service DODGE RAM 1999 Service Repair Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 1209 of 1691
STA R TE R
1999 D odge P ic ku p R 1500
1999 STARTING & CHARGING SYSTEMS
CHRY - Starters - Except Avenger & Sebring Coupe
Breeze, Caravan, Cirrus, Concorde, Dakota, Durango, Intrepid,
LHS, Neon, Ram Pickup, Ram Van, Ram Wagon, Sebring
Convertible, Stratus, Town & Country, Voyager, 300M
NOTE: For models not covered in this article, see STARTERS -
AVENGER, SEBRING COUPE & TALON article.
DESCRIPTION
Bosch, Melco and Mitsubishi starters use a planetary gear
train that transmits power from starter motor to pinion shaft. Six
permanent magnets (Bosch and Melco starters) or 4 permanent magnets
(Mitsubishi starters) are used, eliminating potential field wire-to-
frame short circuits.
Nippondenso starter is a 4-field, 4-brush, 12-volt motor with
a solenoid mounted within the housing. The unit has a 2-to-1 reduction
gear set in a die cast aluminum housing. Starter has serviceable gear
and clutch assembly only. If starter solenoid fails, entire starter
motor must be replaced.
All models use a starter relay in starter circuit between the
battery and starter solenoid terminal. Automatic Transmission (A/T)
equipped vehicles use a Park/Neutral Position (PNP) switch or a
Transmission Range (TR) sensor to provide ground path for the starter
relay. Manual Transmission (M/T) equipped vehicles use a clutch pedal
position switch to provide battery voltage from ignition switch to the
starter relay. See WIRING DIAGRAMS.
STARTER APPLICATIONS - CARS
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Model Type
Breeze & Stratus 2.0L ........................................ Bosch
Cirrus, Sebring Convertible & Stratus
2.4L ................................................. Nippondenso
2.5L ....................................................... Melco
Concorde, Intrepid, LHS & 300M
2.7L ....................................................... Melco
3.3L & 3.5L .......................................... Nippondenso
Neon ......................................................... Bosch
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STARTER APPLICATIONS - TRUCKS \
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Model Type
Caravan, Town & Country, & Voyager ..................... Nippondenso
Dakota & Durango
2.5L .................................................. Mitsubishi
3.9L & 5.2L .......................................... Nippondenso
Ram Pickup, Ram Van & Ram Wagon ........................ Nippondenso
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TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTING article in GENERAL INFORMATION.
Page 1229 of 1691
clockspring connector. Connect negative battery cable. On column shift
models, install NEW shift lever bushing using pliers and back-up
washer to snap bushing into place. Use a multipurpose grease to aid
installation.
6) Connect gearshift cable rod to shift lever by snapping rod
into bushing with pliers.
Fig. 1: Exploded View Of Steering Column (Typical)
Courtesy of Chrysler Corp.
OVERHAUL
NOTE: Steering column is not serviceable, except for trim, switches
and steering wheel. If service is required, replace column.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Application Ft. Lbs. (N.m)\
Steering Wheel Nut
Except Dakota ............................................ 45 (61)\
Dakota ................................................... 35 (47)\
Upper Coupler Bolt
Dakota, Ram Pickup & Ram Van/Wagon ....................... 36 (49)\
Caravan, Town & Country, & Voyager ....................... 20 (27)\
INCH Lbs. (N.m)
Steering Column-To-Instrument Panel Bracket Bolt/Nut
Except Dakota ........................................... 105 (12)\
Page 1230 of 1691
STE ER IN G C O LU M N S W IT C HES
1999 D odge P ic ku p R 1500
1999 ACCESSORIES & EQUIPMENT
CHRY - Steering Column Switches
Dakota, Durango & Ram Pickup
WARNING: Deactivate air bag system before performing any service
operation involving steering column components. See
appropriate AIR BAG RESTRAINT SYSTEMS article. DO NOT apply
electrical power to any component on steering column without
first disconnecting air bag module. Air bag may deploy. Wait
at least 2 minutes after disconnecting negative battery cable
before servicing air bag system. System reserve capacitor,
integral to ACM, maintains air bag system voltage for about 2
minutes after battery is disconnected. Servicing air bag
system before 2-minute period may cause accidental air bag
deployment and possible personal injury.
DESCRIPTION
Turn signal, hazard flasher, headlight beam selector,
headlight flash-to-pass, windshield wipe, pulse wipe and windshield
wash systems use a common switch assembly (multifunction switch)
mounted within upper steering column housing.
Ignition switch and lock cylinder are incorporated into an
assembly attached to side of steering column. Ignition switch assembly
can be serviced as a separate unit, but requires removal of lock
cylinder.
COMPONENT LOCATIONS
COMPONENT LOCATIONS \
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Component Location
Combination Flasher Relay ........................... Junction Block
Horn ............................... In Right Front Corner Of Engine
Compartment
Horn Relay ............................ In Power Distribution Center
Junction Block ................. Under Left Side Of Instrument Panel
Power Distribution Center ...... In Left Side Of Engine Compartment,
On Left Inner Panel
Relay/Flasher Module ........ Under Right Side Of Instrument Panel,
Behind Glove Box
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TROUBLE SHOOTING
TURN SIGNAL AND HAZARD FLASHER SYSTEM
Bulbs Burn Out Rapidly
Check charging system. See appropriate GENERATORS &
REGULATORS article in STARTING & CHARGING SYSTEMS.
Hazard Flashers Inoperative
Blown fuse. Faulty hazard flasher. Open circuit in feed wire
to hazard switch. Faulty turn signal/hazard switch. Open or grounded
circuit in wiring to external lights.
Page 1236 of 1691
switch connector. See Fig. 4. If continuity does not exist, repair
open Black/Red wire. If continuity exists, go to next step.
3) Check continuity between ground and Black/Red wire at
steering column horn switch connector. If continuity does not exist,
go to next step. If continuity exists, repair short to ground in
Black/Red wire.
4) Continuity between horn switch terminal and ground.
Continuity should exist with horn switch depressed. Continuity should
not exist without horn switch depressed. If continuity is not as
specified, replace horn switch. If continuity is as specified, install
horn relay and go to HORN under COMPONENT TESTS.
TURN SIGNAL & HAZARD WARNING SYSTEMS
1) If bulbs burn out rapidly, check charging system for
overcharging condition. See appropriate GENERATORS & REGULATORS
article in STARTING & CHARGING SYSTEMS. If charging system is okay, go
to next step. If charging system is not okay, repair as necessary.
2) If problem is turn signals failing to cancel after a turn,
inspect multifunction switch or cancelling cam lobes on clockspring
for damage or improper installation. If problem exists, repair as
necessary. If problem does not exist, go to next step.
3) Turn ignition on. Actuate turn signal switch or hazard
warning switch. Observe turn signal indicator light(s) in instrument
cluster. If flash rate is very high, check for a bulb that is not lit
or is dimly lit. Repair circuit or replace bulb as necessary. If turn
signals fail to light, go to next step.
4) Turn ignition off. Check turn signal fuse in junction
block and/or hazard warning fuse in PDC. If fuses are okay, go to next
step. If either fuse is blown, repair short circuit and replace fuse.
5) Check for battery voltage at hazard warning fuse in PDC.
Turn ignition on. Check for battery voltage at turn signal fuse in
junction block. If battery voltage exists, go to next step. If battery
voltage does not exist, repair open circuit to battery or ignition
switch as necessary.
6) Turn ignition off. Disconnect negative battery cable.
Remove combination flasher from junction block and replace with a
known good unit. Connect battery cable and test operation of turn
signal and hazard warning systems. If operation is okay, discard
faulty flasher. If operation is not okay, go to next step.
7) Turn ignition on. Check for battery voltage at combination
flasher terminals No. 51 and 48 in junction block. If battery voltage
exists, go to next step. If battery voltage does not exist, repair
open circuit to fuse in junction block or PDC as necessary.
8) Disconnect negative battery cable. Check continuity
between combination flasher terminal No. 50 and ground. If continuity
exists, go to next step. If continuity does not exist, repair open
ground circuit.
9) Disconnect multifunction switch harness connector. Check
continuity between junction block terminal No. 4 and multifunction
switch terminal No. 13 (Pink wire). If continuity exists, go to next
step. If continuity does not exist, repair open in Pink wire between
multifunction switch and junction block.
10) Check continuity between junction block terminal No. 13
and multifunction switch terminal No. 17 (Red/White wire). If
continuity exists, test multifunction switch. See MULTIFUNCTION SWITCH
under COMPONENT TESTS. If continuity does not exist, repair open in
Red/White wire between junction block and multifunction switch.
REMOVAL & INSTALLATION
WARNING: Deactivate air bag system before performing any service
Page 1257 of 1691
pitman arm. Remove drag link. To install, reverse removal procedure.
Tighten nuts to specification. See TORQUE SPECIFICATIONS. Install
cotter pins.
IDLER ARM
Removal & Installation
Remove cotter pin and nut from idler arm. Separate idler arm
from center link. Remove idler arm bolts. Remove idler arm. To
install, reverse removal procedure. Tighten bolts to specification.
See TORQUE SPECIFICATIONS. Install NEW cotter pin.
PITMAN ARM
Removal & Installation
1) Remove cotter pin and nut at pitman arm-to-center link or
drag link. Separate pitman arm from center link or drag link. Mark
location of pitman arm on steering gear shaft. Remove pitman arm-to-
steering gear shaft nut. Separate pitman arm from steering gear.
CAUTION: Stake pitman arm nut against steering gear shaft to ensure
proper retention.
2) To install, reverse removal procedure. Ensure reference
marks are aligned. Tighten bolts and nuts to specification. Install
NEW cotter pin.
TIE ROD END
Removal
Remove cotter pin and nut from tie rod end. Using Tie Rod End
Puller (C-3894-A), remove tie rod end from steering knuckle or center
link. Loosen lock nut or clamp bolt. Remove tie rod end. Note number
of turns required for removal.
NOTE: Use Tie Rod End Puller (C-3894-A) to prevent tie rod end seal\
damage.
Installation
1) To install, reverse removal procedure. Ensure tie rod end
is installed at same location. Position clamp sleeve with bolt located
on bottom. Clamp opening should be aligned with slot in sleeve.
2) Tighten the tie rod end nut to specification. Install a
NEW cotter pin. Check and adjust toe-in. See appropriate
SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT. Tighten clamp
bolt to specification. See TORQUE SPECIFICATIONS.
OVERHAUL
POWER STEERING PUMP OVERHAUL
Only fluid reservoirs, caps, pulleys, "O" rings, seals and
flow control valve are replaceable on pump. See Figs. 7 and 8.
Internal components are non-serviceable. If internal components fail,
replace pump. Replace reservoir, or "O" ring and seals if damaged.
NOTE: If expansion plug is deformed or dislodged, DO NOT remove it.
Replace pump housing.
STEERING GEAR OVERHAUL
Page 1259 of 1691
* S TE ER IN G U NIF O RM IN SPEC TIO N G UID ELIN ES *
1 999 D odge P ic ku p R 1500
GENERAL INFORMATION
Steering, Suspension, Wheel Alignment, Wheels and Tires
Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Steering and Suspension
AIR RIDE SUSPENSION
AIR RIDE SUSPENSION - AIR SHOCKS AND AIR STRUTS
AIR RIDE SUSPENSION - AIR SPRING VALVES
AIR RIDE SUSPENSION - AIR SPRINGS
AIR RIDE SUSPENSION - COMPRESSORS
AIR RIDE SUSPENSION - HEIGHT SENSORS
AIR RIDE SUSPENSION - MODULES
AIR RIDE SUSPENSION - RELAYS (COMPRESSOR)
AIR RIDE SUSPENSION - SWITCHES (ON/OFF)
AIR RIDE SUSPENSION - TORSION SPRINGS (COUNTER BALANCING)
AIR RIDE SUSPENSION - TUBING
AIR RIDE SUSPENSION - WARNING LAMPS
AIR RIDE SUSPENSION - WIRING HARNESSES
BALL JOINTS
BUSHINGS
CENTER LINKS
CONTROL ARM SHAFTS
CONTROL ARMS
DRAG LINKS
ELECTRONIC RIDE CONTROL SHOCKS AND STRUTS
IDLER ARMS
KING PINS
PITMAN ARMS
POWER STEERING HOSES
POWER STEERING (HYDRAULIC) PUMPS
RADIUS ARMS
RELAY RODS
SHOCK ABSORBERS, STRUT CARTRIDGES AND STRUT ASSEMBLIES
SPINDLES
SPRINGS - COIL, LEAF AND TORSION BAR
STEEL POWER STEERING LINES
STEERING ARMS
STEERING DAMPERS
STEERING GEARS (EXCEPT RACK AND PINION)
STEERING GEARS - RACK AND PINION
STEERING KNUCKLES
STRIKE OUT BUMPERS
STRUT RODS
STRUT UPPER BEARING PLATE ASSEMBLIES
SWAY BAR LINKS
SWAY BARS
Page 1260 of 1691
TIE ROD ENDS (INNER AND OUTER)
TRACK BARS
TRAILING ARMS
WHEEL BEARINGS, RACES AND SEALS
Wheel Alignment
WHEEL ALIGNMENT
Wheels and Tires
TIRES
VALVE STEMS
WHEEL ATTACHMENT HARDWARE
WHEELS (RIMS)
MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
1) a Pledge of Assurance to their Customers and 2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards
are continually re-published. In addition to these, standards for
Drive Train and Transmissions have recently been promulgated.
Participating shops utilize these Uniform Inspection & Communication
Standards as part of the inspection process and for communicating
their findings to their customers.
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
(and their representatives), concerned with auto repair and/or
consumer protection, are conducted. Feedback from these sessions is
brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not
satisfied with a repair transaction, the Motorist Assurance Program
offers mediation and arbitration through MAP/BBB-CARE and other non-
Page 1261 of 1691
profit organizations. MAP conducted pilot programs in twelve states
before announcing the program nationally in October, 1998. During the
pilots, participating repair shops demonstrated their adherence to the
Pledge and Standards and agreed to follow the UICS in communicating
the results of their inspection to their customers. To put some
"teeth" in the program, an accreditation requirement for shops was
initiated. The requirements are stringent, and a self-policing method
has been incorporated which includes the "mystery shopping" of
outlets.
We welcome you to join us as we continue our outreach... with
your support, both the automotive repair industry and your customers
will reap the benefits. Please visit MAP at our Internet site www.
motorist.org or contact us at:
1444 I Street, NW Suite 700
Washington, DC 20005
Phone (202) 712-9042 Fax (202) 216-9646
January 1999
MAP UNIFORM INSPECTION GENERAL GUIDELINES
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
It is MAP policy that all exhaust, brake, steering,
suspension, wheel alignment, drive-line, engine performance and
maintenance, and heating, ventilation and air conditioning, and
electrical services be offered and performed under the standards and
procedures specified in these sections.
Before any service is performed on a vehicle, an inspection
of the appropriate system must be performed. The results of this
inspection must be explained to the customer and documented on an
inspection form. The condition of the vehicle and its components will
indicate what services/part replacements may be "Required" or
"Suggested". In addition, suggestions may be made to satisfy the
requests expressed by the customer.
When a component is suggested or required to be repaired or
replaced, the decision to repair or replace must be made in the
customer's best interest, and at his or her choice given the options
available.
This section lists the various parts and conditions that
indicate a required or suggested service or part replacement.
Although this list is extensive, it is not fully inclusive. In
addition to this list, a technician may make a suggestion. However,
any suggestions must be based on substantial and informed experience,
or the vehicle manufacturer's recommended service interval and must be
documented.
Some conditions indicate that service or part replacement is
required because the part in question is no longer providing the
function for which it is intended, does not meet a vehicle
manufacturer's design specification or is missing.
Example:
An exhaust pipe has corroded severely and has a hole in it
through which exhaust gases are leaking. Replacement of the
exhaust pipe in this case is required due to functional
failure.
Example:
A brake rotor has been worn to the point where it measures
less than the vehicle manufacturer's discard specifications.
Replacement of the rotor is required because it does not meet
design specifications.
Page 1262 of 1691
Some conditions indicate that a service or part replacement
is suggested because the part is close to the end of its useful life
or addresses a customer's need, convenience or request. If a
customer's vehicle has one of these conditions, the procedure may be
only to suggest service.
Example:
An exhaust pipe is rusted, corroded or weak, but no leaks are
present. In this case, the exhaust pipe has not failed.
However, there is evidence that the pipe may need replacement
in the near future. Replacement of the pipe may be suggested
for the customer's convenience in avoiding a future problem.
Example:
The customer desires improved ride and/or handling, but the
vehicle's shocks or struts have not failed. In this case,
replacement may be suggested to satisfy the customer's
wishes. In this case, replacement of the shocks or struts may
not be sold as a requirement.
A customer, of course, has the choice of whether or not a
shop will service his or her vehicle. He or she may decide not to
follow some of your suggestions. When a repair is required, a MAP shop
must refuse partial service on that system if, in the judgment of the
service provider, proceeding with the work could create or continue an
unsafe condition. When a procedure states that required or suggested
repair or replacement is recommended, the customer must be informed of
the generally acceptable repair/replacement options whether or not
performed by the shop.
When presenting suggested repairs to the customer, you must
present the facts, allowing the customer to draw their own conclusions
and make an informed decision about how to proceed.
The following reasons may be used for required and suggested
services. These codes are shown in the "Code" column of the MAP
Uniform Inspection & Communications Standards that follow:
Reasons to Require Repair or Replacement
A - Part no longer performs intended purpose
B - Part does not meet a design specification (regardless of
performance)
C - Part is missing
NOTE: When a repair is required, the shop must refuse partial
service to the system in question, if the repair creates
or continues an unsafe condition.
Reasons to Suggest Repair or Replacement
1 - Part is close to the end of its useful life (just above
discard specifications, or weak; failure likely to occur
soon, etc.)
2 - To address a customer need, convenience, or request (to
stiffen ride, enhance performance, eliminate noise,
etc.)
3 - To comply with maintenance recommended by the vehicle's
Original Equipment Manufacturer (OEM)
4 - Technician's recommendation based on substantial and
informed experience
NOTE: Suggested services are always optional. When presenting
suggested repairs to the customer, you must present
Page 1263 of 1691
the facts, allowing the customer to draw their own
conclusions and make an informed decision about how to
proceed.
STEERING AND SUSPENSION
SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER VEHICLE
OPERATION
Steering and suspension are complex systems made up of a
variety of interdependent components. For proper vehicle handling,
ride, and tire wear, a thorough inspection is required whenever
suspension work is being performed.
Conditions listed assume that the problem has been isolated
to the specific component by proper testing procedures.
NOTE: When replacing steering and/or suspension components which
may affect an alignment angle, you are required to check
and adjust alignment as needed. Refer to the OEM
specifications.
CAUTION: DO NOT use ride height altering or load compensating
components, such as variable rate springs and coil over
shocks, on vehicles with height or load sensing
proportioning valve-equipped braking systems, unless
these components are original equipment.
AIR RIDE SUSPENSION
NOTE: Depending on the air suspension design, there are some
aftermarket products available to eliminate the air ride
suspension on certain vehicles. If the system has been
eliminated with one of these products, then no service is
suggested or required.
AIR RIDE SUSPENSION - AIR SHOCKS AND AIR STRUTS
NOTE: This section covers the air spring portion of the
air shock or strut. For damping portion of shock
or strut conditions and procedures, refer to the
SHOCK ABSORBERS, STRUT CARTRIDGES AND STRUT ASSEMBLIES
section.
AIR RIDE SUSPENSION - AIR SHOCK AND AIR STRUT INSPECTION
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Condition Code Procedure
Inner fabric of air bag
damaged ................ A ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Outer covering of air bag
is cracked to the extent
that inner fabric of air
bag is visible ......... 1 ............ Suggest replacement.
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AIR RIDE SUSPENSION - AIR SPRING VALVES
AIR RIDE SUSPENSION - AIR SPRING VALVE INSPECTION \
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Condition Code Procedure