1998 DODGE RAM 1500 Workshop Manual

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Page 297 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual REMOVAL
(1) Remove the front rotor (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).
(2) Remove the wheel speed sensor mounting bolt
from the hub. (Fig. 3)
(3) Remove the wheel speed senso

REMOVAL
(1) Remove the front rotor (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).
(2) Remove the wheel speed sensor mounting bolt
from the hub. (Fig. 3)
(3) Remove the wheel speed sensor from the hub.
(4) Remove the wiring from the clips and discon-
nect the electrical connector.
INSTALLATION
(1) Install the wiring to the clips and Reconnect
the electrical connector.
(2) Install the wheel speed sensor to the hub.
(3) Install the wheel speed sensor mounting bolt to
the hub. Tighten the bolt to 21 N´m (190 in. lbs.).
(4) Install the front rotor and brake caliper assem-
bly (Refer to 5 - BRAKES/HYDRAULIC/MECHANI-
CAL/ROTORS - INSTALLATION).
REAR WHEEL SPEED SENSOR
DIAGNOSIS AND TESTING - REAR WHEEL
ANTILOCK
Diagnosis of base brake conditions which are
mechanical in nature should be performed first. This
includes brake noise, lack of power assist, parking
brake, or vehicle vibration during normal braking.
The RWAL brake system performs several self-
tests every time the ignition switch is turned on and
the vehicle is driven. The CAB monitors the system
inputs and outputs circuits to verify the system is
operating properly. If the CAB senses a malfunction
in the system it will set a DTC into memory and trig-
ger the warning lamp.NOTE: The MDS or DRB III scan tool is used to
diagnose the RWAL system. For test procedures
refer to the Chassis Diagnostic Manual.
REMOVAL
(1) Raise the vehicle on a hoist.
(2) Remove the brake line mounting nut and
remove the brake line from the sensor stud.
(3) Remove the mounting stud from the sensor and
shield (Fig. 4).
(4) Remove the sensor and shield from the differ-
ential housing.
(5) Disconnect the sensor wire harness and remove
the sensor.
INSTALLATION
(1) Connect the harness to the sensor.Be sure
the seal is securely in place between the sensor
and the wiring connector.
(2) Install the O-ring on the sensor (if removed).
(3) Insert the sensor in the differential housing.
(4) Install the sensor shield.
(5) Install the sensor mounting stud and tighten to
24 N´m (200 in. lbs.).
(6) Install the brake line on the sensor stud and
install the nut.
(7) Lower the vehicle.
Fig. 3 WHEEL SPEED SENSOR
1 - WHEEL SPEED SENSOR MOUNTING BOLT
2 - WHEEL SPEED SENSOR
3 - HUB/BEARINGFig. 4 REAR WHEEL SPEED SENSOR
1 - WHEEL SPEED SENSOR
2 - MOUNTING BOLT
3 - AXLE HOUSING
5 - 48 BRAKES - ABSDR
FRONT WHEEL SPEED SENSOR (Continued)

Page 298 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual TONE WHEEL
DIAGNOSIS AND TESTING - REAR WHEEL
SPEED SENSOR
Diagnosis of base brake conditions which are
mechanical in nature should be performed first. This
includes brake noise, lack of power assist,

TONE WHEEL
DIAGNOSIS AND TESTING - REAR WHEEL
SPEED SENSOR
Diagnosis of base brake conditions which are
mechanical in nature should be performed first. This
includes brake noise, lack of power assist, parking
brake, or vehicle vibration during normal braking.
The Antilock brake system performs several self-
tests every time the ignition switch is turned on and
the vehicle is driven. The CAB monitors the system
inputs and outputs circuits to verify the system is
operating properly. If the CAB senses a malfunction
in the system it will set a DTC into memory and trig-
ger the warning lamp.
NOTE: The MDS or DRB III scan tool is used to
diagnose the Antilock Brake system. For test proce-
dures refer to the Chassis Diagnostic Manual.
HYDRAULIC/MECHANICAL
DESCRIPTION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING
Vehicles equipped with ABS use electronic variable
brake proportioning (EVBP) to balance front-to-rear
braking. The EVBP is used in place of a rear propor-
tioning valve. The EVBP system uses the ABS sys-
tem to control the slip of the rear wheels in partial
braking range. The braking force of the rear wheels
is controlled electronically by using the inlet and out-
let valves located in the integrated control unit
(ICU).
OPERATION - ELECTRONIC VARIABLE BRAKE
PROPORTIONING
EVBP is able to decrease, hold and increase rear
brake pressure without activating full ABS control.
Upon entry into EVBP the inlet valve for the rear
brake circuit is switched on so that the fluid supply
from the master cylinder is shut off. In order to
decrease the rear brake pressure, the outlet valve for
the rear brake circuit is pulsed. This allows fluid to
enter the low pressure accumulator (LPA) in the
hydraulic control unit (HCU) resulting in a drop in
fluid pressure to the rear brakes. In order to increase
the rear brake pressure, the outlet valve is switched
off and the inlet valve is pulsed. This increases the
pressure to the rear brakes.
The EVBP will remain functional during many
ABS fault modes. If both the red BRAKE and amber
ABS warning indicators are illuminated, the EVBP
may not be functioning.
HCU (HYDRAULIC CONTROL
UNIT)
DESCRIPTION
The HCU consists of a valve body, pump motor, low
pressure accumulators, inlet valves, outlet valves and
noise attenuators.
OPERATION
Accumulators in the valve body store extra fluid
released to the system for ABS mode operation. The
pump provides the fluid volume needed and is oper-
ated by a DC type motor. The motor is controlled by
the CAB.
The valves modulate brake pressure during
antilock braking and are controlled by the CAB.
The HCU provides three channel pressure control
to the front and rear brakes. One channel controls
the rear wheel brakes in tandem. The two remaining
channels control the front wheel brakes individually.
During antilock braking, the solenoid valves are
opened and closed as needed.
During normal braking, the HCU solenoid valves
and pump are not activated. The master cylinder and
power booster operate the same as a vehicle without
an ABS brake system.
NOTE: The three modes mentioned below do occur
but not necessarily in the order listed everytime.
During antilock braking, solenoid valve pressure
modulation occurs in three stages, pressure increase,
pressure hold, and pressure decrease. The valves are
all contained in the valve body portion of the HCU.
PRESSURE DECREASE
The outlet valve is opened and the inlet valve is
closed during the pressure decrease cycle.
A pressure decrease cycle is initiated when speed
sensor signals indicate high wheel slip at one or
more wheels. At this point, the CAB closes the inlet
then opens the outlet valve, which also opens the
return circuit to the accumulators. Fluid pressure is
allowed to bleed off (decrease) as needed to prevent
wheel lock.
Once the period of high wheel slip has ended, the
CAB closes the outlet valve and begins a pressure
increase or hold cycle as needed.
PRESSURE HOLD
Both solenoid valves are closed in the pressure
hold cycle but only the inlet valve is energized. Fluid
apply pressure in the control channel is maintained
at a constant rate. The CAB maintains the hold cycle
until sensor inputs indicate a pressure change is nec-
essary.
DRBRAKES - ABS 5 - 49

Page 299 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual PRESSURE INCREASE
The inlet valve is open and the outlet valve is
closed during the pressure increase cycle. The pres-
sure increase cycle is used to reapply thew brakes.
This cycle controls re-applic

PRESSURE INCREASE
The inlet valve is open and the outlet valve is
closed during the pressure increase cycle. The pres-
sure increase cycle is used to reapply thew brakes.
This cycle controls re-application of fluid apply pres-
sure.
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 two electrical harness connec-
tors (Fig. 5).
(5) Remove the five brake lines from the HCU
(Fig. 5).
(6) Remove HCU/CAB mounting bolts and remove
the HCU/CAB (Fig. 5).
INSTALLATION
NOTE: If the CAB is being replaced with a new CAB
is must be reprogrammed with the use of a DRB III.
(1) Install HCU/CAB on the mounts and Tighten
the bolts to 15N´m (11 ft. lbs.) (Fig. 5).
(2) Install the five brake lines to the HCU and
tighten to 19 N´m (170 in. lbs.) (Fig. 5).
(3) Install the two electrical harness connectors to
the HCU/CAB and push down on the release to
secure the connectors.
(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).
RWAL VALVE
DESCRIPTION
Rear Wheel Antilock (RWAL) brake system is stan-
dard equipment on 1500 series vehicles. The RWAL
brake system is designed to prevent rear wheel
lock-up on virtually all types of road surfaces. RWAL
braking is desirable because a vehicle which is
stopped without locking the rear wheels will retain
directional stability. This allows the driver to retain
greater control of the vehicle during braking.
The valve is located on the drivers side inner
fender under the hood. The valve modulates hydrau-
lic pressure to the rear brakes.
The RWAL components include:
²RWAL Valve
²Controller Antilock brake (CAB)
²Rear Wheel Speed Sensor (WSS)
OPERATION
When the brakes are applied, hydraulic fluid is
routed from the master cylinder's secondary circuit to
the RWAL valve. From there hydraulic fluid is routed
to the rear brakes. The Controller Antilock Brake
(CAB) contains an Electronic Variable Brake Propor-
tioning (EVBP) control algorithm, which proportions
the applied braking force to the rear wheels during
braking. The EVBP function of the RWAL system
takes the place of a conventional hydraulic propor-
tioning valve. The CAB monitors the rear wheel
speed through the rear wheel speed sensor and cal-
culates an estimated vehicle deceleration. When an
established deceleration threshold is exceeded, an
isolation valve is closed to hold the applied brake
pressure to the rear brakes constant. Upon further
increases in the estimated vehicle deceleration, the
isolation valve is selectively opened to increase rear
brake pressure in proportion to the front brake pres-
sure. If impending rear wheel lock-up is sensed, the
CAB signals the RWAL valve to modulate hydraulic
brake pressure to the rear wheels to prevent lock-up.
NORMAL BRAKING Since the RWAL valve also
performs the EVBP or proportioning function, vehicle
deceleration under normal braking may be sufficient
to trigger the EVBP function of the RWAL system
without full RWAL activity as would normally occur
during an impending rear wheel lock-up. As previ-
ously mentioned, the isolation valve is selectively
closed and opened to increase rear brake pressure in
proportion to the front brake pressure under EVBP
control. Slight brake pedal pulsations may be noticed
as the isolation valve is opened.
Fig. 5 HYDRAULIC CONTROL UNIT
1 - HYDRAULIC CONTROL UNIT
2 - MOUNTING BOLTS
5 - 50 BRAKES - ABSDR
HCU (HYDRAULIC CONTROL UNIT) (Continued)

Page 300 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual 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 harnes

Page 301 of 2627

Page 302 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual CLUTCH
TABLE OF CONTENTS
page page
CLUTCH
WARNING.............................1
DIAGNOSIS AND TESTING................1
SPECIFICATIONS........................5
CLUTCH DISC
REMOVAL......................

CLUTCH
TABLE OF CONTENTS
page page
CLUTCH
WARNING.............................1
DIAGNOSIS AND TESTING................1
SPECIFICATIONS........................5
CLUTCH DISC
REMOVAL.............................5
INSTALLATION..........................5
CLUTCH HOUSING
DIAGNOSIS AND TESTING................7
REMOVAL.............................9
INSTALLATION..........................9
CLUTCH RELEASE BEARING
REMOVAL.............................9
INSTALLATION.........................10
FLYWHEEL
DIAGNOSIS AND TESTING................10REMOVAL.............................11
DISASSEMBLY.........................11
ASSEMBLY............................11
INSTALLATION.........................11
PILOT BEARING
REMOVAL.............................11
INSTALLATION.........................12
LINKAGE
REMOVAL.............................12
INSTALLATION.........................12
CLUTCH PEDAL POSITION SWITCH
DESCRIPTION.........................13
OPERATION...........................13
DIAGNOSIS AND TESTING................13
CLUTCH
WARNING
WARNING: Exercise care when servicing clutch
components. Factory installed clutch discs do not
contain asbestos fibers. Dust and dirt on clutch
parts may contain asbestos fibers from aftermarket
components. Breathing excessive concentrations of
these fibers can cause serious bodily harm. Wear a
respirator during service and never clean clutch
components with compressed air or with a dry
brush. Either clean the components with water
dampened rags or use a vacuum cleaner specifi-
cally designed to remove asbestos fibers and dust.
Do not create dust by sanding a clutch discs.
Replace the disc if the friction material is damaged.
Dispose of all dust and dirt containing asbestos
fibers in sealed bags or containers. This will mini-
mize exposure to yourself and to others. Follow all
recommended safety practices prescribed by the
occupational safety and health administration
(OSHA) and the environmental safety agency (EPA),
for the handling and disposal of products contain-
ing asbestos. Failure to follow these instructions
may result in personal injury or death
DIAGNOSIS AND TESTING
Road test and inspect components to determine a
clutch problem. Road test the vehicle at normalspeeds. Shift the transmission through all gear
ranges and observe clutch action. If clutch chatters,
grabs, slips or does not release properly, remove and
inspect clutch components. If problem is noise or
hard shifting, further diagnosis may be needed to the
transmission and driveline component.
CLUTCH CONTAMINATION
Contamination is a frequent cause of clutch mal-
functions. Oil, water or clutch fluid on the clutch disc
and pressure plate surfaces will cause chatter, slip
and grab. Oil contamination indicates a leak at
either the rear main seal or transmission input shaft.
Clutch fluid leaks are usually from damaged slave
cylinder push rod seals. Heat buildup caused by slip-
page between the pressure plate, disc and flywheel
can bake the oil residue onto the components. The
glaze-like residue ranges in color from amber to
black.
Road splash contamination is dirt/water entering
the clutch housing due to loose bolts, housing cracks.
Driving through deep water puddles can force water/
road splash into the housing through such openings.
IMPROPER RELEASE OR CLUTCH ENGAGEMENT
Clutch release or engagement problems can be
caused by worn or damage clutch components.
Release problems can cause hard shifting and
noise. Look for leaks at clutch cylinders, connecting
line and loose slave cylinder bolts. Also worn/loose
release fork, pivot stud, clutch disc, pressure plate or
release bearing.
DRCLUTCH 6 - 1

Page 303 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual Engagement problems can cause slip, chatter/shud-
der and noisy operation. The causes may be clutch
disc contamination, wear, distortion or flywheel dam-
age.
CLUTCH MISALIGNMENT
Clutch components mus

Engagement problems can cause slip, chatter/shud-
der and noisy operation. The causes may be clutch
disc contamination, wear, distortion or flywheel dam-
age.
CLUTCH MISALIGNMENT
Clutch components must be in proper alignment
with the crankshaft and transmission input shaft.
Misalignment caused by excessive runout or warpage
of any clutch component will cause grab, chatter and
improper clutch release.
CLUTCH COVER AND DISC RUNOUT
Check the clutch disc before installation. Axial
(face) runout of anewdisc should not exceed 0.50
mm (0.020 in.). Measure runout about 6 mm (1/4 in.)
from the outer edge of the disc facing. Obtain
another disc if runout is excessive.
Check condition of the clutch before installation. A
warped cover or diaphragm spring will cause grab
and incomplete release or engagement. Be careful
when handling the cover and disc. Impact can distort
the cover, diaphragm spring, release fingers and the
hub of the clutch disc.
Use an alignment tool when positioning the disc on
the flywheel. The tool prevents accidental misalign-
ment which could result in cover distortion and disc
damage.
A frequent cause of clutch cover distortion (and
consequent misalignment) is improper bolt tighten-
ing.
FLYWHEEL RUNOUT
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.
Common causes of runout are:
²heat warpage
²improper machining
²incorrect bolt tightening
²improper seating on crankshaft flange shoulder
²foreign material on crankshaft flange
Flywheel machining is not recommended. The fly-
wheel clutch surface is machined to a unique contour
and machining will negate this feature. Minor fly-
wheel scoring can be cleaned up by hand with 180
grit emery or with turning equipment. Remove only
enough material to reduce scoring (approximately
0.001 - 0.003 in.). Heavy stock removal isnot rec-
ommended.Replace the flywheel if scoring is severe
and deeper than 0.076 mm (0.003 in.). Excessive
stock removal can result in flywheel cracking or
warpage after installation; it can also weaken the fly-
wheel and interfere with proper clutch release.
Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may
cock the flywheel causing excessive runout. Use new
bolts when remounting a flywheel and secure the
bolts with Mopar Lock And Seal or equivalent.
Tighten flywheel bolts to specified torque only. Over-
tightening can distort the flywheel hub causing
runout.
DIAGNOSIS CHART
The diagnosis charts Diagnosis Chart describe
common clutch problems, causes and correction.
DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
Disc facing worn out 1. Normal wear. 1. Replace cover and disc.
2. Driver frequently rides (slips) the
clutch. Results in rapid overheating
and wear.2. Replace cover and disc.
3. Insufficient clutch cover
diaphragm spring tension.3. Replace cover and disc.
6 - 2 CLUTCHDR
CLUTCH (Continued)

Page 304 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual CONDITION POSSIBLE CAUSES CORRECTION
Clutch disc facing contaminated with
oil, grease, or clutch fluid.1. Leak at rear main engine seal or
transmission input shaft seal.1. Replace appropriate seal.
2.

CONDITION POSSIBLE CAUSES CORRECTION
Clutch disc facing contaminated with
oil, grease, or clutch fluid.1. Leak at rear main engine seal or
transmission input shaft seal.1. Replace appropriate seal.
2. Excessive amount of grease
applied to the input shaft splines.2. Remove grease and apply the
correct amount of grease.
3. Road splash, water entering
housing.3. Replace clutch disc. Clean clutch
cover and reuse if in good condition.
4. Slave cylinder leaking. 4. Replace hydraulic clutch linkage.
Clutch is running partially
disengaged.1. Release bearing sticking or
binding and does not return to the
normal running position.1. Verify failure. Replace the release
bearing and transmission front
bearing retainer as necessary.
Flywheel below minimum thickness
specification.1. Improper flywheel machining.
Flywheel has excessive taper or
excessive material removal.1. Replace flywheel.
Clutch disc, cover and/or diaphragm
spring warped or distorted.1. Rough handling. Impact bent
cover, spring, or disc.1. Replace disc or cover as
necessary.
2. Improper bolt tightening
procedure.2. Tighten clutch cover using proper
procedure.
Facing on flywheel side of disc torn,
gouged, or worn.1. Flywheel surface scored or
nicked.1. Correct surface condition if
possible. Replace flywheel and disc
as necessary.
2. Clutch disc sticking or binding on
transmission input shaft.2. Inspect components and
correct/replace as necessary.
Clutch disc facing burnt. Flywheel
and cover pressure plate surfaces
heavily glazed.1. Frequent operation under high
loads or hard acceleration
conditions.1. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
2. Driver frequently rides (slips)
clutch. Results in rapid wear and
overheating of disc and cover.2. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
Clutch disc binds on input shaft
splines.1. Clutch disc hub splines damaged
during installation.1. Clean, smooth, and lubricate hub
splines if possible. Replace disc if
necessary.
2. Input shaft splines rough,
damaged, or corroded.2. Clean, smooth, and lubricate
shaft splines if possible. Replace
input shaft if necessary.
Clutch disc rusted to flywheel and/or
pressure plate.1. Clutch not used for an extended
period of time (e.g. long term
vehicle storage).1. Sand rusted surfaces with 180
grit sanding paper. Replace clutch
cover and flywheel if necessary.
DRCLUTCH 6 - 3
CLUTCH (Continued)

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