0L engines.
( 2) - Different interval may be required for normal and severe
service. Severe service is described as long periods of engine
idling, frequent short trip operation of less than 5 miles,
trailer towing, off-highway operation, snow removal operation,
or operating in dusty or excessively hot conditions.
( 3) - Monthly interval is not available from manufacturer.
( 4) - Inspect air filter every 15,000 miles and replace as necessary.
Replace at 30,000 miles unless previously replaced during
inspection.
( 5) - Replace coolant at 45,000 miles or 36 months whichever occurs
first. Replace coolant at 36 months regardless of mileage. After
first coolant change, replace coolant every 24 months or 30,000
miles thereafter.
( 6) - Inspect at scheduled interval and replace as necessary.
( 7) - Service interval is not available from manufacturer.
( 8) - Normal service interval is not available from manufacturer.
Manufacturer lists service schedule only under severe service
conditions.









\









\









\









\









\









\









\







REPLACEMENT INTERVALS (RAM PICKUP - MEDIUM-DUTY - GASOLINE) ( 1)( 2)








\









\









\









\









\









\









\







Component Months Miles
Air Filter
Normal Service ...................... 30 ................ 30,000
Severe Service ...................... ( 3) ........... ( 4) 15,000
Coolant ............................... ( 5) .................. ( 5)
Engine Oil & Filter
Normal Service ....................... 6 .................. 6000
Severe Service ...................... ( 3) ................. 3000


SEA TS - P O W ER

1999 D odge P ic ku p R 1500
1999 ACCESSORIES & EQUIPMENT
CHRY - Power Seats
Ram Pickup, Ram Van & Ram Wagon
DESCRIPTION & OPERATION
Driver's power seat can be adjusted in 6 different
directions: up, down, forward, back, tilt forward, or tilt rearward.
The power seat system consists of a 6-way switch, motor assembly, seat
adjuster, motor cable, housing and wiring harness.
The power seat system receives battery power through circuit
breaker and a fuse in the Power Distribution Center (PDC). Battery
voltage is available to power seat system at all times. Three
permanent magnet reversible motors are coupled through cables to worm
gear box assemblies located in the seat tracks, providing the various
seat movements.
On Ram Pickup with extended cab (club cab and quad cab),
driver's seat also includes power operated lumbar support. Lumbar
support can be inflated or deflated as needed, using additional
switch. On seats with lumbar support, seat back remains at same
height, while seat cushion raises and lowers. On seats without lumbar
support, entire seat raises and lowers. On all seats, entire seat
moves forward and backward.
TROUBLE SHOOTING
NOTE: Before any testing is attempted, the battery should be fully
charged and all connections and terminals cleaned and
tightened to ensure proper continuity and chassis grounds.
POWER SEAT INOPERATIVE
With dome light on, apply power seat switch in direction of
failure. If dome light dims, power seat may be jamming. Check for
binding or obstructions. If dome light does not dim, check individual
components. See COMPONENT TESTS.
COMPONENT TESTS
HARNESS VOLTAGE TEST
NOTE: This test will determine whether or not voltage is continuous
through body harness to power seat switch.
1) Remove power seat switch from mounting position and
disconnect switch from wiring harness. See POWER SEAT SWITCH under
REMOVAL & INSTALLATION.
2) Connect test light lead to ground terminal (Black wire on
Ram Van and Ram Wagon; Black/Orange wire on Ram Pickup) at power seat
switch harness connector. Using test light, probe power supply wire
(Red/Light Blue wire) at power seat switch harness connector.
3) If test light comes on, power and ground circuits to power
seat switch are good. If test light does not come on, check ground
circuit. See WIRING DIAGRAMS. Repair as necessary. If ground circuit
is okay, check power supply. See CIRCUIT BREAKER. Check ground circuit
for continuity.

CIRCUIT BREAKER
1) Circuit breaker is located in fuse block. On Ram Van and
Ram Wagon, fuse block is located under glove box door. On Ram Pickup,
fuse block is located at extreme left end of instrument panel under
protective cover. On all models, pull circuit breaker outward
slightly, ensuring circuit breaker terminals still contact terminals
in fuse block. Connect negative voltmeter lead to ground. With
positive lead, check each terminal of circuit breaker for voltage.
2) If battery voltage exists at both terminals, circuit
breaker is good. If battery voltage exists at only one terminal,
circuit breaker is defective. Replace circuit breaker. If battery
voltage does not exist at either terminal, check for open or shorted
circuit to fuse box. Repair as necessary.
MOTOR
1) Operate power seat switch to move all 3 seat motors. Seat
should move in all directions. If one or more motors operate, see
POWER SEAT SWITCH. If no motors operate, go to next step.
2) Check circuit breaker in fuse block. See CIRCUIT BREAKER.
If circuit breaker is good, go to next step. If circuit breaker is
faulty, replace circuit breaker and retest system.
3) Remove power seat switch. See POWER SEAT SWITCH under
REMOVAL & INSTALLATION. Check for battery voltage at power supply (Red
wire on Ram Van and Ram Wagon; Red/Light Blue wire on Ram Pickup). If
battery voltage exists, go to next step. If battery voltage does not
exist, repair open in wire.
4) Check for continuity between switch connector ground
circuit (Black wire on Ram Van and Ram Wagon; Black/Orange wire on Ram
Pickup) and ground. If continuity exists, go to next step. If
continuity does not exist, repair open in wire.
5) Test power seat switch. See POWER SEAT SWITCH. Replace
switch as necessary and retest system. If switch tests good, check
wiring harness between switch connector and motor. Repair as
necessary. If wiring is okay, replace defective power seat
adjuster/motors assembly.
POWER SEAT SWITCH
Remove switch from mounting position. See POWER SEAT SWITCH
under REMOVAL & INSTALLATION. Using an ohmmeter, check continuity
between power seat switch terminals as indicated. See POWER SEAT
SWITCH CONTINUITY TEST (RAM PICKUP) or POWER SEAT SWITCH CONTINUITY
TEST (RAM VAN & RAM WAGON) table. See Fig. 1 or 2. If continuity does
not exist as specified, replace switch. If continuity exists as
specified, switch is okay.
Fig. 1: Testing Power Seat Switch Terminals (Ram Pickup)
Courtesy of Chrysler Corp.

ON-VEHICLE TESTING
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
COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION
before disconnecting battery.
DISABLING/ENABLING IGNITION & FUEL SYSTEMS
WARNING: To prevent engine from starting while performing tests,
always disable ignition and fuel systems.
Disabling Ignition & Fuel Systems
Remove Automatic Shutdown Relay (ASD) located in Power
Distribution Center (PDC). Refer to PDC cover for proper relay
location. PDC is located in engine compartment. On 5.9L diesel
engines, also disconnect fuel shutdown solenoid connector. Solenoid is
located behind upper intake manifold. See appropriate SYSTEM &
COMPONENT TESTING article in ENGINE PERFORMANCE section.
Enabling Ignition & Fuel Systems
When testing and/or repairs have been completed, verify
battery condition. Recharge battery as necessary, after starter tests
have been completed. Disconnect all test equipment. Install ASD relay.
On 5.9L diesel engines, reconnect fuel shutdown relay connector. On
all models, start engine several times to verify malfunction has been
corrected.
CRANKING TEST
NOTE: Ensure engine is at normal operating temperature. High
viscosity oil, extreme cold temperatures, or tight engine
will increase amperage draw.
1) Using a battery load tester, connect positive and negative
leads to battery. Connect inductive ammeter pick-up to positive
battery cable. Disable ignition and fuel systems. See
DISABLING/ENABLING IGNITION & FUEL SYSTEMS.
2) Ensure all lights and accessories are off. Place A/T in
Park position or M/T in Neutral position. Apply parking brake. Crank
engine and observe voltmeter reading. If voltage is more than 9.6
volts and cranking amperage draw is more than specified amps, proceed
to CIRCUIT RESISTANCE TESTS. See STARTER SPECIFICATIONS - CARS or
STARTER SPECIFICATIONS - TRUCKS.
3) If voltage is 12.5 volts or more and cranking amperage
draw is less than specified, check starter circuit components in the
following order:
starter solenoid, starter relay, starter relay circuit, park/neutral
position switch or transmission range sensor (A/T), clutch pedal
position switch (M/T), ignition switch, wiring harness and
connections.
CIRCUIT RESISTANCE TESTS
NOTE: If excessive resistance is not found in circuits being
tested, remove starter and proceed to BENCH TESTING.
Battery Connection Resistance Test
1) Disable vehicle ignition and fuel systems. See
DISABLING/ENABLING IGNITION & FUEL SYSTEMS. A voltmeter accurate to
one tenth of a volt will be needed for the following tests.

WARNING: Wait about 2 minutes after disconnecting negative battery
cable before servicing air bag system. System reserve
capacitor maintains air bag system voltage for about 2
minutes after battery is disconnected. Servicing air bag
system before 2 minutes may cause accidental air bag
deployment and possible personal injury.
REMOVAL & INSTALLATION
WARNING: All models are equipped with Air Bag Restraint System (ABRS).
See AIR BAG PRECAUTIONS before working on vehicle. Use
caution when working around steering column (air bag could
deploy).
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
COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION
before disconnecting battery.
HORN PAD & STEERING WHEEL
Removal & Installation
1) Disable air bag system. See AIR BAG DISABLING. Ensure
steering wheel is in straight-ahead position. Remove nuts mounting air
bag module to steering wheel. Remove screws securing cruise control
switch to steering wheel (if equipped).
2) Disconnect wiring connectors. Remove air bag module and
cruise control switch assembly. Pry trim covers from back of steering
wheel and remove horn switch mounting screws. Disconnect horn wires.
Remove horn switch.
3) Remove steering wheel retaining nut. Reference mark
steering wheel and steering shaft. Using puller, remove steering
wheel. To install, reverse removal procedure. Align marks made during
removal. Tighten steering wheel retaining nut to specification.
STEERING COLUMN
Removal & Installation
1) Position front wheels straight ahead. Disconnect and
isolate negative battery cable. On column shift models, remove link
rod from bushing in shift lever. Discard bushing. On all models,
remove steering wheel using Puller (C-3428-B). See HORN PAD & STEERING\
WHEEL.
2) Remove steering column shaft-to-coupler retaining pin.
Push upper coupler shaft down into lower steering coupler. Remove dash
panel column cover. On column shift models, disconnect shift indicator
cable.
3) On all models, remove tilt lever (if equipped). Remove
upper and lower shroud. Remove lower fixed shroud. Disconnect
multifunction switch harness connector. Disconnect harness connectors
from ignition switch, key-in light, horn and cruise control (if
equipped).
4) Loosen upper support bracket nuts and allow column to drop
slightly. Remove upper fixed shroud. Disconnect wiring harness
retainers from column, and move harness to one side. Remove lower dash
panel. Remove lower steering column nuts. Remove column.
CAUTION: DO NOT reuse bushing in shift rod lever once shift rod is
removed. Always install a NEW bushing.
5) To install column, reverse removal procedure. Connect

STE ER IN G C O LU M N S W IT C HES
1999 D odge P ic ku p R 1500
1999 ACCESSORIES & EQUIPMENT
CHRY - Steering Column Switches
Dakota, Durango & Ram Pickup
WARNING: Deactivate air bag system before performing any service
operation involving steering column components. See
appropriate AIR BAG RESTRAINT SYSTEMS article. DO NOT apply
electrical power to any component on steering column without
first disconnecting air bag module. Air bag may deploy. Wait
at least 2 minutes after disconnecting negative battery cable
before servicing air bag system. System reserve capacitor,
integral to ACM, maintains air bag system voltage for about 2
minutes after battery is disconnected. Servicing air bag
system before 2-minute period may cause accidental air bag
deployment and possible personal injury.
DESCRIPTION
Turn signal, hazard flasher, headlight beam selector,
headlight flash-to-pass, windshield wipe, pulse wipe and windshield
wash systems use a common switch assembly (multifunction switch)
mounted within upper steering column housing.
Ignition switch and lock cylinder are incorporated into an
assembly attached to side of steering column. Ignition switch assembly
can be serviced as a separate unit, but requires removal of lock
cylinder.
COMPONENT LOCATIONS
COMPONENT LOCATIONS








\









\









\









\









\









\









\







Component Location
Combination Flasher Relay ........................... Junction Block
Horn ............................... In Right Front Corner Of Engine
Compartment
Horn Relay ............................ In Power Distribution Center
Junction Block ................. Under Left Side Of Instrument Panel
Power Distribution Center ...... In Left Side Of Engine Compartment,
On Left Inner Panel
Relay/Flasher Module ........ Under Right Side Of Instrument Panel,
Behind Glove Box









\









\









\









\









\









\









\







TROUBLE SHOOTING
TURN SIGNAL AND HAZARD FLASHER SYSTEM
Bulbs Burn Out Rapidly
Check charging system. See appropriate GENERATORS &
REGULATORS article in STARTING & CHARGING SYSTEMS.
Hazard Flashers Inoperative
Blown fuse. Faulty hazard flasher. Open circuit in feed wire
to hazard switch. Faulty turn signal/hazard switch. Open or grounded
circuit in wiring to external lights.