1998 DODGE RAM 1500 fig

REMOVAL
(1) Install a prop rod on the brake pedal to keep
pressure on the brake system.
(2) Disconnect the battery cables from the battery.
(3) Remove the battery.
(4) Disconnect the electrical harness connector
(Fig. 6).
(5) Remove the brake lines from the rwal valve
(Fig. 6).
(6) Remove rwal valve mounting nuts and remove
the rwal valve (Fig. 6).
INSTALLATION
(1) Install rwal valve and Tighten the nuts to 15
N´m (11 ft. lbs.) (Fig. 6).
(2) Install the brake lines to the rwal valve and
tighten to 19 N´m (170 in. lbs.) (Fig. 6).
(3) Install the electrical harness connector to the
rwal valve and secure the connector.
(4) Install the battery.
(5) Install the battery cables to the battery.
(6) Remove the prop rod on the brake pedal.
(7) Bleed ABS brake system (Refer to 5 - BRAKES
- STANDARD PROCEDURE).
Fig. 6 RWAL VALVE
1 - RWAL VALVE
2 - MOUNTING NUTS
DRBRAKES - ABS 5 - 51
RWAL VALVE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Partial engagement of clutch disc.
One side of disc is worn and the
other side is glazed and lightly
worn.1. Clutch pressure plate position
incorrect.1. Replace clutch disc and cover.
2. Clutch cover, spring, or release
fingers bent or distorted.2. Replace clutch disc and cover.
3. Clutch disc damaged or
distorted.2. Replace clutch disc.
4. Clutch misalignment. 4. Check alignment and runout of
flywheel, disc, pressure plate, andùr
clutch housing. Correct as
necessary.
SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Slave Cylinder Nuts 23 17 -
Clutch Master Cylinder
Nuts28 21 -
Pressure Plate Bolts - V6
&V850 37 -
Pressure Plate Bolts - V10 30 22.5 -
Pressure Plate Bolts -
Diesel30 22.5 -
Release Bearing Pivot 23 17 -
Flywheel Bolts 95 70 -
CLUTCH DISC
REMOVAL
(1) Support engine with wood block and adjustable
jack stand, to prevent strain on engine mounts.
(2) Remove transmission and transfer case, if
equipped.
(3) If pressure plate will be reused, mark the posi-
tion on flywheel with paint or scriber (Fig. 1). Also
note location marks on the pressure next to the bolt
holes. The mark will be a L or a circle with an X in
it.
(4) Insert clutch alignment tool through clutch disc
and into pilot bushing, to hold disc in place while
removing bolts.
(5) Loosen pressure plate bolts evenly, a few
threads at a time and in a diagonal pattern to pre-
vent warping the plate.
(6) Remove bolts completely and remove pressure
plate, disc and alignment tool.
INSTALLATION
(1) Check runout and free operation of new clutch
disc.
(2) Lubricate crankshaft pilot bearing with a NLGI
- 2 rated grease.
(3) Install clutch alignment tool in clutch disc hub
with the raised side of hub is facing away from the
flywheel.
NOTE: Flywheel side is imprinted on the disc face.
(4) Install alignment tool in pilot bearing and posi-
tion disc on the flywheel.
(5) Position pressure plate over disc and onto the
flywheel (Fig. 2).
(6) Align and hold pressure plate in position and
install bolts finger tight.
(7) Tighten bolts evenly and a few threads at a
time in a diagonal pattern.
CAUTION: Bolts must be tightened evenly and to
specified torque to avoid warping pressure plate
cover.
DRCLUTCH 6 - 5
CLUTCH (Continued)

(8) Tighten pressure plate bolts to:
²V6 & V8 Engines - 50 N´m (37 ft. lbs.)
²V10 & Diesel Engines - 30 N´m (22.5 ft. lbs.)
(9) Remove release lever and release bearing from
clutch housing. Apply Mopar high temperature bear-
ing grease to bore of release bearing, release lever
contact surfaces and release lever pivot stud (Fig. 3).
(10) Apply light coat of Mopar high temperature
bearing grease to splines of transmission input shaft
and to release bearing slide surface of the transmis-
sion front bearing retainer (Fig. 4).CAUTION: Do not over lubricate shaft splines. This
can result in grease contamination of the disc.
Fig. 1 PRESSURE PLATE POSITION-TYPICAL
1 - FLYWHEEL
2 - ALIGNMENT MARKS
3 - PRESSURE PLATE
Fig. 2 CLUTCH DISC AND PRESSURE PLATE
1 - FLYWHEEL
2 - PRESSURE PLATE AND DISC
3 - ALIGNMENT TOOL
Fig. 3 LUBRICATION POINTS
1 - CLUTCH HOUSING
2 - FORK PIVOT BALL
3 - RELEASE FORK
4 - RELEASE BEARING BORE
5 - LUBE POINTS
Fig. 4 INPUT SHAFT LUBRICATION POINTS
1 - INPUT SHAFT
2 - BEARING RETAINER
3 - SPLINE AND RELEASE BEARING SURFACE
6 - 6 CLUTCHDR
CLUTCH DISC (Continued)

(11) Wipe pilot bearing surface clean.
(12) Install release lever and bearing in clutch
housing. Verify spring clips that retain fork on pivot
ball and release bearing on fork are installed prop-
erly (Fig. 5).
NOTE: If release lever is installed correctly, the
lever part number will be toward the bottom of the
transmission and right side up. There is also a
stamped ªIº in the lever which goes to the pivot ball
side of the transmission.
(13) Install transmission and transfer case if
equipped.
(14) Check fluid level in clutch master cylinder.
CLUTCH HOUSING
DIAGNOSIS AND TESTING
The clutch housing maintains alignment between
the crankshaft and transmission input shaft. Mis-
alignment can cause clutch noise, hard shifting,
incomplete release and chatter. Also premature pilot
bearing, cover release fingers and clutch disc wear.
In severe cases, it can cause premature wear of the
transmission input shaft and front bearing.
NOTE: Only the NV4500 clutch housing can be
checked using the following bore and face runout
procedures. The NV5600 clutch housing is a inte-
gral part of the transmission and can only be
checked off the vehicle.
CLUTCH HOUSING BORE RUNOUT
CAUTION: On diesel engines if housing bore runout
exceeds 0.015 inch, the clutch housing/transmis-
sion adapter plate must be replaced. On gas
engines if housing bore runout exceeds 0.053 in.
the clutch housing must be replaced.
NOTE: Offset dowels are available for gas engines
to correct housing bore runout. They are not avail-
able for diesel engines.
(1) Remove the clutch housing.
(2) Remove the clutch cover and disc.
(3) Replace one of the flywheel bolts with an
appropriate size threaded rod that is 10 in. (25.4 cm)
long (Fig. 6). The rod will be used to mount the dial
indicator.
(4) Remove release fork from the clutch housing.
(5) Install clutch housing. Tighten the housing
bolts nearest the alignment dowels first.
(6) Mount dial indicator on the threaded rod and
position indicator plunger on the clutch housing bore
(Fig. 7).
(7) Rotate crankshaft until indicator plunger is at
the topof the housing bore. Zero the indicator at this
point.
(8) Rotate crankshaft and record indicator read-
ings at eight points (45É apart) around the bore (Fig.
8). Take measurement at least twice for accuracy.
(9) Subtract each reading from the one 180É oppo-
site to determine runout and direction. Bore runout
example (Fig. 8):
²0.000 ± (±0.007) = 0.007 in.
²+0.002 ± (±0.010) = 0.012 in.
²+0.004 ± (±0.005) = 0.009 in.
²±0.001 ± (+0.001) = ±0.002 in.
Fig. 5 FORK, BEARING AND SPRING CLIPS
1 - FORK
2 - SPRING CLIP
3 - BEARING
4 - SPRING CLIP
Fig. 6 DIAL INDICATOR MOUNTING STUD
1 - 7/16 - 20 THREAD
2 - NUT
3 - STUD OR THREADED ROD
4 - 10 INCHES LONG
DRCLUTCH 6 - 7
CLUTCH DISC (Continued)

In this example the largest or total indicator read-
ing (TIR) difference is 0.012 inch. This means the
housing bore is offset from the crankshaft centerline
by 0.006 in. which is 1/2 of 0.012 inch. The dowels
needed to correct this have an offset of 0.007 in. (Fig.
9).
Remove housing and install dowels with the slotted
side facing out so they can be turned with a screw-
driver. Then install the housing and mount the dial
indicator and check bore runout again. Rotate the
dowels until the TIR is less than 0.010 inch.
Clutch Housing Face Runout
(1) Position dial indicator towards the housing face
(Fig. 10) with indicator plunger on the rim of the
housing bore.
(2) Rotate crankshaft until indicator plunger is at
the 10 O'clock position and zero the dial indicator.(3) Measure and record face runout readings at
four points 90É apart (Fig. 11). Take measurement at
least twice for accuracy.
(4) Subtract lowest reading from highest to deter-
mine total runout. If low reading wasminus0.004
in. and highest reading wasplus0.009 in. the total
runout is 0.013 inch.
NOTE: Maximum acceptable face runout is 0.010
inch.
Fig. 7 CLUTCH HOUSING BORE RUNOUT
1 - MOUNTING STUD OR ROD
2 - DIAL INDICATOR
3 - INDICATOR PLUNGER
4 - CLUTCH HOUSING BORE
Fig. 8 MEASUREMENT POINTS AND READINGS
1 - CLUTCH HOUSING BORE CIRCLE
Fig. 9 ALIGNMENT DOWEL SELECTION
1 - SLOT DIRECTION OF OFFSET
2 - OFFSET DOWEL
TIR VALUE OFFSET DOWEL REQUIRED
0.011 - 0.021 inch 0.007 inch
0.022 - 0.035 inch 0.014 inch
0.036 - 0.052 inch 0.021 inch
Fig. 10 DIAL INDICATOR LOCATION
1 - INDICATOR PLUNGER
2 - DIAL INDICATOR
3 - CLUTCH HOUSING FACE
4 - INDICATOR MOUNTING STUD OR ROD
6 - 8 CLUTCHDR
CLUTCH HOUSING (Continued)

To correct this example (Fig. 11) the shims needed
between the clutch housing and transmission are:
²0.009 in. at the 0.000 corner
²0.012 in. at the ±0.003 corner
²0.013 in. at the ±0.004 corner
After installing the clutch assembly and housing,
tighten the housing bolts nearest the alignment dow-
els first.
NOTE: Shims can be made from shim stock or sim-
ilar materials of the required thickness (Fig. 12).
REMOVAL
(1) Remove transmission and transfer case (Fig.
13).
(2) Remove starter from clutch housing.
(3) Remove structural dust cover bolts from clutch
housing.
CAUTION: Do not remove structural dust cover
from enigne block. If cover is removed clutch hous-
ing and cover must be aligned with the engine.(4) Remove clutch housing bolts and remove hous-
ing from the engine.
INSTALLATION
(1) Clean housing mounting surface of engine
block with wax and grease remover.
(2) Verify that clutch housing alignment dowels
are in good condition and properly seated.
(3) Transfer slave cylinder, release fork and boot,
fork pivot stud and wire/hose brackets to new hous-
ing.
(4) Install structural dust cover if removed (Refer
to 9 - ENGINE/ENGINE BLOCK/STRUCTURAL
COVER - INSTALLATION).
(5) Align and install clutch housing on engine (Fig.
14). Tighten housing bolts across the top of the hous-
ing first and to the following torque values:
²ªAº bolts 1/4in. diameter - 4.5 N´m (40 in.lb.)
²ªAº bolts 3/8in. diameter - 40 N´m (30 ft.lb.)
²ªAº bolts 7/16in. diameter - 68 N´m (50 ft.lb.)
²ªBº bolts for 5.7L 5.9L TD/8.0L engines - 47.5
N´m (40 ft.lb.)
²ªCº bolts for 5.7L engine - 68 N´m (50 ft.lb.)
²ªCº bolts for 5.9L TD engine - 47.5 N´m (35
ft.lb.)
²ªCº bolts for 8.0L engine - 74.5 N´m (55 ft.lb.)
(6) Install starter to clutch housing.
(7) Install transmission and transfer case, if
equipped.
CLUTCH RELEASE BEARING
REMOVAL
(1) Remove transmission and transfer case, if
equipped.
(2) Remove spring clip.
Fig. 11 MEASUREMENT POINTS AND READINGS
1 - CLUTCH HOUSING FACE CIRCLE (AT RIM OF BORE)
Fig. 12 ALIGNMENT SHIMS
1 - CUT/DRILL BOLT HOLE TO SIZE
2 - SHIM STOCK
3 - MAKE SHIM 1-INCH DIAMETER
Fig. 13 TRANSMISSION/CLUTCH HOUSING-NV4500
1 - CLUTCH HOUSING
2 - TRANSMISSION
DRCLUTCH 6 - 9
CLUTCH HOUSING (Continued)

(3) Disconnect release bearing from release fork
and remove bearing (Fig. 15).
INSTALLATION
(1) Inspect bearing slide surface on transmission
front bearing retainer. Replace retainer if slide sur-
face is scored, worn, or cracked.
(2) Inspect release lever and pivot stud. Be sure
stud is secure and in good condition. Be sure fork is
not distorted or worn. Replace fork spring clips if
bent or damaged.
(3) Lubricate input shaft splines, bearing retainer
slide surface, lever pivot ball stud, and release lever
pivot surface with Moparthigh temperature bearing
grease.
(4) Install release fork and release bearing (Fig.
16). Be sure fork and bearing are properly secured by
spring clips. Also be sure that the release fork is
installed properly. The rear side of the release lever
has one end with a raised area. This raised area goes
toward the slave cylinder side of the transmission.
(5) Install clutch housing, if removed.
(6) Install transmission and transfer case.(7) Check clutch master cylinder fluid level.
FLYWHEEL
DIAGNOSIS AND TESTING
Check flywheel runout whenever misalignment is
suspected. Flywheel runout should not exceed 0.08
mm (0.003 in.). Measure runout at the outer edge of
the flywheel face with a dial indicator. Mount the
indicator on a stud installed in place of one of the fly-
wheel bolts.
Fig. 14 CLUTCH HOUSING - NV4500
1 - ENGINE BLOCK
2 - CLUTCH DISC/PRESSURE PLATE
3 - CLUTCH HOUSING
4 - DUST COVER
Fig. 15 CLUTCH RELEASE COMPONENTS
1 - CONED WASHER
2 - CLUTCH HOUSING
3 - RELEASE FORK
4 - RELEASE BEARING AND SLEEVE
5 - PIVOT 23 N´m (200 IN. LBS.)
6 - SPRING CLIP
Fig. 16 Clutch Release Fork And
1 - PIVOT BALL
2 - FORK
3 - SLAVE CYLINDER OPENING
4 - BEARING
6 - 10 CLUTCHDR
CLUTCH RELEASE BEARING (Continued)

INSTALLATION
(1) Clean bearing bore with solvent and wipe dry
with shop towel.
(2) Install new bearing with clutch alignment tool
(Fig. 17). Drive bearing into place with the letter side
of the bearing facing the transmission. Bearing
should be flush with edge of bearing bore.
CAUTION: Do not allow bearing to become cocked
and do not recess bearing.
(3) Install clutch disc, pressure plate and trans-
mission.
LINKAGE
REMOVAL
CAUTION: The hydraulic linkage has a quick dis-
connect at the slave cylinder. This fitting should
never be disconnected or tampered with. Once the
hydraulic line is connected to the slave cylinder, it
should never be disconnected.
(1) Raise and support vehicle.
(2) Remove nuts attaching slave cylinder to studs
on clutch housing (Fig. 18).
(3) Remove slave cylinder from clutch housing.
(4) Remove plastic clip securing the hydraulic line
to the dash panel from the lower dash panel flange.(5) Remove plastic clip securing hydraulic line to
the dash panel from the upper dash panel stud.
(6) Lower vehicle.
(7) Disconnect clutch pedal interlock switch wires
(Fig. 19).
(8) Remove clutch master cylinder rod pin.
(9) Verify that cap on clutch master cylinder reser-
voir is tight. This will avoid spillage during removal.
(10) Remove clutch master cylinder nuts holding
the to the dash panel.
(11) Remove clutch cylinders, reservoir and con-
necting lines from vehicle.
INSTALLATION
(1) Position cylinders and connecting line in vehi-
cle engine compartment. Position clutch hydraulic
line against the dash panel and behind all engine
hoses and wiring.
Fig. 17 PILOT BEARING
1 - PILOT BEARING
2 - ALIGNMENT TOOL
3 - LETTER SIDE MUST FACE TRANSMISSION
Fig. 18 SLAVE CYLINDER
1 - MOUNTING NUTS
2 - SLAVE CYLINDER
Fig. 19 CLUTCH MASTER CYLINDER
1 - MASTER CYLINDER
2 - INTERLOCK CONNECTOR
3 - ROD PIN
6 - 12 CLUTCHDR
PILOT BEARING (Continued)