1998 DODGE RAM 1500 service

PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring and pinion gears are service in a
matched set. Never replace the ring gear/pinion
gear without replacing the other matching gear.
(1) Mark pinion flange and propeller shaft for
installation alignment.
(2) Disconnect propeller shaft from pinion flange
and remove propeller shaft.
(3) Remove differential from the housing.
(4) Place differential on Plug 8964. Drive exciter
ring off the differential case with a hammer and
punch (Fig. 49).
NOTE: Do not remove the exciter ring if it is not
being replaced.
(5) Place differential case in a vise with soft metal
jaw protectors
(6) Remove bolts holding ring gear to differential
case.
(7) Drive ring gear from differential case with a
soft hammer (Fig. 50).
(8) Hold pinion flange with Flange Wrench 8979
(Fig. 51) and remove pinion flange nut.
(9) Remove pinion flange from pinion with Pinion
Flange Puller 8992 (Fig. 52).
Fig. 47 DIFFERENTIAL CASE BEARING
1 - BRIDGE
2 - SPLITTER
3 - BEARING
4 - PLUG
Fig. 48 DIFFERENTIAL CASE BEARINGS
1 - HANDLE
2 - DIFFERENTIAL CASE
3 - BEARING
4 - INSTALLER
Fig. 49 EXCITER RING
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - PUNCH
4 - EXCITER RING
3 - 162 REAR AXLE - 11 1/2 AADR
DIFFERENTIAL CASE BEARINGS (Continued)

²Pedal Adjustment Inhibitors: Pedal adjust-
ment is inhibited when the vehicle is in reverse or
when cruise control is activated.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the kneeblocker (Refer to 23 - BODY/
INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - REMOVAL).
(3) Remove the brake light switch and discard
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/BRAKE LAMP SWITCH - REMOVAL).
(4) Disconnect the adjustable pedal cables from the
brake and accelerator pedalsAlso clutch pedal if
equipped with a manual transmission.
(5) Disconnect the electrical connector.
(6) Unclip the cable fasteners to the support.
(7) Remove the one mounting bolt for the adjust-
able pedal motor (Fig. 4).
(8) Remove the adjustable pedal motor with the
cables.
NOTE: Adjustable pedal cables are not serviceable.
If they need service the adjustable pedal motor with
the cables must be installed.
INSTALLATION
NOTE: Adjustable pedal cables are not serviceable.
If they need service the adjustable pedal motor with
the cables must be installed.
(1) Install the adjustable pedal motor with the
cables.
(2) Install the one mounting bolt for the adjustable
pedal motor (Fig. 4).
(3) Clip the cable fasteners to the support.
(4) Reconnect the electrical connector.
(5) Reconnect the adjustable pedal cables to the
brake and accelerator pedalsAlso clutch pedal if
equipped with a manual transmission.
(6) Install the new brake light switch (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL).
(7) Install the kneeblocker (Refer to 23 - BODY/IN-
STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - INSTALLATION).
(8) Reconnect the negative battery cable.
(9) Check for proper operation of the pedals.
Fig. 3 ADJUSTABLE PEDAL MOTOR
1 - ADJUSTABLE PEDAL MOTOR
2 - CABLES
3 - ELECTRICAL CONNECTOR
Fig. 4 ADJUSTABLE PEDAL MOTOR
1 - ADJUSTABLE PEDAL MOTOR
2 - MOUNTING BOLT
DRBRAKES - BASE 5 - 7
ADJUSTABLE PEDAL MOTOR (Continued)

(5) Remove the reservoir from the master cylinder
by pulling upwards.
(6) Remove old grommets from cylinder body (Fig.
42).
INSTALLATION
CAUTION: Do not use any type of tool to install the
grommets. Tools may cut, or tear the grommets cre-
ating a leak problem after installation. Install the
grommets using finger pressure only.
(1) Lubricate the new grommets with clean brake
fluid and Install new grommets in cylinder body. Use
finger pressure to install and seat grommets.
(2) Start the reservoir in grommets. Then rock the
reservoir back and forth while pressing downward to
seat it into the grommets.
(3) Install the mounting bolt for the reservoir to
the master cylinder.
(4) Reconnect the electrical connector to the fluid
reservoir level switch.
(5) Remove the prop rod from the vehicle.
(6) Fill and bleed base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE).
BRAKE JUNCTION BLOCK
REMOVAL
(1) Remove the brake lines from the junction block
(Fig. 43).
(2) Remove the junction block mounting bolt and
remove the junction block from the bracket (Fig. 43).
INSTALLATION
(1) Position the junction block on the bracket and
install the mounting bolt. Tighten the mounting bolt
to 23 N´m (210 in. lbs.) (Fig. 43).
(2) Install the brake lines into the junction block
and tighten to 19-23 N´m (170-200 in. lbs.) (Fig. 43).
(3) Bleed the base brake system, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - STAN-
DARD PROCEDURE).
MASTER CYLINDER
DESCRIPTION
A two-piece master cylinder is used on all models.
The cylinder body containing the primary and sec-
ondary pistons is made of aluminum. The removable
fluid reservoir is made of nylon reinforced with glass
fiber. The reservoir stores reserve brake fluid for the
hydraulic brake circuits and has a switch for indicat-
ing low fluid levels. The reservoir is the only service-
able component.
The fluid compartments of the nylon reservoir are
interconnected to permit fluid level equalization.
However, the equalization feature does not affect cir-
cuit separation in the event of a front or rear brake
malfunction. The reservoir compartments will retain
enough fluid to operate the functioning hydraulic cir-
cuit.
Care must be exercised when removing/installing
the master cylinder connecting lines. The threads in
the cylinder fluid ports can be damaged if care is not
exercised. Start all brake line fittings by hand to
avoid cross threading.
Fig. 42 FLUID RESERVOIR
1 - MASTER CYLINDER CAP
2 - FLUID RESERVOIR
3 - FLUID LEVEL SWITCH
4 - MASTER CYLINDER
5 - MOUNTING BOLT
6 - GROMMETS
Fig. 43 JUNCTION BLOCK
1 - BRAKE LINES
2 - JUNCTION BLOCK
5 - 24 BRAKES - BASEDR
FLUID RESERVOIR (Continued)

PEDAL
DESCRIPTION
NOTE: The brake pedal is serviced as a complete
assembly including accelerator pedal and the
bracket.
A suspended-type brake pedal is used. The pedal is
attached to the pedal support bracket with a pivot
shaft pin and bushings. If the bushings become dry a
spray lubricant can be used to eliminate noises. The
booster push rod is attached to the pedal with a clip.
The pedal, bushings, pivot pin and support bracket
are not serviceable components (Fig. 50).
OPERATION
The brake pedal is attached to the booster push
rod. When the pedal is depressed, the primary
booster push rod is depressed which moves the
booster secondary rod. The booster secondary rod
depress the master cylinder piston.
REMOVAL
NOTE: The brake pedal is serviced as a complete
assembly including accelerator pedal and the
bracket.
(1) Disconnect the negative battery cable.
(2) Remove the steering column opening cover(Re-
fer to 23 - BODY/INSTRUMENT PANEL/STEERING
COLUMN OPENING COVER - REMOVAL).(3) Remove the brake lamp switch and discard(Re-
fer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTE-
RIOR/BRAKE LAMP SWITCH - REMOVAL).
(4)On vehicles equipped with adjustable ped-
als.Disconnect the adjuster cable to the pedal (Fig.
51).
(5) Remove the steering column (Refer to 19 -
STEERING/COLUMN - REMOVAL).
(6) Remove the brake booster (Fig. 52)(Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/POWER
BRAKE BOOSTER - REMOVAL).
(7) Disconnect the electrical connectors.
(8) Remove the module mounting bolts.
(9) Disconnect the accelerator pedal cable.
(10) Remove the pedal assembly mounting nuts/
fasteners (Fig. 52).
INSTALLATION
(1) Install the pedal assembly to the vehicle (Fig.
52).
(2) Install the mounting bolts (Fig. 52) and tighten
to 28 N´m (21 ft. lbs.).
(3) Reconnect the accelerator cable to the pedal.
(4) Install the module mounting bolts and tighten
to 38 N´m (28 ft. lbs.).
(5) Reconnect the electrical connectors.
(6) Install the brake booster (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/POWER BRAKE
BOOSTER - INSTALLATION).
(7) Install the steering column (Refer to 19 -
STEERING/COLUMN - INSTALLATION).
(8) Install a new brake lamp switch. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL).
Fig. 50 BRAKE PEDAL
1 - CLIP
2 - BUSHINGS
3 - PIVOT SHAFT PIN
4 - PEDAL ASSEMBLY
ADJUSTABLE PEDAL SHOWN
NON ADJUSTABLE PEDAL IS SIMILIAR
5-PAD
Fig. 51 PEDAL/CABLE
1 - CABLE
2 - BRAKE PEDAL ASSEMBLY
5 - 28 BRAKES - BASEDR

REMOVAL - REAR
(1) Raise and support the vehicle
(2) Remove the tire and wheel assembly.
(3) Remove the disc brake caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).
(4) Remove the caliper adapter bolts (Fig.
61).(Refer to 5 - BRAKES/HYDRAULIC/MECHANI-
CAL/DISC BRAKE CALIPER ADAPTER -
REMOVAL)
(5) Remove the retaining clips and rotor assembly
(Fig. 61).
REMOVAL - REAR DUAL WHEELS
(1) Raise and support the vehicle
(2) Remove the tire and wheel assembly.
(3) Remove the disc brake caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).
(4) Remove the caliper adapter bolts.
(5) Remove the rear axle shaft from the housing
on dual rear wheels, (Refer to 3 - DIFFERENTIAL &
DRIVELINE/REAR AXLE - 286RBI/AXLE SHAFTS -
REMOVAL).
(6) Remove the hub and rotor assembly (C3500
only) (Fig. 62).
INSTALLATION
INSTALLATION - FRONT
(1) On models with all-wheel antilock system
(ABS), check condition of tone wheel on hub/bearing.
If teeth on wheel are damaged, hub/bearing assembly
will have to be replaced (tone wheel is not serviced
separately).
(2) Install the rotor onto the hub/bearing wheel
studs.
(3) Install the caliper adapter assembly,(Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION) and tighten
adapter bolts to:
(4) Install the wheel and tire assembly, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE) and lower the vehicle.
(5) Apply the brakes several times to seat brake
pads. Be sure to obtain firm pedal before moving
vehicle.
INSTALLATION - REAR
(1) Install the rotor to the axleshaft (Fig. 61).
Fig. 60 8 LUG ROTOR ASSEMBLY
1 - SPRING
2 - SHOCK
3 - UPPER AND LOWER SUSPENSION ARMS
4 - DISC BRAKE CALIPER
5 - DISC BRAKE CALIPER ADAPTER
6 - ROTOR
Fig. 61 REAR ROTOR
1 - ROTOR
2 - CALIPER ADAPTER
3 - CALIPER
Fig. 62 ROTOR / HUB REMOVAL
5 - 34 BRAKES - BASEDR
ROTORS (Continued)

(2) Install the bolts/nuts and tighten to 28 N´m (21
ft. lbs.) (Fig. 84).
(3) Install the park brake release rod.
(4) Connect the front cable to the arm on the pedal
assembly.
(5) Install the front cable grommet into the floor-
pan and the cable retainer, roll the carpet back.
(6) Connect the wires to the brake lamp switch.
(7) Install the knee bolster, (Refer to 23 - BODY/
INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - INSTALLATION).
(8) Raise the vehicle.
(9) Adjust the parking brake cable tensioner (Refer
to 5 - BRAKES/PARKING BRAKE/CABLE TEN-
SIONER - ADJUSTMENTS).
CABLE TENSIONER
ADJUSTMENTS
ADJUSTMENT
NOTE: Tensioner adjustment is only necessary
when the tensioner, or a cable has been replaced or
disconnected for service. When adjustment is nec-
essary, perform adjustment only as described in the
following procedure. This is necessary to avoid
faulty park brake operation.
(1) Raise the vehicle.
(2) Back off the cable tensioner adjusting nut to
create slack in the cables.
(3) Remove the rear wheel/tire assemblies. Then
remove the brake rotors (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - REMOVAL).
(4) Verify the brakes are in good condition and
operating properly.
(5) Verify the park brake cables operate freely and
are not binding, or seized.
(6) Check the rear brake shoe adjustment with
standard brake gauge (Refer to 5 - BRAKES/PARK-
ING BRAKE/SHOES - ADJUSTMENTS).
(7) Install the rotors (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - INSTALLA-
TION) and verify that the rotors rotate freely
without drag.
(8) Install the wheel/tire assemblies, (Refer to 22 -
TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(9) Lower the vehicle enough for access to the park
brake foot pedal. Then fully apply the park brakes.
NOTE: Leave park brakes applied until adjustment
is complete.
(10) Raise the vehicle again.
(11) Mark the tensioner rod 6.35 mm (1/4 in.) from
edge of the tensioner (Fig. 85).
(12) Tighten the adjusting nut on the tensioner rod
until the mark is no longer visible.
CAUTION: Do not loosen, or tighten the tensioner
adjusting nut for any reason after completing
adjustment.
(13) Lower the vehicle until the rear wheels are
15-20 cm (6-8 in.) off the shop floor.
(14) Release the park brake foot pedal and verify
that rear wheels rotate freely without drag. Then
lower the vehicle.
Fig. 83 PARKING BRAKE PEDAL
1 - RELEASE ROD
2 - PEDAL ASSEMBLY
Fig. 84 PARKING BRAKE ASSEMBLY
1 - PEDAL ASSEMBLY
2 - MOUNTING NUT
DRBRAKES - BASE 5 - 43
PEDAL (Continued)

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

(2) Apply a light coating of grease to the inside
diameter of the master cylinder push rod eye.
(3) Install clutch master cylinder on dash panel
and tighten clutch master cylinder nuts to 28 N´m
(21 ft. lbs.).
(4) Install clutch master cylinder push rod pin.
(5) Connect clutch pedal position interlock switch
wires.
(6) Install plastic clip securing hydraulic line to
the dash panel into the lower dash panel flange.
(7) Install plastic clip securing hydraulic line to
the dash panel onto the upper dash panel stud.
(8) Raise vehicle.
(9) Install slave cylinder and verify cylinder rod is
properly seated in release lever.
(10) Install and tighten slave cylinder nuts to 23
N´m (17 ft. lbs.).
(11) Ifnewclutch linkage is being installed, con-
nect the clutch hydraulic line to the clutch slave cyl-
inder.
CAUTION: Once the clutch hydraulic line is con-
nected to the slave cylinder, it should never be dis-
connected.
(12) Lower vehicle.
(13) Operate linkage several times to verify proper
operation.
CLUTCH PEDAL POSITION
SWITCH
DESCRIPTION
A clutch pedal position switch (CPPS) is mounted
on the clutch master cylinder push rod (Fig. 20). The
wiring harness connector is inside of the vehicle
under the left side of the instrument panel.
NOTE: Switch is serviced with clutch master cylin-
der.
OPERATION
The clutch pedal position switch is used to prevent
starter motor engagement unless the clutch pedal is
depressed. An input from this switch is also used to
either shut down/prevent operation of the speed con-
trol system when pedal is depressed. The position
switch is an integral part of the clutch master cylin-
der push rod.
DIAGNOSIS AND TESTING
(1) Disconnect switch 2-wire connector attached to
pedal support bracket, under instrument panel to left
of clutch pedal (Fig. 21).(2) Check switch continuity with an ohmmeter
while operating clutch pedal.
²Pedal Depressed - Continuity
²Pedal Released - No Continuity
(3) If continuity is not present or always present,
replace clutch master cylinder. Switch is not serviced
separately.
Fig. 20 LOCATION, CLUTCH PEDAL
POSITION SWITCH
1 - CLUTCH MASTER CYLINDER
2 - CLUTCH PEDAL POSITION SWITCH
Fig. 21 CLUTCH SWITCH TEST POINT
1 - PEDAL SUPPORT BRACKET
2 - ELECTRICAL CONNECTOR
DRCLUTCH 6 - 13
LINKAGE (Continued)