boot DODGE RAM 1999 Service Owner's Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
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threads damaged ........ A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Dust boot missing ....... 2 ........ (1) Suggest replacement.
Dust boot split ......... 2 ........ ( 1) Suggest replacement.
Dust boot torn .......... 2 ........ ( 1) Suggest replacement.
Housing cracked ......... A ............ Require replacement.
Lead routing incorrect .. B .. Require rerouting according to
vehicle manufacturer's
specifications.
Loose ................... B ... Require adjustment to vehicle
manufacturer's specifications.
Missing ................. C ............ Require replacement.
Output signal incorrect . A .. Require repair or replacement.
Wire lead damaged ....... A .. Require repair or replacement.
( 1) - This condition can lead to damage of the sliding magnet,
which, in turn, causes premature sensor failure.
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AIR RIDE SUSPENSION - MODULES
AIR RIDE SUSPENSION - MODULE INSPECTION \
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Condition Code Procedure
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part.
Attaching hardware
missing ................ C .. Require replacement of missing
part.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Housing cracked ......... 2 .. Suggest repair or replacement.
Inoperative ............. A ............ Require replacement.
Missing ................. C ............ Require replacement.
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AIR RIDE SUSPENSION - RELAYS (COMPRESSOR)
AIR RIDE SUSPENSION - RELAY (COMPRESSOR) INSPECTION \
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Condition Code Procedure
Housing cracked ......... 2 ........ ( 1) Suggest replacement.
Intermittent ............ A ............ Require replacement.
Missing ................. C ............ Require replacement.
Output signal incorrect . A ............ Require replacement.
( 1) - If moisture enters the relay, it can reduce life
expectancy or impair function.
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AIR RIDE SUSPENSION - SWITCHES (ON/OFF)
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previously diagnosed by the "perceptible movement"
standard. Before requiring or suggesting any parts be
replaced based on "perceptible movement," consult your
repair manual to determine if OEM specifications exist.
You are not required to replace ball joints in axle sets.
However, when replacing a ball joint due to wear exceeding
manufacturer's specification, you may suggest replacement of the other
ball joint if its measurement shows it is close to the end of its
useful life, for preventive maintenance.
BALL JOINT INSPECTION
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Condition Code Procedure
Attaching hardware bent . B ... Require repair or replacement
of bent part if available;
otherwise, replace ball joint.
Attaching hardware
broken ................. A ... Require replacement of broken
part if available; otherwise,
replace ball joint.
Attaching hardware
corroded, affecting
structural integrity ... A . Require replacement of corroded
part if available; otherwise,
replace ball joint.
Attaching hardware
incorrect ............... A .......... Require replacement of
incorrect part if available;
otherwise, replace ball joint.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part if available;
otherwise, replace ball joint.
Attaching hardware
missing ................ C .. Require replacement of missing
part if available; otherwise,
replace ball joint.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads if
available; otherwise, replace
ball joint.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads if
available; otherwise, replace
ball joint.
Binding ................. A .......... (1) Further inspection
required.
Grease boot cracked ..... 2 ........ ( 2) Suggest replacement.
Grease boot missing ..... 2 ........ ( 3) Suggest replacement.
Grease boot torn ........ 2 ........ ( 4) Suggest replacement.
Grease fitting broken ... A ... Require replacement of grease
fitting.
Grease fitting missing .. C ... Require replacement of grease
fitting.
Grease fitting
won't seal ............. A ... Require replacement of grease
fitting.
Greaseable ball joint will
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not take grease ........ 2 ...... (5) Suggest replacement of
grease fitting.
Nut on ball joint loose . A ........... ( 6) Require repair or
replacement.
Pre-load adjustment
incorrect .............. B .. Require repair or replacement.
Seized .................. A ............ Require replacement.
Stud bent ............... B ........ ( 7) Require replacement.
Stud broken ............. A ........ ( 7) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ........ ( 7) Require replacement.
Wear exceeds
manufacturer's
specifications ......... B ............ Require replacement.
( 1) - If greaseable, grease ball joint. If problem persists
or joint is non-greaseable, require replacement.
( 2) - Cracked grease boot will allow contaminants to enter
the ball joint and will accelerate wear.
( 3) - Lack of grease boot will allow contaminants to enter
the ball joint and will accelerate wear.
( 4) - Torn grease boot will allow contaminants to enter the
ball joint and will accelerate wear.
( 5) - If the greaseable ball joint still will not take grease
after replacing the grease fitting, suggest replacement
of ball joint.
( 6) - Check for bent stud or damaged taper hole.
( 7) - Check for damaged taper hole.
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BUSHINGS
BUSHING INSPECTION \
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Condition Code Procedure
Attaching hardware bent . B ... Require repair or replacement
of bent part if available;
otherwise, replace bushing.
Attaching hardware
broken ................. A ... Require replacement of broken
part if available; otherwise,
replace bushing.
Attaching hardware
corroded, affecting
structural integrity ... A . Require replacement of corroded
part if available; otherwise,
replace bushing.
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part if available;
otherwise, replace bushing.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part if available;
otherwise, replace bushing.
Attaching hardware
missing ................ C .. Require replacement of missing
part if available; otherwise,
replace bushing.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
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available; otherwise, replace
center link.
Bent .................... B ............ Require replacement.
Binding ................. A ........... (1) Further inspection
required.
Grease boot cracked ..... 2 ........ ( 2) Suggest replacement.
Grease boot missing ..... 2 ........ ( 3) Suggest replacement.
Grease boot torn ........ 2 ........ ( 4) Suggest replacement.
Grease fitting broken ... A ... Require replacement of grease
fitting.
Grease fitting missing .. C ... Require replacement of grease
fitting.
Grease fitting
won't seal ............. A ... Require replacement of grease
fitting.
Grease seal missing ..... 2 ........ ( 3) Suggest replacement.
Grease seal torn ........ 2 ........ ( 4) Suggest replacement.
Looseness (perceptible
horizontal movement) ... 1 ........ ( 5) Suggest replacement.
Looseness that is
excessive .............. B ..... ( 5)( 6) Require replacement.
Seized .................. A ............ Require replacement.
Stud bent ............... B ........ ( 7) Require replacement.
Stud broken ............. A ........ ( 7) Require replacement.
Stud loose in
taper hole ............. A ........... ( 7) Require repair or
replacement.
Taper hole elongated .... A ........ ( 8) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped
(threads missing) ...... A ........ ( 7) Require replacement.
Wear exceeds
manufacturer's
specifications ......... B ............ Require replacement.
( 1) - If greaseable, grease joint. If problem persists or
joint is non-greaseable, require replacement.
( 2) - Cracked grease boot will allow contaminants to enter
the joint and will accelerate wear.
( 3) - Lack of grease boot will allow contaminants to enter
the joint and will accelerate wear.
( 4) - Torn grease boot will allow contaminants to enter the
joint and will accelerate wear.
( 5) - If manufacturer's procedures for inspection exist, use
those procedures; otherwise, use an approved inspection
method such as the dry park check.
CAUTION: DO NOT use pliers or pry bar to check ball and socket
movement. Use only moderate hand pressure.
( 6) - Excessive looseness is defined as being significant
enough to affect vehicle handling or structural
integrity.
( 7) - Check for damaged taper hole.
( 8) - Check for damaged stud.
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CONTROL ARM SHAFTS
CONTROL ARM SHAFT INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require replacement of broken
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if available; otherwise,
replace control arm.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
control arm.
Bent .................... B ............ Require replacement.
Bushing hole oversized .. B ............ Require replacement.
Ball joint hole oversized
(loose interference or
press fit) ............. B .......... (1) Further inspection
required.
Corroded, affecting
structural integrity ... A ............ Require replacement.
Holes distorted ......... A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - If oversized ball joint is available, require
replacement of ball joint. If oversized ball joint
is not available, require replacement of control arm.
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DRAG LINKS
DRAG LINK INSPECTION \
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Condition Code Procedure
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace drag link.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace drag link.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace drag link.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace drag link.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
drag link.
Bent .................... B ............ Require replacement.
Binding ................. A .......... ( 1) Further inspection
required.
Grease boot cracked ..... 2 ........ ( 2) Suggest replacement.
Grease boot missing ..... 2 ........ ( 3) Suggest replacement.
Grease boot torn ........ 2 ........ ( 4) Suggest replacement.
Grease fitting broken ... A ... Require replacement of grease
fitting.
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Grease fitting missing .. C ... Require replacement of grease
fitting.
Grease fitting
won't seal ............. A ... Require replacement of grease
fitting.
Grease seal missing ..... 2 ........ (5) Suggest replacement.
Grease seal torn ........ 2 ........ ( 4) Suggest replacement.
Looseness (perceptible
horizontal movement) ... 1 ........ ( 6) Suggest replacement.
Looseness that is
excessive .............. B ..... ( 6)( 7) Require replacement.
Seized .................. A ............ Require replacement.
Stud bent ............... B ........ ( 8) Require replacement.
Stud broken ............. A ........ ( 8) Require replacement.
Stud loose in
taper hole ............. A ........... ( 8) Require repair or
replacement.
Taper hole elongated .... A ........ ( 9) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ........ ( 8) Require replacement.
Wear exceeds
manufacturer's
specifications ......... B ............ Require replacement.
( 1) - If greaseable, grease joint. If problem persists or
joint is non-greaseable, require replacement.
( 2) - Cracked grease boot will allow contaminants to enter
the joint and will accelerate wear.
( 3) - Lack of grease boot will allow contaminants to enter
the joint and will accelerate wear.
( 4) - Torn grease boot will allow contaminants to enter the
joint and will accelerate wear.
( 5) - Missing grease seal will allow contaminants to enter
the joint and will accelerate wear.
( 6) - If manufacturer's procedures for inspection exist, use
those procedures; otherwise, use an approved inspection
method such as the dry park check.
CAUTION: DO NOT use pliers or pry bar to check ball and
socket movement. Use only moderate hand pressure.
( 7) - Excessive looseness is defined as being significant
enough to affect vehicle handling or structural
integrity.
( 8) - Check for damaged taper hole.
( 9) - Check for damaged stud.
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ELECTRONIC RIDE CONTROL SHOCKS AND STRUTS
NOTE: This section covers the electronic damping control portion
of the electronic shock or strut. For dampening portion of
shock or strut conditions and procedures, refer to the
SHOCK ABSORBERS, STRUT CARTRIDGES AND STRUT ASSEMBLIES
section.
ELECTRONIC RIDE CONTROL SHOCK AND STRUT INSPECTION
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Condition Code Procedure
Connector bent .......... A .. Require repair or replacement.
Connector broken ........ A .. Require repair or replacement.
Connector loose ......... A .. Require repair or replacement.
Electronic valve control
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inoperative ............ 2 ........ (1) Suggest replacement.
Terminal bent ........... A .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal corroded ....... A .. Require repair or replacement.
Terminal loose .......... A .. Require repair or replacement.
( 1) - It is acceptable to replace with a non-electronically
controlled unit, where available.
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IDLER ARMS
IDLER ARM INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require replacement of broken
part, if available; otherwise,
replace idler arm.
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace idler arm.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace idler arm.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace idler arm.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace idler arm.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
idler arm.
Binding ................. A .......... ( 1) Further inspection
required.
Grease boot cracked ..... 2 ........ ( 2) Suggest replacement.
Grease boot missing ..... 2 ........ ( 3) Suggest replacement.
Grease boot torn ........ 2 ........ ( 4) Suggest replacement.
Grease fitting broken ... A ... Require replacement of grease
fitting.
Grease fitting missing .. C ... Require replacement of grease
fitting.
Grease fitting
won't seal ............. A ... Require replacement of grease
fitting.
Grease seal missing ..... 2 ........ ( 5) Suggest replacement.
Grease seal torn ........ 2 ........ ( 4) Suggest replacement.
Greaseable joint will not
take grease ............ 2 ...... ( 1) Suggest replacement of
grease fitting.
Looseness at frame
bracket end ............ B ........ ( 6)( 7) Require repair or
replacement.
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Looseness at link end
(perceptible horizontal
movement) .............. 1 ........ (8) Suggest replacement.
Looseness at link end
that is excessive ...... B ..... ( 8)( 9) Require replacement.
Mounted out of position
(center link
not parallel) .......... B .......... Require repositioning.
Nut on stud loose ....... A .......... ( 10) Require repair or
replacement.
Seized .................. A ............ Require replacement.
Stud bent ............... B ....... ( 11) Require replacement.
Stud broken ............. A ....... ( 11) Require replacement.
Taper hole elongated .... A ....... ( 12) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ....... ( 11) Require replacement.
Wear exceeds
manufacturer's
specifications ......... B ............ Require replacement.
( 1) - If greaseable, grease joint. If problem persists or
joint is non-greaseable, require replacement.
( 2) - Cracked grease boot will allow contaminants to enter
joint and will accelerate wear.
( 3) - Lack of grease boot will allow contaminants to enter
joint and will accelerate wear.
( 4) - Torn grease boot will allow contaminants to enter
joint and will accelerate wear.
( 5) - Missing grease seal will allow contaminants to enter
joint and will accelerate wear.
( 6) - If manufacturer's procedures and specifications exist,
use those procedures and specifications; otherwise, use
an approved inspection method such as the dry park check.
( 7) - Looseness is defined as movement that creates excessive
toe change.
( 8) - If manufacturer's procedures for inspection exist, use
those procedures; otherwise, use an approved inspection
method such as the dry park check.
CAUTION: DO NOT use pliers or pry bar to check ball and
socket movement. Use only moderate hand pressure.
( 9) - Excessive looseness is defined as significant enough
to affect vehicle handling or structural integrity.
( 10 ) - Check for bent stud or damaged taper hole.
( 11 ) - Check for damaged taper hole.
( 12 ) - Check for damaged stud.
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KING PINS
You are not required to replace king pins in axle sets.
However, when replacing a king pin due to wear exceeding
manufacturer's specifications, you may suggest replacement of the
other king pin on the axle if its measurement shows it is close to the
end of its useful life.
KING PIN INSPECTION
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Condition Code Procedure
Bearing balls pitted .... A ........... Require replacement.
Bearing balls worn ...... A ........... Require replacement.
Bearing races pitted .... A ........... Require replacement.
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replace pitman arm.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
pitman arm.
Bent .................... B ............ Require replacement.
Binding ................. A .......... (1) Further inspection
required.
Grease boot cracked ..... 2 ........ ( 2) Suggest replacement.
Grease boot missing ..... 2 ........ ( 3) Suggest replacement.
Grease boot torn ........ 2 ........ ( 4) Suggest replacement.
Grease fitting broken ... A ...... Require replacement grease
fitting.
Grease fitting missing .. C ... Require replacement of grease
fitting.
Grease fitting
won't seal ............. A ... Require replacement of grease
fitting.
Grease seal missing ..... 2 ......... ( 3) Suggest replacement
of seal.
Grease seal torn ........ 2 ......... ( 4) Suggest replacement
of seal.
Looseness (perceptible
horizontal movement) ... 1 ........ ( 5) Suggest replacement.
Looseness that is
excessive .............. B ..... ( 5)( 6) Require replacement.
Nut on stud loose ....... A ........... ( 7) Require repair or
replacement.
Seized .................. A ............ Require replacement.
Splines damaged ......... A .. Require repair or replacement.
Splines stripped
(splines missing) ...... A ............ Require replacement.
Stud bent ............... B ........ ( 8) Require replacement.
Stud broken ............. A ........ ( 8) Require replacement.
Stud loose in
taper hole ............. A ........... ( 8) Require repair or
replacement.
Taper hole elongated .... A ........ ( 9) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ........ ( 8) Require replacement.
( 1) - If greaseable, grease joint. If problem persists or
joint is non-greaseable, require replacement.
( 2) - Cracked grease boot will allow contaminants to enter
joint and will accelerate wear.
( 3) - Lack of grease boot will allow contaminants to enter
joint and will accelerate wear.
( 4) - Torn grease boot will allow contaminants to enter joint
and will accelerate wear.
( 5) - If manufacturer's procedures for inspection exist, use
those procedures; otherwise, use an approved inspection
method such as the dry park check.
CAUTION: DO NOT use pliers or pry bar to check ball and socket
movement. Use only moderate hand pressure.
( 6) - Excessive looseness is defined as being significant
enough to affect vehicle handling or structural integrity.
( 7) - Check for bent stud of damaged taper hole.
( 8) - Check for damaged taper hole.
( 9) - Check for damaged stud.
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Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Bent .................... B ............ Require replacement.
Corroded, affecting
structural integrity ... A ............ Require replacement.
Holes distorted ......... A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped
(threads missing) ...... A ............ Require replacement.
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RELAY RODS
RELAY ROD INSPECTION \
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Condition Code Procedure
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace relay rod.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace relay rod.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace relay rod.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace relay rod.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
relay rod.
Bent .................... B ............ Require replacement.
Binding ................. A .......... ( 1) Further inspection
required.
Grease boot cracked ..... 2 ........ ( 2) Suggest replacement.
Grease boot missing ..... 2 ........ ( 3) Suggest replacement.
Grease boot torn ........ 2 ........ ( 4) Suggest replacement.
Grease fitting broken ... A ...... Require replacement grease
fitting.
Grease fitting missing .. C ... Require replacement of grease
fitting.
Grease fitting
won't seal ............. A ... Require replacement of grease
fitting.
Grease seal missing ..... 2 ........ ( 3) Suggest replacement.
Grease seal torn ........ 2 ........ ( 4) Suggest replacement.
Looseness (perceptible
horizontal movement) ... 1 ........ ( 5) Suggest replacement.
Looseness that is
excessive .............. B ..... ( 5)( 6) Require replacement.
Seized .................. A ............ Require replacement.
Stud bent ............... B ........ ( 7) Require replacement.