remove seats DODGE RAM 1999 Service Repair Manual

Fig. 5: Exploded View Of A/C-Heater Assembly (Ram Pickup)
Courtesy of Chrysler Corp.
Removal & Installation (Durango - Rear)
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Remove
headliner from passenger compartment of vehicle. Remove sun visors and
sun visor arm supports.
2) Remove coat hooks, overhead assist handle and dome light.
If equipped, remove overhead console. Remove air outlet bezel from
rear A/C-heater assembly. Remove rear blower motor switch. Remove
upper liftgate opening trim. Disengage "A", "B", "C", and "D" pillar
trim as necessary to prevent trim panel interference.
3) Move second and third row seats to cargo position. Move
front seats to full recline position. Remove headliner fasteners.
Carefully bow headliner and remove through lift gate opening.
4) Disconnect "B" pillar drain hoses from "Y" fittings.
Disconnect "B" pillar refrigerant lines and plug or cover all openings
in A/C system. Disconnect rear A/C-heater assembly harness connector.
Loosen but DO NOT remove screws securing left end of rear A/C-heater
assembly. Support right end of rear A/C-heater assembly. Remove screws
from right side of rear A/C-heater assembly. Slide rear A/C-heater

procedure.
NOTE: On Durango rear A/C-heater assembly, blower motor and fan are
serviced as an assembly.
Removal (Durango - Rear)
1) Disconnect negative battery cable. Remove headliner from
passenger compartment of vehicle. Remove sun visors and sun visor arm
supports.
2) Remove coat hooks, overhead assist handle and dome light.
If equipped, remove overhead console. Remove air outlet bezel from
rear A/C-assembly. Remove rear blower motor switch. Remove upper
liftgate opening trim. Disengage "A", "B", "C", and "D" pillar trim as
necessary to prevent trim panel interference.
3) Move second and third row seats to cargo position. Move
front seats to full recline position. Remove headliner fasteners.
Carefully bow headliner and remove through lift gate opening.
4) Disconnect "B" pillar drain hoses from "Y" fittings.
Remove lower A/C-heater assembly cover. Disconnect blower motor
harness connector. Remove blower motor and fan assembly. To install,
reverse removal procedure.
Removal (Ram Pickup - Front)
1) Disconnect negative battery cable. Disconnect blower motor
cooling tube. Remove blower motor electrical connector from retainer.
Disconnect electrical connector. See Fig. 5.
2) Remove blower motor and fan assembly mounting screws.
Remove blower motor and fan assembly. Place reference marks on blower
motor and fan for reassembly reference. Remove blower motor fan
retainer clip. Pull blower motor fan off blower motor shaft.
Installation
Align reference marks made during removal. Press blower fan
hub onto blower motor shaft. Ensure retainer clip ears are indexed
over flats of blower motor shaft and fan hub. Ensure blower motor seal
is installed on housing. To complete installation, reverse removal
procedure.
BLOWER MOTOR RESISTOR
Removal & Installation (Dakota & Durango - Front)
Blower motor resistor is located in engine compartment, under
upper right corner of dash panel. Disconnect negative battery cable.
Remove cowl plenum cover to access resistor. Remove blower motor
resistor connector. Remove resistor retaining screws. Remove blower
motor resistor. To install, reverse removal procedure.
Removal & Installation (Durango - Rear)
1) Rear blower motor resistor is located in A/C-heater
assembly. Disconnect negative battery cable. Remove headliner from
passenger compartment of vehicle. Remove sun visors and sun visor arm
supports.
2) Remove coat hooks, overhead assist handle and dome light.
If equipped, remove overhead console. Remove air outlet bezel from
rear A/C-assembly. Remove rear blower motor switch. Remove upper
liftgate opening trim. Disengage "A", "B", "C", and "D" pillar trim as
necessary to prevent trim panel interference.
3) Move second and third row seats to cargo position. Move
front seats to full recline position. Remove headliner fasteners.
Carefully bow headliner and remove through lift gate opening.
4) Disconnect "B" pillar drain hoses from "Y" fittings.
Remove lower A/C-heater assembly cover. Disconnect rear blower motor
resistor connector. Remove screw and rear blower motor resistor. To

from housing. To install, reverse removal procedure. Install new "O"
rings to A/C fittings. Evacuate and charge A/C system.
Removal & Installation (Durango - Rear Evaporator Core)
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Remove
headliner from passenger compartment of vehicle. Remove sun visors and
sun visor arm supports.
2) Remove coat hooks, overhead assist handle and dome light.
If equipped, remove overhead console. Remove air outlet bezel from
rear A/C-heater assembly. Remove rear blower motor switch. Remove
upper liftgate opening trim. Disengage "A", "B", "C", and "D" pillar
trim as necessary to prevent trim panel interference.
3) Move second and third row seats to cargo position. Move
front seats to full recline position. Remove headliner fasteners.
Carefully bow headliner and remove through lift gate opening.
4) Disconnect "B" pillar drain hoses from "Y" fittings.
Disconnect "B" pillar refrigerant lines and plug or cover all openings
in A/C system. Remove lower A/C-heater assembly cover. Remove screws
securing refrigerant tube and retaining strap to right side of upper
housing cover. Remove evaporator core. To install, reverse removal
procedure. Install new "O" rings to A/C fittings. Evacuate and charge
A/C system.
Removal & Installation (Ram Pickup - Front)
1) Remove and disassemble A/C-heater housing. See
A/C-HEATER ASSEMBLY . Separate halves of A/C-heater housing and remove
top half. Remove evaporator or heater core from housing.
2) To install, reverse removal procedure. Install new "O"
rings to A/C fittings. Evacuate and charge A/C system. Fill cooling
system. On 5.9L diesel engine, engine is equipped with a one-way check
valve. DO NOT run engine while filling cooling system. Fill engine
with engine turned off.
INSTRUMENT PANEL
Removal & Installation (Dakota & Durango)
1) Disconnect negative battery cable. Disable air bag system.
See AIR BAG SYSTEM SAFETY article. Place front wheels in straight-
ahead position. Remove sill trim from both doorways. Remove kick panel
covers from both sides of vehicle. Remove mounting screws for hood
release handle.
2) Remove steering column trim panel and support bracket.
Remove tilt steering column lever (if equipped). Remove upper and
lower shrouds from steering column. Unplug driver's side air bag
module. Loosen multifunction switch wiring harness connector screw and
disconnect from switch. Screw will remain in connector.
3) Disconnect PRNDL cable. Disconnect shift cable from
steering column. Remove steering coupler lock pin. Remove toe plate
retaining screws. Remove steering column mounting bolts and remove
steering column from vehicle.
4) Remove screw from bulkhead wiring harness connector and
disconnect. Disconnect 2 body wiring harness connectors located next
to bulkhead connector. Disconnect 3 wiring harness connectors, from
junction block, located nearest to dash panel. Disconnect brake light
switch connector. Disconnect Rear Wheel Anti-Lock (RWAL) brake module
(if equipped), located near steering column support brackets.
5) Disconnect plastic retainer clip from parking brake
linkage rod, located at back of parking brake release handle. Remove
rod end from parking brake handle. Remove instrument panel center
support bracket. Unplug vacuum harness connector located at left end
of A/C-heater housing. Disconnect Air Bag Control Module (ACM)
connector.

NOTE: For additional information on fuel pressure and fuel pump
testing procedures, see appropriate NO TROUBLE CODE (NTC)
TEST and NO START (NS) TEST in SELF-DIAGNOSTICS - JEEP,
TRUCKS & RWD VANS article.
Vehicles With Fuel Rail Test Port
1) Disconnect negative battery cable. Release fuel pressure.
See FUEL PRESSURE RELEASE. Install fuel pressure gauge with hose on
fuel pressure test port.
2) Start engine and allow to idle. Fuel pressure should be
44-54 psi (3.1-3.8 kg/cm
). If no fuel pressure exists and engine will
not start, fuel pump relay and control circuit may be defective. See
FUEL PUMP RELAY.
3) If fuel pressure exceeds specification, fuel pump is okay,
but fuel pressure regulator is defective. Replace fuel pressure
regulator. Fuel pressure regulator is incorporated with the fuel
filter. Fuel filter/fuel pressure regulator is located on top of fuel
tank, in fuel pump module. See REMOVAL, OVERHAUL & INSTALLATION -
TRUCKS & RWD VANS - GASOLINE article.
Vehicles Without Fuel Rail Test Port
1) Disconnect negative battery cable. Release fuel pressure.
See FUEL PRESSURE RELEASE. Fuel pressure gauge is installed between
fuel supply line and fuel line fitting on fuel rail.
2) To disconnect fuel supply line from fuel rail, ensure area
around fuel supply line and fuel rail are clean. Note direction of
latch clip installation. Latch clip is located on top of fuel supply
line at fuel rail. See Fig. 1. Using 2 screwdrivers, pry latch clip
upward, and remove from fuel rail.
3) Pull fuel supply line from fuel rail. Install Adapter
(6923) into fuel rail. Ensure adapter is fully seated in fuel rail.
Install latch clip into fuel rail, with latch clip fingers pointing
downward. If latch clip will not fully seat so latch clip fingers
extend downward below fitting on fuel rail, adapter may not be fully
seated in fuel rail.
4) Connect fuel supply line to adapter. Ensure fuel supply
line fully seats in adapter. Remove protective cap from test port, and
install Fuel Pressure Gauge/Hose (5069) at test port.
5) Start engine and allow to idle. Fuel pressure should be
44-54 psi (3.1-3.8 kg/cm
). If no fuel pressure exists and engine will
not start, fuel pump relay and control circuit may be defective. See
FUEL PUMP RELAY.
6) If fuel pressure exceeds specification, fuel pump is okay,
but fuel pressure regulator is defective. Replace fuel pressure
regulator. Fuel pressure regulator is incorporated with the fuel
filter. Fuel filter/fuel pressure regulator is located on top of fuel
tank, in fuel pump module. See REMOVAL, OVERHAUL & INSTALLATION -
TRUCKS & RWD VANS - GASOLINE article.
7) On all models, release fuel pressure. See FUEL PRESSURE
RELEASE. Remove latch clip. Remove test equipment. Before reinstalling
fuel supply line, ensure fuel supply line fitting and fitting on fuel
rail are clean.
8) Lubricate fuel supply line fitting and fitting on fuel
rail with engine oil. Install fuel supply line on fuel rail.
9) Install latch clip into fuel rail, with latch clip fingers
pointing downward. Ensure latch clip is fully seated. Latch clip
fingers should extend downward below fitting on fuel rail when fully
seated.
10) Pull on fuel supply line to ensure fuel supply line is
fully locked on fuel rail. Reinstall negative battery cable. Start
engine and check for fuel leaks.

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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

axle housing.
CAUTION: DO NOT damage axle shaft bearing in axle housing when
removing axle shaft.
3) Inspect axle shaft-to-axle shaft bearing contact area for
damage. Replace axle shaft and axle shaft bearing if axle shaft is
damaged. Using small pry bar, pry oil seal from axle housing (if
necessary).
4) If replacing axle shaft bearing, use appropriate bearing
puller and slide hammer to remove axle shaft bearing. Rotate threaded
shaft on bearing puller to remove axle shaft bearing.
CAUTION: Ensure axle shaft bearing surface in axle housing is free of
burrs and clean before installing axle shaft bearing.
Installation
1) Using appropriate bearing/seal installer, install bearing.
Ensure axle shaft bearing is bottomed against shoulder in bore.
Install NEW oil seal in axle housing until installer contacts axle
housing.
2) Lubricate axle shaft bearing and oil seal lip with gear
lube. Install axle shaft so splines engage with splines on side gear.
DO NOT damage oil sea when installing axle shaft.
3) Install clip on end of axle shaft. Pull axle shaft
outward, ensuring clip fully seats in counterbore on side gear.
Install pinion shaft ensuring pinion shaft hole aligns with lock bolt
hole.
4) Apply Loctite to CLEAN threads on lock bolt. Install and
tighten lock bolt to specification. See TORQUE SPECIFICATIONS. Ensure
axle housing and axle housing cover sealing surfaces are clean.
5) Apply a 1/4" thick bead of silicone sealant on inside of
bolt holes and along sealing surfaces on axle housing cover. Install
axle housing cover, axle identification tag, and retaining bolts.
Tighten bolts in crisscross pattern to proper specification. See
TORQUE SPECIFICATIONS.
6) To install remaining components, reverse removal
procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
Fill differential. See LUBRICATION.
DRIVE SHAFT
Removal
1) Raise and support vehicle. Ensure transmission and
transfer case are in Neutral. Scribe mark on drive shaft-to-pinion
flange for reassembly reference.
2) On 2-piece drive shafts, scribe center carrier bearing-to-
frame bracket reference line for reassembly reference. On all drive
shafts, remove bolts and "U" joint straps at pinion flange. Remove
center carrier bearing bolts (if equipped). Remove drive shaft(s).
CAUTION: "U" joint straps and bolts must be replaced. DO NOT reuse.
Installation
To install, reverse removal procedure using NEW "U" joint
straps and bolts. Ensure all reference marks are aligned. Tighten
bolts to specification. See TORQUE SPECIFICATIONS.
PINION FLANGE & OIL SEAL
CAUTION: Following procedure must be used to retain proper pinion
bearing preload. Failure to follow procedure may result in
premature axle assembly or component failure. Ensure pinion

cylinder head design and type of metal used.
Remove valve guide from cylinder head by pressing or tapping
on a stepped drift. See Fig. 8. Once valve guide is installed,
distance from cylinder head to top of valve guide must be checked.
This distance must be within specification.
Aluminum heads are often heated before installing valve
guide. Guide is sometimes chilled in dry ice before installation.
Combination of a heated head and chilled guide insures a tight guide
fit upon assembly. The new guide must be reamed to specification.
Fig. 8: Typical Valve Guide Remover & Installer
This Graphic For General Information Only
VALVES & VALVE SEATS
Valve Grinding
Valve stem O.D. should be measured in several areas to
indicate amount of wear. Replace valve if not within specification.
Valve margin area should be measured to ensure that valve can be
grounded. See Fig. 9.
Fig. 9: Measuring Valve Head Margin - Typical
This Graphic For General Information Only
If valve margin is less than specification, this will burn
the valves. Valve must be replaced. Due to minimum margin dimensions

during manufacture, some new type valves cannot be reground.
Resurface valve on proper angle specification using valve
grinding machine. Follow manufacturer's instructions for valve
grinding machine. Specifications may indicate a different valve face
angle than seat angle.
Measure valve margin after grinding. Replace valve if not
within specification. Valve stem tip can be refinished using valve
grinding machine.
Valve Lapping
During valve lapping of recent designed valves, be sure to
follow manufacturers recommendations. Surface hardening and materials
used with some valves do not permit lapping. Lapping process will
remove excessive amounts of the hardened surface.
Valve lapping is done to ensure adequate sealing between
valve face and seat. Use either a hand drill or lapping stick with
suction cup attached.
Moisten and attach suction cup to valve. Lubricate valve stem
and guide. Apply a thin coat of fine valve grinding compound between
valve and seat. Rotate lapping tool between the palms or with hand
drill.
Lift valve upward off the seat and change position often.
This is done to prevent grooving of valve seat. Lap valve until a
smooth polished seat is obtained. Thoroughly clean grinding compound
from components. Valve to valve seat concentricity should be checked.
See VALVE SEAT CONCENTRICITY.
CAUTION: Valve guides must be in good condition and free of carbon
deposits prior to valve seat grinding. Some engines contain
an induction hardened valve seat. Excessive material removal
will damage valve seats.
Valve Seat Grinding
Select coarse stone of correct size and angle for seat to be
ground. Ensure stone is true and has a smooth surface. Select correct
size pilot for valve guide dimension. Install pilot in valve guide.
Lightly lubricate pilot shaft. Install stone on pilot. Move stone off
and on the seat approximately 2 times per second during grinding
operation.
Select a fine stone to finish grinding operation. Grinding
stones with 30 and 60 degree angles are used to center and narrow the
valve seat as required. See Fig. 10.
Fig. 10: Adjusting Valve Seat Width - Typical
This Graphic For General Information Only
Valve Seat Replacement
Replacement of valve seat inserts is done by cutting out

the old insert and machining an oversize insert bore. Replacement
oversize insert is usually chilled and the cylinder head is sometimes
warmed. Valve seat is pressed into the head. This operation requires
specialized machine shop equipment.
Valve Seat Concentricity
Using dial gauge, install gauge pilot in valve guide.
Position gauge arm on the valve seat. Adjust dial indicator to zero.
Rotate arm 360 degrees and note reading. Runout should not exceed
specification.
To check valve-to-valve seat concentricity, coat valve face
lightly with Prussian Blue dye. Install valve and rotate it on valve
seat. If pattern is even and entire seat is coated at valve contact
point, valve is concentric with the seat.
REASSEMBLY
Valve Stem Installed Height
Valve stem installed height must be checked when new valves
are installed or when valves or valve seats have been ground. Install
valve in valve guide. Measure distance from tip of valve stem to
spring seat. See Fig. 11. Distance must be within specifications.
Fig. 11: Measuring Valve Stem Installed Height - Typical
This Graphic For General Information Only
Remove valve and grind valve stem tip if height exceeds
specification. Valve tips are surface hardened. DO NOT remove more

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