brake sensor DODGE RAM 1999 Service Service Manual

Brake On/Off (BOO) Switch ................... Cruise Control Systems\
Engine Performance
Shift Interlock Systems
Buzzer Module ...................................... Warning Systems
Camshaft Position (CMP) Sensor .................. Engine Performance\
Central Control Module ........................... Anti-Theft System
Clockspring ............................... Air Bag Restraint System
Cruise Control Systems
Steering Column Switches
Clutch Pedal Position Switch .............................. Starters
Clutch Start Switch ....................................... Starters
Combination Meter ......................... Analog Instrument Panels
Constant Control Relay Module (CCRM) ............ Engine Performance\
Electric Cooling Fans
Convenience Center .............................. Power Distribution
Illumination/Interior Lights
Convertible Top Motor ........................ Power Convertible Top
Convertible Top Switch ....................... Power Convertible Top
Crankshaft Position (CKP) Sensor ................ Engine Performance\
Cruise Control Module ....................... Cruise Control Systems
Cruise Control Switch ....................... Cruise Control Systems
Condenser Fan Relay(s) ....................... Electric Cooling Fans\
Data Link Connector (DLC) ....................... Engine Performance\
Daytime Running Lights Module ............... Daytime Running Lights
Exterior Lights
Defogger Relay ................................ Rear Window Defogger
Diagnostic Energy Reserve Module (DERM) ... Air Bag Restraint System\
Discriminating Sensor (Air Bag) ........... Air Bag Restraint System\
Distributor ..................................... Engine Performance
Door Lock Actuators ............................... Power Door Locks
Remote Keyless Entry
Door Lock Relay(s) ................................ Power Door Locks\
Electrochromic Mirror ................................ Power Mirrors
Electronic Level Control (ELC)
Height Sensor .............................. Electronic Suspension
Electronic Level Control (ELC) Module ........ Electronic Suspension\
Engine Coolant Temperature (ECT)
Sending Unit ............................ Analog Instrument Panels
Engine Coolant Temperature (ECT) Sensor ......... Engine Performance\
Engine Control Module ........................... Engine Performance
Generators & Regulators
Starters
ETACS ECU .......................................... Warning Systems
Power Windows
Remote Keyless Entry
Evaporative (EVAP) Emissions Canister ........... Engine Performance\
EVAP Canister Purge Solenoid .................... Engine Performance
EVAP Canister Vent Solenoid ..................... Engine Performance
Exhaust Gas Recirculation (EGR) Valve ........... Engine Performance\
Fuel Tank Vacuum Sensor ......................... Engine Performance
Fog Lights ....................................... Headlight Systems
Daytime Running Lights
Fog Light Relay .................................. Headlight Systems
Daytime Running Lights
Fuel Door Release Solenoid ................. Power Fuel Door Release
Fuel Gauge Sending Unit ................... Analog Instrument Panels
Fuel Injectors .................................. Engine Performance
Fuel Pump ....................................... Engine Performance
Fuel Pump Relay ................................. Engine Performance
Power Distribution
Fuse/Relay Block ................................ Power Distribution
Fusible Links ................................... Power Distribution
Generators & Regulators

Parking Brake Switch ...................... Analog Instrument Panels
Park Lights ........................................ Exterior Lights
Park/Neutral Position Switch .............................. Starters
Engine Performance
Anti-Theft System
Body Control Module
Perimeter Lighting Control Relay ................... Exterior Lights
Power Amplifier ..................................... Power Antennas
Power Antenna Module ................................ Power Antennas
Power Antenna Motor ................................. Power Antennas
Power Distribution Center ....................... Power Distribution
Generators & Regulators
Starters
Power Door Lock Motors ............................ Power Door Locks
Power Mirror Motors .................................. Power Mirrors
Memory Systems
Power Sliding Door Controller .............. Power Sliding Side Door
Power Seat Motors ...................................... Power Seats
Memory Systems
Power Steering Pressure Switch .................. Engine Performance
Power Top Motor .............................. Power Convertible Top
Power Top Relay(s) ........................... Power Convertible Top\
Powertrain Control Module ....................... Engine Performance
Analog Instrument Panels
Cruise Control Systems
Data Link Connectors
Generators & Regulators
Starters
Power Window Motors .................................. Power Windows
Power Window Relay(s) ................................ Power Windows\
Radiator Fan Motor(s) ........................ Electric Cooling Fans\
Radiator Fan Relay(s) ........................... Engine Performance\
Electric Cooling Fans
Rainsense Module .............................. Wiper/Washer Systems
Raise Relay .................................. Power Convertible Top
Remote Anti-Theft Personality (RAP) Module ....... Anti-Theft System\
Starters
Warning Systems
Seat Belt Pretensioners ................... Air Bag Restraint System
Seat Belt Retractor Solenoid .................... Passive Restraints
Seat Belt Switch .......................... Air Bag Restraint System
Passive Restraints
Shift Interlock Solenoid ................... Shift Interlock Systems
Shift Lock Actuator ........................ Shift Interlock Systems
Side Marker Lights ................................. Exterior Lights
SIR Coil Assembly (Clockspring) ........... Air Bag Restraint System\
Slip Ring (Clockspring) ................... Air Bag Restraint System\
Steering Column Switches
SRS Control Module ........................ Air Bag Restraint System
Starter Motor ............................................. Starters
Starter Interrupt Relay ................................... Starters
Starter Solenoid .......................................... Starters
Starter Relay ............................................. Starters
Steering Wheel Position Sensor .................... Anti-Lock Brakes
Stoplights ......................................... Exterior Lights
Stoplight Switch ................................ Engine Performance
Cruise Control Systems
Anti-Lock Brakes
Sun Roof ECU ........................................ Power Sun Roof
Sun Roof Motor ...................................... Power Sun Roof
Sun Roof Position Sensor ............................ Power Sun Roof
Taillights ......................................... Exterior Lights
Throttle Position (TP) Sensor ................... Engine Performance\

Torque Converter Clutch Solenoid/Switch ......... Engine Performance
Traction Control Switch ........................... Anti-Lock Brakes
Trailer Tow Connector .............................. Exterior Lights
Trailer Tow Relay .................................. Exterior Lights
Transmission/Transaxle .......................... Engine Performance
Transmission Control Module (TCM) ............... Engine Performance\
Starters
Transmission Range Sensor ................................. Starters
Back-Up Lights
Engine Performance
Transmission Range Switch ........................... Back-Up Lights
Engine Performance
Anti-Theft System
Turn Signal Flasher ................................ Exterior Lights
Turn Signal Lights ................................. Exterior Lights
Twilight Sentinel Switch ......................... Headlight Systems
Daytime Running Lights
Vapor Canister Leak Detection Pump .............. Engine Performance
Vehicle Control Module (VCM) .................... Engine Performance\
Vehicle Dynamic Module ....................... Electronic Suspension
Vehicle Speed Control Servo ................. Cruise Control Systems
Vehicle Speed Sensor .......................... Data Link Connectors
Analog Instrument Panels
Cruise Control Systems
Electronic Suspension
Voltage Regulator .......................... Generators & Regulators
Water-In-Fuel Sensor ............................ Engine Performance
Analog Instrument Panels
Wheel Speed Sensors ............................... Anti-Lock Brakes
Window Timer Module .......................... Power Convertible Top
Windshield Intermittent Wiper Relay ........... Wiper/Washer Systems
Windshield Washer Motor ....................... Wiper/Washer Systems
Wiper Motor ................................... Wiper/Washer Systems









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Removal (A/T Models)
Raise and support vehicle. Disconnect electrical connector
from park/neutral switch. Park/neutral switch is located on side of
transmission case, near shift linkage. Unscrew park/neutral switch
from transmission case. Remove seal ring from park/neutral switch.
Installation
1) Apply parking brake. Place shift lever in Park and
Neutral. Ensure park/neutral switch operating levers in transmission
are centered in the park/neutral switch opening on transmission case.
2) Using NEW seal ring, install park/neutral switch. Tighten
park/neutral switch to specification. See TORQUE SPECIFICATIONS.
Install electrical connector. Add ATF as necessary.
ACCELERATOR PEDAL POSITION SENSOR (APPS)
NOTE: APPS is replaced as assembly, including lever, brackets, and
sensor.
Removal
1) Disconnect negative battery cables. Remove cable cover.
Using finger pressure only, disconnect end of speed control servo
cable from throttle lever pin by pulling forward on connector while
holding lever rearward. Using 2 small screwdrivers, pry throttle cable
connector socket from throttle lever ball.
2) Disconnect transmission kickdown cable (if equipped).
Compress pinch tabs on cruise control and throttle cables. Pull cables
rearward to remove from cable mounting brackets. See Fig. 4.
Disconnect electrical connector and retaining bolts. Remove APPS
sensor.
Installation
To install, reverse removal procedure. To calibrate ECM, turn
ignition on. Without starting engine, slowly press throttle pedal to
floor and then slowly release.
Fig. 4: Locating Throttle Position (TP) Sensor
Courtesy of Chrysler Corp.
RELAYS & SOLENOIDS

FUEL LINE BLEEDING
NOTE: Fuel line bleeding is necessary if fuel injection pump is
replaced, fuel filter/water separator is not filled with
diesel fuel before installing or vehicle ran out off fuel.
Bleed high-pressure fuel lines if connections are loosened or
replaced. If engine has not been operated for an extended
time, bleed fuel lines before next initial engine start-up.
WARNING: DO NOT bleed fuel lines on a hot engine, as high exhaust
temperatures may cause a fire. Carefully bleed fuel lines, as
fuel is under extremely high pressure and could penetrate
skin. Use safety goggles and protective clothing when
bleeding fuel lines.
1) Loosen banjo bolt holding low-pressure fuel supply line to
side of fuel injection pump. Wrap a towel around banjo fitting to
catch fuel. Crank engine quickly and release key before engine starts.
This will operate fuel transfer pump for about 25 seconds.
2) If fuel is not present at fuel supply line after 25
seconds, turn ignition off. Repeat engine crank procedure until fuel
is present at fuel supply line. Tighten banjo bolt at fuel supply line
to specification. See TORQUE SPECIFICATIONS.
CAUTION: Ensure parking brake is applied and transmission is in
Neutral before bleeding fuel injection pump or high-pressure
fuel lines. DO NOT operate starter for more than 30 seconds
when bleeding fuel injection pump or high-pressure fuel
lines. Allow 2-minute intervals between starter operations.
3) To bleed air from fuel injection pump, ensure parking
brake is applied and transmission is in Neutral, as engine may start
when operating starter to bleed air from fuel injection pump. Operate
starter for 30 seconds to bleed any trapped air in fuel injection
pump.
4) To bleed high-pressure fuel lines, ensure parking brake is
applied and transmission is in Neutral, as engine may start when
operating starter to bleed high-pressure fuel lines. Loosen high-
pressure fuel line nut at fuel injector.
5) Operate starter until steady fuel flow exists at high-
pressure fuel line. Tighten high-pressure fuel line nut to
specification. See TORQUE SPECIFICATIONS. Start engine. Repeat
procedure on each high-pressure fuel line until engine operates
smoothly.
FUEL FILTER/WATER SEPARATOR & WATER-IN-FUEL SENSOR
NOTE: Vehicle also contains an in-tank fuel filter located on
bottom of fuel tank module. For servicing procedure, see FUEL
TANK MODULE & IN-TANK FUEL FILTER under FUEL SYSTEM.
NOTE: When fuel filter/water separator is being replaced,
manufacturer recommends cleaning the pre-filter. See FUEL
HEATER under FUEL SYSTEM for servicing of pre-filter.
Removal
1) Ensure engine is off. Place drain pan below drain tube at
fuel filter/water separator. See Fig. 3. Rotate handle on drain valve
forward, toward front of vehicle to DRAIN position. Drain valve is
located near top of fuel filter/water separator. See Fig. 3. Once fuel
is drained from fuel filter/water separator, rotate handle on drain
valve back to CLOSE position.

Procedure For Programming PCM & Clearing DTCs From ABS & SRS
Modules
Connect scan tool to Data Link Connector (DLC). DLC is
located under left side of instrument panel. Using scan tool, enter
correct VIN and mileage into PCM. Using scan tool manufacturer's
instructions, clear DTCs from ABS and SRS modules.
Procedure For Updating Secret Key Data
1) Connect scan tool to Data Link Connector (DLC). DLC is
located under left side of instrument panel.
2) Go to ENGINE and then MISC menus on scan tool. Place the
SKIM in SECURED ACCESS MODE by using the appropriate Personal
Identification Number (PIN) for this vehicle. PIN may be obtained from\
the owner, vehicle's invoice, or from the manufacturer. Select UPDATE
THE SECRET KEY DATA. The data will be transferred from Smart Key
Immobilizer Module (SKIM) to the PCM, allowing the vehicle to start.
NOTE: On Ram Van and Ram Wagon, if 3 attempts are made to enter the
SECURED ACCESS MODE using the incorrect Personal
Identification Number (PIN), the SECURED ACCESS MODE will be
locked out for one hour. To exit this locked out mode, leave
ignition switch in the ON position for one hour with all
accessories turned off. It may be necessary to monitor
battery state and connect a battery charger if necessary.
ENGINE SENSORS & SWITCHES
BATTERY TEMPERATURE SENSOR
Removal & Installation
Battery temperature sensor is snapped into center of battery
tray, directly below the battery. Remove battery. Disconnect
electrical connector for battery temperature sensor. Pry battery
temperature sensor straight upward from battery tray. To install,
reverse removal procedure.
BRAKE SWITCH
NOTE: Brake switch may also be referred to as brakelight switch or
stoplight switch.
Removal (Dakota, Durango & Ram Pickup)
1) Brake switch is located near top of brake pedal. Remove
lower instrument panel cover for access to brake switch if necessary.
Disconnect electrical connector from brake switch. Depress and hold
brake pedal downward.
2) Rotate brake switch counterclockwise approximately 30
degrees so alignment tab on brake switch aligns with opening on
mounting bracket. Pull brake switch rearward from mounting bracket.
NOTE: Before installing brake switch, plunger on brake switch must
be pulled outward to fully extended position and then pushed
inward 4 detent positions to ensure proper brake switch
adjustment.
Installation
1) Pull plunger on brake switch outward to the fully extended
position. Push plunger on brake switch inward 4 detent positions. The
brake switch will click at each detent position when pushing plunger
inward.
2) Install electrical connector on brake switch. Depress
brake pedal as far as possible. Install brake switch in mounting

bracket. Ensure alignment tab on brake switch aligns with opening on
mounting bracket.
CAUTION: When adjusting brake switch, DO NOT pull brake pedal back
toward brake switch with excessive pressure, or brake switch
may be damaged.
3) When brake switch is fully installed in mounting bracket,
rotate brake switch clockwise approximately 30 degrees. To ensure
proper brake switch adjustment, gently pull brake pedal back toward
brake switch as far as possible. DO NOT apply excessive pressure on
brake pedal and brake switch.
Removal (Ram Van & Ram Wagon)
1) Brake switch is located near top of brake pedal. Remove
lower steering column cover. Remove data link connector, hood release
lever and parking brake lever from lower instrument panel cover.
2) Remove lower instrument panel cover for access to brake
switch. Depress and hold brake pedal downward. Rotate brake switch
counterclockwise approximately 1/16 turn to so locking collar on brake
switch aligns with opening on mounting bracket. Pull brake switch
rearward from mounting bracket. Disconnect electrical connector from
brake switch.
NOTE: Before installing brake switch, plunger on brake switch must
be pulled outward to fully extended position and then pushed
inward 4 detent positions to ensure proper brake switch
adjustment.
Installation
1) Pull plunger on brake switch outward to the fully extended
position. Push plunger on brake switch inward 4 detent positions. The
brake switch will click at each detent position when pushing plunger
inward.
2) Install electrical connector on brake switch. Depress
brake pedal as far as possible. Install brake switch in mounting
bracket. Ensure locking collar on brake switch aligns with opening on
mounting bracket.
CAUTION: When adjusting brake switch, DO NOT pull brake pedal back
toward brake switch with excessive pressure, or brake switch
may be damaged.
3) When brake switch is fully installed in mounting bracket,
rotate brake switch clockwise approximately 1/16 turn. To ensure
proper brake switch adjustment, gently pull brake pedal back toward
brake switch as far as possible. DO NOT apply excessive pressure on
brake pedal and brake switch.
CAMSHAFT POSITION SENSOR
Removal & Installation
See CAMSHAFT POSITION SENSOR under IGNITION SYSTEM.
CRANKSHAFT POSITION SENSOR
Removal & Installation
See CRANKSHAFT POSITION SENSOR under IGNITION SYSTEM.
DOWNSTREAM OXYGEN SENSOR
NOTE: Downstream oxygen sensor may also be referred to as post
-catalyst oxygen sensor.

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(
1) - SAE 10W-30 engine oil is preferred. Use only API approved 

oil with Starburst Symbol. 

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FLUID CAPACITIES 

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Item  Condition  Specification (1) 

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Engine Oil  5.9L: Drained, W/New Filter  5 Qts. (4.7L) 


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 8.0L: Drained, W/New Filter  5 Qts. (4.7L) 


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 5.9L: Drained  4.5 Qts. (4.2L) 

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Engine  5.9L: Drained  20 Qts. (19L) 

Coolant 
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 8.0L: Drained  24 Qts. (22.7L) 

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(
1) - Capacities are recommended or calculated levels. Always use 

dipstick (if available) to measure level. 
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82,500 MILE (132,000 KM)/82 MONTH NORMAL SERVICE
82,500 MILE (132,000 KM)/82 MONTH NORMAL SERVICE
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VERIFY 

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Last Major Service Was Performed. 

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REPLACE 

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 Oxygen Sensor (5.9L Only) (
1) 

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(
1)  Requires service reminder indicator light. If so equipped, 

these parts are to be replaced at the indicated mileage 

when the service reminder indicator light remains on 

continuosly with the key in the "ON" position, which occurs 

first. 
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84,000 MILE (134,000 KM) SEVERE DUTY SERVICE
84,000 MILE (134,000 KM) SEVERE DUTY SERVICE
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VERIFY 

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Last Major Service Was Performed. 

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INSPECT 

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 Exhaust System 


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 Brake Hoses 


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 Engine Coolant Level, Hoses & Clamps 


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 Engine Air Cleaner & Air Pump Filters 


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 Brake Linings 

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SERVICE 

ON-VEHICLE TESTING
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.
DISABLING/ENABLING IGNITION & FUEL SYSTEMS
WARNING: To prevent engine from starting while performing tests,
always disable ignition and fuel systems.
Disabling Ignition & Fuel Systems
Remove Automatic Shutdown Relay (ASD) located in Power
Distribution Center (PDC). Refer to PDC cover for proper relay
location. PDC is located in engine compartment. On 5.9L diesel
engines, also disconnect fuel shutdown solenoid connector. Solenoid is
located behind upper intake manifold. See appropriate SYSTEM &
COMPONENT TESTING article in ENGINE PERFORMANCE section.
Enabling Ignition & Fuel Systems
When testing and/or repairs have been completed, verify
battery condition. Recharge battery as necessary, after starter tests
have been completed. Disconnect all test equipment. Install ASD relay.
On 5.9L diesel engines, reconnect fuel shutdown relay connector. On
all models, start engine several times to verify malfunction has been
corrected.
CRANKING TEST
NOTE: Ensure engine is at normal operating temperature. High
viscosity oil, extreme cold temperatures, or tight engine
will increase amperage draw.
1) Using a battery load tester, connect positive and negative
leads to battery. Connect inductive ammeter pick-up to positive
battery cable. Disable ignition and fuel systems. See
DISABLING/ENABLING IGNITION & FUEL SYSTEMS.
2) Ensure all lights and accessories are off. Place A/T in
Park position or M/T in Neutral position. Apply parking brake. Crank
engine and observe voltmeter reading. If voltage is more than 9.6
volts and cranking amperage draw is more than specified amps, proceed
to CIRCUIT RESISTANCE TESTS. See STARTER SPECIFICATIONS - CARS or
STARTER SPECIFICATIONS - TRUCKS.
3) If voltage is 12.5 volts or more and cranking amperage
draw is less than specified, check starter circuit components in the
following order:
starter solenoid, starter relay, starter relay circuit, park/neutral
position switch or transmission range sensor (A/T), clutch pedal
position switch (M/T), ignition switch, wiring harness and
connections.
CIRCUIT RESISTANCE TESTS
NOTE: If excessive resistance is not found in circuits being
tested, remove starter and proceed to BENCH TESTING.
Battery Connection Resistance Test
1) Disable vehicle ignition and fuel systems. See
DISABLING/ENABLING IGNITION & FUEL SYSTEMS. A voltmeter accurate to
one tenth of a volt will be needed for the following tests.


STE ER IN G K NUCKLE S - 4 W D

1999 D odge P ic ku p R 1500
1998-99 DRIVE AXLES
CHRY - 4WD Steering Knuckles
Ram Pickup
DESCRIPTION
Open type steering knuckles are used on all models. Open type
knuckles provide sharper turning angle, decreasing turning radius.
Axle shafts are free floating. Steering knuckles are attached to axle
housing by ball joints.
REMOVAL & INSTALLATION
REMOVAL
1) Raise and support vehicle. Remove wheels. Remove brake
caliper, and support aside. DO NOT allow caliper to hang by brake
hose. On one ton models, remove adapter hub bolts and hub from rotor
and hub assembly. On all models, remove cotter pin from rotor and hub
nut.
2) Remove rotor and hub nut. Remove bolts securing rotor and
hub assembly to steering knuckle. Bolts are accessible from inboard
side of steering knuckle. Remove rotor and hub assembly. Remove hub
spacer from steering knuckle. Note spacer position for installation
reference.
3) Disconnect tie rod end and drag link studs. Remove anti-
lock brake sensor from steering knuckle. Remove ball joint cotter pins
and nuts. Discard lower nut. Using a soft-face hammer, tap steering
knuckle to free it from ball joints.
4) Clean all components with solvent, and dry with compressed
air. Inspect all parts for burrs, chips, wear, flat spots or cracks.
Replace all damaged or worn parts.
INSTALLATION
NOTE: When aligning upper ball joint nut to install cotter pin,
always tighten nut to align holes. Never loosen nut to align
holes.
1) Position steering knuckle on ball joints, and install NEW
lower ball joint nut. Tighten nut to specification. See TORQUE
SPECIFICATIONS. Install upper ball joint nut, and tighten to
specification. Tighten, DO NOT loosen, nut to install NEW cotter pin.
2) Install hub bearing and axle shaft. Connect drag link stud
to steering knuckle arm. Install retaining nut, and tighten to
specification. Install NEW cotter pin. Connect tie rod end stud to
steering knuckle arm. Install retaining nut and tighten to
specification. Install NEW cotter pin. Install anti-lock brake sensor
to steering knuckle.
3) Apply anti-seize compound to splines of front drive axle.
Inspect hub grease seal and wheel bearing. Replace as necessary. From
rear of steering knuckle, install 2 rearward rotor and hub assembly
bolts in steering knuckle.
4) Apply chassis grease to hub spacer to secure on steering
knuckle. Position spacer on rotor and hub assembly bolts. Ensure
spacer is installed with flat edge toward rear of vehicle. Apply
Loctite to rotor and hub assembly bolt threads. Install rotor and hub