differential DODGE RAM 1999 Service Workshop Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 476 of 1691
![DODGE RAM 1999 Service Workshop Manual refer to the component listing in this document. \
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refer to the component listing in this document. \
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TRANSFER CASE ASSEMBLIES
TRANSFER CASE ASSEMBLY INSPECTION \
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Condition Code Procedure
Any internal component
failure that requires
removal of the assembly
from the vehicle for
service. ( 1) ........... A ... Require repair or replacement
of the transfer case
differential assembly.
( 1) - For components not requiring removal of the assembly,
refer to the component listing in this document.
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DRIVE TRAIN/COMPONENTS
The conditions listed for the components included in this
section assume that the problem has been isolated to the specific
component through proper testing.
ACTUATORS (ELECTRICAL)
ACTUATOR (ELECTRICAL) INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted,
affecting performance .. A ........... ( 1) Require repair or
replacement.
Connector melted, not
affecting performance .. 2 ........... ( 1) Suggest repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. A ........ ( 2) Require replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Out of adjustment ....... B .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 1 ........... ( 1) Suggest repair or
Page 495 of 1691
![DODGE RAM 1999 Service Workshop Manual See DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES .
LINES
See HOSES, LINES AND TUBES .
LINKAGES (EXTERNAL)
LINKAGE (EXTERNAL) INSPECTION \](/img/12/56915/w960_56915-494.png "DODGE RAM 1999 Service Workshop Manual See DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES .
LINES
See HOSES, LINES AND TUBES .
LINKAGES (EXTERNAL)
LINKAGE (EXTERNAL) INSPECTION \")
See DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES .
LINES
See HOSES, LINES AND TUBES .
LINKAGES (EXTERNAL)
LINKAGE (EXTERNAL) INSPECTION \
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Condition Code Procedure
Components missing ...... C .. Require replacement of missing
components.
Linkage bent, affecting
performance ............ A ... Require repair or replacement
of linkage.
Linkage bent, not
affecting performance .. 2 ... Suggest repair or replacement
of linkage.
Linkage binding, affecting
performance ............ A ... Require repair or replacement
of linkage.
Linkage binding, not
affecting performance .. 1 ... Suggest repair or replacement
of linkage.
Linkage broken .......... A ... Require repair or replacement
of linkage.
Linkage loose, affecting
performance ............ A ... Require repair or replacement
of linkage.
Linkage loose, not
affecting performance .. 1 ... Suggest repair or replacement
of linkage.
Linkage missing ......... C ............ Require replacement.
Linkage noisy ........... 2 .. Suggest repair or replacement.
Out of adjustment ....... B .. Require repair or replacement.
Worn to the extent that it
no longer performs its
intended function ...... A .. Require repair or replacement.
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LOCKING HUB ASSEMBLIES
LOCKING HUB ASSEMBLY INSPECTION \
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Condition Code Procedure
Inoperative ............. A ........... ( 1) Require repair or
replacement.
Loose ................... A .. Require repair or replacement.
Seized in any position .. A .. Require repair or replacement.
( 1) - Inoperative includes intermittent operation.
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LOCKING HUB CONTROL KNOBS
LOCKING HUB CONTROL KNOB INSPECTION \
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Condition Code Procedure
Page 532 of 1691
Manifold Air Pressure (MAP)
Sensor (Diesel) In left rear side of intake
manifold.
Rear Wheel Speed Sensor In differential housing.
Page 635 of 1691
reference marks on torque converter and flexplate are aligned.
Evacuate and charge A/C system.
Removal (Durango 4WD & Dakota 4WD)
1) Release fuel pressure. See FUEL PRESSURE RELEASE.
Disconnect and remove battery. Scribe hood hinges for installation
reference and remove hood.
2) Drain cooling system. Disconnect coolant hoses. Remove
radiator, fan and shroud. Discharge A/C system (if equipped) using
approved refrigerant recovery/recycling equipment. Disconnect A/C
lines, and plug openings. Remove air cleaner, vacuum lines,
distributor cap and wiring.
3) Disconnect necessary electrical wiring. Disconnect fuel
lines. See FUEL LINE DISCONNECT FITTINGS. Disconnect accelerator
linkage. Remove throttle body. Remove starter and generator.
Disconnect power steering hoses. Raise and support vehicle. Drain oil.
Disconnect exhaust pipe at exhaust manifold.
NOTE: Engine, transmission and front axle are connected and
supported with insulators and brackets. See Fig. 3.
4) On left side, remove 2 bolts attaching differential pinion
nose bracket-to-bellhousing bolts. Remove pinion nose bracket-to-
adapter bolts (located on top of differential, near pinion). Separate
engine from engine mount by removing engine mount through-bolt and nut
located on top of engine mount.
5) On right side, remove 2 axle-to-bracket bolts and bracket-
to-bellhousing bolt. Separate engine from engine mount by removing
engine mount through-bolt and nut located on top of engine mount.
Remove engine from vehicle.
Page 649 of 1691
components, reverse removal procedure.
Removal (Dakota 4WD & Durango 4WD)
1) Disconnect negative battery cable. Remove oil dipstick.
Drain engine oil. Remove exhaust pipe crossover and lower transmission
cover.
2) Remove front drive axle for access to oil pan. For front
drive axle removal, loosen wheel lug nuts. Remove cotter pin, lock nut
and spring washer. Loosen axle shaft nut with vehicle on floor and
brakes applied. Raise and support vehicle.
CAUTION: DO NOT pull on rubber boot during axle shaft removal. Pull on
outer CV joint only.
3) Remove wheels and skid plate. Remove axle shaft nut.
Remove axle shaft-to-differential flange bolts at front drive axle.
Support axle shaft, and separate axle splines from wheel hub by
pulling inward at outer CV joint.
4) Remove remaining axle shaft. Mark front drive shaft and
transfer case yoke for installation reference. Remove front drive
shaft from transfer case. Disconnect vacuum hoses from shift motor and
electrical connections at shift indicator switch.
5) Support front drive axle using a floor jack. Remove front
drive axle and shift motor bolts. Lower floor jack, and remove front
drive axle with drive shaft. Remove transmission lower cover. Remove
bolts, oil pan and gasket.
Installation
1) To install, reverse removal procedure. Before installing
oil pan, apply RTV sealant where front cover contacts cylinder block,
oil pan side gaskets meet end seals and end seals contact cylinder
block. See Fig. 14.
2) To facilitate oil pan installation, fabricate 4 alignment
dowels from 1 1/2" x 5/16" bolts. See Fig. 15. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table.
3) To install remaining components, reverse removal
procedure. When installing front drive axle, loosely install all bolts
before tightening to specification. Tighten axle shaft nut to
specification with vehicle on ground. See TORQUE SPECIFICATIONS table.
Ensure reference marks on transfer case yoke and front drive shaft are
aligned.
Removal (Ram Pickup & Ram Van/Wagon - 3.9L)
1) Disconnect negative battery cable. Remove oil dipstick. On
Ram Van/Wagon, remove engine cover. On all models, remove air cleaner
and engine controller. Raise and support vehicle. Drain engine oil.
2) Remove left engine-to-transmission strut. Loosen exhaust
pipe support bracket. Disconnect exhaust pipe. On Ram Pickup, remove
oil pan and gasket.
3) On Ram Van/Wagon, remove starter, transmission dust
shield, oxygen sensor and air injection tube. On all models, remove
right engine mount nut. Loosen, but DO NOT remove, left engine mount
nut.
4) Support right side of engine using jackstand. Remove
transmission mount through-bolt, and support transmission using
jackstand. Raise engine and transmission enough for oil pan removal.
Remove bolts, oil pan and gasket.
Installation
1) To install, reverse removal procedure. Before installing
oil pan, apply RTV sealant where front cover contacts cylinder block,
oil pan side gaskets meet end seals and end seals contact cylinder
block. See Fig. 14.
Page 658 of 1691
![DODGE RAM 1999 Service Workshop Manual OIL PUMP SPECIFICATIONS \
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OIL PUMP SPECIFICATIONS \
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Application Specification
Inner & Outer Rotor Thickness ................ .825" (20.96 mm) Min.\
Outer Rotor Diameter .......................... 2.47" (62.7 mm) Min.\
Outer Rotor-To-Pump Body Clearance ............. .014" (.36 mm) Max.\
Pump Cover Warpage ........................... .0015" (.038 mm) Max.\
Rotor End Clearance ................................. .004" (.10 mm)\
Rotor Tip Clearance ............................ .008" (.20 mm) Max.\
Spring Free Length ................................. 1.95" (49.5 mm)\
Spring Tension ......... 19.5-20.5 Lbs. @ 1.34" (8.8-9.3 kg @ 34 mm)\
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CAUTION: Ensure oil pump fully engages with distributor drive shaft
before tightening bolt. It may be necessary to slightly
rotate oil pump during installation to align with distributor
drive shaft.
Reassembly & Installation
To reassemble, reverse disassembly procedure. Install NEW
relief valve retainer cap and oil seal ring. Tighten pump cover bolts.
Fill rotor cavity with engine oil before installing. To install,
reverse removal procedure.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Application Ft. Lbs. (N.m)\
Axle Bracket-To-Bellhousing Bolt
Dakota 4WD & Durango 4WD ................................. 65 (88)\
Axle Shaft Nut
Dakota 4WD & Durango 4WD ............................... 180 (244)\
Axle Shaft-To-Differential Flange Bolt
Dakota 4WD & Durango 4WD ................................. 65 (88)\
Axle-To-Insulator Bolt
Dakota 4WD & Durango 4WD ................................ 75 (102)\
Camshaft Sprocket Bolt ..................................... 50 (68)\
Camshaft Thrust Plate Bolt ................................. 18 (24)\
Clutch Housing-To-Cylinder Block Bolt
Dakota
(1) ..................................................... 30 (41)
( 2) ..................................................... 50 (68)
Ram Pickup
( 1)
3/8" Bolt ............................................ 33 (45)\
7/16" Bolt ........................................... 50 (68)\
( 2) ........................................................ N/A
Connecting Rod Bolt ........................................ 45 (61)\
Crankshaft Pulley Bolt ..................................... 18 (24)\
Cylinder Head Bolt ( 3)
Step 1 ................................................... 50 (68)\
Step 2 ................................................. 105 (142)\
Step 3 (Verify Torque) ................................. 105 (142\
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Differential Pinion Nose Bracket-To-Adapter Bolt
Dakota 4WD & Durango 4WD ................................. 65 (88)\
Differential Pinion Nose Bracket-To-Bellhousing Bolt
Dakota 4WD & Durango 4WD ................................. 65 (88)\
Engine Mount Bracket-To-Frame Rail Bolt
Dakota 2WD & Durango 2WD ................................. 30 (41)\
Page 677 of 1691
than .010" (.25 mm) from tip. Chamfer sharp edge of reground valve
tip. Recheck valve stem installed height.
VALVE STEM OIL SEALS
Valve stem oil seals must be installed on valve stem. See
Fig. 2 . Seals are needed due to pressure differential at the ends of
valve guides. Atmospheric pressure above intake guide, combined with
manifold vacuum below guide, causes oil to be drawn into the cylinder.
Exhaust guides also have pressure differential created by
exhaust gas flowing past the guide, creating a low pressure area. This
low pressure area draws oil into the exhaust system.
Replacement (On Vehicle)
Mark rocker arm or overhead cam components for location.
Remove rocker arm components or overhead cam components. Components
must be installed in original location. Remove spark plugs. Valve stem
oil seals may be replaced by holding valves against seats using air
pressure.
Air pressure must be installed in cylinder using an adapter
for spark plug hole. An adapter can be constructed by welding air hose
connection to spark plug body with porcelain removed.
Install adapter in spark plug hole. Apply a minimum of 140
psi (9.8 kg/cm
) to adapter. Air pressure should hold valve closed. If
air pressure does not hold valve closed, check for damaged or bent
valve. Cylinder head must be removed for service.
Using valve spring compressor, compress valve springs. Remove
valve locks. Carefully release spring compressor. Remove retainer or
rotator and valve spring. Remove valve stem oil seal.
If oversized valves have been installed, oversized oil seals
must be used. Coat valve stem with engine oil. Install protective
sleeve over end of valve stem. Install new oil seal over valve stem
and seat on valve guide. Remove protective sleeve. Install spring
seat, valve spring and retainer or rotator. Compress spring and
install valve locks. Remove spring compressor. Ensure valve locks
are fully seated.
Install rocker arms or overhead cam components. Tighten all
bolts to specification. Adjust valves if required. Remove adapter.
Install spark plugs, valve cover and gasket.
VALVE SPRING INSTALLED HEIGHT
Valve spring installed height should be checked during
reassembly. Measure height from lower edge of valve spring to the
upper edge. DO NOT include valve spring seat or retainer. Distance
must be within specifications. If valves and/or seats have been
ground, a valve spring shim may be required to correct spring height.
See Fig. 12 .
Fig. 12: Measuring Valve Spring Installed Height - Typical
This Graphic For General Information Only
Page 819 of 1691
Fig. 1: Drive Axle Gear Tooth Patterns
ADJUSTMENTS
GEAR BACKLASH & PINION SHIM CHANGES
NOTE: Backlash is adjusted by either moving shims from one side of
differential case to the other or by turning adjusting nuts
on which side bearing races ride. Changing of pinion shims
alters the distance from face of pinion of centerline of
ring gear.
1) With no change in backlash, moving pinion further from
ring gear moves drive pattern toward heel and top of tooth, and moves
coast pattern toward toe and top of tooth.
2) With no change in backlash, moving pinion closer to ring
gear moves drive pattern toward toe and bottom of tooth, and moves
coast pattern toward heel and bottom of tooth.
3) With no change in pinion shim thickness, an increase in
backlash moves ring gear further from pinion. Drive pattern moves
toward heel and top of tooth, and coast pattern moves toward heel and
top of tooth.
Page 888 of 1691
(
1) - SAE 10W-30 engine oil is preferred for use in all Dodge
trucks. Use only API approved oil with Starburst Symbol.
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2) - Axles with Limited-Slip Differentials require the use of
a 5% Friction Modifier, such as Mopar Gear Oil Additive
Friction Modifier.
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3) - Never add gear oil, automatic transmission fluid or
hydroboost power steering fluid.
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FLUID CAPACITIES - DIESEL
FLUID CAPACITIES TABLE - DIESEL \
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Item Condition Specification (1)
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Engine Oil Capacity, Upper Safe Mark 10 Qts. (9.5L)
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Capacity, Lower Safe Mark 8 Qts. (7.5L)
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Engine Drained 26 Qts. (24.5L)
Coolant
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Automatic 46RE: Dry Fill 17 Qts. (16L)
Transmission
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Fluid 47RE: Dry Fill 17 Qts. (16L)
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Manual NV4500 4 Qts. (3.8L)
Transmission
Fluid
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Rear Axle DANA 70 Model 267 (2WD) 7 Pts. (3.3L)
Lubricant
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DANA 70 Model 267 (4WD) 7.8 Pts. (3.6L)
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DANA 80 Model 286 (2WD) 6.8.Pts. (3.2L)
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DANA 80 Model 286 (4WD) 10.1 Pts. (4.8L)
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Rear Axle Model 267 (2WD) 7 Pts. (3.3L)
Limited Slip
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Differential Model 267 (4WD) 7.8 Pts. (3.6L)
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Model 286 (2WD) 6.8 Pts. (3.2L)
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Model 286 (4WD) 10.1 Pts. (4.8L)
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Front Axle Model 248 7.6 Pts. (3.6L)
Lubricant
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Transfer Case NV241 HD 6.5 Pts. (3.1L)
Fluid
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Power Take NV021 4.6 Pts. (2.1L)
Off Adapter
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Power Drained 2.7 Pts. (1.3L)
Steering
Fluid
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A/C Charge Capacity 32 Oz. (.9Kg)
Refrigerant
Page 890 of 1691
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Refrigerant
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A/C All Polyalkalene Glycol
Refrigerant SP10 PAG
Oil Refrigerant Oil
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1) - SAE 10W-30 engine oil is preferred for use in all Dodge
trucks. Use only API approved oil with Starburst Symbol.
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2) - Limited-Slip Differentials require the use of a 5% Friction
Modifier. Mopar Gear Oil Additive Friction Modifier
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3) - Never add gear oil, automatic transmission fluid or
hydroboost power steering fluid.
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FLUID CAPACITIES - GAS
FLUID CAPACITIES TABLE - GAS \
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Item Condition Specification (1)
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Engine Oil 3.9L: Drained, W/New Filter 4 Qts. (3.8L)
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5.2L: Drained, W/New Filter 5 Qts. (4.7L)
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5.9L: Drained, W/New Filter 5 Qts. (4.7L)
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3.9L: Drained 3.5 Qts. (3.3L)
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5.2L: Drained 4.5 Qts. (4.2L)
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5.9L: Drained 4.5 Qts. (4.2L)
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Engine 3.9L: Drained 20 Qts. (19L)
Coolant
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5.2L: Drained 20 Qts. (19L)
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5.9L: Drained 20 Qts. (19L)
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Automatic 42RE: Dry Fill 17-22 Pts. (8-10.4L)
Transmission
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Fluid 46RE: Dry Fill 1726 Pts. (812.3L)
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Manual NV3500: Drained 4.2 Pts. (2L)
Transmission
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Fluid NV3500: Drained 8 Pts. (3.8L)
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Rear Axle 9-1/4: Drained 4.8 Pts. (2.3L)
Fluid
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Model 248 (2WD) 6.3 Pts. (3L)
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Model 248 (4WD) 7.3 Pts. (3.4L)
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Model 267 (2WD) 7 Pts. (3.3L)
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Model 267 (4WD) 7.8 Pts. (3.6L)
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Model 286 (2WD) 6.8.Pts. (3.2L)
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Model 286 (4WD) 10.1 Pts. (4.8L)
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Rear Axle Model 248 (2WD) 6.3 Pts. (3L)