DODGE RAM 1999 Service Repair Manual
Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 371 of 1691
Fig. 4: Measuring Clutch Housing Bore
Courtesy of Chrysler Corp.
Fig. 5: Measurement Of Clutch Housing Bore (Example)
Courtesy of Chrysler Corp.
Clutch Housing Face Runout (NV4500)
1) After performing a clutch housing bore runout check,
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reposition dial indicator plunger on housing face. Place indicator
plunger at rim of housing bore. See Fig. 6. Rotate crankshaft until
indicator plunger is at 10 o'clock position on bore. Zero dial
indicator. Measure and record face runout at 4 points 90 degrees apart
around housing face. See Fig. 7.
2) Perform measurement at least twice. Subtract lowest
reading from highest. For example: 0.009" minus (-0.004")=0.013".
Total allowable face runout is 0.010".
3) Correct housing face runout by installing shims between
clutch housing and transmission. Shims have to be made using shim
stock or similar materials. Use clutch housing face measurement
illustration as an example. See Fig. 7. Three shims will be needed.
Shim thicknesses should be 0.009" at 0.000 corner, 0.012" at -0.003
corner and 0.013" at -0.004 corner.
Fig. 6: Measuring Clutch Housing Face
Courtesy of Chrysler Corp.
Fig. 7: Measurement Of Clutch Housing Face (Example)
Courtesy of Chrysler Corp.
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REMOVAL & INSTALLATION
TRANSFER CASE
CAUTION: When removing transfer case, DO NOT allow drive shafts to
hang free, as damage to "U" joints may result.
Removal (NV231HD, NV241HD & NV241LD - Ram Pickup)
1) Raise and support vehicle. Remove skid plate (if
equipped). Drain lubricant from transfer case if transfer case is
being repaired. Mark drive shafts and "U" joints for reassembly
reference. Disconnect speed sensor wires. Disconnect vent harness and
vent hose from transfer case switch.
2) Disconnect shift rod from grommet in transfer case shift
lever, or from floor arm, whichever provides easy access. Using slip
joint pliers, press rod out of lever grommet. See Fig. 8. Support
transmission with jackstand. Remove rear crossmember. Remove front and
rear drive shafts. Remove transfer case-to-transmission housing nuts.
Using transmission jack, support transfer case. Move transfer case
rearward until free of transmission. Remove transfer case from under
vehicle.
Removal (NV231 & NV242 - Dakota)
1) Shift transfer case into neutral. Raise vehicle. If
transfer case will be repaired, drain lubricant. Mark driveshafts and
"U" joints for reassembly reference. Support transmission with
jackstand. Remove rear crossmember and skid plate, if equipped.
2) Disconnect front and rear driveshafts at transfer case.
Disconnect transfer case linkage rod from shift lever. Disconnect
transfer case vent hose and electrical connectors. Support transfer
case with transmission jack. Remove nuts attaching transfer case to
transmission. Remove transfer case.
Installation (All Models)
To install, reverse removal procedure. If necessary fill
transfer case with MOPAR ATF Plus or Dexron-II. Tighten all nuts and
bolts to specification. See TORQUE SPECIFICATIONS table. Adjust shift
linkage, if necessary. See SHIFT LINKAGE ADJUSTMENT under ADJUSTMENTS.
Fig. 8: Removing Transfer Case Shift Mechanism (NV4500 & NV4500HD)
Courtesy of Chrysler Corp.
TRANSMISSION (DAKOTA)
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Removal (AX15 & NV1500)
1) Shift gear selector into 1st or 3rd gear. Raise and
support vehicle. Disconnect necessary exhaust system components.
Remove "Y" pipe and position remaining pipes for working clearance.
Support transmission adjustable jackstand. Disconnect rear cushion and
mounting bracket from transmission or transfer case.
2) Remove rear crossmember. If transmission will be
disassembled for repair, drain transmission fluid. Disconnect
transmission shift linkage, speedometer cable, transfer case vacuum
lines and clutch hydraulic lines. Lower transmission/transfer case
assembly no more than 3" (76 mm). Reaching around transmission case,
unseat and lift shift lever dust boot. Press shift lever retainer
downward, turn retainer counterclockwise, and lift lever and retainer
out of shift tower.
3) Mark front and rear drive shaft and "U" joint for
reassembly reference. Disconnect and remove both drive shafts. Remove
crankshaft position sensor (AX15). Disconnect transmission/transfer
case assembly vent hoses. Remove slave cylinder from clutch housing.
Remove wire harness from clips on transmission case and transfer case.
4) Support transmission/transfer case assembly with
transmission jack. Secure assembly to jack with safety chains.
Reposition adjustable jackstand under engine. Remove clutch housing
brace rod. Remove clutch housing nuts and bolts. Remove
transmission/transfer case assembly.
Installation
To install, reverse removal procedure. Apply high-temperature
grease to release fork, lever, pivot ball stud and pilot bushing
located in end of crankshaft. Fill transmission with appropriate
fluid, if necessary. Tighten all nuts and bolts to specification. See
TORQUE SPECIFICATIONS table.
Removal (NV 3500)
1) Disconnect negative battery cable. Shift transmission to
Neutral. Open console lid and remove bolts attaching console to floor
pan. Lift cup holder bin and remove bolt attaching console to floor
pan. Lift rear of console and pull console rearward to separate from
shift bezel. Remove console from vehicle. Remove screws attaching
shift boot to floor pan and slide boot upward on lever extension.
2) Remove shift lever extension. Raise and support vehicle.
On 4WD models, remove skid plate, if equipped. Mark drive shaft and
axle yoke for alignment reference. Remove drive shaft. Remove exhaust
"Y" pipe. On 4WD models, disconnect and lower remaining exhaust pipes
for clearance as necessary. Disconnect speed sensor harness connector
and back-up light harness connector.
3) Support engine using adjustable jackstand. If transmission
is to be disassembled for repair, drain lubricant from transmission.
On 4WD models, disconnect transfer case shift linkage at transfer case
range lever and remove shift lever from transmission. Remove
bolts/nuts attaching transmission to rear mount.
4) Support transmission with a transmission jack. Secure
transmission with safety chains. Remove rear crossmember. On 4WD
models, support transfer case with transmission jack and secure
transfer case to jack with safety chains. Remove transfer case
attaching nuts and move transfer case rearward until input gear clears
transmission output shaft.
5) Lower transfer case assembly and remove it from under
vehicle. On 4WD models, remove clutch slave cylinder splash shield, if
equipped. Remove clutch slave cylinder and move aside for working
clearance. Remove starter. Remove transmission splash shield. Remove
transmission harness wires from clips on transmission shift cover.
6) Lower transmission slightly. Remove shift tower and lever
assembly. Remove transmission-to-engine attaching bolts. Slide
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transmission and jack rearward until input shaft clears clutch disc.
Lower transmission jack and remove transmission from under vehicle.
Installation
1) To install, reverse removal procedure. Apply high-
temperature grease to pilot bushing located in end of crankshaft. Also
apply grease to release bearing bore, release fork, release fork ball
stud and drive shaft slip yoke. Apply sealer to threads of drain plug
before installing in case.
2) Align reference marks made on drive shaft(s) and "U"
joints during removal. After installing clutch assembly and housing,
tighten housing bolts nearest alignment dowels first. During final
transmission installation, install shims between clutch housing and
transmission at appropriate bolt location. Tighten all nuts and bolts
to specification. See TORQUE SPECIFICATIONS table.
TRANSMISSION (RAM PICKUP)
Removal (NV3500 & NV5600)
1) Disconnect negative battery cable. Shift transmission to
Neutral. Remove shift boot bezel screws and slide boot upward on lever
extension. Remove shift tower and lever assembly. Raise and support
vehicle.
2) On 4WD models, remove skid plate, if equipped. Remove
crankshaft position sensor. Mark drive shaft and axle yoke for
alignment reference. Remove drive shaft. Remove exhaust "Y" pipe. On
4WD models, disconnect and lower remaining exhaust pipes for
clearance, as necessary. Disconnect speed sensor harness connector.
3) Support engine using adjustable jackstand. If transmission
is to be disassembled for repair, drain lubricant from transmission.
On 4WD models, disconnect transfer case shift linkage at transfer case
range lever and remove shift lever from transmission. Remove
bolts/nuts attaching transmission to rear mount.
4) Support transmission with a transmission jack. Secure
transmission with safety chains. Remove rear crossmember. On 4WD
models, support transfer case with transmission jack and secure
transfer case to jack with safety chains. Remove transfer case
attaching nuts and move transfer case rearward until input gear clears
transmission output shaft.
5) Lower transfer case assembly and remove it from under
vehicle. On 4WD models, remove clutch slave cylinder splash shield, if
equipped. Remove clutch slave cylinder and move aside for working
clearance. Remove starter. Remove transmission splash shield. Remove
transmission harness wires from clips on transmission shift cover. On
some models, it may be necessary to remove front axle struts and oil
filter for access and removal clearance.
6) Lower transmission slightly. Remove shift tower and lever
assembly. Remove transmission-to-engine bolts. Slide transmission and
jack rearward until input shaft clears clutch disc. Lower transmission
jack and remove transmission from under vehicle.
Installation
1) To install, reverse removal procedure. Apply high-
temperature grease to pilot bushing located in end of crankshaft. Also
apply grease to release bearing bore, release fork, release fork ball
stud and drive shaft slip yoke.
2) Apply sealer to threads of drain plug before installing in
case. Align reference marks made on drive shaft(s) and axle yoke(s)
during removal. After installing clutch assembly and housing, tighten
housing bolts nearest alignment dowels first. Tighten all nuts and
bolts to specification. See TORQUE SPECIFICATIONS table.
Removal (NV4500 & NV4500HD)
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1) Disconnect negative battery cable. Shift transmission to
Neutral. Remove shift boot bezel screws and slide boot upward on lever
extension. Scribe mark position of extension on shank of shift lever.
2) Raise and support vehicle. On 4WD models, remove skid
plate, if equipped. Mark drive shaft and axle yoke for alignment
reference. Remove drive shaft. Remove exhaust "Y" pipe. On 4WD models,
disconnect and lower remaining exhaust pipes for clearance as
necessary. Disconnect speed sensor harness connector and back-up light
harness connector.
3) Support engine using adjustable jackstand. If transmission
is to be disassembled for repair, drain lubricant from transmission.
See Fig. 9 . On 4WD models, disconnect transfer case shift linkage at
transfer case range lever and remove shift lever from transmission.
Remove bolts/nuts attaching transmission to rear mount.
4) Support transmission with a transmission jack. Secure
transmission with safety chains. Remove rear crossmember. On 4WD
models, support transfer case with transmission jack and secure
transfer case to jack with safety chains. Remove transfer case
attaching nuts and move transfer case rearward until input gear clears
transmission output shaft.
5) Lower transfer case assembly and move it from under
vehicle. On 4WD models, remove clutch slave cylinder splash shield, if
equipped. Remove clutch slave cylinder, and move aside. Remove
starter. Remove transmission splash shield. Remove transmission
harness wires from clips on transmission shift cover. On some models,
it may be necessary to remove front axle struts and oil filter for
access and removal clearance.
6) Lower transmission slightly. Remove shift tower and lever
assembly. Remove transmission-to-engine bolts. Slide transmission and
jack rearward until input shaft clears clutch disc. Lower transmission
jack and remove transmission from under vehicle.
Installation
1) To install, reverse removal procedure. Apply high-
temperature grease to pilot bushing located in end of crankshaft. Also
apply grease to release bearing bore, release fork, release fork ball
stud and propeller shift slip yoke.
2) Apply sealer to threads of drain plug before installing in
case. Align reference marks made on drive shaft(s) and axle yoke(s)
during removal. After installing clutch assembly and housing, tighten
housing bolts nearest alignment dowels first.
3) During final transmission installation, install shims
between clutch housing and transmission at appropriate bolt location.
See CLUTCH HOUSING BORE RUNOUT and CLUTCH HOUSING FACE RUNOUT under
CLUTCH HOUSING (RAM PICKUP) under TESTING. Press extension to scribe
mark made during removal. A 0.12-0.20" (3-5 mm) space should exist
between shift lever isolator, top edge of stub shaft and tool lower
jaw. Tighten all nuts and bolts to specification. See TORQUE
SPECIFICATIONS table.
Fig. 9: Identifying Transmission Drain Bolt (NV4500 & NV4500HD)
Courtesy of Chrysler Corp.
CLUTCH ASSEMBLY
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CAUTION: Clutch disc may contain asbestos fibers which can cause
serious health risk. DO NOT sand clutch components. DO NOT
clean components using compressed air. To clean components,
use a water-dampened cloth.
Removal
With transmission and clutch housing removed, mark pressure
plate and flywheel for reassembly reference. Install clutch aligner in
clutch disc to prevent disc from falling. Loosen pressure plate bolts
evenly and in rotation to avoid warping pressure plate. Remove
pressure plate and disc from flywheel. See Fig. 10.
Inspection
1) Check for oil leakage through engine rear main bearing oil
seal and transaxle input shaft seal. Check flywheel and pressure plate
for burned areas, discoloration, cracks, grooves or ridges. Replace as
necessary.
2) Use medium sandpaper (80-180 grade) to clean flywheel
surface, then wipe with mineral spirits. DO NOT flat-machine flywheel
surface. Check facing surfaces for grease or oil contamination. Check
clutch disc for wear. Clutch disc face-to-rivet head distance should
be at least .008" (.20 mm). Check splines of disc hub and transaxle
input shaft.
3) Using straightedge, check pressure plate. Friction area
should be flat to slightly concave, with the inner diameter about 0-.
0039" (0-0.1 mm) less than outer diameter. Using surface plate, check
clutch cover for flatness. Sections around bolt holes should contact
surface plate within .015" (.38 mm). Ensure cover-to-flywheel dowel
fit is snug. Replace clutch assembly as necessary.
NOTE: Before installing clutch disc, ensure flywheel mating
surface, pilot bearing/bushing and clutch release bearing are
in satisfactory condition. Repair and/or replace components
as necessary.
Installation
To install, reverse removal procedure using clutch aligner.
Ensure reference marks are aligned. Tighten pressure plate retaining
bolts evenly a few threads at a time to prevent warpage. See TORQUE
SPECIFICATIONS table.
Fig. 10: Exploded View Of Clutch Assembly (Typical)
Courtesy of Chrysler Corp.
PILOT BEARING, CLUTCH RELEASE BEARING & FORK
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NOTE: Clutch release bearing is packed with grease. DO NOT use
cleaning solvent to clean release bearing.
Removal
1) Remove transmission and clutch housing. See TRANSMISSION
(DAKOTA) or TRANSMISSION (RAM PICKUP). Disconnect release bearing fr\
om
fork, and remove bearing. See Fig. 11. Remove release fork.
2) Inspect bearing. Bearing should turn smoothly under a
light thrust load. Inspect release fork and fork ball pivot for
distortion and wear.
Installation
1) Lubricate crankshaft pilot bearing, input shaft splines,
bearing retainer slide surface, fork pivot and release fork pivot
surface with high-temperature bearing grease.
2) Install release fork and release bearing. Ensure fork and
bearing are properly secured. Install transmission and clutch housing.
Fig. 11: Exploded View Of RWD Clutch Release Bearing Assembly
Courtesy of Chrysler Corp.
CLUTCH MASTER CYLINDER
Removal
1) Disconnect clutch pedal interlock switch wires. Remove
locating clip from clutch master cylinder mounting bracket. Remove
retaining clip, flat washer and wave washer that attach clutch master
cylinder push rod to clutch pedal. Slide clutch master cylinder push
rod off pedal pin. Ensure cap on clutch master cylinder reservoir is
tight.
2) Remove clutch fluid reservoir. Rotate clutch master
cylinder 45 degrees counterclockwise to unlock it. Remove cylinder
from dash panel. Remove clutch master cylinder rubber seal from dash
panel.
Installation
Lubricate cylinder seal with liquid soap to ease
installation. Seat seal in dash and around cylinder. To install,
reverse removal procedure.
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![DODGE RAM 1999 Service Repair Manual TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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TORQUE SPECIFICATIONS \
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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Application Ft. Lbs. (N.m)\
Clutch Master Cylinder Nuts ................................ 40 (54)\
Clutch Slave Cylinder Nuts ................................. 17 (23)\
Crossmember-To-Frame Bolts
AX15 & NV3500 (Dakota) ..................................... 30 (41\
)
NV3500 (Ram Pickup) ........................................ 50 (68\
)
Crossmember-To-Transmission Insulator Nuts
2WD (NV3500 - Ram Pickup) ................................ 50 (68\
)
4WD (NV3500 - Ram Pickup) .......................... 40-45 (54-61\
)
Flywheel Bolts
Dakota 2.5L ................................................ 70 (95)\
Dakota V6 & V8 ............................................. 55 (75)\
Pressure Plate Bolts
5/16" .................................................... 17 (23)\
3/8" ..................................................... 30 (41)\
Transfer Case To Transmission Nuts
AX15 ................................................. 26 (35 N.m)\
NV3500, NV4500, NV4500HD & NV5600
5/16" ............................................. 22-30 (30-41)\
3/8" .............................................. 30-35 (41-47)\
Transmission-To-Clutch Housing Bolts
AX15 ..................................................... 27 (37)\
NV3500 (Ram Pickup) & NV5600 ....................... 40-45 (54-61\
)
NV1500, NV3500 (Dakota), NV4500 & NV 4500HD ............. 80 (108\
)
"U" Joint Clamp Bolts ...................................... 14 (19)\
INCH Lbs. (N.m)
Shift Tower Bolts (NV3500) ............................ 62-89 (7-10\
)
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CO M PU TE R R ELE A R N P R O CED URES
1999 D odge P ic ku p R 1500
GENERAL INFORMATION
DaimlerChrysler Computer Relearn Procedures
INTRODUCTION
Vehicles equipped with engine or transmission/transaxle
computers may require a computer relearn procedure after the vehicle
battery is disconnected. Vehicle computers memorize and store vehicle
operation patterns for optimum driveability and performance. When the
vehicle battery is disconnected, this memory is lost, resulting in a
driveability problem. Depending on the vehicle and how it is equipped,
the following driveability problems may exist:
* Rough or unstable idle.
* Hesitation or stumble.
* Rich or lean running.
* Poor fuel mileage.
* Harsh or poor transmission/transaxle shift quality.
Default data is used until NEW data from each key start is
stored. As the computer restores its memory from each new key start,
driveability is restored.
Driveability problems may occur during the computer relearn
stage. To accelerate computer relearn process after battery removal
and installation, specified computer relearn procedures should be
performed. See appropriate procedures under specified manufacturer.
COMPUTER RELEARN PROCEDURES
ALL MODELS
NOTE: Read all procedures listed to determine why each procedure is
to be performed before proceeding.
Vehicle Driveability Computer Relearn Procedure
Manufacturer does not provide a specified computer relearn
procedure for obtaining proper driveability. If vehicle battery was
disconnected or Powertrain Control Module (PCM) was replaced, driving
the vehicle will enable the PCM to perform a computer relearn
procedure for obtaining proper driveability. Inform customer that
driveability may differ from what they are accustomed to until the PCM
completes the computer relearn procedure.
NOTE: If Powertrain Control Module (PCM) was replaced, the correct
vehicle mileage and Vehicle Identification Number (VIN) must
be programmed into the PCM to prevent Diagnostic Trouble
Codes (DTCs) from being set in the Anti-Lock Brake System
(ABS) module and Supplemental Restraint System (SRS) module\
.
To program PCM and clear DTCs from ABS and SRS modules,
proceed to appropriate procedure listed. If replacing
Powertrain Control Module (PCM) on models equipped with a
Smart Key Immobilizer Module (SKIM), the secret key data must\
also be updated to enable engine starting. To update secret
key data, proceed to appropriate procedure listed.
Programming PCM & Clearing DTCs From ABS & SRS Modules
Connect scan tool to Data Link Connector (DLC) below driver's\
side of instrument panel. Using scan tool, enter correct VIN and
mileage into PCM. Using scan tool manufacturer's instructions, clear