diesel DODGE RAM 1999 Service Owner's Manual

CLUTCH HOUSING (RAM PICKUP)
NOTE: Only NV4500 clutch housing can be checked using the following
bore and face runout procedures. The NV1500, NV3500 and
NV5600 clutch housings are an integral part of transmission
front case and can only be checked off vehicle.
Clutch Housing Bore Runout (NV4500)
1) Remove clutch housing. Remove clutch cover and disc. See
CLUTCH ASSEMBLY under REMOVAL & INSTALLATION. Replace one flywheel
bolt with a threaded rod. See Fig. 2. Remove release fork from clutch
housing. Reinstall clutch housing. Tighten housing bolts nearest
alignment dowels first. Mount dial indicator on threaded rod and
position indicator plunger on surface of clutch housing bore. See
Fig. 4 .
2) Rotate crankshaft until indicator plunger is at top center
of housing bore. Zero dial indicator. Rotate crankshaft and record
indicator readings at 8 points, 45 degrees apart, around bore. See
Fig. 5 .
3) Repeat measurement at least twice. Subtract each reading
from one 180 degrees opposite to determine magnitude and direction of
runout. For example: 0.000" minus (-0.007") = 0.007", 0.002" minus (-\
0.010") = 0.01", 0.004" minus (-0.005") = 0.009" or -0.001" minus (0\
.
001") = -0.002" which will be 0.002". In this example, largest
difference is 0.012" (total indicator reading). This means housing
bore is offset from crankshaft centerline by 0.006" (1/2 of 0.012").
4) On gas engines, acceptable total indicator reading is 0.
010". If measured total indicator reading is more than 0.010", bore
runout will have to be corrected using offset dowels. Offset dowels
are available in 0.007", 0.014" and 0.021". See DOWEL SELECTION table.
If total indicator reading is 0.053" or greater, replace clutch
housing. If dial indicator reads positive when plunger moves inward
(toward indicator) and negative when moves outward away from
indicator), lowest or most negative reading determines direction of
housing bore offset (runout).
5) On diesel engines, offset dowels are not available to
correct runout. If total indicator reading exceeds bore runout of 0.
015", replace either clutch housing, or transmission adapter plate. On
gas engines, if bore is offset, remove housing and original dowels,
install new offset dowels in direction need to center bore with
crankshaft centerline. Install new dowels with slotted side facing
out. Using a screwdriver, rotate dowels until total indicator reading
is less than 0.010". Ensure clutch housing face runout is within
specification.
DOWEL SELECTION









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Application - In. (mm) Offset Dowel - In. (mm\
)
0.011-0.021 (0.2794-0.5334) ......................... 0.007 (0.1778\
)
0.022-0.035 (0.5588-0.8890) ......................... 0.014 (0.3556\
)
0.036-0.052 (0.9144-1.3208) ......................... 0.021 (0.5334\
)









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Fig. 3: Manufactured Stud Or Threaded Rod
Courtesy of Chrysler Corp.

gauge. Vacuum reading should be a minimum of 10 in. Hg. Turn engine
off. Vacuum should continue to hold at a minimum of 10 in. Hg.
2) If vacuum is not as specified, check for kinked or leaking
vacuum lines, defective check valve, defective vacuum reservoir or
poor engine performance. If no problems are found, check speed control
servo. See SPEED CONTROL SERVO.
Diesel Engines
1) Disconnect vacuum hose at speed control servo. Install
vacuum gauge to disconnected vacuum hose. Start engine and observe
gauge. Vacuum reading should be a minimum of 25 in. Hg. A vacuum
reservoir is not used on diesel vehicles.
2) If vacuum is not as specified, disconnect vacuum supply
hose from vacuum pump. Install vacuum gauge to vacuum pump. Start
engine and observe gauge. If vacuum reading is not 25 in. Hg or more,
replace vacuum pump. If vacuum reading 25 in. Hg or more, go to next
step.
3) Check all vacuum hoses to speed control servo, vacuum pump
and heater-A/C system for leaks. Check vacuum check valve for leaks
and proper operation. Vacuum check valve is located in vacuum hose
between speed control servo and vacuum pump. If no problems are found,
check speed control servo. See SPEED CONTROL SERVO.
CONNECTOR IDENTIFICATION
Fig. 1: Identifying Brake Switch Terminals
Courtesy of Chrysler Corp.

under VERIFICATION TESTS. If voltage is one volt or more, go to next
step.
2) Turn ignition off. Using an ohmmeter, check resistance of
RESUME/ACCEL switch ground circuit at RESUME/ACCEL switch connector.
If resistance is 5 ohms or more, repair open ground circuit. Perform
TEST VER-4A under VERIFICATION TESTS. If resistance is less than 5
ohms, repair open S/C switch signal circuit. Perform TEST VER-4A under
VERIFICATION TESTS.
VERIFICATION TESTS
TEST VER-4A
NOTE: If PCM has been replaced and correct VIN and mileage have not
been programmed, a FTC will be set in ABS and air bag
modules. If vehicle is equipped with a Sentry Key Immobilizer
Module (SKIM), sentry key data must be updated to enable
starting. See COMPUTER RELEARN PROCEDURES article in GENERAL
INFORMATION.
1) If vehicle is not equipped with a diesel engine, go to
next step. If vehicle is equipped with a diesel engine, and PCM has
been disconnected or replaced, battery has been disconnected, or
Accelerator Pedal Position Sensor (APPS) has been disconnected or
replaced, APPS calibration must be programmed into PCM (diesel only).
Turn ignition on. Slowly press accelerator pedal to floor and slowly
release. DO NOT attempt to adjust screws or disassemble APPS. Go to
next step.
2) On all engines, if vehicle is equipped with ABS or air
bag, enter correct VIN and mileage in PCM. Erase DTCs in ABS and air
bag modules. Inspect vehicle to ensure all engine and speed control
system components are connected. Reassemble and reconnect components
as necessary. Using scan tool, erase DTCs from PCM.
3) Road test vehicle at a speed greater than 35 MPH. Turn S/C
switch on. Press and release SET button. If S/C does not engage,
repair is not complete. Check for related TSBs and return to TROUBLE
SHOOTING, if necessary. If speed control engages, go to next step
4) Quickly depress and release RESUME/ACCEL switch. If
vehicle speed increases by 2 MPH, go to next step. If vehicle speed
does not increase by 2 MPH, repair is not complete. Check for related
TSBs and return to TROUBLE SHOOTING, if necessary.
5) Press and hold COAST switch. Vehicle speed should
decrease. If vehicle speed decreases, go to next step. If vehicle
speed does not decrease, repair is not complete. Check for related
TSBs and return to TROUBLE SHOOTING, if necessary.
6) Using caution, depress and release brake pedal. If S/C
disengages, go to next step. If S/C does not disengage, repair is not
complete. Check for related TSBs and return to TROUBLE SHOOTING, if
necessary.
7) Bring vehicle speed to 35 MPH. Depress speed control
RESUME/ACCEL switch. If vehicle resumes to previously set speed, go to
next step. If vehicle does not resume to previously set speed, repair
is not complete. Check for related TSBs and return to TROUBLE
SHOOTING, if necessary.
8) Hold down SET switch. Vehicle speed should decrease. If
vehicle speed decreases, go to next step. If vehicle speed did not
decrease, repair is not complete. Check for related TSBs and return to
TROUBLE SHOOTING, if necessary.
9) Ensure vehicle speed is more than 35 MPH and release SET
switch. If vehicle sets a new speed, go to next step. If vehicle did
not set a new speed, repair is not complete. Check for related TSBs
and return to TROUBLE SHOOTING, if necessary.

10) Depress and release CANCEL switch. If S/C disengages, go
to next step. If S/C did not disengage, repair is not complete. Check
for related TSBs and return to TROUBLE SHOOTING, if necessary.
11) Ensure vehicle speed is greater than 35 MPH. Engage speed
control. Turn S/C on/off switch to OFF position. If speed control
disengages, system is operating correctly. Repair is complete. If
speed control does not disengage, repair is not complete. Check for
related TSBs and return to TROUBLE SHOOTING, if necessary.
TEST VER-5A
NOTE: If PCM has been replaced and correct VIN and mileage have not
been programmed, a FTC will be set in ABS and air bag
modules. If vehicle is equipped with a Sentry Key Immobilizer
Module (SKIM), sentry key data must be updated to enable
starting. See COMPUTER RELEARN PROCEDURES article in GENERAL
INFORMATION.
1) If vehicle is not equipped with a diesel engine, go to
next step. If vehicle is equipped with a diesel engine, and PCM has
been disconnected or replaced, battery has been disconnected, or
Accelerator Pedal Position Sensor (APPS) has been disconnected or
replaced, APPS calibration must be programmed into PCM (diesel only).
Turn ignition on. Slowly press accelerator pedal to floor and slowly
release. DO NOT attempt to adjust screws or disassemble APPS. Go to
next step.
2) On all engines, if vehicle is equipped with ABS or air
bag, enter correct VIN and mileage in PCM. Erase DTCs in ABS and air
bag modules. Inspect vehicle to ensure all engine and speed control
system components are connected.
3) If there are any DTCs that have not been repaired, go to
SELF-DIAGNOSTIC SYSTEM. After all DTCs have been repaired, run
appropriate monitor for previously repaired FTC.
4) Connect scan tool to DLC. Ensure fuel tank is at least 1/4
full. Turn off all accessories. Allow PCM to run appropriate monitor
and increment appropriate good trip. Enabling conditions must be met
before monitor will run.
5) Using scan tool, monitor pretest enabling conditions until
all conditions have been met. Once enabling conditions have been met,
monitor appropriate monitor.
6) If repaired FTC has reset or was seen in monitor while on
road test, repair is not complete. Check for TSBs or flash updates and
return to TROUBLE SHOOTING.
7) If appropriate monitor ran, good trip counter incremented
and no DTCs have been set, repair is complete.
REMOVAL & INSTALLATION
WARNING: Vehicle is equipped with an air bag. Air bag must be
deactivated before servicing speed control components on or
around steering column. See AIR BAG RESTRAINT SYSTEMS -
TRUCKS article.
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.
BRAKE SWITCH
Removal

Center Carrier Bearing Bolt ................................ 50 (68)\
Pinion Nut (Minimum Torque) .............................. 210 (285\
)
Ring Gear Bolt (1)
Dakota
8 1/4" ................................................. 75 (102)\
9 1/4" ................................................. 115 (157)\
Ram Pickup ............................................... 70 (95)\
Ram Van/Wagon ........................................... 75 (102)\
Shock Absorber Nut ......................................... 60 (81)\
"U" Bolt Nut
8 1/4" Ring Gear
Dakota 2WD .............................................. 65 (88)\
Dakota 4WD ............................................ 110 (149)\
9 1/4" Ring Gears
1/2" X 20 Bolt Thread ................................... 65 (88)\
9/16" X 18 Bolt Thread ................................ 110 (149)\
"U" Joint Strap Bolt
Diesel Models ............................................ 25 (34)\
Gasoline Models .......................................... 14 (19)\
Wheel Lug Nut
Dakota .......................................... 85-110 (115-149)\
Ram Pickup
5-Lug .......................................... 80-110 (108-149)\
8-Lug (Single Wheel) .......................... 120-150 (163-203\
)
8-Lug (Dual Wheel) ............................ 130-160 (176-217\
)
Ram Van/Wagon
1/2" Stud
60-Degree Cone ............................... 80-110 (108-149)\
90-Degree Cone ............................... 85-115 (115-156)\
5/8" Stud
90-Degree Cone .............................. 175-225 (237-305)\
Flanged Nut ................................. 300-350 (407-474)\
INCH Lbs. (N.m)
Adjuster Lock Bolt ......................................... 90 (10)\
Pinion Shaft Lock Bolt ( 2) ................................. 96 (11)
( 1) - Left-hand threaded bolts.
( 2) - Apply Loctite to bolt threads.









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ELE C TR IC AL C O M PO NEN T L O CATO R

1999 D odge P ic ku p R 1500
1999 ELECTRICAL COMPONENT LOCATION
Chrysler Motors Electrical Component Location
Dodge; Ram Pickup
SAFETY PRECAUTION
WARNING: When working on vehicles equipped with Supplemental Restraint
System (SRS), never apply electrical voltage to the system.
This could cause the SRS (air bag) to be deployed.
BUZZERS, RELAYS & TIMERS









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Component Component Location








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A/C Compressor Clutch Relay On power distribution center.
Automatic Shut Down Relay On power distribution center.
Blower Motor Relay On power distribution center.
Central Timer Module Left side of dash, inboard of
steering column opening.
Combination Flasher Left side of dash, on
junction block.
Engine Starter Motor Relay On power distribution center.
Fog Lamp Relay On power distribution center.
Fuel Heater Relay (Diesel) On power distribution center.
Fuel Pump Relay On power distribution center.
Horn Relay On power distribution center.
Intake Air Heater Relay No. 1
(Diesel) On left inner fender, below
left battery.
Intake Air Heater Relay No. 2
(Diesel) On left inner fender, below
left battery.
Quad High Beam Relay On power distribution center.
Radio Choke Relay Behind center of dash, on
support.
Security Relay On power distribution center.
Trailer Tow Relay On power distribution center.
Transmission Control Relay On power distribution center.
Wiper Motor Relay On power distribution center.









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CIRCUIT PROTECTION DEVICES









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Component Component Location








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Circuit Breakers In junction block.
Junction Block Left end of dash.
Power Distribution Center In engine compartment, on left
inner fender panel, near
battery.









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CONTROL UNITS









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Component Component Location








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Air Bag Control Module Behind lower center of dash.
Controller Anti-Lock Brake (4WABS) Engine compartment, mounted on\
top of hydraulic control unit.
Controller Anti-Lock Brake (RWAL) In engine compartment, on left\
front inner fender.
Daytime Running Lamp (DRL) Module In engine compartment, on left\
inner fender panel.
Engine Control Module (Diesel) On left side of engine, behind\
fuel filter.
Fuel Pump Module Top of fuel tank.
Integrated Electronic Module Left side of dash, inboard of
steering column opening.
Powertrain Control Module (PCM) In engine compartment, on
right side of firewall.
Seat Belt Control Module Under front seat center
cushion.









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MOTORS









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Component Component Location








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Blower Motor Behind right side of dash.
Fuel Injection Pump (Diesel) On left side of engine, on
rear of timing gear housing.
Fuel Transfer Pump (Diesel) On left side of engine, below
and rearward of fuel filter.

Leak Detection Pump Right front inner fender.
Windshield Washer Pump In bottom of windshield washer
reservoir.
Windshield Wiper Motor In engine compartment, on
center of firewall.









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SENDING UNITS & SENSORS









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Component Component Location








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Accelerator Pedal Position
Sensor (Diesel) At left front of engine, below\
cable/lever/linkage cover.
Ambient Temperature Sensor Underside of hood panel, near
latch striker.
Battery Temperature Sensor Below battery tray.
Camshaft Position Sensor (3.9L) Inside distributor.
Camshaft Position Sensor (5.2L) Inside distributor.
Camshaft Position Sensor (5.9L) Inside distributor.
Camshaft Position Sensor (8.0L) In timing chain case/cover, on
left front side of engine.

cylinder block, above oil
pan rail.
Engine Coolant Temperature
Sensor (Diesel) On front of cylinder head,
near thermostat housing.
Engine Coolant Temperature
Sensor (3.9L) In water jacket, at front of
intake manifold.

Sensor (8.0L) On thermostat housing.
Engine Oil Pressure Sensor
(Diesel) On left side of engine, near
ECM.
Engine Oil Pressure Sensor
(3.9L) Near distributor.
Engine Oil Pressure Sensor
(5.2L) Near distributor.
Engine Oil Pressure Sensor
(5.9L) Near distributor.