1999 DODGE RAM height

"G" ABBREVIATION TABLE

"G" ABBREVIATION TABLE
ABBREVIATION DEFINITION G grams GND or GRND Ground GRN Green GRY Gray Ga. Gauge Gals. gallons Gov. Governor

"H" ABBREVIATION TABLE

"H" ABBREVIATION TABLE
ABBREVIATION DEFINITION H/D Heavy Duty HAC High Altitude Compensation HC Hydrocarbons HEDF High Speed Electro Drive Fan relay or
circuit HEGO Heated Exhaust Gas Oxygen Sensor HEGOG or HEGO Ground circuit HEI High Energy Ignition HLDT Headlight HO High Output HP High Performance HSC High Swirl Combustion HSO High Specific Output HTR Heater HVAC Heating Headlt. Headlight Hg Mercury Hgt. Height Htr. Heater Hz Hertz (Cycles Per Second)

"I" ABBREVIATION TABLE

"I" ABBREVIATION TABLE
ABBREVIATION DEFINITION I.D. Inside Diameter IAC Idle Air Control IACV Idle Air Control Valve IC Integrated Circuit ID Identification IDM Ignition Diagnostic Monitor IGN Ignition system or circuit ILC Idle Load Compensator In. Hg Inches of Mercury INCH Lbs. Inch Pounds INFL REST Inflatable Restraint INJ Injector or Injection IP Instrument Panel IPC Instrument Panel Cluster

1) Start engine, and check booster vacuum hose connections. A
hissing noise indicates a vacuum leak. Repair any vacuum leaks before
proceeding. Stop engine, and shift transmission into Neutral. Pump
brake pedal until all vacuum reserve in booster is depleted.
2) Hold brake pedal under light pressure. If pedal does not
hold firm and falls away, master cylinder may be faulty. Bleed system
using appropriate method, and repeat step 1). See BLEEDING PROCEDURES
under BLEEDING BRAKE SYSTEM.
3) If pedal still does not hold firm, master cylinder is
faulty. If pedal holds firm, start engine and observe pedal height. If
pedal height change is not apparent, power booster or vacuum check
valve is faulty. Install good check valve, and repeat steps 1) and 2).\
If pedal falls away slightly under light pressure and then holds firm,
go to next step .
4) Start engine. Release brake pedal. Increase engine speed
to 1500 RPM. Close throttle and immediately turn off ignition. Wait at
least 90 seconds, and try brake action again. Booster should provide 2
or more vacuum assisted pedal applications. If vacuum assist is not
provided, perform booster and check valve vacuum tests.
POWER BRAKE BOOSTER VACUUM TEST
Connect vacuum gauge to booster check valve using "T"
fitting. Start engine, and run at idle speed for one minute. Clamp
hose shut between vacuum source and check valve. Stop engine, and
observe vacuum gauge. If vacuum drops more than one in. Hg within 15
seconds, booster diaphragm or check valve is faulty.
POWER BRAKE BOOSTER CHECK VALVE TEST
Disconnect vacuum hose from check valve. Remove check valve
and valve seal from booster. Use a hand-operated vacuum pump for
testing. Apply 15-20 in. Hg at large end of check valve. Vacuum should
hold steady. If gauge on pump indicates vacuum loss, check valve is
faulty and should be replaced.
COMBINATION VALVE METERING VALVE TEST
Metering valve operation can be checked visually with aid of
an assistant. While an assistant applies and releases brake pedal,
observe metering valve stem. If valve is operating correctly, stem
will extend slightly when brakes are applied, and contract when brakes
are released. If valve is faulty, replace combination valve assembly.
COMBINATION VALVE PRESSURE DIFFERENTIAL SWITCH TEST
1) Using an assistant, apply brake pedal. Observe brake
warning light. Raise and support vehicle, and connect a bleed hose to
one rear wheel cylinder. Submerge other end of hose into container
partially filled with brake fluid. Have assistant press and hold brake
pedal down while observing brake warning light. Open bleeder screw. If
warning light glows, switch is operating properly.
2) If warning light fails to glow, check circuit fuse, bulb
and wiring. Repair as necessary. Repeat step 1). If warning light
fails to glow, check brakelight, parking brake switches and related
wiring. Repair as necessary. Repeat step 1). If warning light fails to
glow, pressure differential switch is faulty. Replace combination
valve assembly, and bleed brake system. Verify proper valve operation.
REMOVAL & INSTALLATION

Installation
To install, reverse removal procedure using NEW "U" joint
straps and bolts. Ensure all reference marks are aligned. Tighten
bolts to specification. See TORQUE SPECIFICATIONS table.
PINION FLANGE & OIL SEAL
Removal
1) Raise and support vehicle. Reference mark drive shaft and
pinion flange on differential for reassembly. Remove bolts and "U"
joint straps at pinion flange on differential. Disconnect drive shaft
from differential, and support it aside.
2) Using INCH-lb. torque wrench, measure amount of force
required to rotate pinion. This is pinion bearing preload. Record
pinion bearing preload for reassembly reference.
3) Remove pinion nut and washer from pinion. Scribe reference
mark on pinion flange and pinion for reassembly. Using Holder (C-3281)\
and appropriate flange remover, remove pinion flange from pinion.
Remove oil seal from axle housing.
Installation
1) Ensure oil seal surface in axle housing is clean. Coat lip
of oil seal with gear lube. Using appropriate oil seal installer and
handle, install oil seal.
2) Install pinion flange on pinion with reference mark
aligned. Press pinion flange onto pinion. Install washer and pinion
nut. Tighten pinion nut while rotating pinion, ensuring bearings are
properly seated. Tighten nut until preload measured before disassembly
is achieved. DO NOT exceed maximum torque specification. See TORQUE
SPECIFICATIONS table.
3) To install remaining components, reverse removal procedure
using NEW "U" joint straps and bolts. Ensure all reference marks are
aligned. Tighten bolts to specification. See TORQUE SPECIFICATIONS
table. Check lubricant level and add if necessary.
AXLE HOUSING ASSEMBLY
NOTE: Removing axle housing assembly is not necessary unless axle
housing is damaged. Differential carrier and components can
be serviced by removing differential assembly from axle
housing.
Removal
1) Raise and support vehicle. Remove front wheels. Reference
mark drive shaft to pinion flange for reassembly. Remove bolts and "U"
joint straps at pinion flange. Remove drive shaft, and support aside.
Remove brake calipers, and support aside with wire. DO NOT allow
calipers to hang from brake hoses.
2) Disconnect ABS sensor harness connectors (if equipped).
Disconnect drag link and tie rod from steering knuckles. Disconnect
shock absorber from axle housing. Disconnect stabilizer bar links at
spring brackets.
3) Disconnect electrical connector and vacuum hoses at vacuum
shift motor. Support axle housing assembly with floor jack. Remove
bolts from upper and lower suspension arms. Lower axle housing
assembly from vehicle and remove.
Installation
To install, reverse removal procedure. Ensure reference marks
on drive shaft and pinion flange align. Tighten suspension arms with
vehicle at normal operating height. Tighten bolt/nuts to
specification. See TORQUE SPECIFICATIONS table. Check axle fluid level

original pinion depth shims. Replace shims with NEW shims of same
thickness.
4) If only pinion and ring gear are being replaced and
original axle housing is used, note pinion depth variance marking on
old pinion and replacement pinion.
5) Using etched markings and pinion depth shim adjustment
chart, determine amount to be added or subtracted from thickness of
original pinion depth shims. See Fig. 4. For example, if etched
marking is +4 on original pinion and -4 on replacement pinion,
thickness of pinion depth shims should be increased by .008" (.20 mm).\
NOTE: When using pinion depth shim adjustment chart, if result is a
negative (-) reading, subtract this amount from thickness of
pinion depth shim pack to obtain thickness of correct shim.
If result is positive (+), add this amount to thickness of
pinion depth shim pack to obtain thickness of correct shim.
If result is zero, this will be nominal standard pinion depth
setting and no shims are required. When using pinion depth
shim adjustment chart, thickness of original pinion depth
shim pack must be accurately determined. If original pinion
depth shim pack dimension cannot be accurately determined,
pinion depth gauge set must be used to properly determine
pinion depth setting. Pinion depth gauge set must also be
used if using replacement axle housing. Proceed to
DETERMINING PINION DEPTH USING PINION DEPTH GAUGE SET.
NOTE: If slinger is used, slinger thickness must also be included
in pinion depth shim pack.
Fig. 4: Pinion Depth Shim Adjustment Chart
Courtesy of Chrysler Corp.
Determining Pinion Depth Using Pinion Depth Gauge Set
1) Use Pinion Depth Gauge Set for all axle models. Place
master pinion block in pinion bore of axle housing. See Fig. 5.
Install discs on arbor. Install arbor in axle housing, with discs
positioned in differential bearing bores. See Fig. 5.
2) Install pinion height block on top of master pinion block,
against arbor. Place gauge block with dial indicator on lowest step of

pinion height block. Zero dial indicator with gauge block flat on
pinion height block.
3) Move gauge block so dial indicator stem contacts arbor.
Move gauge block back and forth (perpendicular to arbor) to get
highest reading. This reading is thickness of required pinion depth
shim pack.
4) To select correct shim, note etched markings on end of
pinion face. Etched marking (in thousandths of an inch) indicates
deviation from standard dimension.
5) When etched marking is negative (-), add this amount to
pinion depth shim pack to obtain correct shim thickness. When etched
marking is positive (+), subtract this amount from pinion depth shim
pack to obtain correct shim thickness. If etched marking is zero, no
change is required in pinion depth shim pack thickness.
6) Measure pinion depth shims separately using micrometer. If
slinger is used, slinger thickness must also be included in pinion
depth shim pack. Remove pinion depth gauge set components from axle
housing.
7) Place pinion depth shim pack in axle housing bore for rear
(inner) bearing race. Using appropriate bearing race installer, drive
rear (inner) bearing race into axle housing. Ensure bearing race is
fully seated.
8) Using bearing race installer, drive front (outer) bearing\
race into axle housing. Ensure bearing race is fully seated. Proceed
to PINION BEARING PRELOAD.
Fig. 5: Checking Pinion Depth
Courtesy of Chrysler Corp.
Pinion Bearing Preload
1) Install slinger on pinion (if equipped). Press rear

number is stamped on pinion face. This number must be same as number
on ring gear. A pinion depth variance marking is etched on pinion
face. See Fig. 4.
2) Etched marking, in thousandths of an inch, indicates
deviation from standard pinion depth setting. Standard pinion depth
setting is distance from center line of axle shaft to rear pinion
bearing shoulder area. See Fig. 4. Standard pinion depth setting
varies with axle model. See STANDARD PINION DEPTH SETTING table.
STANDARD PINION DEPTH SETTING









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Application In. (mm)\
248 RBI ............................................. 5.000 (127.00)\
267 RBI ............................................. 5.375 (136.52)\
286 RBI ............................................. 5.812 (147.62)\









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3) If original pinion, ring gear and axle housing are being
used, and pinion depth shims are being replaced, determine thickness
of original pinion depth shims. Replace shims with NEW shims of same
thickness.
4) If only pinion and ring gear are being replaced, and
original axle housing is used, note pinion depth variance marking on
old pinion and replacement pinion.
5) Using etched markings and pinion depth shim adjustment
chart, determine amount to be added or subtracted from thickness of
original pinion depth shims. See Fig. 5. For example, if etched
marking is +4 on original pinion and -4 on replacement pinion,
thickness of pinion depth shims should be increased by .008" (.20 mm).\
NOTE: When determining shim thickness, if result is a negative (-)
reading, subtract this amount from thickness of pinion depth
shim pack to obtain thickness of correct shim. If result is
positive (+), add this amount to thickness of pinion depth
shim pack to obtain thickness of correct shim. If result is
zero, this will be nominal standard pinion depth setting and
no shims are required. When using PINION DEPTH SHIM
ADJUSTMENT CHART, thickness of original pinion depth shim
pack must be accurately determined. If original pinion depth
shim pack dimension cannot be accurately determined, pinion
depth gauge set must be used to properly determine pinion
depth setting. Pinion depth gauge set must also be used if
using replacement axle housing. Proceed to DETERMINING PINION
DEPTH USING PINION DEPTH GAUGE SET procedure.
NOTE: If slinger is used, slinger thickness must also be included
in pinion depth shim pack.
Determining Pinion Depth Using Pinion Depth Gauge Set
1) Use pinion depth gauge set for all axle models. Place
master pinion block into pinion bore of axle housing. See Fig. 6.
Install discs on arbor. Install arbor in axle housing with discs
positioned in differential bearing bores. See Fig. 6.
2) Install pinion height block on top of master pinion block,
against arbor. Place gauge block with dial indicator on lowest step of
pinion height block. Zero dial indicator with gauge block flat on
pinion height block.
3) Move gauge block so dial indicator stem contacts arbor.
Move gauge block back and forth (perpendicular to arbor) to get
highest reading. This reading is thickness of required pinion depth
shim pack.
4) To select correct shim, note etched markings on end of

Fig. 13: Drive Belt Routing (5.9L - Heavy Duty Cycle)
Courtesy of Chrysler Corp.
OIL PAN
Removal (Dakota 2WD & Durango 2WD)
1) Disconnect negative battery cable. Remove oil dipstick and
distributor cap. Raise and support vehicle. Drain engine oil.
2) Remove exhaust pipe. Remove side engine mount bolts.
Slightly raise engine. When engine is at adequate height, install
bolts in side engine mount-to-frame bracket holes to support engine.
3) Lower engine, and allow it to rest on bolts installed in
side engine mounts. Remove oil pan bolts, oil pan and gaskets.
Installation
1) To install, reverse removal procedure. Before installing
oil pan, apply RTV sealant where front cover contacts cylinder block,
where oil pan side gaskets meet end seals, and where end seals contact
cylinder block. See Fig. 14.
2) To facilitate oil pan installation, fabricate 4 alignment
dowels from 1 1/2" x 5/16" bolts. See Fig. 15. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table. To install remaining

CYLINDER HEAD
Cylinder Head
Check cylinder head warpage. Repair or replace cylinder head
if warpage exceeds specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS.
Valve Springs
1) Check valve spring free length, out-of-square and
pressure. Replace valve spring if not within specification. See VALVES
& VALVE SPRINGS table under ENGINE SPECIFICATIONS.
2) Measure valve spring installed height from bottom of
spring seat (cylinder head surface) to bottom of spring retainer. If
spacers are installed, measure from top of spacer.
3) If height exceeds 1.687" (42.86 mm), install a .066" (1.\
58
mm) thick spacer in cylinder head counterbore to obtain correct
installed spring height. See VALVES & VALVE SPRINGS table.
Valve Stem Oil Seals
Cup-type oil seals are used on all valves. Ensure oversize
valve stem oil seals are used when oversize valves are installed. When
installing valves, DO NOT overcompress valve springs, or damage to
valve stem oil seal may result.
NOTE: DO NOT ream valve guides from standard to maximum oversize in
one step. Ream valve guides to oversize in gradual steps so
guides are reamed true in relation to valve seat. After
reaming valve guides, valve seat runout must be checked.
Valve Guides
Check valve stem oil clearance. Ensure valve stem diameter is
within specification. Valve guide must be reamed for valve with
oversize valve stem if oil clearance exceeds specification. See
CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valves are available
with stems of .015" (.38 mm) and .030" (.76 mm) oversize.
Valve Seat
Check valve seat width and runout. Grind valve seat if not
within specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS.
Valves
Ensure valve margin, head diameter and stem diameter are
within specification. See VALVES & VALVE SPRINGS table under ENGINE
SPECIFICATIONS. Valves are available with stems of .015" (.38 mm) and
.030" (.76 mm) oversize.
Valve Seat Correction Angles
Use a 15-degree stone to lower valve seat, and a 60-degree
stone to raise valve seat.
VALVE TRAIN
Rocker Arms & Pivots
Remove rocker arms and pivots. Inspect for wear. Replace as
necessary.
NOTE: Cylinder block must be marked to indicate oversize valve
lifters. See SPECIAL ENGINE MARKS.
Valve Lifters
Measure valve lifter diameter and bore diameter in cylinder