DODGE RAM 1999 Service Repair Manual
Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
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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
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Fully depress brake pedal and rotate brake switch
counterclockwise approximately 30 degrees. Remove brake switch from
bracket. Depress lock tabs holding brake switch mounting bracket and
separate harness connector from brake switch.
Installation
1) Before installing brake switch, reset adjustable plunger
by pulling on plunger head until plunger reaches end of travel.
Connect harness connector to brake switch. Depress brake pedal and
insert brake switch into keyed hole in mounting bracket. Rotate brake
switch clockwise into locked position.
2) Gently pull back on brake pedal until pedal will go no
further. This causes the brake switch plunger to ratchet backward to
the correct position. No further adjustment is required.
SPEED CONTROL SERVO
Removal (Except Ram Van & Ram Wagon)
1) Disconnect negative battery cable. Disconnect electrical
connector and vacuum hose from servo. Using finger pressure only, push
servo cable connector from throttle body bellcrank pin. DO NOT pull
cable connector perpendicular to bellcrank.
2) Remove 2 servo cable mounting nuts. Pull servo cable
sleeve away from mounting bracket to expose cable retaining clip.
Remove retaining clip. Remove servo.
Removal (Ram Van & Ram Wagon)
1) Disconnect negative battery cable. Remove engine cover.
Remove air cleaner assembly. Using finger pressure only, push servo
cable connector from throttle body bellcrank pin. DO NOT pull cable
connector perpendicular to bellcrank.
2) Remove right headlight assembly. Disconnect vacuum hose
and electrical connector at servo. Remove 2 servo mounting bracket
bolts. Remove 2 servo cable mounting nuts. Pull servo cable sleeve
away from mounting bracket to expose cable retaining clip. Remove
retaining clip. Remove servo.
Installation (All Models)
With throttle in full open position, align hole in speed
control cable sleeve with hole in servo pin. Install retaining clip.
To complete installation, reverse removal procedure. Tighten mounting
bolts/nuts to 75 INCH lbs. (8.5 N.m).
SPEED CONTROL SWITCHES
Removal & Installation
Turn ignition off. Disconnect negative battery cable. Wait 2
minutes for air bag system to discharge reserve voltage. Remove 2
screws holding air bag assembly to steering column. Separate air bag
assembly from steering column and disconnect air bag, horn and speed
control switch connectors. Remove screws securing speed control switch
to air bag assembly. Separate speed control switch from air bag
assembly. To install, reverse removal procedure.
WIRING DIAGRAMS
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Fig. 5: Cruise Control System Wiring Diagram (Dakota)
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Fig. 6: Cruise Control System Wiring Diagram (Durango)
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Fig. 7: Cruise Control System Wiring Diagram (Ram Pickup)
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Fig. 8: Cruise Control System Wiring Diagram (Ram Van & Ram Wagon)
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DRIV E A XLE - F B I S EM I- F LO ATIN G
1999 D odge P ic ku p R 1500
1998-99 DRIVE AXLES
CHRY - FBI Semi-Floating Axles
Ram Pickup
IDENTIFICATION
DRIVE AXLE APPLICATION \
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Application Axle Ring Axle
Model Gear Size Ratio
Front Axle ........ 216 FBI ......... 8.50" .. 3.54, 3.92 & 4.09
Front Axle ........ 248 FBI ......... 9.75" ........ 3.54 & 4.10
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DESCRIPTION & OPERATION
The Front Beam-Design Iron (FBI) axles is of an iron center
casting (differential housing) with axle shaft tubes extending from
both sides. The tubes are pressed in to form a one-piece axle housing
and is a semi-floating design.
Axle contains an integral carrier with hypoid-type ring gear
and pinion with semi-floating axle shafts. Load is supported by hub
bearings. Axle shafts are retained by nuts at the hub bearings. Hub
bearings are bolted to steering knuckle at outboard end of axle tube
yoke. Hub bearings are serviced as an assembly. On vehicles equipped
with Anti-Lock (ABS) brakes, a brake sensor is mounted on knuckle
assemblies, and tone rings are pressed onto axle shaft.
Differential is a one-piece design and differential pinion
mate shaft is retained with a roll pin. Differential bearing preload
and ring gear backlash is adjusted by use of shims, and pinion bearing
preload is set and maintained by use of a collapsible spacer.
Axle shaft is engaged or disengaged by an axle vacuum shift
motor. Vacuum shift motor is operated by engine vacuum and is
controlled by a switch mounted on transfer case.
AXLE RATIO & IDENTIFICATION
NOTE: Axle ratio can be identified by axle identification tag
attached to axle housing cover. See IDENTIFICATION.
LUBRICATION
CAPACITY
DRIVE AXLE CAPACITY ( 1) \
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Application Pts. (L)\
216 FBI .................................................. 4.8 (2.3)\
248 FBI .................................................. 7.6 (3.6)\
(1) - Approximate drive axle capacity listed. Lubricant level should
be 1/2" below oil filler hole in axle housing cover.
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FLUID TYPE
Use SAE 80W-90 or 90W hypoid gear lubricant with MIL-L-2105-C
and API GL-5 ratings.
TROUBLE SHOOTING
NOTE: See appropriate table in TROUBLE SHOOTING article in GENERAL
INFORMATION.
REMOVAL & INSTALLATION
AXLE SHAFT & HUB BEARING
Removal
1) Raise and support vehicle. Remove wheel. Remove brake
caliper with hose attached, and secure aside. DO NOT allow brake
caliper to hang by brake hose. Remove brake rotor. Remove ABS wheel
speed sensor (if equipped). Remove grease cap from center of front
hub. Remove cotter pin from end of axle shaft. Remove axle nut and
washer.
2) Remove hub/bearing assembly-to-knuckle bolts. Remove
hub/bearing assembly from steering knuckle and axle shaft. Remove
brake dust shield. To remove right (passenger-side) axle shaft,
carefully pull axle shaft from axle housing.
NOTE: Left axle shaft will disengage from collar located on
intermediate axle shaft.
3) To remove left (driver's side) axle shaft, disconnect
electrical connector and vacuum hoses at vacuum shift motor. Remove
bolts, vacuum shift motor and gasket. Carefully pull axle shaft from
axle housing and collar on intermediate axle shaft.
Installation
1) Install NEW oil seal on axle shaft with seal lip facing
toward splines on differential end of axle shaft. Coat seal lip with
wheel bearing grease.
2) Install right axle shaft into axle housing. Ensure axle
shaft engages with side gears in differential.
3) To install left axle shaft, ensure collar is engaged with
splines on intermediate axle shaft. Install left axle shaft into axle
housing. Ensure axle shaft engages with splines on collar. Install
vacuum shift motor, ensuring fork on vacuum shift motor engages groove
on collar. Install and tighten bolts to specification. See TORQUE
SPECIFICATIONS table.
4) To complete installation, reverse removal procedure. Apply
silicone rubber sealant to edge of grease cap before installing.
Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS table.
DRIVE SHAFT
Removal
1) Raise and support vehicle. Ensure transmission and
transfer selector levers case are in Neutral. Reference mark drive
shaft and pinion flange for reassembly reference.
2) Remove bolts and "U" joint straps at pinion flange. Remove
center carrier bearing bolts (if equipped). Remove drive shaft.
CAUTION: The "U" joint components are not serviceable. Replace
complete assembly. DO NOT reuse.
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Installation
To install, reverse removal procedure using NEW "U" joint
straps and bolts. Ensure all reference marks are aligned. Tighten
bolts to specification. See TORQUE SPECIFICATIONS table.
PINION FLANGE & OIL SEAL
Removal
1) Raise and support vehicle. Reference mark drive shaft and
pinion flange on differential for reassembly. Remove bolts and "U"
joint straps at pinion flange on differential. Disconnect drive shaft
from differential, and support it aside.
2) Using INCH-lb. torque wrench, measure amount of force
required to rotate pinion. This is pinion bearing preload. Record
pinion bearing preload for reassembly reference.
3) Remove pinion nut and washer from pinion. Scribe reference
mark on pinion flange and pinion for reassembly. Using Holder (C-3281)\
and appropriate flange remover, remove pinion flange from pinion.
Remove oil seal from axle housing.
Installation
1) Ensure oil seal surface in axle housing is clean. Coat lip
of oil seal with gear lube. Using appropriate oil seal installer and
handle, install oil seal.
2) Install pinion flange on pinion with reference mark
aligned. Press pinion flange onto pinion. Install washer and pinion
nut. Tighten pinion nut while rotating pinion, ensuring bearings are
properly seated. Tighten nut until preload measured before disassembly
is achieved. DO NOT exceed maximum torque specification. See TORQUE
SPECIFICATIONS table.
3) To install remaining components, reverse removal procedure
using NEW "U" joint straps and bolts. Ensure all reference marks are
aligned. Tighten bolts to specification. See TORQUE SPECIFICATIONS
table. Check lubricant level and add if necessary.
AXLE HOUSING ASSEMBLY
NOTE: Removing axle housing assembly is not necessary unless axle
housing is damaged. Differential carrier and components can
be serviced by removing differential assembly from axle
housing.
Removal
1) Raise and support vehicle. Remove front wheels. Reference
mark drive shaft to pinion flange for reassembly. Remove bolts and "U"
joint straps at pinion flange. Remove drive shaft, and support aside.
Remove brake calipers, and support aside with wire. DO NOT allow
calipers to hang from brake hoses.
2) Disconnect ABS sensor harness connectors (if equipped).
Disconnect drag link and tie rod from steering knuckles. Disconnect
shock absorber from axle housing. Disconnect stabilizer bar links at
spring brackets.
3) Disconnect electrical connector and vacuum hoses at vacuum
shift motor. Support axle housing assembly with floor jack. Remove
bolts from upper and lower suspension arms. Lower axle housing
assembly from vehicle and remove.
Installation
To install, reverse removal procedure. Ensure reference marks
on drive shaft and pinion flange align. Tighten suspension arms with
vehicle at normal operating height. Tighten bolt/nuts to
specification. See TORQUE SPECIFICATIONS table. Check axle fluid level
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and fill if necessary.
STEERING KNUCKLES
Removal & Installation
1) Raise and support vehicle. Remove hub bearing and axle
shaft. Remove tie rod or drag link end from steering knuckle arm.
Remove ABS sensor harness and bracket from steering knuckle.
2) Remove cotter pin from upper ball stud nut. Remove upper
and lower ball stud nuts. Using a brass hammer, strike steering
knuckle to remove knuckle from axle tube yokes.
3) To install, reverse removal procedure. On 216 FBI axles,
tighten lower and upper ball stud nuts to specification. See TORQUE
SPECIFICATIONS table.
4) On 248 FBI axles, tighten lower ball stud nut to
specification. DO NOT install cotter pin at this time. Install and
tighten upper ball stud nut to specification. Retorque lower ball stud
nut to specification. See TORQUE SPECIFICATIONS table.
AXLE SHIFT MOTOR
Removal & Installation
1) Disconnect vacuum and wiring connector from shift housing.
Remove indicator switch, shift motor housing cover, gasket and shield
from housing.
2) To install, reverse removal procedure. Ensure shift fork
is correctly guided into shift collar groove. Tighten mounting bolts
to 96 INCH lbs. (11 N.m). Add 5 ounces (148 ml) of GL-5 gear lubrica\
nt
to shift motor housing through indicator switch mounting hole.
DIFFERENTIAL ASSEMBLY
NOTE: Differential assembly consists of differential case and
components mounted in axle housing. For differential assembly
servicing, see DIFFERENTIAL ASSEMBLY under OVERHAUL.
OVERHAUL
DIFFERENTIAL ASSEMBLY
Disassembly
1) Remove axle shafts from differential. See AXLE SHAFT & HUB
BEARING under REMOVAL & INSTALLATION.
2) Note identification marks on bearing caps and axle housing
for reassembly reference. Bearing caps must be installed in original
location. If marks are not present, place marks on bearing caps and
axle housing.
3) Remove bolts and bearing caps. Place Axle Housing Spreader
(W-129-B) on axle housing so dowel pins engage with locating holes.
See Fig. 1 . Install hold-down clamps. Finger tighten turnbuckle on
axle housing spreader.
4) Install pilot stud and dial indicator on axle housing.
Position dial indicator so stem is resting against opposite side of
axle housing, with pressure on stem.
CAUTION: DO NOT spread axle housing more than .020" (.50 mm), or axle
housing may be damaged.
5) Adjust dial indicator to zero. Tighten turnbuckle enough
to spread axle housing for differential case removal while noting
reading on dial indicator. Dial indicator reading should not exceed .
020" (.50 mm).