1998 DODGE RAM 1500 wheel

(7) Install the flywheel or converter drive plate.
Tighten the bolts to 137 N´m (101 ft. lbs.) torque.
(8) Install the clutch cover and disc (if equipped)
(Refer to 6 - CLUTCH/CLUTCH DISC - INSTALLA-
TION).
(9) Install the transmission and transfer case (if
equipped).
(10) Lower vehicle.
(11) Connect battery negative cables.
(12) Check engine oil level and adjust, if necessary.
(13) Start engine and check for oil leaks.
CRANKSHAFT REAR OIL SEAL
RETAINER
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Remove the oil pan drain plug and drain the
engine oil. Re-install plug and torque to 50 N´m (44
ft. lbs.) torque.
(4) Remove transmission and transfer case (if
equipped) from vehicle.
(5)
Remove flywheel or torque converter drive plate.
(6) Disconnect starter cables from starter motor.
(7) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
and transmission adapter plate assembly.
(8) Remove four (4) oil pan rear bolts. Slide a
feeler gauge between the seal retainer and oil pan
gasket to break the seal.(9) Remove the six (6) retainer-to-block bolts (Fig.
73).
(10) Remove the rear seal retainer and gasket
(Fig. 73).
(11) Support the seal retainer and drive out the
crankshaft seal with a hammer and suitable punch.
INSTALLATION
(1) If using the old seal retainer, the crankshaft
seal must be replaced.
(2) Inspect oil pan gasket for nickes or cuts. If gas-
ket is damaged, the oil pan must be removed and
gasket must be replaced. Wipe oil pan gasket dry and
apply light coating of RTV.
(3) Using the retainer alignment/seal installation
tool provided in the seal service kit, install the align-
ment tool into the retainer and install to the cylinder
block (Fig. 74), using a new gasket. Tighten the six
(6) mounting bolts by hand.
(4) The seal alignment tool is used to align rear
cover properly. Starting with the center two bolts,
tighten the retainer in a circular pattern to 10 N´m
(89 in. lbs.). Remove the alignment tool.
CAUTION: The seal lip and the sealing surface on
the crankshaft must be free from all oil residue to
prevent seal leaks. The crankshaft and seal sur-
faces must be completely dry when the seal is
installed. Use a soap and water solution on outside
diameter of seal to ease assembly.
Fig. 72 Seal Installation Using Alignment Tool and
Hammer
1 - SEAL PILOT TOOL
2 - INSTALLATION TOOL
3 - SEAL
4 - RETAINER
Fig. 73 Crankshaft Rear Seal Retainer and Gasket
1 - RETAINER
2 - GASKET
3 - BOLT
DRENGINE 5.9L DIESEL 9 - 277
CRANKSHAFT OIL SEAL - REAR (Continued)

(5) Make sure the provided seal pilot is installed
into the new crankshaft seal. Use the alignment/in-
stallation tool and press the seal onto the crankshaft
(Fig. 75). Alternately drive the seal at the 12, 3, 6
and 9 o'clock positions.
(6) Remove the alignment tool and trim the
retainer gasket even with the oil pan mounting sur-
face (Fig. 76).
(7) Remove the seal pilot.
(8) Apply a small amount of MopartSilicone Rub-
ber Adhesive Sealant to the oil pan rail T-joints.
(9) Install the four (4) oil pan rear mounting bolts
and torque to 28 N´m (21 ft. lbs.).
(10) Install new rectangular ring seal for cam bore.
(11) Install the flywheel housing and bolts. Torque
bolts to 77 N´m (57 ft. lbs.).
(12) Install the flywheel or converter drive plate.
Tighten bolts to 137 N´m (101 ft. lbs.).
(13) Install the starter motor Refer to (Refer to 8 -
ELECTRICAL/STARTING/STARTER MOTOR -
INSTALLATION).
(14) Install the transmission and transfer case (if
equipped).
(15) Lower vehicle.(16) Fill the crankcase with new engine oil.
(17) Connect the battery negative cables.
(18) Start engine and check for oil leaks.
Fig. 74 Aligning Seal Retainer with Alignment/
Installation Tool
1 - ALIGNMENT / INSTALLATION TOOL
2 - SEAL RETAINER
Fig. 75 Installing Seal Using Alignment Tool and
Hammer
1 - SEAL PILOT TOOL
2 - INSTALLATION TOOL
3 - SEAL
4 - RETAINER
Fig. 76 Trimming Excess Gasket Material
1 - GASKET
9 - 278 ENGINE 5.9L DIESELDR
CRANKSHAFT REAR OIL SEAL RETAINER (Continued)

OIL COOLER & LINES
CLEANING
CLEANING AND INSPECTION
Clean the sealing surfaces.
Apply 483 kPa (70 psi) air pressure to the element
to check for leaks. If the element leaks, replace the
element.
OIL FILTER
REMOVAL
(1) Clean the area around the oil filter head.
Remove the filter from below using a cap-style filter
wrench.
(2) Clean the gasket surface of the filter head. The
filter canister O-Ring seal can stick on the filter
head. Make sure it is removed.
INSTALLATION
(1) Fill the oil filter element with clean oil before
installation. Use the same type oil that will be used
in the engine.
(2) Apply a light film of lubricating oil to the seal-
ing surface before installing the filter.
CAUTION: Mechanical over-tightening may distort
the threads or damage the filter element seal.
(3) Install the filter until it contacts the sealing
surface of the oil filter adapter. Tighten filter an
additional
1¤2turn.
OIL PAN
REMOVAL
(1) Disconnect the battery negative cables.
(2) Install engine support fixture # 8534.
(3) Raise vehicle on hoist.
(4) Disconnect starter cables from starter motor.
(5) Remove transmission and transfer case (if
equipped).
(6) Remove flywheel or flexplate.
(7) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
and transmission adapter plate assembly.
WARNING: HOT OIL CAN CAUSE PERSONAL
INJURY.
(8) Drain the engine oil (Refer to 9 - ENGINE/LU-
BRICATION/OIL - STANDARD PROCEDURE).(9) Install the oil pan drain plug if sealing surface
is not damaged and tighten to 50 N´m (37 ft. lbs.)
torque.
(10) Remove oil pan bolts, break the pan to block
seal, and lower pan slightly and remove oil suction
tube fasteners.
(11) Remove oil pan and suction tube.
CLEANING
Remove all gasket material from the oil pan and
cylinder block sealing surfaces. Extra effort may be
required around T-joint areas. Clean oil pan and
flush suction tube with a suitable solvent.
INSPECTION
Inspect the oil pan, suction tube, and tube braces
for cracks and damage. Replace any defective compo-
nent. Inspect the oil drain plug and drain hole
threads. Inspect the oil pan sealing surface for
straightness. Repair any minor imperfections with a
ball-peen hammer. Do not attempt to repair an oil
pan by welding.
INSTALLATION
(1) Fill the T-joint between the pan rail/gear hous-
ing and pan rail/rear seal retainer with sealant. Use
MopartSilicone Rubber Adhesive Sealant or equiva-
lent.
(2) Place suction tube in oil pan and guide them
into place. Using a new tube to block gasket, install
and tighten the suction tube bolts by hand. Starting
with the oil pump inlet bolts, tighten the bolts to 24
N´m (18 ft. lbs.) torque. Tighten the remaining tube
brace bolts to 43 N´m (32 ft. lbs.) torque.
(3) Starting in the center and working outward,
tighten the oil pan bolts to 28 N´m (21 ft. lbs.)
torque.
(4) Install the flywheel housing assembly with the
starter motor attached and tighten bolts to 77 N´m
(57 ft. lbs.) torque.
(5) Connect starter motor cables.
(6) Install the flywheel or flexplate. Torque to 137
N´m (101 ft. lbs.).
(7) Install transmission and transfer case (if
equipped).
(8) Lower vehicle.
(9) Remove the engine support fixture # 8534.
(10) Install battery negative cables.
(11) Fill the crankcase with new engine oil.
(12) Start engine and check for leaks. Stop engine,
check oil level, and adjust, if necessary.
DRENGINE 5.9L DIESEL 9 - 293

OPERATION
Exhaust gas pressure and energy drive the tur-
bine, which in turn drives a centrifugal compressor
that compresses the inlet air, and forces the air into
the engine through the charge air cooler and plumb-
ing. Since heat is a by-product of this compression,
the air must pass through a charge air cooler to cool
the incoming air and maintain power and efficiency.
Increasing air flow to the engine provides:
²Improved engine performance
²Lower exhaust smoke density
²Improved operating economy
²Altitude compensation
²Noise reduction.
The turbocharger also uses a wastegate (Fig. 16),
which regulates intake manifold air pressure and
prevents over boosting at high engine speeds. When
the wastegate valve is closed, all of the exhaust gases
flow through the turbine wheel. As the intake mani-
fold pressure increases, the wastegate actuator opens
the valve, diverting some of the exhaust gases away
from the turbine wheel. This limits turbine shaft
speed and air output from the impeller.
The turbocharger is lubricated by engine oil that is
pressurized, cooled, and filtered. The oil is delivered
to the turbocharger by a supply line that is tapped
into the oil filter head. The oil travels into the bear-
ing housing, where it lubricates the shaft and bear-
ings (Fig. 17). A return pipe at the bottom of the
bearing housing, routes the engine oil back to the
crankcase.
The most common turbocharger failure is bearing
failure related to repeated hot shutdowns with inad-
equate ªcool-downº periods. A sudden engine shut
down after prolonged operation will result in the
transfer of heat from the turbine section of the tur-
bocharger to the bearing housing. This causes the oil
to overheat and break down, which causes bearing
and shaft damage the next time the vehicle is
started.
Letting the engine idle after extended operation
allows the turbine housing to cool to normal operat-
ing temperature. The following chart should be used
as a guide in determining the amount of engine idle
time required to sufficiently cool down the turbo-
charger before shut down, depending upon the type
of driving and the amount of cargo.
Fig. 16 Wastegate Operation
1 - SIGNAL LINE
2 - EXHAUST BYPASS VALVE
3 - WASTEGATE
4 - EXHAUST
5 - TURBINE
DREXHAUST SYSTEM 11 - 13
TURBOCHARGER (Continued)

(9) Remove the turbocharger and gasket from the
exhaust manifold.
(10) If the turbocharger is not to be installed
immediately, cover the opening to prevent material
from entering into the manifold.
(11) If replacing the turbocharger, transfer the tur-
bocharger oil supply fitting to the new assembly.
Tighten fitting to 36 N´m (27 ft. lbs.).
(12) Clean and inspect the sealing surface.
CAUTION: The turbocharger is only serviced as an
assembly. Do not attempt to repair the turbocharger
as turbocharger and/or engine damage can result.
CLEANING
WARNING: To prevent damage or personal injury,
do not use a combustable cleaner to clean the tur-
bocharger.
Clean the turbocharger and exhaust manifold
mounting surfaces with a suitable scraper.
INSPECTION
Visually inspect the turbocharger and exhaust
manifold gasket surfaces. Replace stripped or eroded
mounting studs.
(1) Visually inspect the turbocharger for cracks.
The following cracks are NOT acceptable:
²Cracks in the turbine and compressor housing
that go completely through.
²Cracks in the mounting flange that are longer
than 15 mm (0.6 in.).
²Cracks in the mounting flange that intersect
bolt through-holes.
²Two (2) Cracks in the mounting flange that are
closer than 6.4 mm (0.25 in.) together.
(2) Visually inspect the impeller and compressor
wheel fins for nicks, cracks, or chips. Note: Some
impellers may have a factory placed paint mark
which, after normal operation, appears to be a crack.
Remove this mark with a suitable solvent to verify
that it is not a crack.
(3) Visually inspect the turbocharger compressor
housing for an impeller rubbing condition (Fig. 20).
Replace the turbocharger if the condition exists.
(4) Measure the turbocharger axial end play:
(a) Install a dial indicator as shown in (Fig. 21).
Zero the indicator at one end of travel.
(b) Move the impeller shaft fore and aft and
record the measurement. Allowable end play is
0.026 mm (0.0001 in.) MIN. and 0.127 mm (0.005
in.) MAX. If the recorded measurement falls out-
side these parameters, replace the turbocharger
assembly.(5) Measure the turbocharger bearing radial clear-
ance:
(a) Insert a narrow blade or wire style feeler
gauge between the compressor wheel and the hous-
ing (Fig. 22).
(b) Gently push the compressor wheel toward
the housing and record the clearance.
(c) With the feeler gauge in the same location,
gently push the compressor wheel away from the
housing and again record the clearance.
(d) Subtract the smaller clearance from the
larger clearance. This is the radial bearing clear-
ance.
(e) Allowable radial bearing clearance is 0.33
mm (0.013 in.) MIN. and 0.50 mm (0.020 in.) MAX.
If the recorded measurement falls outside these
specifications, replace the turbocharger assembly.
INSTALLATION
(1) Install the turbocharger. Apply anti-seize to the
studs and then tighten the turbocharger mounting
nuts to 43 N´m (32 ft. lbs.) torque.
Fig. 20 Inspect Compressor Housing for Impeller
Rubbing Condition
Fig. 21 Measure Turbocharger Axial End Play
DREXHAUST SYSTEM 11 - 15
TURBOCHARGER (Continued)

FRONT AIR DAM
REMOVAL
(1) Remove the two outboard screws.
(2) Remove the three middle screws and remove
the air dam.
INSTALLATION
(1) Position the air dam onto the bumper and seat
the carrot type fasteners fully.
(2) Starting at the center screw install the three
middle screws.
(3) Install the two outboard screws.
FRONT BUMPER
REMOVAL
(1) Using a grease pencil or equivalent, mark the
position of the bumper on the frame rail tip to aid
installation.
(2) Disconnect the fog lamp electrical connector at
the left frame rail.
(3) Support the bumper with a suitable lifting
device.
(4) Remove the center bracket nuts and bolts and
remove bumper. (Fig. 1)
INSTALLATION
(1) Install the bumper onto the frame rails and
position the wheelhouse splash shield into the sup-
port brackets.
(2) Install the bolts and nuts.
(3) Line up the bumper with the marks made pre-
viously and tighten the bolts and nuts to 95 N´m (70
ft. lbs.).
(4) Check and adjust the bumper alignment as
necessary. (Refer to 23 - BODY/BODY STRUCTURE/
GAP AND FLUSH - SPECIFICATIONS)
FRONT FASCIA
REMOVAL
ST/SLT/SLT+ - FASCIA REMOVAL
(1) Remove the two screws at each trailing edge of
the fascia. (Fig. 2)
(2) Remove the four push pin fasteners from the
upper edge of the close out panel.
(3) Using a trim stick C-4755 or equivalent, care-
fully release the six lower clips and remove the close
out panel.
(4) Using a trim stick C-4755 or equivalent, care-
fully remove the step pad.
(5) Remove and discard the four push pin fasten-
ers and remove the fascia.
Fig. 1 BUMPER SUPPORT BRACKET - TYPICAL
1 - FASCIA - SPORT MODEL
2 - SUPPORT BRACKET
3 - FASCIA SUPPORT BRACKET
4 - WHEELHOUSE SPLASH SHIELD SUPPORT BRACKET
5 - BUMPER CENTER BRACKET
6 - NUTS (4 PER SIDE)
7 - FRAME RAIL TIP
8 - CENTER BRACKET NUTS (2 PER SIDE)
9 - CENTER BRACKET BOLTS ASSEMBLY (1 PER SIDE)
10 - FOG LAMPFig. 2 UPPER FASCIA - ST/SLT/SLT+
1 - STEP PAD
2 - UPPER FASCIA (ST/SLT/SLT+ MODEL ONLY)
3 - INBOARD BUMPER BRACKET ATTACHMENTS
4 - SCREWS (4)
5 - PUSH PIN FASTENERS (4)
13 - 2 FRAMES & BUMPERSDR

SPORT FASCIA REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Remove the three screws at each trailing edge
of the fascia. (Fig. 3)
(3) Remove the five lower screws.
(4) Remove and discard the four upper push pins.
(5) Using a trim stick C-4755 or equivalent, care-
fully release the six lower clips and remove the close
out panel.
(6) Using a trim stick C-4755 or equivalent, care-
fully remove the step pad.
(7) Spread the fascia out at the wheels and remove
from the vehicle.
INSTALLATION
NOTE: The left and right inboard bumper to bracket
attachments must be secured before installing the
fascia and step pad.
ST/SLT/SLT+ FASCIA INSTALLATION
(1) Install the fascia.
(2) Position the close out panel and seat the 6
lower clips fully.
(3) Install four new upper push pin fasteners.
(4) Position the step pad onto the fascia and fully
seat the attachment clips.(5) Align the fascia to the fender with a 19 mm
(0.75 inch) gap and install the two screws at each
trailing edge of the fascia.
SPORT FASCIA INSTALLATION
(1) Position the fascia onto the bumper.
(2) Position the step pad onto the fascia and fully
seat the attachment clips.
(3) Install four new upper push pin fasteners.
(4) Install the five lower screws.
(5) Install the three screws at each trailing edge of
the fascia.
REAR BUMPER
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Remove the license plate.
(3) Remove the bolts behind the plate.
(4) Disconnect the license plate light electrical con-
nectors.
(5) Disconnect the trailer light connector electrical
connection, if equipped.
(6) Remove the two bolts along the front upper
edge of the bumper near the frame tips.
(7) Support the bumper with a suitable lifting
device.
(8) Remove the bolts attaching the bumper support
brackets to the trailer hitch. (Fig. 4)
Fig. 3 SPORT FASCIA
1 - STEP PAD
2 - FASCIA (SPORT MODEL ONLY)
3 - SCREWS (3 PER SIDE)
4 - UPPER FASCIA SUPPORT BRACKET
5 - WHEELHOUSE SPLASH SHIELD BRACKET
6 - INBOARD BUMPER BRACKET ATTACHMENTS
7 - PUSH PIN FASTENERS (4)
8 - LOWER SCREWS (5)
Fig. 4 TRAILER HITCH
1 - HITCH
2 - LD HITCH BOLTS (4)/HD (6)
3 - BUMPER BRACKET BOLTS (4)
4 - BUMPER SUPPORT BRACKETS
DRFRAMES & BUMPERS 13 - 3
FRONT FASCIA (Continued)

INSTALLATION
(1) Align the holes in the bumpers to the trailer
hitch pins and install the bumper.
(2) Install the support bracket to the hitch bolts,
loosely.
(3) Install the front upper edge to the trailer hitch
bolts and tighten to 54 N´m (40 ft. lbs.).
(4) Install the license plate reinforcement to hitch
bolts and tighten to 54 N´m (40 ft. lbs.).
(5) Tighten the left bumper bracket bolts to 54
N´m (40 ft. lbs.).
(6) Tighten the right bumper bracket bolts to 54
N´m (40 ft. lbs.).
(7) Connect the trailer light connector electrical
connection, if equipped.
(8) Connect the license plate light electrical con-
nectors.
(9) Install the license plate.
FRAME
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT.
²BEFORE PROCEEDING WITH FRAME REPAIR
INVOLVING GRINDING OR WELDING, VERIFY THAT
VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN
CONTACT WITH REPAIR AREA, PERSONAL INJURY
CAN RESULT.
²DO NOT ALLOW OPEN FLAME OR HEAT AND
METAL SPATTER FROM ARC WELDING, TO CON-
TACT PLASTIC BODY PANELS. FIRE OR EXPLO-
SION CAN RESULT.
²WHEN WELDED FRAME COMPONENTS ARE
REPLACED, ENSURE COMPLETE PENETRATION
WELD IS ACHIEVED DURING INSTALLATION. IF
NOT, DANGEROUS OPERATING CONDITIONS CAN
RESULT.
²STAND CLEAR OF CABLES OR CHAINS ON
PULLING EQUIPMENT DURING FRAME STRAIGHT-
ENING OPERATIONS, PERSONAL INJURY CAN
RESULT.
²DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT SUPPORTED ON SAFETY
STANDS, PERSONAL INJURY CAN RESULT.
CAUTION: 1500 series Dodge Ram Trucks (2002 and
later) are not designed for snow plow equipment.The front collision repair tips must not be installed
on any truck equipped with a snow plow, or even
intended to be equipped with a snow plow.
CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect. Failure to use only pro-
duction fasteners or fasteners of equivalent hard-
ness can result in loosening or failure. Do not drill
any holes in the frame that are not specifically out-
lined in this or other, DaimlerChrysler procedure as
frame rail failure can result. When using heat to
straighten frame components do not exceed 566ÉC
(1050ÉF), metal fatigue can result.
STANDARD PROCEDURE
STANDARD PROCEDURE - LIGHT DUTY FRONT
FRAME RAIL TIP REPLACEMENT
CAUTION: This procedure is designed to replace
the front frame rail tips that have been damaged in
the crush initiator zones. Prior to any cutting, the
vehicle must be mounted on the appropriate frame
repair equipment (ªframe rackº), checked with three
dimensional measuring equipment, and the neces-
sary pull corrections made. If damage remains in
the frame beyond the area covered by this service
part after the pull, the frame must be replaced in its
entirety.
NOTE: Procedures for 4X2 and 4X4 are common
except as noted in this procedure.
(1) Before proceding with this repair procedure
review the required service warnings and precau-
tions. (Refer to 13 - FRAME & BUMPERS/FRAME -
WARNING)
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the front wheelhouse splash shield.
(Refer to 23 - BODY/EXTERIOR/FRONT WHEEL-
HOUSE SPLASH SHIELD - REMOVAL)
(4) Remove the bolts and position aside the wire
harness and grounds, if required.
(5) Remove the front bumper. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/FRONT BUMPER
- REMOVAL)
(6) Loosen and lower the stabilizer bar mount and
bar. (Refer to 2 - SUSPENSION/FRONT/STABI-
LIZER BAR - REMOVAL)
13 - 4 FRAMES & BUMPERSDR
REAR BUMPER (Continued)