weight DODGE RAM 1999 Service User Guide
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 489 of 1691
Condition Code Procedure
Application incorrect ... B .. Require repair or replacement.
Cracked ................. A .. Require repair or replacement.
Distorted ............... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Positioned incorrectly .. B .. Require repair or replacement.
Stepped ................. A .. Require repair or replacement.
Worn to the extent that it
no longer performs its
intended function ...... A .. Require repair or replacement.
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DRIVE SHAFT FLANGES
See COMPANION FLANGES .
DRIVE SHAFTS AND HALF SHAFTS
DRIVE SHAFT AND HALF SHAFT INSPECTION \
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Condition Code Procedure
Balance weight missing .. C .. Require repair or replacement.
Bearing cap bore
distorted .............. A .. Require repair or replacement.
Bent .................... A ............ Require replacement.
Bolt holes elongated .... A .. Require repair or replacement.
Bushing or seal surface
worn, affecting
performance ............ A .. Require repair or replacement.
Leaking through soft yoke
plug ................... A ... Require repair or replacement
of soft yoke plug.
Out of balance .......... A .. Require repair or replacement.
Retainer strap bent ..... A .......... Require replacement of
retainer strap.
Slip yoke broken ........ A ............ Require replacement.
Splines worn, affecting
performance ............ A ............ Require replacement.
Splines worn close to
the end of their
useful life ............ 1 ............ Suggest replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
U-bolt damaged, affecting
performance ............ A . Require replacement of U-bolts.
Yoke damaged, affecting
performance ............ A .. Require repair or replacement.
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DUST BOOTS
NOTE: Does not include CV boots.
DUST BOOT INSPECTION
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Condition Code Procedure
Cracked, not leaking .... 1 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Page 491 of 1691
![DODGE RAM 1999 Service User Guide performs its intended
function ............... A ............ Require replacement.
Weights missing ......... A ............ Require replacement.
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\](/img/12/56915/w960_56915-490.png "DODGE RAM 1999 Service User Guide performs its intended
function ............... A ............ Require replacement.
Weights missing ......... A ............ Require replacement.
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performs its intended
function ............... A ............ Require replacement.
Weights missing ......... A ............ Require replacement.
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FLUID LEVEL INDICATORS
See DIP STICKS (FLUID LEVEL INDICATORS) .
FLUIDS AND LUBRICANTS
FLUID AND LUBRICANT INSPECTION \
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Condition Code Procedure
Application incorrect ... B ........ ( 1) Require replacement.
At service interval ..... 3 ............ Suggest replacement.
Beyond service interval . 3 ............ Suggest replacement.
Burned .................. .. ......... ( 2) Further inspection
required.
Contaminated, for example,
fluid other than hydraulic
fluid present .......... A or B .... ( 3)( 4) Require service.
Exceeding service
interval ............... 3 ............ Suggest replacement.
Hydraulic fluid
incorrect .............. B ............ ( 5) Require service.
Level incorrect ......... B ..... Require correction of fluid
level.
Near service interval ... 3 ............ Suggest replacement.
Rubber master cylinder
cover gasket distorted
and gummy .............. A ............ ( 3) Require service.
Varnished ............... .. ......... ( 6) Further inspection
required.
( 1) - Determine and correct cause.
( 2) - Fluid that is burned indicates a serious problem.
Determine and correct the cause.
( 3) - If a fluid other than hydraulic fluid is present in the
hydraulic system which DOES affect the rubber parts, the
required service is to: 1) remove all components having
rubber parts from the system, 2) flush lines with
denatured alcohol or hydraulic cleaner, 3) repair or
replace all components having rubber parts, and 4) bleed
and flush with correct hydraulic fluid. (Code A)
( 4) - If a fluid other than hydraulic fluid is present in the
hydraulic system which DOES NOT affect the rubber parts,
the required service is to flush and fill with the
correct hydraulic fluid. (Code B)
( 5) - If a fluid other than specification hydraulic fluid is
present in the hydraulic system, the required service
is to flush and fill with the correct hydraulic fluid.
( 6) - Fluid that is varnished may indicate a serious problem.
Determine and correct the cause.
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FLYWHEELS
NOTE: Clutch disc replacement does not necessitate flywheel
reconditioning, unless other conditions justify the
reason to do so.
Page 497 of 1691
Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Broken .................. A ............ Require replacement.
Leaking (hydraulic
mount) ................. A ............ Require replacement.
Mounting hole worn,
affecting performance .. A ............ Require replacement.
Mounting hole worn, not
affecting performance .. .. ........ No service suggested or
required.
Rubber deteriorated,
affecting performance .. A ............ Require replacement.
Rubber deteriorated, not
affecting performance .. .. ........ No service suggested or
required.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
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ODOMETER DRIVES (MECHANICAL)
See SPEEDOMETER/ODOMETER DRIVES (MECHANICAL) .
ODOMETER HEADS (MECHANICAL)
See SPEEDOMETER/ODOMETER HEADS (MECHANICAL) .
OIL PANS
See TRANSMISSION PANS .
PANS
See TRANSMISSION PANS .
PILOT HOLES
See DOWEL PINS, GUIDES AND PILOT HOLES .
PRESSURE PLATES
PRESSURE PLATE INSPECTION \
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Condition Code Procedure
Balance weight missing .. C ............ Require replacement.
Broken .................. A ............ Require replacement.
Contact surface
distorted .............. B ............ Require replacement.
Cracks .................. B ............ Require replacement.
Fingers bent ............ A ............ Require replacement.
Hard spots .............. B ............ Require replacement.
Page 505 of 1691
incorrect .............. B ............ Require replacement.
Teeth broken ............ A ............ Require replacement.
Teeth damaged, affecting
performance ............ A ............ Require replacement.
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TORQUE CONVERTERS
TORQUE CONVERTER INSPECTION \
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Condition Code Procedure
Converter clutch lock-up
operation is faulty .... A ............ Require replacement.
Cover shell damaged,
affecting performance .. A ............ Require replacement.
Does not meet stall speed
specification .......... B ............ Require replacement.
End play exceeds
specifications ......... B ............ Require replacement.
Hub broken .............. A ............ Require replacement.
Hub cracked ............. A ............ Require replacement.
Internal component
failure ................ A ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Pilot broken ............ A ............ Require replacement.
Pilot worn, affecting
performance ............ A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Weights missing ......... C ............ Require replacement.
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TRANSAXLE MOUNTS
See MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION) .
TRANSDUCERS (TRANSMISSION)
See SENSORS.
TRANSMISSION COOLERS
TRANSMISSION COOLER INSPECTION \
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Condition Code Procedure
Air flow obstruction .... A ................. Require repair.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A .. Require repair or replacement
of hardware.
Connection leaking ...... A .. Require repair or replacement.
Contaminated ............ A .. Require repair or replacement.
Corroded ................ 1 .. Suggest repair or replacement.
Fins damaged, affecting
Page 629 of 1691
![DODGE RAM 1999 Service User Guide
3.9 L V 6, 5 .2 L & 5 .9 L V 8 - V IN [ T , X , Y , Z ]
1 999 D odge P ic ku p R 1500
1998-99 ENGINES
CHRY - 3.9L V6, & 5.2L & 5.9L V8
Chrysler Corp. Dakota, Du](/img/12/56915/w960_56915-628.png "DODGE RAM 1999 Service User Guide
3.9 L V 6, 5 .2 L & 5 .9 L V 8 - V IN [ T , X , Y , Z ]
1 999 D odge P ic ku p R 1500
1998-99 ENGINES
CHRY - 3.9L V6, & 5.2L & 5.9L V8
Chrysler Corp. Dakota, Du")
3.9 L V 6, 5 .2 L & 5 .9 L V 8 - V IN [ T , X , Y , Z ]
1 999 D odge P ic ku p R 1500
1998-99 ENGINES
CHRY - 3.9L V6, & 5.2L & 5.9L V8
Chrysler Corp. Dakota, Durango, Ram Pickup, Ram Van/Wagon
Jeep Grand Cherokee
ENGINE IDENTIFICATION
Engine may be identified by eighth character of Vehicle
Identification Number (VIN) stamped on metal tab located near lower
left corner of windshield. See ENGINE IDENTIFICATION CODES table.
Engine serial number may be required when ordering
replacement parts. Engine serial number is located on left front
corner of cylinder block just below cylinder head.
ENGINE IDENTIFICATION CODES
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Engine Code
3.9L PFI ......................................................... X
5.2L PFI ......................................................... Y
5.2L MFI CNG ..................................................... T
5.9L PFI
Light Duty Cycle ............................................... Z
Heavy Duty Cycle ( 1) ........................................... 5
( 1) - Heavy Duty Cycle (HDC) engine uses an engine mounted air
injection pump.
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SPECIAL ENGINE MARKS
Information identifying undersize and oversize components is
found at various engine locations and is decoded as follows:
Crankshaft & Rod Journals
The letter "M" (main) or "R" (rod) followed by number
indicates which main or rod bearing journal is .001" (.02 mm)
undersize. The mark is stamped on No. 6 crankshaft counterweight on 3.
9L, No. 8 crankshaft counterweight on 5.2L and No. 3 crankshaft
counterweight on 5.9L engines.
Cylinder Block - Letter "A" following engine serial number
indicates .020" (.51 mm) oversize cylinder bores:
* A diamond-shaped stamp, located on top pad at front of engine
and stamped on flat area of each oversize lifter bore,
indicates .008" (.20 mm) oversize lifters.
* A stamp "X" indicates .005" (.13 mm) oversize valve stems.
The stamp is found on machined pad, near two 3/8" tapped
holes on each end of cylinder head.
ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
Hydraulic valve lifters are used. No valve adjustment is
required.
Page 680 of 1691
interchangeable. Inspect all components for wear. Note amount of wear
in lifter body-to-camshaft contact area. Surface must have smooth and
convex contact face. If wear is apparent, carefully inspect cam lobe.
Inspect push rod contact area and lifter body for scoring
or signs of wear. If body is scored, inspect lifter bore for damage
and lack of lubrication. On roller type lifters, inspect roller for
flaking, pitting, loss of needle bearings and roughness during
rotation.
Measure lifter body O.D. in several areas. Measure lifter
bore I.D. of cylinder block. Some models offer oversized lifters.
Replace lifter if damaged.
If lifter check valve is not operating, obstructions may be
preventing it from closing or valve spring may be broken. Clean or
replace components as necessary.
Check plunger operation. Plunger should drop to bottom of the
body by its own weight when assembled dry. If plunger is not free,
soak lifter in solvent to dissolve deposits.
Lifter leak-down test can be performed on lifter. Lifter
must be filled with special test oil. New lifters contain special test
oil. Using lifter leak-down tester, perform leak-down test following
manufacturer's instructions. If leak-down time is not within
specifications, replace lifter assembly.
Lifters should be soaked in clean engine oil several hours
prior to installation. Coat lifter base, roller (if equipped) and
lifter body with ample amount of Molykote or camshaft lubricant. See
Fig. 13. Install lifter in original location. Install remaining
components. Valve lash adjustment is not required on most hydraulic
lifters. Preload of hydraulic lifter is automatic. Some models may
require adjustment.
Mechanical Lifters
Lifter assemblies must be installed in original locations.
Remove rocker arm assembly and push rod. Mark components for location.
Some applications require intake manifold or lifter cover removal.
Remove lifter retainer plate (if used). To remove lifters, use lifter
remover or magnet.
Inspect push rod contact area and lifter body for scoring or
signs of wear. If body is scored, inspect lifter bore for damage and
lack of lubrication. Note amount of wear in lifter body-to-camshaft
contact area. Surface must have smooth and convex contact face. If
wear is apparent, carefully inspect cam lobe.
Coat lifter base, roller (if equipped) and lifter body with
ample amount of Molykote or camshaft lubricant. Install lifter in
original location. Install remaining components. Tighten bolts to
specification. Adjust valves. See VALVE ADJUSTMENT in this article.
PISTONS, CONNECTING RODS & BEARINGS
* PLEASE READ THIS FIRST *
NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
RIDGE REMOVAL
Ridge in cylinder wall must be removed prior to piston
removal. Failure to remove ridge prior to removing pistons will cause
piston damage in piston ring locations.
With the piston at bottom dead center, place a rag in the
bore to trap metal chips. Install ridge reamer in cylinder bore.
Adjust ridge reamer using manufacturer's instructions. Remove ridge
Page 871 of 1691
![DODGE RAM 1999 Service User Guide Numbers preceding the explanations in the legend below refer
to the sequence of characters as listed on VIN identification label.
See VIN example below.
\](/img/12/56915/w960_56915-870.png "DODGE RAM 1999 Service User Guide Numbers preceding the explanations in the legend below refer
to the sequence of characters as listed on VIN identification label.
See VIN example below.
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Numbers preceding the explanations in the legend below refer
to the sequence of characters as listed on VIN identification label.
See VIN example below.
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(VIN) 1 B 4 G D 2 2 Z X J S 0 0 0 0 0 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
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1 - Country Of Origin
1
* United States
3 * Mexico
2 - Vehicle Make
B * Dodge
3 - Type Of Vehicle
4 * Multi-Purpose Vehicle
5 * Bus
6 * Incomplete
7 * Truck
4 - Gross Vehicle Weight
H * 6001-7000 Lbs.
J * 7001-8000 Lbs.
K * 8001-9000 Lbs.
L * 9001-10000 Lbs.
M * 10001-14000 Lbs.
W * Hydraulic Brakes
5 - Truck Line
C * Ram Chassis/Ram Pick Up (4x2)
F * Ram Chassis/Ram Pick Up (4x4)
6 - Series
1 * 1500
2 * 2500
3 * 3500
7 - Body Style
3 * Club Cab
6 * Conventional Cab/Cab Chassis
8 - Engine Type
D * 5.9L 6-Cylinder Diesel
W * 8.0L 10-Cylinder MPI
X * 3.9L 6-Cylinder MPI
Y * 5.2L 8-Cylinder MPI
Z * 5.9L 8-Cylinder MPI-LDC
5 * 5.9L 8-Cylinder MPI-HDC
9 - Check Digit
* 0 Through 9 Or X
10 - Model Year
V * 1997
W * 1998
X * 1999
11 - Assembly Plant
J * St. Louis North, Missouri
S * Dodge City, Michigan
G * Saltillo, Mexico
Page 872 of 1691
M * Lago Alberto, Mexico
12-17 - Serial Number
* Sequential Production Number
MAINTENANCE SERVICE INFORMATION
LIGHT & HEAVY DUTY SERVICE DEFINITIONS
Maintenance service is recommended at different mileage
intervals based on Gross Vehicle Weight Rating (GVWR). See appropriate\
SERVICE SCHEDULES article.
Light Duty
Vehicles with GVWR of 8500 lbs. or less.
Heavy Duty
Vehicles with GVWR of 8501 lbs. or more.
SEVERE & NORMAL SERVICE DEFINITIONS
Service is recommended at mileage intervals based on vehicle
operation. Normal Service and Severe Service schedules are based on
the following primary operating conditions:
Normal Service
* Driven More Than 10 Miles Daily
* NO Severe Service Operating Conditions
Severe Service
NOTE: Use the Severe Service schedule if the vehicle to be serviced
is operated under ANY (one or more) of these conditions:
* Frequent Short Trips Of Less than 5 Miles (8 KM)
* Frequent Driving In Dusty Conditions
* Frequent Trailer Towing
* Frequent Idling
* More Than 50% Of Your Driving Is At Sustained High Speeds
During Hot Weather, Above 90
\bF (32\bC)
SERVICE POINT LOCATIONS
Page 900 of 1691
METR IC C O NVER SIO NS
1999 D odge P ic ku p R 1500
GENERAL INFORMATION
METRIC CONVERSIONS
METRIC CONVERSIONS
Metric conversions are making life more difficult for the
mechanic. In addition to doubling the number of tools required,
metric-dimensioned nuts and bolts are used alongside English
components in many new vehicles. The mechanic has to decide which tool
to use, slowing down the job. The tool problem can be solved by trial
and error, but some metric conversions aren't so simple. Converting
temperature, lengths or volumes requires a calculator and conversion
charts, or else a very nimble mind. Conversion charts are only part of
the answer though, because they don't help you "think" metric, or
"visualize" what you are converting. The following examples are
intended to help you "see" metric sizes:
LENGTH
Meters are the standard unit of length in the metric system.
The smaller units are 10ths (decimeter), 100ths (centimeter), and
1000ths (millimeter) of a meter. These common examples might help you
to visualize the metric units:
* A meter is slightly longer than a yard (about 40 inches).
* An aspirin tablet is about one centimeter across (.4 inches).
* A millimeter is about the thickness of a dime.
VOLUME
Cubic meters and centimeters are used to measure volume, just
as we normally think of cubic feet and inches. Liquid volume
measurements include the liter and milliliter, like the English quarts
or ounces.
* One teaspoon is about 4 cubic centimeters.
* A liter is about one quart.
* A liter is about 61 cubic inches.
WEIGHT
The metric weight system is based on the gram, with the most
common unit being the kilogram (1000 grams). Our comparable units are
ounces and pounds:
* A kilogram is about 2.2 pounds.
* An ounce is about 28 grams.
TORQUE
Torque is somewhat complicated. The term describes the amount
of effort exerted to turn something. A chosen unit of weight or force
is applied to a lever of standard length. The resulting leverage is
called torque. In our standard system, we use the weight of one pound
applied to a lever a foot long, resulting in the unit called a foot-
pound. A smaller unit is the inch-pound (the lever is one inch long).
Metric units include the meter kilogram (lever one meter long
with a kilogram of weight applied) and the Newton-meter (lever one
Page 901 of 1691
meter long with force of one Newton applied). Some conversions are:
* A meter kilogram is about 7.2 foot pounds.
* A foot pound is about 1.4 Newton-meters.
* A centimeter kilogram (cmkg) is equal to .9 inch pounds.
PRESSURE
Pressure is another complicated measurement. Pressure is
described as a force or weight applied to a given area. Our common
unit is pounds per square inch. Metric units can be expressed in
several ways. One is the kilogram per square centimeter (kg/cm
).
Another unit of pressure is the Pascal (force of one Newton on an area
of one square meter), which equals about 4 ounces on a square yard.
Since this is a very small amount of pressure, we usually see the
kiloPascal, or kPa (1000 Pascals). Another common automotive term for
pressure is the bar (used by German manufacturers), which equals 10
Pascals. Thoroughly confused? Try the examples below:
* Atmospheric pressure at sea level is about 14.7 psi.
* Atmospheric pressure at sea level is about 1 bar.
* Atmospheric pressure at sea level is about 1 kg/cm
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* One pound per square inch is about 7 kPa.
CONVERSION FACTORS
CONVERSION FACTORS\
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LENGTH
Millimeters (mm) Inches .03937
Inches Millimeters 25.4
Meters (M) Feet 3.28084
Feet Meters .3048
Kilometers(Km) Miles .62137
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AREA
Square Centimeters (cm ) Square Inches .155
Square Inches Square Centimeters 6.45159
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VOLUME
Cubic Centimeters Cubic Inches .06103
Cubic Inches Cubic Centimeters 16.38703
Liters Cubic Inches 61.025
Cubic Inches Liters .01639
Liters Quarts 1.05672
Quarts Liters .94633
Liters Pints 2.11344
Pints Liters .47317
Liters Ounces 33.81497
Ounces Liters .02957
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WEIGHT
Grams Ounces .03527
Ounces Grams 28.34953
Kilograms Pounds 2.20462
Pounds Kilograms .45359
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WORK
Centimeter Kilograms Inch Pounds .8676
Pounds/Sq. Inch Kilograms/Sq.Centimeter .07031
Bar Pounds/Sq. Inch 14.504