tow DODGE RAM 1999 Service Service Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 418 of 1691
reusing original differential bearings and bearing races, ensure
bearing races are installed in original locations.
13) Place axle housing spreader on axle housing so dowel pins
engage with locating holes. See Fig. 1. Use Axle Housing Spreader (W-
129-B). Install hold-down clamps. Tighten turnbuckle on axle housing
spreader finger tight.
14) Install pilot stud and dial indicator on axle housing.
See Fig. 1 . 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.
15) 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).
16) Remove dial indicator. Install differential case and
bearing races in axle housing. Ensure differential bearings and races
are fully seated. Remove axle housing spreader.
17) Install bearing caps in original location. Install
bearing cap bolts, and tighten to specification. See TORQUE
SPECIFICATIONS table. Rotate differential case several times to seat
differential bearings.
18) Using dial indicator, check ring gear backlash. See
Fig. 6 . Ensure ring gear backlash is as specified. See AXLE ASSEMBLY
SPECIFICATIONS.
19) If ring gear backlash exceeds specification, move ring
gear toward pinion. If ring gear backlash is less than specification,
move ring gear away from pinion. To change ring gear backlash, move
preload shims from one side of differential case to other.
20) Check ring gear backlash every 90 degrees to check for
variation. Ring gear backlash variation should not exceed .002" (.05
mm). For example, if ring gear backlash is .005" (.15 mm) at minimum
point, ring gear backlash should not exceed .008" (.20 mm) anywhere on\
ring gear.
Final Inspection & Assembly
1) With ring gear backlash properly adjusted, check gear
tooth pattern contact. See GEAR TOOTH CONTACT PATTERNS article in
GENERAL INFORMATION.
2) When differential is complete and correctly adjusted,
install axle housing cover using NEW gasket (if equipped). If gasket
is not available, apply a 1/4" thick bead of silicone sealant on
inside of bolt holes and along sealing surfaces on axle housing cover.
3) Install axle housing cover, axle identification tag and
retaining bolts. Tighten bolts to specification. See TORQUE
SPECIFICATIONS table. Fill differential with gear lube. See
LUBRICATION.
Fig. 6: Checking Ring Gear Backlash
Courtesy of Chrysler Corp.
Page 436 of 1691
bearing races in axle housing. Ensure differential bearings and races
are fully seated. Remove axle housing spreader.
17) Install bearing caps in original location. Install and
tighten bearing cap bolts to specification. See TORQUE SPECIFICATIONS
table. Rotate differential case several times to seat differential
bearings.
18) Using dial indicator, check ring gear backlash. See
Fig. 7. Ensure ring gear backlash is as specified. See AXLE ASSEMBLY
SPECIFICATIONS.
19) If ring gear backlash exceeds specification, move ring
gear toward pinion. If ring gear backlash is less than specification,
move ring gear away from pinion. To change ring gear backlash, move
preload shims from one side of differential case to other.
20) Check ring gear backlash every 90 degrees to check for
variation. Ring gear backlash variation should not exceed .002" (.05
mm). For example, if ring gear backlash is .005" (.15 mm) at the
minimum point, ring gear backlash should not exceed .007" (.18 mm)
anywhere on ring gear.
Final Inspection & Assembly
1) With ring gear backlash properly adjusted, check gear
tooth pattern contact. See GEAR TOOTH CONTACT PATTERNS article in
GENERAL INFORMATION.
2) When differential is complete and correctly adjusted,
install axle housing cover using NEW gasket (if equipped). If gasket
is not available, apply a 1/4" thick bead of silicone sealant on
inside of bolt holes and along sealing surfaces on axle housing cover.
3) Install axle housing cover, axle identification tag and
retaining bolts. Tighten bolts to proper specification. See TORQUE
SPECIFICATIONS. Fill differential with gear lube. See LUBRICATION.
Fig. 7: Checking Ring Gear Backlash
Courtesy of Chrysler Corp.
AXLE ASSEMBLY SPECIFICATIONS
Page 439 of 1691
![DODGE RAM 1999 Service Service Manual NOTE: Axle ratio can be identified by axle identification tag
attached to axle housing cover. See AXLE RATIO SPECIFICATIONS
table.
AXLE RATIO SPECIFICATIONS
\](/img/12/56915/w960_56915-438.png "DODGE RAM 1999 Service Service Manual NOTE: Axle ratio can be identified by axle identification tag
attached to axle housing cover. See AXLE RATIO SPECIFICATIONS
table.
AXLE RATIO SPECIFICATIONS
\")
NOTE: Axle ratio can be identified by axle identification tag
attached to axle housing cover. See AXLE RATIO SPECIFICATIONS
table.
AXLE RATIO SPECIFICATIONS
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Application Ratio
8 1/4" Ring Gear ........................... 3.21:1, 3.55:1 & 3.90:1
9 1/4" Ring Gear ........................... 3.21:1, 3.55:1 & 3.92:1
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LUBRICATION
CAPACITY
DRIVE AXLE CAPACITY ( 1) \
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Application Pts. (L)\
8 1/4" Ring Gears .................................... ( 2) 4.4 (2.1)
9 1/4" Ring Gear ..................................... ( 2) 4.9 (2.3)
( 1) - Approximate drive axle capacity listed. Lubricant level should
be within 1/2" below bottom of oil filler hole in axle housing
cover.
( 2) - Add 5 ounces of (148 ml) Trac-Loc additive.
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FLUID TYPE
Use SAE 80W-90 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 & BEARING
CAUTION: When servicing differential, DO NOT rotate one axle shaft
unless both axles are installed into differential. Rotation
of one axle shaft without other in place may result in
misalignment of side gears in differential. This would
require difficult realignment of side gears before axle
shafts can be installed.
Removal
1) Raise and support vehicle. Remove wheel and brake drum.
Clean area around axle housing cover. Loosen axle housing cover bolts.
Drain lubricant from axle housing. Remove bolts and axle housing
cover. Rotate differential carrier for access to lock bolt. See Fig. 1
.
2) Remove lock bolt and pinion shaft from differential
carrier. See Fig. 1. Push axle shaft inward, toward center of vehicle.
Remove clip from groove in end of axle shaft. Remove axle shaft from
Page 472 of 1691
VEHICLE SPEED SENSORS
VENTS
VIBRATION DAMPERS
WHEEL ATTACHMENT HARDWARE
WHEEL SPEED SENSORS
WIRING HARNESSES AND CONNECTORS
YOKES AND SLIP YOKES
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
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 were recently published.
Further, revisions to all of these inspection communication standards
are continually republished. 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-
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
Page 511 of 1691
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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Page 544 of 1691
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-
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.
Page 596 of 1691
B - E M IS SIO N A PPLIC ATIO N
1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
Emission Applications - Trucks
CHRY
EMISSION APPLICATIONS
EMISSION APPLICATIONS \
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Engine & Major Emission Components & Other
Fuel Systems Systems & Devices Related Devices
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2.4L 4-Cyl. SFI PCV, EVAP, TWC, FR, (
2) EVAP-PSOL, EVAP-PRRV,
Caravan & Voyager SPK, (
1) HO2S, CEC, ( 2)( 3) EVAP-LDP,
MIL (
3) EVAP-LDPF, EVAP-VC,
SPK-CC
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\b\
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\b\
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2.5L 4-Cyl. SFI (
4) CCV, EVAP, TWC, ( 2) EVAP-PSOL, EVAP-PRRV,
Dakota FR, SPK, (
1) HO2S, ( 2)( 3) EVAP-LDP,
CEC, MIL (
3) EVAP-LDPF,
(
5) EVAP-CVV, EVAP-VC,
SPK-CC
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\b\
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\b\
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3.0L V6 SFI PCV, EVAP, TWC, FR, (
2) EVAP-PSOL, EVAP-PRRV,
Caravan & Voyager BP/EGR, SPK, (
2)( 6) EVAP-LDP,
(
1) HO2S, CEC, MIL ( 6) EVAP-LDPF, EVAP-VC,
(
2) BP/EGR-BPT, SPK-CC
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\b\
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\b\
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3.3L V6 SFI PCV, EVAP, TWC, FR, (
2) EVAP-PSOL, EVAP-PRRV,
Caravan, BP/EGR, SPK, (
2)( 3) EVAP-LDP,
Town & Country & (
1) HO2S, CEC, MIL ( 3) EVAP-LDPF, EVAP-VC,
Voyager (
2) BP/EGR-BPT, SPK-CC
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\b\
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\b\
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3.8L V6 SFI PCV, EVAP, TWC, FR, (
2) EVAP-PSOL, EVAP-PRRV,
Caravan & BP/EGR, SPK, (
2)( 3) EVAP-LDP,
Town & Country (
1) HO2S, CEC, MIL ( 3) EVAP-LDPF, EVAP-VC,
(
2) BP/EGR-BPT, SPK-CC
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\b\
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3.9L V6 SFI PCV, EVAP, TWC, FR, (
2) EVAP-PSOL, EVAP-PRRV,
Dakota & Durango SPK, (
1) HO2S, CEC, ( 2)( 3) EVAP-LDP,
MIL (
3) EVAP-LDPF,
(
5) EVAP-VV, EVAP-VC,
SPK-CC
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\b\
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\b\
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3.9L V6 SFI PCV, EVAP, TWC, FR, (
2) EVAP-PSOL, EVAP-PRRV,
Ram Pickup SPK, (
1) HO2S, CEC, ( 2)( 6) EVAP-LDP,
MIL (
6) EVAP-LDPF,
(
6) EVAP-VV, EVAP-VC,
SPK-CC
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\b\
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3.9L V6 SFI PCV, EVAP, TWC, FR, (
2) EVAP-PSOL, EVAP-PRRV,
Ram Van & SPK, (
1) HO2S, CEC, ( 2)( 3) EVAP-LDP,
Ram Wagon MIL (
3) EVAP-LDPF,
(
5) EVAP-VV, EVAP-VC,
SPK-CC
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5.2L V8 SFI PCV, EVAP, TWC, FR, (
2) EVAP-PSOL, EVAP-PRRV,
Dakota & Durango SPK, (
1) HO2S, CEC, ( 2)( 3) EVAP-LDP,
MIL (
3) EVAP-LDPF,
(
5) EVAP-VV, EVAP-VC,
SPK-CC
Page 599 of 1691
A - E N G IN E/V IN ID
1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Chrysler Corp. Introduction - Trucks
MODEL IDENTIFICATION
1999 MODEL COVERAGE \
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MODEL BODY ENGINE ENGINE FUEL IGNITION
CODE ID
(1) SYSTEM SYSTEM
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Caravan & NS 2.4L B SFI (
2) DIS ( 3)
Grand Caravan
\b\
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\b\
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3.0L 3 SFI (
2) Hall Effect
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\b\
\b\
\b\
3.3L R SFI DIS (
3)
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\b\
\b\
\b\
3.3L G (
4) SFI DIS ( 3)
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\b\
\b\
\b\
3.8L L SFI DIS (
3)
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\b\b\
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\b\b\
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\b\
Dakota AN 2.5L P SFI (
2) Hall Effect
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\b\
\b\
\b\
3.9L X SFI (
2) Hall Effect
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\b\
\b\
\b\
5.2L Y SFI (
2) Hall Effect
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\b\
\b\
\b\
5.9L Z SFI (
2) Hall Effect
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\b\b\
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\b\b\
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\b\
Durango DN 3.9L X SFI (
2) Hall Effect
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\b\
\b\
\b\
5.2L Y SFI (
2) Hall Effect
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\b\
\b\
\b\
5.9L Z SFI (
2) Hall Effect
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\b\b\
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\b\b\
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\b\
Ram Pickup (
5) 3.9L X SFI ( 2) Hall Effect
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\b\
\b\
\b\
5.2L Y SFI (
2) Hall Effect
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\b\
\b\
\b\
5.9L LD (
6) Z SFI ( 2) Hall Effect
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\b\
\b\
\b\
5.9L HD (
7) 5 SFI ( 2) Hall Effect
\
\b\
\b\
\b\
5.9L Diesel 6 EFI (
8) N/A
\
\b\
\b\
\b\
8.0L W SFI (
2) DIS ( 3)
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\b\b\
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\b\b\
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\b\
Ram Van & AB 3.9L X SFI (
2) Hall Effect
Ram Wagon
\b\
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\b\b\
\b\
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5.2L Y SFI (
2) Hall Effect
\
\b\
\b\
\b\
5.2L 2 (
9) SFI ( 2) Hall Effect
\
\b\
\b\
\b\
5.2L T (
10) SFI ( 2) Hall Effect
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\b\
\b\
\b\
5.9L Z SFI (
2) Hall Effect
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\b\b\
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\b\b\
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\b\
Town & Country NS 3.3L R SFI DIS (
3)
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\b\
\b\
\b\
3.3L G (
4) SFI DIS ( 3)
\
\b\
\b\
\b\
Page 601 of 1691
![DODGE RAM 1999 Service Service Manual \
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VIN Code](/img/12/56915/w960_56915-600.png "DODGE RAM 1999 Service Service Manual \
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VIN Code")
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VIN Code Model Year
V ............................................................. 1997
W ............................................................. 1998
X ............................................................. 1999
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ENGINE CODE LOCATION
ENGINE CODE LOCATION\
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Application Location
Caravan, Grand Caravan,
Grand Voyager, Town & Country,
& Voyager
2.4L 4-Cyl. .............................. Rear Of Cylinder Block,
Below Cylinder Head Surface,
Just Above Flywheel
3.0L V6 ......................... Firewall Side Of Cylinder Block,
Below Cylinder Head,
Near Rear Of Exhaust Manifold
3.3L & 3.8L V6 ........................... Rear Of Cylinder Block,
Below Cylinder Head,
Just Above Flywheel
Dakota, Durango, Ram Pickup,
Ram Van & Ram Wagon
2.5L 4-Cylinder ................... Machined Pad On Right Side Of
Cylinder Block, Between Cylinders
No. 3 & 4
3.9L V6, 5.2L V8 & 5.9L V8 .............. Machined Pad Left Front
Corner Of Cylinder Block
5.9L 6-Cyl. Diesel ........................ On Engine Data Plate,
Also Stamped On Right Side Of
Cylinder Block, Above Oil Cooler
8.0L V10 ............................. Lower Left Front Corner Of
Cylinder Block, In Front Of Engine Mount
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Page 617 of 1691
EN G IN E C O OLIN G S PEC IF IC ATIO NS
1999 D odge P ic ku p R 1500
1998-99 ENGINE COOLING
CHRY - Specifications - All Models
1998 Talon
1998-99 Avenger, Breeze, Caravan, Cirrus, Concorde, Dakota,
Durango, Intrepid, Neon, Ram Pickup, Ram Van/Wagon, Sebring
Convertible, Sebring Coupe, Stratus, Town & Country, Voyager
1999 LHS, 300M
BELT ADJUSTMENT
NOTE: For belt routing on models not covered in this article,
information was not available. See underhood label for proper
belt routing.
Belts should be adjusted to proper tension using belt tension
gauge. See appropriate BELT ADJUSTMENT SPECIFICATIONS table. Some
models may be equipped with an automatic belt tensioner. Ensure
serpentine belts are routed properly. See Figs. 5 through 14.
4-CYLINDER BELT ADJUSTMENT SPECIFICATIONS - CARS
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Application New Belt (1) Used Belt
Lbs. (kg) Lbs. (kg\
)
Avenger & Sebring Coupe
2.0L
Generator ................... 110-160 (50-73) .. 90-110 (41-50\
)
Power Steering
With A/C .................. 137-159 (62-72) .. 93-115 (42-52\
)
Without A/C ............... 110-160 (50-73) .. 90-110 (41-50\
)
Breeze, Cirrus & Stratus
2.0L & 2.4L
A/C & Generator .................. 150 (68) ............ 80 (36\
)
Power Steering .................. 130 (59) ............ 80 (36\
)
Neon
2.0L (DOHC & SOHC)
A/C & Pwr. Steering ............. 135 (61) ........... 100 (45\
)
Generator ....................... 135 (61) ........... 100 (45\
)
Sebring Convertible
2.4L .......................... 150 (68) ............ 80 (36\
)
Talon
2.0L Non-Turbo
Generator ................... 110-160 (50-73) .. 90-110 (41-50\
)
Power Steering
With A/C .................. 137-159 (62-72) .. 93-115 (42-52\
)
Without A/C ............... 110-160 (50-73) .. 90-110 (41-50\
)
2.0L Turbo
A/C ........................... 86-99 (39-45) ... 57-75 (26-34\
)
Generator ..................... 110-154 (50-70) ........ 88 (40\
)
Power Steering ............... 110-154 (50-70) .. 77-92 (35-42\
)
( 1) - Belt is considered used after 15 minutes of service.
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V6 BELT ADJUSTMENT SPECIFICATIONS - CARS \
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Application New Belt (1) Used Belt
Lbs. (kg) Lbs. (kg\
)