wheel alignment DODGE RAM 1999 Service Repair Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 54 of 1691
are continually republished. In addition to these, standards for Drive
Train and Transmissions have recently been promulgated. Participating
shops utilize these Uniform Inspection & Communication Standards as
part of the inspection process and for communicating their findings to
their customers.
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
(and their representatives), concerned with auto repair and/or
consumer protection, are conducted. Feedback from these sessions is
brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not
satisfied with a repair transaction, the Motorist Assurance Program
offers mediation and arbitration through MAP/BBB-CARE and other non-
profit organizations. MAP conducted pilot programs in twelve states
before announcing the program nationally in October, 1998. During the
pilots, participating repair shops demonstrated their adherence to the
Pledge and Standards and agreed to follow the UICS in communicating
the results of their inspection to their customers. To put some
"teeth" in the program, an accreditation requirement for shops was
initiated. The requirements are stringent, and a self-policing method
has been incorporated which includes the "mystery shopping" of
outlets.
We welcome you to join us as we continue our outreach... with
your support, both the automotive repair industry and your customers
will reap the benefits. Please visit MAP at our Internet site www.
motorist.org or contact us at:
1444 I Street, NW Suite 700
Washington, DC 20005
Phone (202) 712-9042 Fax (202) 216-9646
January 1999
MAP UNIFORM INSPECTION GENERAL GUIDELINES
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
It is MAP policy that all exhaust, brake, steering,
suspension, wheel alignment, drive-line, engine performance and
maintenance, and heating, ventilation and air conditioning, and
electrical services be offered and performed under the standards and
procedures specified in these sections.
Before any service is performed on a vehicle, an inspection
of the appropriate system must be performed. The results of this
inspection must be explained to the customer and documented on an
inspection form. The condition of the vehicle and its components will
indicate what services/part replacements may be "Required" or
"Suggested". In addition, suggestions may be made to satisfy the
requests expressed by the customer.
When a component is suggested or required to be repaired or
replaced, the decision to repair or replace must be made in the
customer's best interest, and at his or her choice given the options
available.
This section lists the various parts and conditions that
indicate a required or suggested service or part replacement.
Although this list is extensive, it is not fully inclusive. In
addition to this list, a technician may make a suggestion. However,
any suggestions must be based on substantial and informed experience,
Page 61 of 1691
Worn so it contacts
bottom of pulley ....... A ............ Require replacement.
(1) - Determine cause of incorrect alignment and require repair.
( 2) - Determine cause of noise and suggest repair.
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BLEND DOORS
See PLENUMS.
BLOWER FANS (BLOWER WHEEL OR SQUIRREL CAGE)
BLOWER FAN (BLOWER WHEEL OR SQUIRREL CAGE) 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.
Application incorrect ... B .. Require repair or replacement.
Broken .................. A ............ Require replacement.
Cracked ................. A ............. Require replacement
Distorted ............... A ............ Require replacement.
Fins missing ............ C ............ Require replacement.
Hub separated ........... A ............ Require replacement.
Inoperative ............. A ........ ( 1) Require replacement.
Mounting loose .......... A .. Require repair or replacement.
Noisy ................... 2 ............ Suggest replacement.
Out of balance .......... A .. Require repair or replacement.
( 1) - Inoperative includes intermittent operation or out of
OEM specification.
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BLOWER MOTORS
BLOWER MOTOR 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
Page 321 of 1691
satisfied with a repair transaction, the Motorist Assurance Program
offers mediation and arbitration through MAP/BBB-CARE and other non-
profit organizations. MAP conducted pilot programs in twelve states
before announcing the program nationally in October, 1998. During the
pilots, participating repair shops demonstrated their adherence to the
Pledge and Standards and agreed to follow the UICS in communicating
the results of their inspection to their customers. To put some
"teeth" in the program, an accreditation requirement for shops was
initiated. The requirements are stringent, and a self-policing method
has been incorporated which includes the "mystery shopping" of
outlets.
We welcome you to join us as we continue our outreach with
your support, both the automotive repair industry and your customers
will reap the benefits. Please visit MAP at our Internet site www.
motorist.org or contact us at:
1444 I Street, NW Suite 700
Washington, DC 20005
Phone (202) 712-9042 Fax (202) 216-9646
January 1999
MAP UNIFORM INSPECTION GENERAL GUIDELINES
OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS
It is MAP policy that all exhaust, brake, steering,
suspension, wheel alignment, drive-line, engine performance and
maintenance, and heating, ventilation and air conditioning, and
electrical services be offered and performed under the standards and
procedures specified in these sections.
Before any service is performed on a vehicle, an inspection
of the appropriate system must be performed. The results of this
inspection must be explained to the customer and documented on an
inspection form. The condition of the vehicle and its components will
indicate what services/part replacements may be "Required" or
"Suggested". In addition, suggestions may be made to satisfy the
requests expressed by the customer.
When a component is suggested or required to be repaired or
replaced, the decision to repair or replace must be made in the
customer's best interest, and at his or her choice given the options
available.
This section lists the various parts and conditions that
indicate a required or suggested service or part replacement.
Although this list is extensive, it is not fully inclusive. In
addition to this list, a technician may make a suggestion. However,
any suggestions must be based on substantial and informed experience,
or the vehicle manufacturer's recommended service interval and must be
documented.
Some conditions indicate that service or part replacement is
required because the part in question is no longer providing the
function for which it is intended, does not meet a vehicle
manufacturer's design specification or is missing.
Example:
An exhaust pipe has corroded severely and has a hole in it
through which exhaust gases are leaking. Replacement of the
exhaust pipe in this case is required due to functional
failure.
Example:
A brake rotor has been worn to the point where it measures
less than the vehicle manufacturer's discard specifications.
Page 346 of 1691
![DODGE RAM 1999 Service Repair Manual \
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Condition Code Procedure
Tire diameter incorrect,
affecting ABS or TCS ... A ............ Require replacement.
Tire pressure incorrect,
affecting ABS or TCS ... A .. Require repair or replacement.
Tire size incorrect,
affecting ABS or TCS ... A ............ Require replacement.
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TOOTHED RINGS (TONE WHEEL)
NOTE: Copied from Drivetrain UIGs.
If the toothed ring requires replacement and cannot be
replaced as a separate component, replace the assembly of which the
ring is a part.
TOOTHED RING INSPECTION
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Condition Code Procedure
Alignment incorrect ..... B ............... Require repair or
replacement.
Bent .................... B ............ Require replacement.
Contaminated, affecting
performance ............. A ........ Require repair. Identify
and correct cause.
Cracked ................. B ............ Require replacement.
Loose ................... A ............. Require replacement
of worn parts.
Missing ................. C ............ Require replacement.
Number of teeth
incorrect .............. B ............ Require replacement.
Teeth broken ............ A ............ Require replacement.
Teeth damaged, affecting
performance ............ A ............ Require replacement.
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VACUUM BOOSTERS
VACUUM BOOSTER INSPECTION \
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Condition Code Procedure
Applies too much assist
(oversensitive) ........ 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.
Auxiliary vacuum pump
inoperative ............ A ........... ( 1) Require repair or
replacement.
Check valve grommet
deteriorated, affecting
performance ............ A .. Require replacement of grommet.
Page 370 of 1691
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\
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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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0.011-0.021 (0.2794-0.5334) ......................... 0.007 (0.1778\
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0.022-0.035 (0.5588-0.8890) ......................... 0.014 (0.3556\
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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 429 of 1691
![DODGE RAM 1999 Service Repair Manual pinion flange from pinion. Remove oil seal from axle housing.
11) Remove slinger (if equipped), pinion bearing and preload\
shim(s). See Fig. 1. Note thickness of preload shims for reassembl](/img/12/56915/w960_56915-428.png "DODGE RAM 1999 Service Repair Manual pinion flange from pinion. Remove oil seal from axle housing.
11) Remove slinger (if equipped), pinion bearing and preload\
shim(s). See Fig. 1. Note thickness of preload shims for reassembl")
pinion flange from pinion. Remove oil seal from axle housing.
11) Remove slinger (if equipped), pinion bearing and preload\
shim(s). See Fig. 1. Note thickness of preload shims for reassembly
reference in case shims become misplaced.
12) Remove pinion and bearing from axle housing. Using
appropriate remover, remove front (outer) pinion bearing race from
axle housing. Remove rear (inner) pinion bearing race from axle
housing using remover. Remove pinion bearing depth shims from axle
housing. See Fig. 1. Measure and record shim thickness for reassembly
reference.
13) Remove rear (inner) bearing from pinion, using
appropriate puller. Remove differential bearings from differential
case. Remove preload shims from differential case. See Fig. 1.
Identify preload shim location. Record preload shim thickness for
reassembly reference.
14) Clamp differential case in soft-jaw vise. Remove roll pin
from differential case. Tap pinion shaft from differential case.
Remove pinion gears, pinion gear thrust washers, side gears and side
gear thrust washers from differential case.
Cleaning & Inspection
1) Clean components with solvent and dry with compressed air.
Inspect components for wear. Inspect bearings and bearing races for
wear and pitting. Replace bearings and bearing races as a set. Inspect
ring gear and pinion teeth for wear and chipping. Replace ring gear
and pinion gear as matched set.
2) Check differential case for cracks or scoring of side
gears, thrust washers and pinion thrust faces. Check fit of side gears
to differential case and axle shaft splines. Examine shaft of pinion
shaft for scoring or excessive wear.
3) On axles with Rear Wheel Anti-Lock (RWAL) brakes, if
exciter ring is not removed from differential case, ensure exciter
ring fits tightly on differential case and is fully seated.
NOTE: Lubricate all bearings, bearing races, gears and thrust
washers with gear lube during reassembly.
Reassembly & Adjustments
1) Place differential case in soft-jaw vise. Install side
gears, side gear thrust washers, pinion gears and pinion gear thrust
washers into differential case.
2) Rotate side gears until holes in pinion gears and thrust
washers align with holes in differential case. Install pinion shaft.
Install roll pin in differential case. Stake edge of differential case
in 2 areas, 180 degrees apart, to retain roll pin in place. Remove
differential case from vise.
3) On rear axles with Rear Wheel Anti-Lock (RWAL) brakes,
align tab on exciter ring with slot on differential case if installing
exciter ring. Install ring gear on differential case. Install 2 NEW
ring gear bolts to maintain bolt hole alignment. Using press, press
exciter ring onto differential case using ring gear as a pilot.
4) Install ring gear on differential case (if not previously
installed). Install NEW ring gear bolts. Tighten bolts evenly in
alternating pattern to specification. See TORQUE SPECIFICATIONS table.
Proceed to INITIAL DIFFERENTIAL BEARING PRELOAD.
NOTE: Initial differential bearing preload must be performed to
determine thickness of preload shims in order to obtain zero
end play of differential case. Procedure must be performed
before installing pinion in axle housing.
Initial Differential Bearing Preload
1) Install master bearings on each side of differential case
Page 439 of 1691
![DODGE RAM 1999 Service Repair Manual NOTE: Axle ratio can be identified by axle identification tag
attached to axle housing cover. See AXLE RATIO SPECIFICATIONS
table.
AXLE RATIO SPECIFICATIONS
\](/img/12/56915/w960_56915-438.png "DODGE RAM 1999 Service Repair Manual NOTE: Axle ratio can be identified by axle identification tag
attached to axle housing cover. See AXLE RATIO SPECIFICATIONS
table.
AXLE RATIO SPECIFICATIONS
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NOTE: Axle ratio can be identified by axle identification tag
attached to axle housing cover. See AXLE RATIO SPECIFICATIONS
table.
AXLE RATIO SPECIFICATIONS
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Application Ratio
8 1/4" Ring Gear ........................... 3.21:1, 3.55:1 & 3.90:1
9 1/4" Ring Gear ........................... 3.21:1, 3.55:1 & 3.92:1
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LUBRICATION
CAPACITY
DRIVE AXLE CAPACITY ( 1) \
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Application Pts. (L)\
8 1/4" Ring Gears .................................... ( 2) 4.4 (2.1)
9 1/4" Ring Gear ..................................... ( 2) 4.9 (2.3)
( 1) - Approximate drive axle capacity listed. Lubricant level should
be within 1/2" below bottom of oil filler hole in axle housing
cover.
( 2) - Add 5 ounces of (148 ml) Trac-Loc additive.
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FLUID TYPE
Use SAE 80W-90 hypoid gear lubricant with MIL-L-2105-C and
API GL-5 ratings.
TROUBLE SHOOTING
NOTE: See appropriate table in TROUBLE SHOOTING article in GENERAL
INFORMATION.
REMOVAL & INSTALLATION
AXLE SHAFT & BEARING
CAUTION: When servicing differential, DO NOT rotate one axle shaft
unless both axles are installed into differential. Rotation
of one axle shaft without other in place may result in
misalignment of side gears in differential. This would
require difficult realignment of side gears before axle
shafts can be installed.
Removal
1) Raise and support vehicle. Remove wheel and brake drum.
Clean area around axle housing cover. Loosen axle housing cover bolts.
Drain lubricant from axle housing. Remove bolts and axle housing
cover. Rotate differential carrier for access to lock bolt. See Fig. 1
.
2) Remove lock bolt and pinion shaft from differential
carrier. See Fig. 1. Push axle shaft inward, toward center of vehicle.
Remove clip from groove in end of axle shaft. Remove axle shaft from
Page 457 of 1691
DRIV E S H AFTS & " U " J O IN TS - R W D
1999 D odge P ic ku p R 1500
1998-99 Drive Axles
CHRY - Drive Shafts & "U" Joints - RWD Trucks
Dakota, Ram Pickup, Ram Van/Wagon
DESCRIPTION
Drive shafts are balanced, tubular shafts with "U" joints
attached at each end. Flanges or yokes are used to connect drive shaft
"U" joints to rear differential pinion flange or to transmission
output shaft. "U" joint bearing caps are bolted to shaft flanges, or
are pressed into shaft yokes. Drive shafts can be steel or aluminum.
Number of drive shafts used by vehicle depends on vehicle
length and 4WD capability. Long wheel base vehicles use 2 rear drive
shafts with a center bearing support assembly. See Fig. 1. 4WD
applications use a double cardan constant velocity joint on front axle
drive shaft for correct drive shaft-to-front axle alignment. See
Fig. 12 .
Locations of slip joints and splined shafts vary with model
application. Single tube type drive shaft has slip joint on outside of
"U" joint flange/yoke. This slip joint slides in and out on
transmission's splined main shaft.
Fig. 1: Identifying Common Drive Shaft Combinations
Courtesy of Chrysler Corp.
LUBRICATION
Page 458 of 1691
Apply multipurpose lubricant (NLGI grade 2 EP) to "U" joints
and slip joint fittings.
INSPECTION
Abnormal vibration and noise can come from many driveline
sources. Drive shaft vibration/noise increases with vehicle speed
(MPH). A vibration that occurs within a specific speed is not caused
by drive shaft imbalance. Before overhauling driveline, check for
other causes/sources of possible vibration/noise.
TIRES & WHEELS
Check tire inflation and wheel balance. Check for foreign
objects in tread, damaged tread, mismatched tread patterns or
incorrect tire sizes. Check for bent wheels.
CENTER BEARING
Tighten drive shaft center bearing mounting bolts. If bearing
insulator is deteriorated or oil-soaked, or drive shaft can be moved
up/down in support, replace center bearing support assembly.
ENGINE & TRANSMISSION MOUNTS
Tighten mounting bolts. If rubber mounts are deteriorated or
broken, replace as needed.
DRIVE SHAFT(S)
Check drive shaft(s) for missing weights, broken welds, or
for dents affecting balance. Check for undercoating, mud, snow/ice on
drive shaft(s). Clean shafts thoroughly and test drive.
"U" JOINTS
Check for foreign material lodged in joints and flange/yokes.
Check for loose "U" joint-to-flange mounting bolts. Check for worn "U"
joint needle bearings. Check for Reddish-Brown rust-dust around "U"
joint caps. Replace "U" joints if necessary.
ADJUSTMENTS
CHECKING DRIVE SHAFT PHASING
One-Piece Drive Shafts
1) Ensure "U" joint flanges on either end of drive shaft are
in same plane. See Fig. 2. Drive shafts with slip joints between yokes
often have arrows to aid in alignment. If yokes are not in same plane,
disassemble slip joint from drive shaft splines. Install slip joint
back onto drive shaft splines, aligning "U" joint yokes. Test drive.
2) Single tube type drive shaft has slip joint on outside of
"U" joint yoke (at transmission end). If one-piece tube type drive
shaft yokes are out of alignment, the drive shaft is torque-twisted.
Drive shaft must be replaced.
Page 462 of 1691
perpendicular to each other in vertical plane. See Fig. 6. With non-
parallel or broken-back type installation, working angles of "U"
joints of given drive shaft must be equal (angle "A" = angle "B").
Fig. 6: Identifying Broken-Back Type Drive Shaft
Courtesy of Chrysler Corp.
2) Calculate by subtracting angle of output shaft center line
from angle of drive shaft. Difference should be equal to front shaft
angle subtracted from rear shaft angle.
2-Piece Drive Shafts (Except Broken-Back Type)
1) All yokes must be perpendicular in both vertical and
horizontal planes to engine crankshaft. Using Inclinometer (C-4224),
measure drive shaft vertical angles.
2) Raise and support vehicle so rear wheels can be rotated.
Rotate drive shaft so a pinion flange bearing cap faces downward.
Attach inclinometer magnet to bearing cap, and note angle. See Fig. 4.
Remove inclinometer.
3) Rotate drive shaft 90 degrees until drive shaft rear yoke
bearing cap faces downward. Attach inclinometer magnet to bearing cap,
and note angle. Difference between 2 measured angles is drive shaft
rear angle. See Fig. 5. Remove inclinometer.
4) Rotate drive shaft until a slip joint yoke bearing cap
faces downward. Attach inclinometer magnet to bearing cap, and note
angle. Remove inclinometer. Rotate drive shaft 90 degrees until drive
shaft front yoke bearing cap faces downward. Attach inclinometer
magnet to bearing cap, and note angle. Difference between 2 measured
angles is drive shaft front angle. See Fig. 5. Remove inclinometer.
5) Rotate drive shaft until front yoke of rear shaft faces
downward. Attach inclinometer magnet to bearing cap, and note angle.
Rotate drive shaft until rear yoke of front drive shaft faces
downward. Attach inclinometer magnet to bearing cap, and note angle.
Remove inclinometer.
6) Difference between 2 measured angles is drive shaft center
angle. Compare front, center and rear angles. Vertical alignment of 2
piece drive shafts at yokes should be greater than 1/2 degree and must
be retained as close to one degree as possible. See Fig. 7. If
difference of angles is greater than specified, adjustment is
necessary. See ADJUSTING VERTICAL ANGLE.