flywheel bolt DODGE RAM 1999 Service Repair Manual

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Pages: 1691, PDF Size: 40.34 MB

Page 370 of 1691

DODGE RAM 1999 Service Repair Manual CLUTCH HOUSING (RAM PICKUP)
NOTE: Only NV4500 clutch housing can be checked using the following
bore and face runout procedures. The NV1500, NV3500 and
NV5600 clutch hous

CLUTCH HOUSING (RAM PICKUP)
NOTE: Only NV4500 clutch housing can be checked using the following
bore and face runout procedures. The NV1500, NV3500 and
NV5600 clutch housings are an integral part of transmission
front case and can only be checked off vehicle.
Clutch Housing Bore Runout (NV4500)
1) Remove clutch housing. Remove clutch cover and disc. See
CLUTCH ASSEMBLY under REMOVAL & INSTALLATION. Replace one flywheel
bolt with a threaded rod. See Fig. 2. Remove release fork from clutch
housing. Reinstall clutch housing. Tighten housing bolts nearest
alignment dowels first. Mount dial indicator on threaded rod and
position indicator plunger on surface of clutch housing bore. See
Fig. 4 .
2) Rotate crankshaft until indicator plunger is at top center
of housing bore. Zero dial indicator. Rotate crankshaft and record
indicator readings at 8 points, 45 degrees apart, around bore. See
Fig. 5 .
3) Repeat measurement at least twice. Subtract each reading
from one 180 degrees opposite to determine magnitude and direction of
runout. For example: 0.000" minus (-0.007") = 0.007", 0.002" minus (-\
0.010") = 0.01", 0.004" minus (-0.005") = 0.009" or -0.001" minus (0\
.
001") = -0.002" which will be 0.002". In this example, largest
difference is 0.012" (total indicator reading). This means housing
bore is offset from crankshaft centerline by 0.006" (1/2 of 0.012").
4) On gas engines, acceptable total indicator reading is 0.
010". If measured total indicator reading is more than 0.010", bore
runout will have to be corrected using offset dowels. Offset dowels
are available in 0.007", 0.014" and 0.021". See DOWEL SELECTION table.
If total indicator reading is 0.053" or greater, replace clutch
housing. If dial indicator reads positive when plunger moves inward
(toward indicator) and negative when moves outward away from
indicator), lowest or most negative reading determines direction of
housing bore offset (runout).
5) On diesel engines, offset dowels are not available to
correct runout. If total indicator reading exceeds bore runout of 0.
015", replace either clutch housing, or transmission adapter plate. On
gas engines, if bore is offset, remove housing and original dowels,
install new offset dowels in direction need to center bore with
crankshaft centerline. Install new dowels with slotted side facing
out. Using a screwdriver, rotate dowels until total indicator reading
is less than 0.010". Ensure clutch housing face runout is within
specification.
DOWEL SELECTION
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Application - In. (mm) Offset Dowel - In. (mm\
)
0.011-0.021 (0.2794-0.5334) ......................... 0.007 (0.1778\
)
0.022-0.035 (0.5588-0.8890) ......................... 0.014 (0.3556\
)
0.036-0.052 (0.9144-1.3208) ......................... 0.021 (0.5334\
)
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Fig. 3: Manufactured Stud Or Threaded Rod
Courtesy of Chrysler Corp.

Page 377 of 1691

DODGE RAM 1999 Service Repair Manual CAUTION: Clutch disc may contain asbestos fibers which can cause
serious health risk. DO NOT sand clutch components. DO NOT
clean components using compressed air. To clean components

CAUTION: Clutch disc may contain asbestos fibers which can cause
serious health risk. DO NOT sand clutch components. DO NOT
clean components using compressed air. To clean components,
use a water-dampened cloth.
Removal
With transmission and clutch housing removed, mark pressure
plate and flywheel for reassembly reference. Install clutch aligner in
clutch disc to prevent disc from falling. Loosen pressure plate bolts
evenly and in rotation to avoid warping pressure plate. Remove
pressure plate and disc from flywheel. See Fig. 10.
Inspection
1) Check for oil leakage through engine rear main bearing oil
seal and transaxle input shaft seal. Check flywheel and pressure plate
for burned areas, discoloration, cracks, grooves or ridges. Replace as
necessary.
2) Use medium sandpaper (80-180 grade) to clean flywheel
surface, then wipe with mineral spirits. DO NOT flat-machine flywheel
surface. Check facing surfaces for grease or oil contamination. Check
clutch disc for wear. Clutch disc face-to-rivet head distance should
be at least .008" (.20 mm). Check splines of disc hub and transaxle
input shaft.
3) Using straightedge, check pressure plate. Friction area
should be flat to slightly concave, with the inner diameter about 0-.
0039" (0-0.1 mm) less than outer diameter. Using surface plate, check
clutch cover for flatness. Sections around bolt holes should contact
surface plate within .015" (.38 mm). Ensure cover-to-flywheel dowel
fit is snug. Replace clutch assembly as necessary.
NOTE: Before installing clutch disc, ensure flywheel mating
surface, pilot bearing/bushing and clutch release bearing are
in satisfactory condition. Repair and/or replace components
as necessary.
Installation
To install, reverse removal procedure using clutch aligner.
Ensure reference marks are aligned. Tighten pressure plate retaining
bolts evenly a few threads at a time to prevent warpage. See TORQUE
SPECIFICATIONS table.
Fig. 10: Exploded View Of Clutch Assembly (Typical)
Courtesy of Chrysler Corp.
PILOT BEARING, CLUTCH RELEASE BEARING & FORK

Page 379 of 1691

$DODGE RAM 1999 Service Repair Manual TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS��\ ��\ ��\ ��\ ��\ ��\ ��\ ��$

Page 659 of 1691

$DODGE RAM 1999 Service Repair Manual Engine Mount Through-Bolt Dakota 2WD & Durango 2WD ................................. 50 (68)\ Dakota 4WD, Durango 4WD & Ram Pickup .................... 75 (102)\ Grand Cherokee ............$

Engine Mount Through-Bolt
Dakota 2WD & Durango 2WD ................................. 50 (68)\
Dakota 4WD, Durango 4WD & Ram Pickup .................... 75 (102)\
Grand Cherokee ............................................. 60 (81)\
Engine Mount-To-Cylinder Block Bolt
Dakota & Durango ......................................... 30 (41)\
Ram Pickup ............................................... 60 (81)\
Ram Van/Wagon & Grand Cherokee ............................. 65 (88)\
Engine Mount-To-Frame Bracket Bolt/Nut
Ram Pickup & Ram Van/Wagon .............................. 75 (102)\
Exhaust Manifold Bolt & Nut
Durango .................................................. 18 (24)\
All Others ................................................. 25 (34)\
Flywheel/Flexplate-To-Crankshaft Bolt ...................... 55 (75)\
Front Cover Bolt ........................................... 30 (41)\
Heat Shield Bolts .......................................... 30 (41)\
Main Bearing Cap Bolt ..................................... 85 (115)\
Oil Drain Plug ............................................. 25 (34)\
Oil Filter Adapter Stud .................................... 50 (68)\
Oil Pan Bolt ............................................... 18 (24)\
Oil Pump Bolt .............................................. 30 (41)\
Rocker Arm Bolt ............................................ 21 (28)\
Shift Motor Bolt
Dakota 4WD & Durango 4WD ................................. 65 (88)\
Spark Plug ................................................. 30 (41)\
Starter Bolts .............................................. 50 (68)\
Throttle Body Bolt ......................................... 17 (23)\
Transfer Case Yoke Bolt
Dakota 4WD & Durango 4WD ................................. 20 (27)\
Vibration Damper Bolt .................................... 135 (183)\
Water Pump Bolt ............................................ 30 (41)\
INCH Lbs. (N.m)
Intake Manifold Bolt ( 4)
Step 1 .................................................. 24 (2.7)\
Step 2 .................................................. 48 (5.4)\
Step 3 .................................................. 84 (9.5)\
Step 4 (Verify Torque All Bolts) ........................ 84 (9.5\
)
Intake Manifold Plenum Pan Bolt
Step 1 .................................................. 24 (2.7)\
Step 2 .................................................. 48 (5.4)\
Step 3 .................................................. 84 (9.5)\
Step 4 (Verify Torque) .................................. 84 (9.5\
)
Oil Pump Cover Bolt ........................................ 97 (11)\
Valve Cover Bolts .......................................... 95 (11)\
( 1) - Bolts through clutch housing into cylinder block.
( 2) - Bolts through cylinder block into clutch housing.
( 3) - Tighten bolts in sequence. See 7.
( 4) - Tighten bolts in sequence. See 5 and 6.
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ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS (3.9L)\
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Application Specification
Displacement .................................... 239 Cu. In. (3.9L)\
Bore ............................................... 3.91" (99.3 mm)\
Stroke ............................................. 3.31" (84.1 mm)\

Page 962 of 1691

DODGE RAM 1999 Service Repair Manual Removal & Installation (Dakota 2.5L)
1) Crankshaft position sensor is located on drivers side of
engine at transmission bellhousing. See Fig. 18. Remove air inlet duct
between thro

Removal & Installation (Dakota 2.5L)
1) Crankshaft position sensor is located on driver's side of
engine at transmission bellhousing. See Fig. 18. Remove air inlet duct
between throttle body and air cleaner assembly.
2) Disconnect electrical connector for crankshaft position
sensor. Remove crankshaft position sensor retaining bolts and
crankshaft position sensor.
CAUTION: Retaining bolts for crankshaft position sensor are specially
machined bolts to provide correct clearance between
crankshaft position sensor and the flywheel. DO NOT use any
other type retaining bolts.
3) To install, reverse removal procedure. Tighten crankshaft
position sensor retaining bolts to specification. See TORQUE
SPECIFICATIONS.
Removal & Installation (Dakota 3.9L, 5.2L & 5.9L, & Durango)
1) Crankshaft position sensor is located on passenger side of
engine at transmission bellhousing, just behind the cylinder head. See
Fig. 19 . Passenger's side front fender wheelwell must be removed for
access to crankshaft position sensor.
2) Raise and support vehicle. Remove passenger side front
wheel. Remove wheel opening molding. Remove plastic rivets attaching
wheelwell to front fender. Remove wheelwell.
3) Disconnect electrical connector for crankshaft position
sensor. Remove crankshaft position sensor retaining bolts and
crankshaft position sensor.
4) To install, reverse removal procedure. Tighten crankshaft
position sensor retaining bolts and wheel lug nuts to specification.
See TORQUE SPECIFICATIONS.
Removal & Installation (Ram Pickup 3.9L, 5.2L & 5.9L, Ram Van
& Ram Wagon)
1) Crankshaft position sensor is located on passenger side of
engine at transmission bellhousing, just behind the cylinder head. See
Fig. 19 .
2) On Ram Van and Ram Wagon, remove engine cover. On Ram
Pickup, remove air inlet duct for access to crankshaft position
sensor.
3) On all models, disconnect electrical connector for
crankshaft position sensor. Remove crankshaft position sensor
retaining bolts and crankshaft position sensor.
4) To install, reverse removal procedure. Tighten crankshaft
position sensor retaining bolts to specification. See TORQUE
SPECIFICATIONS.
Removal (Ram Pickup 8.0L)
1) Crankshaft position sensor is located on passenger's side
of cylinder block, just above the oil pan. See Fig. 20.
2) Raise and support vehicle. Disconnect electrical connector
for crankshaft position sensor. Remove plastic tie strap securing
wiring harness to side of cylinder block.
3) Remove crankshaft position sensor retaining bolt. Using 2
small screwdrivers, carefully pry crankshaft position sensor with "O"
ring from cylinder block by rocking crankshaft position sensor back
and forth.
Installation
1) Apply light coat of engine oil on crankshaft position
sensor "O" ring. Install crankshaft position sensor in cylinder block
by rocking crankshaft position sensor back and forth. DO NOT twist
crankshaft position sensor during installation, or "O" ring may be

Page 1177 of 1691

DODGE RAM 1999 Service Repair Manual Drain & Refill .............................. (3) 1.5 Qts. (1.4L)
Dry Refill ....................... ( 4) 10.0-11.5 Qts. (9.5-10.8L)
Manual Transmission ( 5)
AX 15 (SAE 75W-90/API GL-5) 2.

Drain & Refill .............................. (3) 1.5 Qts. (1.4L)
Dry Refill ....................... ( 4) 10.0-11.5 Qts. (9.5-10.8L)
Manual Transmission ( 5)
AX 15 (SAE 75W-90/API GL-5) 2.5L & 3.9L .......... 3.3 Qts. (3.1L\
)
NV 3500 (Mopar M/T Lube, P/N 4761526) 5.2L ....... 2.1 Qts. (2.0L\
)
Front Differential (SAE 80W-90/API GL-5) ........... 3.0 Pts. (1.4L\
)
Rear Differential (SAE 80W-90/API GL-5) ( 6)
8 1/4" Ring Gear ( 7) ............................. 4.4 Pts. (2.1L)
9 1/4" Ring Gear ( 7) ............................. 4.8 Pts. (2.3L)
Power Steering Fluid ( 8)
2WD ............................................... 1.7 Pts. (.8L)\
4WD .............................................. 2.5 Pts. (1.2L)\
Transfer Case (Mopar ATF Plus Type 7176) ........... 2.5 Pts. (1.2L\
)
( 1) - Approximate quantity listed.
( 2) - Use an API energy conserving engine oil that is certified for
gasoline engines.
( 3) - Add this amount of fluid. Start engine and shift transmission
through all gears and back to Neutral. Add additional fluid to
bring fluid level to the MIN mark on dipstick. Recheck fluid
level with transmission at normal operating temperature. Adjust
fluid level to MAX mark on dipstick. Approximate drain and
refill capacity is 4.0 qts. (3.8L).
( 4) - Quantity may vary by type of oil cooler and oil cooler lines.
( 5) - Verify type of transmission used before servicing. The AX 15
uses a flywheel housing bolted to the front of the transmission.
The NV 3500 uses a flywheel housing which is an integral part of
the transmission housing.
( 6) - Models with Trac-Lok limited slip differential must have 5 ozs.
(.15L) of Mopar Trac-Lok Friction Modifier added if lubricant is\
changed.
( 7) - Rear differential may be identified by number of bolts on rear
cover. The 8 1/4" ring gear has 10 bolts on rear cover and 9
1/4" ring gear has 12 bolts on rear cover.
( 8) - Use only Mopar power steering fluid. DO NOT use automatic
transmission fluid.
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FLUID CAPACITIES (DURANGO)\
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Application ( 1) Quantity
Crankcase (Includes Filter) ( 2)
3.9L ............................................. 4.0 Qts. (3.8L)\
5.2L & 5.9L ...................................... 5.0 Qts. (4.7L)\
Cooling System (Includes Heater)
3.9L ........................................... 14.0 Qts. (13.2L)\
5.2L & 5.9L .................................... 14.3 Qts. (13.5L)\
Automatic Transmission
(Mopar ATF Plus Type 7176)
Drain & Refill .............................. ( 3) 1.5 Qts. (1.4L)
Dry Refill ....................... ( 4) 10.0-11.5 Qts. (9.5-10.8L)
Front Differential
(SAE 80W-90/API GL-5) ............................. 3.0 Pts. (1.4L\
)
Rear Differential
(SAE 80W-90/API GL-5) ( 5)
8 1/4" Ring Gear ( 6) ............................ 4.4 Pts. (2.1L)
9 1/4" Ring Gear ( 6) ............................ 4.8 Pts. (2.3L)
Power Steering Fluid ( 7) ........................... 2.5 Pts. (1.2L)
Transfer Case (Mopar ATF Plus Type 7176) ( 8)
NV 231 & NV 231HD ................................ 2.5 Pts. (1.2L)\
NV 242 ........................................... 3.0 Pts. (1.4L)\

Page 1179 of 1691

DODGE RAM 1999 Service Repair Manual (SAE 90W/API GL-5 - 2500) (8) ................... 6.3 Pts. (3.0L)
Dana 70 (Model 267)
(SAE 90W/API GL-5 - 2500) ( 9) ................... 7.0 Pts. (3.3L)
Dana 80 (Model 286)
(SAE 85W-9

(SAE 90W/API GL-5 - 2500) (8) ................... 6.3 Pts. (3.0L)
Dana 70 (Model 267)
(SAE 90W/API GL-5 - 2500) ( 9) ................... 7.0 Pts. (3.3L)
Dana 80 (Model 286)
(SAE 85W-90/API GL-5) ( 10)
2WD 3500 ...................................... 6.8 Pts. (3.2L)\
4WD 3500 ..................................... 10.1 Pts. (4.8L)\
Power Steering Fluid ( 11) .......................... 2.7 Pts. (1.3L)
Power Take-Off (PTO) Adapter
(Mopar ATF Plus Type 7176)
2500 & 3500 Models 2WD With A/T .................. 4.6 Pts. (2.2L)\
Transfer Case (Mopar ATF Plus Type 7176) ( 12)
NV 231HD ......................................... 2.5 Pts. (1.2L)\
NV 241 ........................................... 5.0 Pts. (2.4L)\
NV 241HD ......................................... 6.5 Pts. (3.1L)\
NV 241HD With Power Take-Off (PTO) ............... 9.0 Pts. (4.3L\
)
( 1) - Approximate quantity listed.
( 2) - On gasoline engines, use an API energy conserving engine oil
that is certified for gasoline engines. On diesel engines, use
engine oil with API CF-4/SH or CG-4/SH rating for diesel
engines.
( 3) - Add this amount of fluid. Start engine and shift transmission
through all gears and back to Neutral. Add additional fluid to
bring fluid level to the MIN mark on dipstick. Recheck fluid
level with transmission at normal operating temperature. Adjust
fluid level to MAX mark on dipstick. Approximate drain and
refill capacity is 4.0 qts. (3.8L).
( 4) - Quantity may vary by type of oil cooler and oil cooler lines.
( 5) - Verify type of transmission used before servicing. The NV 3500
uses a flywheel housing which is an integral part of the
transmission housing. The NV 4500 uses a flywheel housing which
is bolted to the front of the transmission and transmission
contains a Power Take-Off (PTO) cover on passenger's side of
transmission.
( 6) - Heavy-duty transmission is used with 5.9L diesel and 8.0L.
( 7) - Models with Trac-Lok limited slip differential must have 5 ozs.
(.15L) of Mopar Trac-Lok Friction Modifier added if lubricant is\
changed.
( 8) - Models with Trac-Lok limited slip differential must have 6 ozs.
(.18L) of Mopar Trac-Lok Friction Modifier added if lubricant is\
changed.
( 9) - Models with Power-Lok limited slip differential must have 8 ozs.
(.24L) of Mopar Trac-Lok Friction Modifier added if lubricant is\
changed.
( 10 ) - Models with Trac-Lok limited slip differential must have Mopar
Trac-Lok Friction Modifier added if lubricant is changed. Add
7 ozs. (.24L) of modifier on 2WD models or 10 ozs. (.30L) on
4WD models.
( 11 ) - Use only Mopar power steering fluid. DO NOT use automatic
transmission fluid.
( 12 ) - Transfer case may be identified by model number stamped on
identification tag on rear of transfer case, just above filler
plug.
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FLUID CAPACITIES (RAM VAN & RAM WAGON)\
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Application ( 1) Quantity
Crankcase (Includes Filter) ( 2)
3.9L ............................................. 4.0 Qts. (3.8L)\
5.2L & 5.9L ...................................... 5.0 Qts. (4.7L)\