transmission DODGE RAM 1999 Service Repair Manual

converter lock-up. ECM uses various input signals such as transmission
temperature, output shaft speed, central module timer, engine speed,
APPS and brake switch position to determine operation of transmission
torque converter clutch solenoid. Transmission torque converter clutch
solenoid is located on transmission valve body.
FUEL SYSTEM
FUEL DELIVERY
Fuel Injection Pump
A camshaft-driven Bosch VP44 in-line fuel injection pump is
used to supply high pressure fuel to each fuel injector in precise
metered amounts at the correct time. See Fig. 2. The pump is timed to
camshaft gear. Pump output is controlled by integral Fuel Pump Control
Module (FPCM). Because of electronic control, idle speeds and pump
timing are not adjustable. See ON-VEHICLE ADJUSTMENTS - TRUCKS -
DIESEL article. FPCM can operate engine if crankshaft position sensor
signal does not exist. Fuel injection occurs near completion of
compression stroke for each cylinder.
Fuel injection pump contains an overflow valve which allows
excess fuel to return to the fuel tank. Overflow valve is located on
side of fuel injection pump and is used to attach the fuel return line
to the fuel injection pump.
Fuel Transfer Pump
Fuel transfer pump is located on driver's side of cylinder
block, above starter. See Fig. 2. A 12 volt, 12-amp electric vane-type
pump supplies low fuel pressure from fuel tank, through fuel
heater/fuel filter/water separator to fuel injection pump. Fuel
transfer pump contains internal check valves to prevent fuel from
bleeding back into fuel tank during engine shutdown. Pump will self
prime with ignition on for 2 seconds. Pump has 2 modes, 100 percent
duty cycle (10 psi) when engine is running and 25 percent duty cycle
(7 psi) when engine is cranking.
Fuel Filter/Water Separator
Fuel filter/water separator, located on left side of engine,
protects injection pump by removing water and contaminants from fuel.
See Fig. 2 . Assembly also includes fuel heater and Water-In-Fuel (WIF)
sensor.
In-Tank Fuel Filter
A separate in-tank fuel filter is attached to bottom of fuel
tank module. In-tank fuel filter does not require service under normal
conditions.
FUEL CONTROL
Fuel Injector
Fuel injector delivers atomized fuel into the cylinder.
During fuel injection, fuel pressure from fuel injection pump
increases to fuel injector opening pressure or pop pressure of 4500
psi (316 kg/cm

). This is the pressure required to lift fuel injector
needle valve from its seat, allowing fuel to be injected into the
cylinder. Once fuel pressure decreases to less then the opening
pressure, a spring forces needle valve closed and stops fuel injection
into the cylinders. Each fuel injector is connected to injection pump
by a high pressure (as much as 17,405 psi) line.
Fuel Injection Timing
Pump output is controlled by integral Fuel Pump Control

using DLC and a scan tool. The DLC also provides a means to
communicate with various vehicle control modules, check system
operating conditions and to operate various system components.
MALFUNCTION INDICATOR LIGHT (MIL)
The MIL is located on the instrument panel, just below
tachometer and may also be referred to as the CHECK ENGINE light. MIL
comes on for a short period and then goes off as a bulb and wiring
circuit test each time ignition switch is turned to the ON position.
If Engine Control Module (ECM) receives an incorrect signal or
receives no signal from certain sensors or components, ECM will turn
on the MIL to warn the driver that a malfunction exists in the
electronic system.
MISCELLANEOUS CONTROLS
TRANSMISSION
Transmission Overdrive Solenoid (A/T Models)
Engine Control Module (ECM) operates transmission overdrive
solenoid for controlling transmission overdrive shifts. Transmission
overdrive solenoid is located on transmission valve body.
Transmission Torque Converter Clutch Solenoid (A/T Models)
Engine Control Module (ECM) operates transmission torque
converter clutch solenoid for torque converter lock-up. ECM uses
various input signals such as transmission temperature, output shaft
speed, central module timer, engine speed, APPS and brake switch
position to determine operation of transmission torque converter
clutch solenoid. Torque converter clutch solenoid is located on
transmission valve body.

Power Steering Pressure Switch
On 2.5L Dakota only, power steering pressure switch sends a
signal to PCM. PCM will raise idle speed to prevent stalling during
high power steering pressure (375-575 psi), low RPM conditions.
Serial Communication Interface (SCI) Receive
SCI receive circuit is a serial communication link used when
diagnosing vehicle using scan tool. PCM receives data and device
activation commands from scan tool on this circuit.
Throttle Position (TP) Sensor
TP sensor monitors opening angle of throttle blade. TP sensor
will vary output voltage from about .26 volt at minimum throttle
opening (idle), to about 4.5 volts at Wide Open Throttle (WOT). PCM
uses this information and other sensor inputs to determine engine
operation. In response, PCM will adjust fuel injection pulse width and
ignition timing.
Transmission Governor Pressure Sensor (A/T Models)
Sensor sends PCM a signal indicating governor pressure. PCM
uses signal as feedback for governor solenoid control.
Transmission Overdrive/Override (OD/OR) Switch (A/T Models)
On models with Overdrive (OD), PCM regulates 3-4 OD upshift
and downshift through OD solenoid. Transmission OD/OR switch is
mounted in instrument panel.
OD/OR switch is normally closed. If OD/OR switch is depressed
and it opens, transmission will not enter OD. Transmission will
downshift if it is in OD and OD/OR switch is depressed.
OD/OR switch circuit includes a transmission fluid
temperature sensor. If this sensor opens, transmission will not shift
into overdrive, or will downshift if already in overdrive.
Transmission Temperature Sensor (A/T Models)
Transmission temperature sensor monitors transmission fluid
temperature and sends an input signal to PCM. Input signal is used for
controlling torque converter clutch operation, overdrive shifts, low
temperature shift compensation, wide open throttle shift strategy and
governor pressure. Transmission temperature sensor is located in
transmission valve body, incorporated into governor pressure sensor.
If transmission fluid temperature is more than 260
F (126C),
PCM forces a 4-3 downshift and engages torque converter clutch until
fluid cools. Once fluid cools to less than 230
F (110C), PCM allows a
3-4 shift. PCM prevents torque converter clutch engagement and
overdrive operation when fluid temperature is less than 50
F (10C).
Vehicle Speed Sensor (VSS)
VSS generates 8 pulses per sensor revolution. VSS input is
used by PCM to determine vehicle speed and distance traveled, and to
maintain set speed during cruise control operation.
PCM interprets speed sensor input along with TP sensor closed
throttle input. This enables PCM to determine if a closed throttle
deceleration or normal throttle idle (vehicle stopped) condition
exists. During deceleration, PCM controls IAC motor to maintain a
desired MAP value. During idle (vehicle stopped), PCM controls IAC
motor to maintain a desired idle speed.
OUTPUT SIGNALS
NOTE: Each vehicle may be equipped with different combinations of
computer-controlled components. The following components may
NOT be used on all models. To determine component location
and output usage on a specific model, see appropriate wiring

Transmission Governor Pressure Solenoid
See TRANSMISSION GOVERNOR SOLENOID under MISCELLANEOUS
CONTROLS.
Transmission Overdrive/Override (OD/OR) Switch Indicator
Light
See TRANSMISSION OVERDRIVE/OVERRIDE (OD/OR) SWITCH INDICATOR
under MISCELLANEOUS CONTROLS.
Transmission Overdrive (OD) Solenoid
See TRANSMISSION OVERDRIVE (OD) SOLENOID under MISCELLANEOUS
CONTROLS.
FUEL SYSTEM
FUEL DELIVERY
Auto Shutdown (ASD) Relay
See AUTO SHUTDOWN (ASD) RELAY & FUEL PUMP RELAY under
MISCELLANEOUS CONTROLS.
Fuel Pressure Regulator
Fuel pressure regulator is a mechanical device, used to
maintain a constant pressure across fuel injector tip. Spring and
rubber diaphragm will move from an open to closed position keeping
fuel pressure constant. Excess fuel is returned to fuel tank.
Regulator is located in in-tank fuel pump module. Regulator
includes an internal fuel filter. Excess fuel is routed directly into
fuel tank without using a return line. See Fig. 2.
Fig. 2: Cross-Sectional View Of In-Tank Fuel Filter/Fuel Pressure
Regulator (Typical)
Courtesy of Chrysler Corp.
In-Tank Fuel Pump

PCM controls operation of electric cooling fan. PCM operates fan
through radiator fan relay by grounding or ungrounding relay control
circuit. PCM regulates engine idle speed through IAC motor when fan is
on.
SHIFT INDICATOR LIGHT
PCM provides ground for shift indicator light on models
equipped with manual transmission. Based on engine speed, throttle
position, and vehicle speed, PCM turns shift indicator light on to
advise driver to shift to a higher gear for optimum fuel economy.
SPEED CONTROL SERVO
System is electrically actuated and vacuum operated. Controls
are located on steering wheel. Controls consist of 3 buttons: OFF/ON,
RESUME/ACCEL and SET/DECEL. Speed control servo is controlled by PCM.
System will operate at 35-85 MPH.
TACHOMETER
PCM provides signal to drive tachometer.
TORQUE CONVERTER CLUTCH (TCC) SOLENOID
PCM controls torque converter lock-up through TCC solenoid.
PCM controls lock-up according to various operating conditions.
TRANSMISSION GOVERNOR SOLENOID
PCM controls solenoid to regulate line pressure for shift
control.
TRANSMISSION OVERDRIVE/OVERRIDE (OD/OR) SWITCH INDICATOR
LIGHT
PCM controls indicator light on OD/OR switch on models
equipped with overdrive automatic transmission.
TRANSMISSION OVERDRIVE (OD) SOLENOID
On models equipped with OD transmission, PCM controls 3-4 OD
upshift and downshift through OD solenoid. PCM determines optimum OD
shift scheduling for all operating conditions.

TR AN SM IS SIO N R EM OVA L & IN STA LLA TIO N

1999 D odge P ic ku p R 1500
1998-99 TRANSMISSION SERVICING
CHRY - Trans Removal & Installation - Trucks & RWD Vans
Dakota, Ram Pickup, Ram Van/Wagon
WARNING: 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.
MANUAL TRANSMISSION
NOTE: For manual transmission replacement procedures, see
appropriate article in CLUTCHES.
AUTOMATIC TRANSMISSION
DAKOTA & DURANGO
Removal
1) Disconnect negative battery cable. Raise and support
vehicle. Disconnect and remove necessary skid plates and exhaust
components for transmission removal. Remove engine-to-transmission
struts (if equipped). These struts are located between front of
transmission and engine.
2) Ensure area around transmission oil cooler lines fitting
are clean. Disengage retainer on quick-disconnect cooler line fitting.
Pull cooler line from transmission oil cooler.
CAUTION: Crankshaft position sensor must be removed from transmission
housing before removing transmission to prevent damage to
crankshaft position sensor.
3) Remove starter. Disconnect electrical connector for
crankshaft position sensor. On 2.5L, crankshaft position sensor is
mounted on driver's side of transmission housing. See Fig. 1. On 3.9L,
5.2L and 5.9L, crankshaft position sensor is mounted on passenger's
side of transmission housing. See Fig. 2.
4) Remove crankshaft position sensor bolts or nuts. Remove
crankshaft position sensor from transmission housing. Remove dipstick,
dipstick tube and "O" ring from transmission.
5) Remove torque converter cover. Place reference mark on
flexplate and torque converter for installation reference. Rotate
crankshaft clockwise and remove torque converter bolts.
6) Place reference mark on drive shaft flanges for
installation reference. Remove drive shaft from transmission. On 4WD
models, disconnect drive shaft from transfer case. Disconnect shift
rod for transfer case from transfer case shift lever.
7) On all models, disconnect necessary control cables, wiring
harnesses, and shift linkage or cable from transmission. Support rear
of engine with jack stand. Using transmission jack, slightly raise
transmission to release pressure from rear mount and rear crossmember.
8) Remove bolts securing rear support and rear mount to
transmission and rear crossmember. Raise transmission slightly. Slide
exhaust hanger arm from bracket on rear support. Remove rear support
and rear mount.
9) Remove rear crossmember located below the transmission. On
4WD models, disconnect electrical connectors from transfer case. On

all models, remove transmission-to-cylinder block bolts. Slide
transmission rearward from dowels on cylinder block.
10) Install "C" clamp on edge of transmission housing to hold
torque converter in place. Lower transmission and remove transmission
from vehicle.
Fig. 1: Locating Crankshaft Position Sensor (2.5L)
Courtesy of Chrysler Corp.
Fig. 2: Locating Crankshaft Position Sensor (3.9L, 5.2L & 5.9L
Gasoline)

Courtesy of Chrysler Corp.
Installation
1) To install, reverse removal procedure. Ensure torque
converter is fully seated in transmission by measuring distance from
cylinder block surface on transmission housing to front edge on torque
converter bolt lug on front of torque converter. Distance should be .
50" (12.7 mm) if torque converter is fully seated.
CAUTION: Proper length torque converter bolts must be used. If
replacing any torque converter bolts, ensure proper length
bolt is used.
2) Tighten bolt/nuts to specification. See TORQUE
SPECIFICATIONS. Ensure reference mark on torque converter and
flexplate, and drive shaft flanges are aligned. Adjust shift cable or
linkage, throttle valve cable and transfer case shift linkage if
necessary. See AUTOMATIC TRANSMISSION - TRUCKS & RWD VANS article.
3) Use NEW "O" ring when installing dipstick tube. Before
installing oil cooler lines on transmission, ensure all fittings are
clean. Install oil cooler line into quick-disconnect fitting. Push oil
cooler line inward until a click is heard. Pull on oil cooler line to
ensure oil cooler line is locked in place. Fill transmission with
Mopar ATF Plus Type 7176.
RAM PICKUP
Removal
1) Disconnect negative battery cable. Raise and support
vehicle. Disconnect and remove necessary skid plates and exhaust
components for transmission removal. Remove engine-to-transmission
struts (if equipped). These struts are located between front of
transmission and engine.
2) Ensure area around transmission oil cooler lines fitting
are clean. Disengage retainer on quick-disconnect cooler line fitting.
Pull cooler line from transmission oil cooler. Remove starter.
CAUTION: On 3.9L, 5.2L and 5.9L gasoline models, crankshaft position
sensor must be removed from transmission housing before
removing transmission to prevent damage to crankshaft
position sensor.
3) On 3.9L, 5.2L and 5.9L gasoline models, disconnect
electrical connector for crankshaft position sensor. Crankshaft
position sensor is mounted on passenger's side of transmission
housing. See Fig. 2.
4) Remove crankshaft position sensor bolts. Remove crankshaft
position sensor from transmission housing. Remove dipstick, dipstick
tube and "O" ring from transmission.
5) Remove torque converter cover. Place reference mark on
flexplate and torque converter for installation reference. Rotate
crankshaft clockwise and remove torque converter bolts.
6) Place reference mark on drive shaft flanges for
installation reference. Remove drive shaft from transmission. On 4WD
models, disconnect drive shaft from transfer case. Disconnect shift
rod for transfer case from transfer case shift lever.
7) On all models, disconnect necessary control cables, wiring
harnesses, and shift linkage from transmission. Support rear of engine
with jack stand. Using transmission jack, slightly raise transmission
to release pressure from rear mount and rear crossmember.
8) Remove bolts securing rear support and rear mount to
transmission and rear crossmember. Raise transmission slightly. Slide
exhaust hanger arm from bracket on rear support. Remove rear support

and rear mount.
9) Remove rear crossmember located below the transmission. On
4WD models, disconnect electrical connectors from transfer case. On
all models, remove transmission-to-cylinder block bolts. Slide
transmission rearward from dowels on cylinder block.
10) Install "C" clamp on edge of transmission housing to hold
torque converter in place. Lower transmission and remove transmission
from vehicle.
Installation
1) To install, reverse removal procedure. Ensure torque
converter is fully seated in transmission by measuring distance from
cylinder block surface on transmission housing to front edge on torque
converter bolt lug on front of torque converter. Distance should be .
50" (12.7 mm) if torque converter is fully seated.
CAUTION: Proper length torque converter bolts must be used. If
replacing any torque converter bolts, consult parts
department to ensure proper length bolt is used.
2) Tighten bolt/nuts to specification. See TORQUE
SPECIFICATIONS. Ensure reference mark on torque converter and
flexplate, and drive shaft flanges are aligned. Adjust shift linkage,
throttle valve cable and transfer case shift linkage if necessary. See
AUTOMATIC TRANSMISSION - TRUCKS & RWD VANS article.
3) Use NEW "O" ring when installing dipstick tube. Before
installing oil cooler lines on transmission, ensure all fittings are
clean. Install oil cooler line into quick-disconnect fitting. Push oil
cooler line inward until a click is heard. Pull on oil cooler line to
ensure oil cooler line is locked in place. Fill transmission with
Mopar ATF Plus Type 7176.
RAM VAN/WAGON
Removal
1) Disconnect negative battery cable. Raise and support
vehicle. Remove engine-to-transmission struts. These struts are
located between front of transmission and engine.
2) Remove starter and oil cooler line bracket. Ensure area
around transmission oil cooler lines fitting are clean. Disengage
retainer on quick-disconnect cooler line fitting. Pull cooler line
from transmission oil cooler.
CAUTION: Crankshaft position sensor must be removed from transmission
housing before removing transmission to prevent damage to
crankshaft position sensor.
3) Disconnect electrical connector for crankshaft position
sensor. Crankshaft position sensor is mounted on passenger's side of
transmission housing. See Fig. 2.
4) Remove crankshaft position sensor bolts. Remove crankshaft
position sensor from transmission housing. Remove dipstick, dipstick
tube and "O" ring from transmission.
5) Remove torque converter cover. Place reference mark on
flexplate and torque converter for installation reference. Rotate
crankshaft clockwise and remove torque converter bolts.
6) Place reference mark on drive shaft yokes for installation
reference. Remove drive shaft from transmission. Disconnect necessary
wiring harnesses and control cables from transmission. Support rear of
engine with hoist. Using transmission jack, slightly raise
transmission to release pressure from rear mount and crossmember.
7) Remove rear mount-to-rear crossmember bolts. Remove bolts
and rear crossmember located below the transmission. Remove engine oil

filter (if necessary). Remove transmission-to-cylinder block bolts.
Slide transmission rearward from dowels on cylinder block.
8) Install "C" clamp on edge of transmission housing to hold
torque converter in place. Lower transmission and remove transmission
from vehicle.
Installation
1) To install, reverse removal procedure. Ensure torque
converter is fully seated in transmission by measuring distance from
cylinder block surface on transmission housing to front edge on torque
converter bolt lug on front of torque converter. Distance should be .
50" (12.7 mm) if torque converter is fully seated.
CAUTION: Proper length torque converter bolts must be used. If
replacing any torque converter bolts, ensure proper length
bolt is used.
2) Ensure proper length torque converter bolts are used in
accordance with torque converter diameter and number of torque
converter bolt lugs on front of torque converter. See TORQUE CONVERTER
BOLT APPLICATION table.
TORQUE CONVERTER BOLT APPLICATION









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Torque Converter Diameter Bolt Length
In. (mm)\
9.50" (241.0 mm) 3-Bolt Lug Torque Converter ............ .46 (11.7\
)
9.50" (241.0 mm) 4-Bolt Lug Torque Converter ............ .52 (13.2\
)
10.00" (254.0 mm) 4-Bolt Lug Torque Converter ........... .52 (13.2\
)
10.75" (273.0 mm) 4-Bolt Lug Torque Converter ........... .44 (11.2\
)









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3) Tighten bolt/nuts to specification. See TORQUE
SPECIFICATIONS. Ensure reference mark on torque converter and
flexplate, and drive shaft yokes are aligned. Adjust shift cable and
throttle valve cable if necessary. See AUTOMATIC TRANSMISSION - TRUCKS
& RWD VANS article.
4) Use NEW "O" ring when installing dipstick tube. Before
installing oil cooler lines on transmission, ensure all fittings are
clean. Install oil cooler line into quick-disconnect fitting. Push oil
cooler line inward until a click is heard. Pull on oil cooler line to
ensure oil cooler line is locked in place. Fill transmission with
Mopar ATF Plus Type 7176.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (DAKOTA & DURANGO)








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Application Ft. Lbs.
Crankshaft Position Sensor Bolt/Nut
2.5L ..................................................... 14 (19)\
3.9L, 5.2L & 5.9L ............................................ ( 1)
Front Drive Shaft Universal Joint Strap-To-Transfer
Case Flange Bolt ......................................... 20 (27)\
Rear Crossmember Bolt ...................................... 50 (68)\
Rear Drive Shaft Center Bearing-To-Crossmember Bolt ........ 50 (68)\
Rear Drive Shaft Universal Joint Strap-To-Rear
Axle Flange Bolt ......................................... 14 (19)\
Starter Bolt
2.5L ..................................................... 33 (45)\