lock DODGE RAM 1999 Service Manual PDF
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 316 of 1691
disarm switch state CLOSED, replace CTM.
23) Turn ignition switch to START position. If horn does not
sound, go to next step. If horn sounds, go to step 24).
24) Locate Central Timer Module (CTM). CTM is located behind\
right kick panel. Disconnect CTM 14-pin connector C1. Using an
external voltmeter, measure voltage between ground and CTM 14-pin
connector C1 terminal No. 8 (Dark Blue/White wire). If voltage is more\
than 10 volts, replace CTM. If voltage is 10 volts or less, repair
open Dark Blue/White wire between CTM and RUN-ACC fuse in junction
block.
WINDSHIELD WIPER SYSTEM
WIPER PARK SWITCH FAILURE
NOTE: For connector terminal identification and wiring diagrams,
see BODY CONTROL COMPUTER - INTRODUCTION article. Perform
VERIFICATION TEST VER-1A after each repair.
CAUTION: Always turn ignition switch to OFF position prior to
disconnecting or connecting any module connector.
NOTE: It takes 8 seconds for wiper park switch failure DTC to set.
1) Using scan tool, clear DTCs. See appropriate SELF-
DIAGNOSTICS article. Operate wipers in low speed, then intermittent
mode. Reread DTCs. If WIPER PARK SWITCH FAILURE is displayed, go to
next step. If WIPER PARK SWITCH FAILURE is not displayed, system is
currently functioning properly.
2) Gain access to wiper motor connector. Using an external
voltmeter, measure voltage between ground and wiper motor terminal No.
2 (Dark Green wire). If voltage is more than 9 volts, go to next step.\
If voltage is 9 volts or less, replace wiper motor.
3) Locate Central Timer Module (CTM). CTM is located under
left side of instrument panel. Using an external voltmeter, measure
voltage between ground and backprobe of CTM 14-pin Green connector C1
terminal No. 11 (Dark Green wire). If voltage is 9 volts or less,
replace CTM. If voltage is more than 9 volts, repair short to voltage
in Dark Green wire between CTM and wiper relay or wiper motor.
INTERMITTENT WIPERS INOPERATIVE
NOTE: For connector terminal identification and wiring diagrams,
see BODY CONTROL COMPUTER - INTRODUCTION article. Perform
VERIFICATION TEST VER-1A after each repair.
CAUTION: Always turn ignition switch to OFF position prior to
disconnecting or connecting any module connector.
1) Using scan tool select CENTRAL TIMER MODULE. If scan tool
displays NO RESPONSE, go to appropriate VEHICLE COMMUNICATIONS
article. If scan tool displays any CCD bus failure message, go to
SYMPTOM IDENTIFICATION. If scan tool does not display NO RESPONSE or
any CCD bus failure message, go to next step.
2) If problem is wipers parking in wrong position, go to next
step. If problem is not wipers parking in wrong position, go to step
5).
3) Gain access to wiper motor connector. Turn wipers on to
low speed. Using an external voltmeter, measure voltage between ground
and wiper motor switch terminal No. 2 (Dark Green wire). If voltage
does not cycle between zero and 12 volts, replace wiper motor. If
voltage cycles between zero and 12 volts, go to next step.
Page 319 of 1691
* B RAK E S YSTE M U NIF O RM IN SPEC TIO N G UID ELIN ES *
1 999 D odge P ic ku p R 1500
GENERAL INFORMATION
Brake Systems - Motorist Assurance Program
Standards For Automotive Repair
All Makes & Models
CONTENTS
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS
ACCELEROMETERS (G SENSOR OR LATERAL)
ACCUMULATORS
ANCHOR PINS
ANTI-LOCK BRAKE SYSTEMS
BACKING PLATES
BRAKE FLUID
BRAKE FRICTION MATERIAL
BRAKE PADS
BRAKE PEDALS
BRAKE SHOES
BRAKE SHOE HARDWARE
BRAKE STOPLIGHT SWITCHES
BULB SOCKETS
BULBS AND LEDS
CALIPER HARDWARE
CALIPERS
CONTROLLERS
DIGITAL RATIO AXLE CONTROLLERS AND BUFFERS (DRAC AND DRAB)
DISABLE SWITCHES
DRUMS
ELECTRICAL PUMPS AND MOTORS
ELECTRONIC CONTROLLERS
FLUID
FLUID LEVEL SENSOR SWITCHES
FOUR WHEEL DRIVE SWITCHES
FRICTION MATERIAL
G SENSORS
HOSES
HYDRAULIC MODULATORS
HYDRO-BOOSTERS
HYDRO-ELECTRIC BOOSTERS (POWERMASTER)
IGNITION DISABLE SWITCHES
LATERAL ACCELERATION SWITCHES
LEDS
LENSES
MASTER CYLINDERS
MODULATORS
MOTORS
PARKING BRAKE SWITCHES
PARKING BRAKE SYSTEMS
PADS
PEDAL TRAVEL SWITCHES
PEDALS
POWERMASTER
PUMPS
PRESSURE DIFFERENTIAL SWITCHES
PRESSURE SWITCHES
RELAYS
ROTORS
SELF-ADJUSTING SYSTEMS
Page 323 of 1691
and make an informed decision about how to proceed.
BRAKES
SERVICE PROCEDURES REQUIRED & SUGGESTED FOR PROPER
VEHICLE OPERATION
Some states may have specifications that differ from OEM.
Check your local/state regulations. Where state or local laws are
stricter, they take precedence over these guidelines.
ACCELEROMETERS (G SENSOR OR LATERAL)
ACCELEROMETER INSPECTION \
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Condition Code Procedure
Broken .................. A ............ Require replacement.
Connector loose ......... A .. Require repair or replacement.
Loose ................... B .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Out of position ......... B ....... Require re-positioning to
vehicle manufacturer's
specifications.
Output signal incorrect . B ............ Require replacement.
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ACCUMULATORS
ACCUMULATOR INSPECTION \
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Condition Code Procedure
Leaking ................. B ............ Require replacement.
Missing ................. C ............ Require replacement.
Pre-charge incorrect .... B ............ Require replacement.
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ANCHOR PINS
See BACKING PLATES .
ANTI-LOCK BRAKE SYSTEMS
NOTE: Anti-lock brakes are an integral part of the brake system. It
is essential that the anti-lock brakes function properly when
brake service is performed.
Anti-lock brake systems are commonly referred to as "ABS" and
will be referred to as "ABS" throughout these guidelines. Some ABS
components also function as part of a traction control system (TCS).
WARNING: When diagnosing and servicing high pressure components,
observe safety procedures and equipment requirements
established by the vehicle manufacturer to reduce the
possibility of serious personal injury.
NOTE: Intermittent electrical conditions are often caused by a loss
of ground, poor connection, or water intrusion into the
wiring harness.
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(1) - This condition may be normal on some vehicles equipped with
anti-lock brakes.
( 2) - Refer to OEM procedures for adjusting low fluid level.
Inspect for brake hydraulic system leaks and friction
material wear.
( 3) - This condition may indicate contaminated brake fluid.
See BRAKE FLUID .
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MODULATORS
See HYDRAULIC MODULATORS .
MOTORS
See ELECTRICAL PUMPS AND MOTORS .
PARKING BRAKE SWITCHES
See SWITCHES.
PARKING BRAKE SYSTEMS
NOTE: The parking brake is an integral part of the brake
system. It is important that the parking brake function
properly when brake service is performed.
PARKING BRAKE SYSTEM 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.
Cable improperly
adjusted ............... B ....... Require cable adjustment.
Cable or individual
wires in the cable
are broken ............. A .... Require replacement of cable
assembly.
Cable sticking .......... A ...... Require cable lubrication.
Cable stuck inside conduit
and cannot be lubricated
so that parking brake
functions properly ..... A .... Require replacement of cable
assembly.
Inoperative ( 1) ......... A .......... Require replacement of
inoperative parts.
Parking brake
parts bent ............. B ... Require repair or replacement
of bent parts.
Parking brake
parts broken ........... A ... Require replacement of broken
parts.
Parking brake parts
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Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) - Inoperative includes intermittent operation or out of OEM
specification.
( 2) - Determine cause and correct prior to repair or
replacement of part.
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ROTORS
Determine the need to recondition based upon individual rotor
conditions that follow. Friction material replacement does not require
rotor reconditioning unless other justifications exist. DO NOT
recondition new rotors unless they are being pressed or bolted onto an
existing hub. It is not necessary to replace rotors in axle sets.
However, when replacing or reconditioning a rotor due to the
conditions that follow, you may suggest reconditioning of the other
rotor on the same axle to eliminate uneven braking behavior.
Determine the need to replace based upon the individual rotor
conditions that follow. Reconditioning is defined as machining and
block sanding, or block sanding only. Block sanding is defined as
using 120-150 grit sandpaper with moderate to heavy force for 60
seconds per side. Always wash rotors after servicing or before
installing.
ROTOR INSPECTION
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Condition Code Procedure
Corrosion affecting
structural integrity ... A ........ ( 1) Require replacement.
Cracked ................. B ............ Require replacement.
Hard spots .............. 2 ....... Suggest reconditioning or
replacement of rotor according
to OEM specifications.
Lateral runout (wobble)
exceeds OEM
specifications ......... B ............ Require re-indexing,
reconditioning, or replacement
according to specifications.
Measured thickness is less
than OEM discard
specifications ......... B ............ Require replacement.
Rotor thickness is less
than OEM "machine to"
specifications but thicker
than "discard at"
specifications, and the
rotor does not require
reconditioning ......... 1 ........ ( 2) Suggest replacement.
Rotor thickness will be
less than OEM "machine to"
specifications after
required
Page 352 of 1691
BRAK E S YSTE M
1999 D odge P ic ku p R 1500
1998-99 BRAKES
CHRY - Disc & Drum - Trucks & Vans - Except FWD
Dakota, Ram Pickup, Ram Van
DESCRIPTION & OPERATION
All models are equipped with single-piston, sliding-caliper
front disc brakes with ventilated rotors. All models utilize self-
adjusting rear drum brakes. Rear Wheel Anti-Lock (RWAL) brake system
is standard on all models. Optional 4-wheel Anti-Lock (4WAL) brake
system is available on all models.
System also includes power brake booster, dual-reservoir
master cylinder and combination valve. Combination valve consists of
metering valve and pressure differential switch.
Models with diesel engine include a gear-driven vacuum pump.
Depending on speed of engine, pump produces 8-25 in. Hg. Models
without full-floating rear axle use 9", 10" or 11" single-anchor rear
brakes. Models with full-floating rear axle use 12" or 13" single-
anchor rear brakes.
NOTE: For information on Anti-Lock Brake Systems (ABS), see
appropriate ANTI-LOCK article.
BLEEDING BRAKE SYSTEM
BLEEDING PROCEDURES
Complete Brake System
Before bleeding system, exhaust all vacuum from power unit by
depressing brake pedal several times. Bleed master cylinder using
bleeder screws (if equipped). Bleed wheel cylinders and calipers in
sequence. See BLEEDING SEQUENCE table.
BLEEDING SEQUENCE
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Application Sequence
1999 Dakota & Ram Van .......... Master Cylinder, Combination Valve,
RR, LR, RF & LF
All Other Models ............... Master Cylinder, Combination Valve,
Rear Anti-Lock Valve, RR, LR, RF & LF
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Master Cylinder (Bench Bleeding)
1) Bench bleed master cylinder before installation. Place
master cylinder in soft-jaw vise. Install bleeder tubes in both
outlets of master cylinder. See Fig. 1.
2) Fill master cylinder with clean brake fluid. Ensure ends
of bleeder tubes are submerged in brake fluid.
3) Using a wood dowel, apply and release master cylinder
until no air bubbles exist in brake fluid flow. Leave bleeder tubes
installed on master cylinder during installation. Install master
cylinder. Remove bleeder tubes, and connect brakelines. Bleed brake
system if necessary.
Page 357 of 1691
ROTOR
CAUTION: DO NOT allow caliper to hang by brake hose.
Inspection
1) Raise and support vehicle. Remove wheels. On Dakota 4WD,
reinstall and tighten lug nuts to secure rotor. On Dakota 2WD, Ram
Pickup and Ram Van, remove dust cap, and temporarily adjust wheel
bearings to zero end play.
2) On all models, mount dial indicator on steering arm, with
plunger contacting rotor about 1" (25 mm) from edge of rotor. Slowly
rotate rotor, and note lateral runout. Lateral runout on either side
of rotor should not exceed specification. See DISC BRAKE
SPECIFICATIONS.
3) On Dakota, check runout of hub face if runout exceeds
specification. Before removing rotor, make a chalk mark across rotor
and one wheel stud. Make mark on high side of runout.
4) Remove rotor from hub. Install dial indicator on steering
arm, with stem contacting hub face near outer diameter. Place dial
indicator stem outside stud circle but inside chamfer on hub rim. If
runout exceeds specification See DISC BRAKE SPECIFICATIONS. Hub must
be replaced.
5) If hub runout is within specification, install rotor on
hub with chalk marks 180 degrees apart. Install wheel lug nuts, and
recheck rotor runout. If runout is not within specification, resurface
or replace rotor.
6) On all models, measure rotor parallelism. To measure
parallelism, measure rotor thickness with micrometer at 12 equal
points around rotor radius approximately 1" (25 mm) from edge of
rotor. If thickness varies more than parallelism specification,
resurface or replace rotor. See DISC BRAKE SPECIFICATIONS.
Removal (Dakota 2WD, Ram Pickup 2WD (5 Studs), & Ram Van)
Raise and support vehicle. Remove wheels. Remove brake
caliper from adapter. Support caliper aside. Remove grease cap, cotter
pin, nut lock, nut, thrust washer and outer wheel bearing. Pull rotor
assembly off spindle.
Installation
1) Slide rotor assembly into position on spindle. Pack and
install outer wheel bearing, thrust washer and nut. While rotating
rotor and hub assembly, tighten wheel bearing nut to specification.
See TORQUE SPECIFICATIONS table.
2) Back off nut to release preload. Retighten nut finger
tight. Install nut lock and cotter pin. Coat inside of cap with
grease, and install cap. To complete installation, reverse removal
procedure.
Removal (Ram Pickup With Tapered Bearings)
1) Raise and support vehicle. Remove wheel. Remove brake
caliper and adapter. Support caliper aside. Remove grease cap and
driving hub snap ring. Remove drive hub and spacer.
2) On models with removable adapter hub, remove hub from
rotor. On models with one-piece hub and rotor assembly, remove grease
cap, cotter pin and bearing adjuster nut. Remove thrust washer and
outer wheel bearing. Remove rotor and hub assembly from spindle.
Installation
1) Apply liberal coat of wheel bearing grease to spindle.
Install hub and rotor on spindle. Pack and install outer bearing.
Install thrust washer and bearing adjuster nut. Tighten nut only
enough to remove end play at his time.
2) Install caliper. DO NOT seat caliper pistons and brake
Page 358 of 1691
pads at this time. On models with removable hub, install hub on rotor.
Install wheel and tire assembly. Tighten lug nuts so they are snug,
but DO NOT tighten to final torque specifications.
3) While rotating wheel, tighten adjuster nut sufficiently to
seat bearing. Loosen nut and retighten while still rotating wheel.
Back off adjuster nut to completely release bearing preload torque.
Ensure endplay of .001-.003" (.025-.076 mm). Install lock nut and NEW
cotter pin. If necessary, tighten lock nut slightly to align cotter
pin hole. Install grease cap. Tighten caliper bolts and lug nuts to
specification. See TORQUE SPECIFICATIONS table. To complete
installation, reverse remove procedure.
Removal (Ram Pickup With 8 Studs)
1) Raise and support vehicle. Remove wheel. Remove hub
extension, if equipped. Remove brake caliper. Support caliper aside.
2) On models with removable adapter hub, remove hub from
rotor. On models with one-piece hub and rotor assembly, remove cotter
pin from rotor hub nut. Remove nut. Disconnect ABS wheel speed sensor
wire (if equipped), and remove from frame and steering knuckle. Remove\
bolts securing hub to steering knuckle from inboard side of steering
knuckle. Remove rotor and hub assembly.
Installation
1) Apply anti-seize compound to drive shaft splines. Replace
grease seal in steering knuckle, if necessary. Insert 2 rearmost top
and bottom rotor hub bolts in steering knuckle so they extend through
back of knuckle. Install hub spacer, ensuring flat on space is
positioned to rear. Use chassis grease to hold spacer in position, if
necessary.
NOTE: If equipped with wheel speed sensor, brake shield must be
positioned on hub bearing, and sensor wire must be at top of
knuckle.
2) Align rotor hub with drive shaft and install hub assembly.
Align bolt holes in hub flange with bolts previously installed. Start
nuts on flange bolts sufficiently to hold assembly in place. Install
remaining bolts, and tighten all bolts to specification. See TORQUE
SPECIFICATIONS table.
3) Install washer and hub nut. Tighten nut securely. Install
NEW cotter pin. Install grease cap. Install caliper. Tighten caliper
bolts and lug nuts to specification. See TORQUE SPECIFICATIONS table.
To complete installation, reverse remove procedure.
REAR BRAKE SHOES
WARNING: Use water or brake cleaner to clean brake parts. DO NOT use
compressed air to remove dirt and dust.
Removal (Dakota & Ram Van)
1) Remove wheel and drum. Note how secondary spring overlaps
primary return spring. Using spring remover, remove brake shoe return
springs. Slide automatic adjuster cable off anchor. Disconnect cable
from adjusting lever.
2) Remove cable, cable guide and anchor plate. See Figs. 3,
4, and 5. Disconnect adjusting lever return spring from lever. Remove
lever and return spring from pivot pin. Remove shoe-to-shoe spring.
Spread shoes, and remove adjustment star wheel.
3) Remove shoe retainers, springs and pins. Remove parking
brake lever from secondary shoe. Remove shoes and parking brake strut
with spring.
Page 360 of 1691
first with coil on opposite side of adjusting lever. Install lever
spring and adjusting lever over pivot pin.
5) Slide lever rearward to lock in position. Thread adjuster
cable over guide, and hook end of cable in lever. Verify adjuster
operation. Pull adjuster cable upward. Cable should lift lever and
rotate star wheel. Ensure adjuster lever properly engages star wheel
teeth. Adjust brakes. See REAR BRAKE SHOES under ADJUSTMENTS.
Removal (Ram Pickup)
1) Remove drum. See AXLE BEARING & SEAL (FULL FLOATING AXLE)\
.
Disconnect adjusting lever from cable. Disconnect adjusting lever
return spring from lever. Remove lever, and return spring from pivot
pin. Remove upper shoe-to-shoe spring.
2) Disconnect and remove shoe retainers, springs and hold-
down pins. Disconnect parking brake cable from lever. Remove both
brake shoes, lower shoe-to-shoe spring and adjustment star wheel as an
assembly. See Fig. 4. Remove lower shoe-to-shoe spring.
Fig. 4: Exploded View Of Typical Rear Drum Brake Assembly (Ram
Pickup)
Courtesy of Chrysler Corp.
NOTE: Adjustment star wheel on left brake assembly has left-hand
Page 362 of 1691
Removal & Installation
1) Disconnect and plug primary and secondary brakelines from
master cylinder. Remove master cylinder-to-power brake booster nuts.
Slide master cylinder straight out and away from power brake booster
unit.
2) Ensure reservoir is empty. Install master cylinder in
soft-jaw vise. Pry gently upward between reservoir ports while working
reservoir side to side. Remove reservoir and grommets. See Fig. 6.
3) Install NEW grommets in master cylinder ports. Lubricate
grommets with brake fluid. Firmly and evenly, press reservoir into
grommets by hand.
4) To complete installation, position master cylinder over
studs of power brake booster. Align power cylinder brake push rod with
cylinder piston. Install master cylinder nuts, and tighten to
specification. See TORQUE SPECIFICATIONS table. Connect both
brakelines. Bleed system. See BLEEDING BRAKE SYSTEM.
Fig. 6: Exploded View Of Master Cylinder (Ram Pickup)
Courtesy of Chrysler Corp.
POWER BRAKE BOOSTER
Removal
1) Disconnect vacuum hose from booster check valve. Remove
nuts attaching master cylinder, and move cylinder away from booster.
Inside vehicle, remove booster push rod-to-brake pedal clip. Pry clip
off pedal pivot pin.
2) Remove lock nuts from booster mounting studs. Slide
booster away from dash and out of engine compartment. If booster is