service DODGE RAM 1999 Service Manual Online
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 338 of 1691
![DODGE RAM 1999 Service Manual Online LATERAL ACCELERATION SWITCHES
See ACCELEROMETERS .
LEDS
See BULBS AND LEDS .
LENSES
LENSE INSPECTION \
\](/img/12/56915/w960_56915-337.png "DODGE RAM 1999 Service Manual Online LATERAL ACCELERATION SWITCHES
See ACCELEROMETERS .
LEDS
See BULBS AND LEDS .
LENSES
LENSE INSPECTION \
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LATERAL ACCELERATION SWITCHES
See ACCELEROMETERS .
LEDS
See BULBS AND LEDS .
LENSES
LENSE INSPECTION \
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Condition Code Procedure
Application incorrect ... A ............ Require replacement.
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.
Broken, affecting
performance ............ A ............ Require replacement.
Broken, not affecting
performance ............ .. ........ No service suggested or
required.
Cracked ................. A ............ Require replacement.
Discolored .............. A ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Melted, affecting
performance ............ A ............ Require replacement.
Melted, not affecting
performance ............ 2 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
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MASTER CYLINDERS
MASTER CYLINDER INSPECTION \
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Condition Code Procedure
Brake fluid leaking from
rear of master cylinder
bore ................... B .. Require repair or replacement.
Brake pedal drops
intermittently ......... A ........... ( 1) Require repair or
replacement.
Fluid level low ......... .. ......... ( 2) Further inspection
required.
Internal valve failure .. A .. Require repair or replacement.
Master cylinder leaking
brake fluid internally . A .. Require repair or replacement.
Piston does not return .. A .. Require repair or replacement.
Ports plugged ........... A .. Require repair or replacement.
Rubber master cylinder
cover gasket distorted
and gummy .............. A .. ( 3) Require replacement of the
gasket.
Page 339 of 1691
(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
Page 344 of 1691
specifications.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
(1) - If a sensor is not adjustable, further inspection is
required to identify and correct cause.
( 2) - Determine cause and correct prior to repair or
replacement of part.
( 3) - Determine source of contamination, such as metal
particles or water. Require repair or replacement.
( 4) - Inoperative includes intermittent operation or out of OEM
specification. Some components may be serviceable; check
for accepted cleaning procedure.
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STEEL BRAKE LINES
STEEL BRAKE LINE 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.
Corroded, affecting
structural integrity ... A ............ Require replacement.
Fitting incorrect (for
example, compression
fitting) ............... B ............ Require replacement.
Flare type incorrect .... B .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Line material incorrect
(copper, etc.) ......... B ............ Require replacement.
Restricted .............. A ............ Require replacement.
Routed incorrectly ...... B ..... Require routing correction.
Rust-pitted ............. 1 ............ Suggest replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped
(threads missing) ...... A ............ Require replacement.
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STOPLIGHT SWITCHES
See BRAKE STOPLIGHT SWITCHES .
SWITCHES
NOTE: Copied from Electrical UIGs & added "float saturated" from
old fluid level sensor switches.
STEEL BRAKE LINE INSPECTION
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Page 353 of 1691
Fig. 1: Bleeding Master Cylinder (Typical)
Courtesy of Chrysler Corp.
Vacuum Bleeding
Fill master cylinder. Install vacuum bleed equipment to first
bleeder valve to be serviced. Open bleeder valve 3/4-1 turn. Depress
vacuum pump, and pull fluid into reservoir jar. Bleed each bleeder
valve in sequence. See BLEEDING SEQUENCE table.
CAUTION: When using pressure bleeding method, press and hold in valve
stem on combination valve to properly bleed brake system.
Pressure Bleeding
1) Clean master cylinder cap and surrounding area. Remove
cap. With pressure tank at least 1/2 full, connect it to master
cylinder using appropriate adapters. Attach bleeder hose to first
bleeder valve to be serviced. See BLEEDING SEQUENCE table.
2) Submerge other end of hose in clean glass jar partially
filled with clean brake fluid. Position metering valve properly before
pressure bleeding.
3) Open release valve on pressure bleeder. Follow equipment
manufacturer's pressure bleeding instructions, or see PRESSURE BLEEDER
SETTINGS table. Open bleeder screw 3/4-1 turn, and note fluid flow.
4) Close bleeder screw when fluid flow is free of air
bubbles. Repeat procedure on remaining wheels in proper sequence.
Check brake pedal operation after bleeding.
5) Remove pressure bleeding equipment, and valve retainer
from metering valve. Ensure master cylinder is full of fluid.
PRESSURE BLEEDER SETTINGS
Page 354 of 1691
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Application psi (kg/cm)
All Models ....................................... 10-15 (1.06-1.41)\
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NOTE: When bleeding disc brakes, air may tend to cling to caliper
walls. Lightly tap caliper while bleeding to aid in removal
of air.
Manual Bleeding
1) Fill master cylinder. Install bleeder hose on first
bleeder valve to be serviced. See BLEEDING SEQUENCE table. Submerge
other end of hose in clean glass jar partially filled with clean brake
fluid.
NOTE: When bleeding brake system manually, ensure bleeder valve is
closed when brake pedal is released.
2) Open bleeder valve 3/4-1 turn. Depress brake pedal slowly
through full travel. Close bleeder valve. Release pedal. Repeat
procedure until fluid flow is free of air bubbles.
ADJUSTMENTS
PARKING BRAKE
1) Release parking brake, and loosen cable adjusting nut to
allow slack in cable. Adjust rear brakes. Tighten cable adjusting nut
until a slight drag is felt while rotating rear wheels.
2) Loosen cable adjusting nut until both rear wheels can be
rotated freely. Back off adjusting nut an additional 2 turns. Apply
and release parking brake several times, checking for free rotation at
rear wheels.
REAR BRAKE SHOES
1) Raise and support vehicle. Ensure parking brake lever is
fully released. Back off parking brake cable adjustment to ensure
cable has slack. Remove adjusting hole cover.
2) Using a brake adjuster, expand brake shoes until slight
drag is felt when wheel assembly is rotated. Using thin screwdriver,
hold automatic adjusting lever away from adjustment star wheel.
3) Back off adjustment star wheel until wheel assembly
rotates freely and brake shoe drag is eliminated. Repeat adjustment
for remaining wheels. Adjustment must be equal at all wheels. Replace
adjusting hole covers. Adjust parking brake. See PARKING BRAKE.
STOPLIGHT SWITCH
Stoplight switch is attached to brake pedal support. Push
stoplight switch through clip in mounting bracket until switch seats
in bracket. Pull brake pedal backward as far as pedal will travel.
Brake pedal will ratchet stoplight switch to correct position. Verify
full brake pedal return, and that stoplights glow when brake pedal is
applied.
TESTING
POWER BRAKE BOOSTER FUNCTIONAL TEST
Page 361 of 1691
threads. Right side assembly has right-hand threads.
Installation
1) Lubricate and assemble adjustment star wheel. Apply thin
film of multipurpose grease to shoe contact pads on support plate.
Assemble lower shoe-to-shoe spring, adjustment star wheel and both
shoes. Position shoe assembly on support plate.
2) Attach parking brake cable to lever using NEW "U" clip or
"E" clip. Install shoe hold-down pins, springs and retainers. Install
upper shoe-to-shoe spring. Position adjusting lever return spring on
pivot. Install adjusting lever. Route cable, and connect it to
adjuster. Install drum assembly and wheel. Adjust brakes. See REAR
BRAKE SHOES under ADJUSTMENTS.
WHEEL CYLINDERS
Removal & Installation
1) Remove wheel, drum and brake shoes. Inspect boots for
damage and signs of leakage. Disconnect and plug hydraulic brakeline
from wheel cylinder. Remove attaching bolts, and remove cylinder. See
Fig. 5 .
2) Apply silicone sealant to cylinder mounting surface, and
position cylinder on support plate. Start brakeline fitting in wheel
cylinder. Install and tighten mounting bolts. Tighten brakeline
fitting. To complete installation, reverse removal procedure. Fill
brake fluid reservoir, and bleed hydraulic system. See BLEEDING
PROCEDURES under BLEEDING BRAKE SYSTEM.
Fig. 5: Exploded View Of Rear Wheel Cylinder (Typical)
Courtesy of Chrysler Corp.
MASTER CYLINDER & RESERVOIR
NOTE: Manufacturer does not recommend overhaul of master cylinder.
Removal and replacement of reservoir and grommets are the
only recommended service procedures. Replace master cylinder
if faulty.
Page 367 of 1691
CLU TC H
1999 D odge P ic ku p R 1500
1998-99 CLUTCHES
CHRY - RWD - Trucks
Dakota, Ram Pickup
DESCRIPTION
Clutches on all models are dry, single-disc design.
Adjustment for wear is not possible. Clutch pedal is connected to
release fork through a hydraulic master cylinder and slave cylinder
and is not adjustable. Pre-lubricated clutch bearing is constant
running type. External adjustments cannot be made.
All models are equipped with a clutch pedal position switch.
The switch completes the circuit to the starter relay and is mounted
on clutch master cylinder push rod. The position switch is an integral
part of clutch master cylinder push rod and cannot be serviced
separately.
TRANSMISSION/TRANSFER CASE APPLICATION
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Transmission Transfer Case
Dakota
AX15, NV1500 & NV3500 .............................. NV231 & NV242
Ram Pickup
NV3500, NV4500, NV4500HD & NV5600 ..... NV231HD, NV241LD & NV241HD
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ADJUSTMENTS
CLUTCH PEDAL FREE PLAY
NOTE: Clutches are a single, dry disc type. Adjustment for wear is
not possible. Clutch is actuated through hydraulic master
cylinder and slave cylinder, and is self-adjusting.
SHIFT LINKAGE ADJUSTMENT
NV231 (Dakota)
1) Shift transfer case into 4H position, and secure shift
lever in shift gate. See Fig. 1. Raise and support vehicle. Loosen
shift rod lock bolt at swivel. Ensure shift rod slides freely in
adjusting swivel.
2) Ensure transfer case range lever is in 4H position. Slide
adjusting swivel forward until shift rod contacts shift gate
crossover, then slide adjusting swivel back, allowing a .11-.20" (3-5
mm) gap between shift lever and shift gate.
3) Center pin on adjusting swivel in shift arm and tighten
lock bolt to 90 INCH lbs. (10 N.m.). Lower vehicle, making sure all
wheels are off floor. Start engine. Shift transfer case through all
ranges to verify correct adjustment.
NV231HD, NV241LD & NV241HD (Ram Pickup)
1) Place shift lever into 2H position. Raise and support
vehicle. Loosen shift rod lock bolt at swivel. See Fig. 2. Ensure
shift rod fits in swivel and does not bind.
2) Ensure transfer case shift lever is in 2H position. Lower
vehicle. Position shift lever in cab so distance between instrument
Page 369 of 1691
Fig. 2: Adjusting Transfer Case Shift Linkage (Ram Pickup)
Courtesy of Chrysler Corp.
TROUBLE SHOOTING
NOTE: For trouble shooting not covered in this article, see
appropriate table in TROUBLE SHOOTING article in GENERAL
INFORMATION.
Hydraulic system should not require addition of fluid under
normal circumstances. Reservoir fluid level will increase as normal
clutch wear occurs. Avoid overfilling or removing fluid from
reservoir. This will cause clutch release problems.
TESTING
CLUTCH PEDAL POSITION SWITCH
NOTE: The position switch is an integral part of clutch master
cylinder push rod and cannot be serviced separately.
Disconnect clutch pedal position switch electrical connector.
Depress switch. Using a DVOM, measure continuity between clutch pedal
position switch terminals No. 1 (Yellow/Red wire) and No. 2 (Dark
Blue/Yellow wire). If continuity exists, switch is okay. If continuity
does not exist, replace clutch master cylinder. See CLUTCH MASTER
CYLINDER under REMOVAL & INSTALLATION.
Page 388 of 1691
Fig. 4: Identifying Speed Control (S/C) Servo Connector Terminals
Courtesy of Chrysler Corp.
SELF-DIAGNOSTIC SYSTEM
WARNING: Vehicle is equipped with an air bag. Air bag must be
deactivated before servicing speed control components on or
around steering column. See AIR BAG RESTRAINT SYSTEMS -
TRUCKS article.
SERVICE PRECAUTIONS
Before proceeding with diagnosis, the following precautions
must be followed:
* When using Diagnostic Trouble Code (FTC) tests for diagnosis,
DO NOT skip any steps, or incorrect diagnosis may result.
Always perform indicated verification procedure after repairs are
Page 407 of 1691
DRIV E A XLE - F B I S EM I- F LO ATIN G
1999 D odge P ic ku p R 1500
1998-99 DRIVE AXLES
CHRY - FBI Semi-Floating Axles
Ram Pickup
IDENTIFICATION
DRIVE AXLE APPLICATION \
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Application Axle Ring Axle
Model Gear Size Ratio
Front Axle ........ 216 FBI ......... 8.50" .. 3.54, 3.92 & 4.09
Front Axle ........ 248 FBI ......... 9.75" ........ 3.54 & 4.10
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DESCRIPTION & OPERATION
The Front Beam-Design Iron (FBI) axles is of an iron center
casting (differential housing) with axle shaft tubes extending from
both sides. The tubes are pressed in to form a one-piece axle housing
and is a semi-floating design.
Axle contains an integral carrier with hypoid-type ring gear
and pinion with semi-floating axle shafts. Load is supported by hub
bearings. Axle shafts are retained by nuts at the hub bearings. Hub
bearings are bolted to steering knuckle at outboard end of axle tube
yoke. Hub bearings are serviced as an assembly. On vehicles equipped
with Anti-Lock (ABS) brakes, a brake sensor is mounted on knuckle
assemblies, and tone rings are pressed onto axle shaft.
Differential is a one-piece design and differential pinion
mate shaft is retained with a roll pin. Differential bearing preload
and ring gear backlash is adjusted by use of shims, and pinion bearing
preload is set and maintained by use of a collapsible spacer.
Axle shaft is engaged or disengaged by an axle vacuum shift
motor. Vacuum shift motor is operated by engine vacuum and is
controlled by a switch mounted on transfer case.
AXLE RATIO & IDENTIFICATION
NOTE: Axle ratio can be identified by axle identification tag
attached to axle housing cover. See IDENTIFICATION.
LUBRICATION
CAPACITY
DRIVE AXLE CAPACITY ( 1) \
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Application Pts. (L)\
216 FBI .................................................. 4.8 (2.3)\
248 FBI .................................................. 7.6 (3.6)\
(1) - Approximate drive axle capacity listed. Lubricant level should
be 1/2" below oil filler hole in axle housing cover.
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