1999 DODGE RAM light

next step. If scan tool does not display brake pedal PRESSED and
RELEASED, go to NTC-1: BRAKE SWITCH SENSE.
4) Turn S/C on. On A/T models, move gear selector to Drive.
If scan tool displays park neutral switch D/R, go to next step. If
scan tool does not display park neutral switch D/R, go to FTC P1899:
PARK/NEUTRAL POSITION SWITCH STUCK IN PARK OR IN GEAR under DIAGNOSTIC
TESTS.
5) On all models, using scan tool, actuate S/C vent solenoid.
Using a 12-volt test light, backprobe S/C brake switch output circuit
at S/C servo connector terminal No. 3 (Dark Blue/Red wire). If test
light is illuminated and bright, go to next step. If test light is dim
or is not illuminated, go to NTC-1: BRAKE SWITCH SENSE.
6) Start engine and let idle for one minute. Turn engine off.
Turn ignition on (engine off). Using scan tool, actuate S/C servo
solenoids. If throttle opens and closes, go to NTC-2: CHECKING FOR
SPEED CONTROL DENIED MESSAGE. If throttle does not open and close,
inspect throttle cable and linkage. Check vacuum supply. See VACUUM
SUPPLY under COMPONENT TESTS. Repair as necessary. Perform TEST VER-4A
under VERIFICATION TESTS.
7) While observing scan tool, press CANCEL switch several
times. If scan tool displays PRESSED and RELEASED, go to next step. If
scan tool does not display PRESSED and RELEASED, replace CANCEL
switch. Perform TEST VER-4A under VERIFICATION TESTS.
8) Turn ignition off. Disconnect S/C servo connector. Using
an ohmmeter, check resistance of ground circuit at S/C servo connector
terminal No. 4 (Black wire). If resistance is 5 ohms or more, repair
open ground circuit. Perform TEST VER-4A under VERIFICATION TESTS. If
resistance is less than 5 ohms, go to next step.
9) Reconnect S/C servo connector. Turn ignition and S/C on.
While observing scan tool, press SET switch several times. If scan
tool displays PRESSED and RELEASED, go to next step. If scan tool does
not display PRESSED and RELEASED, replace SET switch. Perform TEST
VER-4A under VERIFICATION TESTS.
10) Turn ignition off. Disconnect S/C servo connector.
Inspect terminals. If any terminal is damaged, pushed out or miswired,
repair as necessary. Perform TEST VER-4A under VERIFICATION TESTS. If
terminals are okay, go to next step.
11) Disconnect S/C servo connector. Disconnect PCM
connectors. Inspect connectors. Clean or repair as necessary. Using an
ohmmeter, check resistance of S/C vacuum solenoid control circuit
between PCM connector C3, terminal No. 4 and S/C servo connector
terminal No. 1 (Tan/Red wire). If resistance is 5 ohms or more, repair\
open circuit. Perform TEST VER-4A under VERIFICATION TESTS. If
resistance is less than 5 ohms, go to next step.
12) Turn S/C on. While observing scan tool, press COAST
switch several times. If scan tool displays PRESSED and RELEASED, go
to next step. If scan tool does not display PRESSED and RELEASED,
replace COAST switch. Perform TEST VER-4A under VERIFICATION TESTS.
13) Using an ohmmeter, check resistance of S/C vent solenoid
control circuit between PCM connector C3, terminal No. 5 and S/C servo
connector terminal No. 2 (Light Green/Red wire). If resistance is 5
ohms or more, repair open circuit. Perform TEST VER-4A under
VERIFICATION TESTS. If resistance is less than 5 ohms, replace S/C
servo. Perform TEST VER-4A under VERIFICATION TESTS.
NTC-1: BRAKE SWITCH SENSE
Possible Causes:
* Ground circuit open.
* Defective brake switch.
* Brake switch sense circuit open or shorted.
* Defective PCM.

* Signal circuit open or shorted.
* S/C ON/OFF switch defective.
* S/C RESUME/ACCEL switch defective.
* Defective PCM.
* Defective clockspring.
1) Turn ignition on. Using scan tool, read S/C switch
voltage. If voltage is more than 4 volts, go to next step. If voltage
is 4 volts or less, go to step 4).
2) Turn ignition off. Disconnect S/C ON/OFF switch. Inspect
connector. Clean or repair as necessary. Connect a jumper wire between
ground and S/C switch signal circuit at S/C ON/OFF switch connector
(Dark Green/Red wire on all models except Ram Van and Ram Wagon; wire
color is not available for Ram Van and Ram Wagon). Turn ignition on.
Using scan tool, read S/C switch voltage. If voltage is less than one
volt, replace S/C ON/OFF switch. Perform TEST VER-4A under
VERIFICATION TESTS. If voltage is one volt or more, go to next step.
3) Using a voltmeter, measure voltage on S/C switch signal
circuit. If voltage is less than 4 volts, repair high resistance in
S/C switch signal circuit. Perform TEST VER-4A under VERIFICATION
TESTS. If voltage is more than 6 volts, repair short to voltage.
Perform TEST VER-4A under VERIFICATION TESTS. If voltage is 4-6 volts,
replace PCM. Perform TEST VER-4A under VERIFICATION TESTS.
4) Turn ignition off. Disconnect S/C ON/OFF switch.
Disconnect PCM. Inspect connectors. Clean or repair as necessary.
Using an ohmmeter, measure resistance between ground and S/C switch
signal circuit at PCM connector C3, terminal No. 32 (White/Light Green
wire on Ram Van & Ram Wagon; Red/Light Green wire on all other
models). If resistance is less than 5 ohms, repair short to ground.
Perform TEST VER-4A under VERIFICATION TESTS. If resistance is 5 ohms
or more, go to next step.
5) Reconnect PCM. Ensure S/C ON/OFF switch is still
disconnected. Turn ignition on. Using scan tool, read S/C switch
voltage. If voltage is more than 4 volts, replace ON/OFF switch.
Perform TEST VER-4A under VERIFICATION TESTS. If voltage is 4 volts or
less, go to next step.
6) Disconnect RESUME/ACCEL switch. Using scan tool, read S/C
switch voltage. If voltage is more than 4 volts, replace RESUME/ACCEL
switch. Perform TEST VER-4A under VERIFICATION TESTS. If voltage is 4
volts or less, go to next step.
7) Disconnect clockspring connector located behind lower
steering column shroud. Inspect connector. Clean or repair as
necessary. Using scan tool, read S/C switch voltage. If voltage is
more than 4 volts, replace clockspring. See AIR BAG RESTRAINT SYSTEMS
- TRUCKS article. Perform TEST VER-4A under VERIFICATION TESTS. If
voltage is 4 volts or less, test is complete.
NTC-4: SPEED CONTROL RESUME/ACCEL SWITCH
Possible Causes:
* Ground circuit open.
* RESUME/ACCEL switch defective.
* Signal circuit open.
1) Turn ignition off. Disconnect RESUME/ACCEL switch. Inspect
connectors. Clean or repair as necessary. Connect a jumper wire
between ground and S/C switch signal circuit at RESUME/ACCEL switch
connector (Dark Green/Red wire on all models except Ram Van and Ram
Wagon; wire color is not available for Ram Van and Ram Wagon). Turn
ignition on. Using scan tool, read S/C switch voltage. If voltage is
less than one volt, replace RESUME/ACCEL switch. Perform TEST VER-4A

Fully depress brake pedal and rotate brake switch
counterclockwise approximately 30 degrees. Remove brake switch from
bracket. Depress lock tabs holding brake switch mounting bracket and
separate harness connector from brake switch.
Installation
1) Before installing brake switch, reset adjustable plunger
by pulling on plunger head until plunger reaches end of travel.
Connect harness connector to brake switch. Depress brake pedal and
insert brake switch into keyed hole in mounting bracket. Rotate brake
switch clockwise into locked position.
2) Gently pull back on brake pedal until pedal will go no
further. This causes the brake switch plunger to ratchet backward to
the correct position. No further adjustment is required.
SPEED CONTROL SERVO
Removal (Except Ram Van & Ram Wagon)
1) Disconnect negative battery cable. Disconnect electrical
connector and vacuum hose from servo. Using finger pressure only, push
servo cable connector from throttle body bellcrank pin. DO NOT pull
cable connector perpendicular to bellcrank.
2) Remove 2 servo cable mounting nuts. Pull servo cable
sleeve away from mounting bracket to expose cable retaining clip.
Remove retaining clip. Remove servo.
Removal (Ram Van & Ram Wagon)
1) Disconnect negative battery cable. Remove engine cover.
Remove air cleaner assembly. Using finger pressure only, push servo
cable connector from throttle body bellcrank pin. DO NOT pull cable
connector perpendicular to bellcrank.
2) Remove right headlight assembly. Disconnect vacuum hose
and electrical connector at servo. Remove 2 servo mounting bracket
bolts. Remove 2 servo cable mounting nuts. Pull servo cable sleeve
away from mounting bracket to expose cable retaining clip. Remove
retaining clip. Remove servo.
Installation (All Models)
With throttle in full open position, align hole in speed
control cable sleeve with hole in servo pin. Install retaining clip.
To complete installation, reverse removal procedure. Tighten mounting
bolts/nuts to 75 INCH lbs. (8.5 N.m).
SPEED CONTROL SWITCHES
Removal & Installation
Turn ignition off. Disconnect negative battery cable. Wait 2
minutes for air bag system to discharge reserve voltage. Remove 2
screws holding air bag assembly to steering column. Separate air bag
assembly from steering column and disconnect air bag, horn and speed
control switch connectors. Remove screws securing speed control switch
to air bag assembly. Separate speed control switch from air bag
assembly. To install, reverse removal procedure.
WIRING DIAGRAMS

1) Place selected shim on pinion. Press rear (pinion gear
side) pinion bearing on pinion. Lubricate pinion bearing with gear
lube.
CAUTION: DO NOT damage collapsible spacer when installing pinion
flange. If collapsible spacer is collapsed, install new
spacer.
2) Install pinion in axle housing. Install new collapsible
spacer and front (pinion flange side) pinion bearing. Using Pinion
Flange Installer (C-3718) and Holder (6719), install pinion flange o\
n
pinion to fully seat pinion bearings.
3) Remove pinion flange installer and pinion flange. Coat lip
of oil seal with gear lube. Install NEW oil seal. Drive NEW oil seal
into axle housing until oil seal installer contacts axle housing.
Install pinion flange, using pinion flange installer and holder.
CAUTION: Washer must be installed on pinion with convex side of washer
facing outward (away from pinion).
4) Install washer on pinion with convex side of washer facing
outward (away from pinion). Install NEW pinion nut. Using Holder
(6719), hold pinion flange. Tighten pinion nut only enough to remove
end play from pinion. Rotate pinion several times when tightening
pinion nut to fully seat pinion bearings.
5) Tighten pinion nut to 210 ft. lbs. (285 N.m). Remove
holder. Rotate pinion several times in both directions to fully seat
pinion bearings. Using INCH-lb. torque wrench, measure amount of force
required to rotate pinion. This is pinion bearing preload.
CAUTION: If original pinion bearings are installed, tighten pinion nut
until original pinion bearing preload is obtained. DO NOT
overtighten or loosen then retighten pinion nut when
adjusting pinion bearing preload. If pinion nut is
overtightened, replace collapsible spacer on pinion.
6) Continue tightening pinion nut in small increments until
correct bearing preload is obtained. See AXLE ASSEMBLY SPECIFICATIONS.
Go to RING GEAR BACKLASH & DIFFERENTIAL BEARING PRELOAD.
Ring Gear Backlash & Differential Bearing Preload
1) Lubricate differential bearings, bearing races and
adjusters with gear lube. Install differential carrier assembly,
bearing races and adjusters into axle housing.
2) Install bearing caps in original location. Install bolts
in bearing caps. Tighten upper bolts to 120 INCH lbs. (14 N.m).
Tighten lower bolts finger tight until bolt head is lightly seated
against bearing cap.
NOTE: To ensure bearing races are fully seated against differential
bearings, after rotating adjuster, rotate pinion back and
forth 5-10 times. This procedure must be performed anytime
adjusters are rotated.
3) Using Adjuster Rotator (C-4164), rotate each adjuster
inward until differential bearing free play is eliminated. Ensure
approximately .010" (.25 mm) ring gear backlash exists between ring
gear and pinion.
4) Install dial indicator on axle housing cover flange.
Position stem of dial indicator against drive side of tooth on ring
gear. Check ring gear backlash every 90 degrees to find point of
minimum ring gear backlash.
5) Mark ring gear at point of minimum ring gear backlash so

horizontally, and clamp straightedge to yoke in a horizontal plane.
Repeat procedure with drive pinion flange. Ensure flange/yokes are
horizontal by checking angle of straightedge using a machinist spirit
level.
4) Measure distance "X" at each side. See Fig. 9. If
measurements are not within 1/16" (1.6 mm) of each other, transmission\
flange is horizontally misaligned.
5) Measure distance "Y" (edge of straightedge to axle shaft
center line) at each side. If measurements are not within 1/8" (3.2
mm) of each other, axle housing is misaligned. Measure distance "W" at
each side. If measurements are not within 1/16" (1.6 mm) of each
other, pinion flange is horizontally misaligned.
ADJUSTING HORIZONTAL ALIGNMENT
NOTE: Excessive difference in measurements may indicate frame
damage. DO NOT attempt to use following correction procedure
if more than slight horizontal misalignment exists.
Minor adjustment of drive shaft horizontal alignment may be
made by loosening axle housing "U" bolts and moving either side of
axle housing forward or backward. If frame is not bent, slight axle
movement should make "W" measurements equal. See Fig. 9.
REMOVAL & INSTALLATION
CENTER BEARING SUPPORT ASSEMBLY
Removal
1) With transmission in neutral and parking brake off, raise
vehicle. Scribe alignment marks on all flange/yokes and slip joints to
be disassembled or disconnected. Remove drive shaft from pinion
flange/yoke.
2) Slide rear drive shaft slip joint from front drive shaft
splines. See Fig. 10. Support drive shaft(s) while removing center
bearing support bracket mounting bolts. Pull to remove front drive
shaft slip joint from transmission extension housing shaft.
Fig. 10: Identifying Center Bearing Support Assembly Components
Courtesy of Chrysler Corp.
CAUTION: DO NOT clamp drive shaft tube or slip joint tube in a vise.
Clamp only forged portion of each yoke in vise. To avoid

distorting yoke, DO NOT overtighten vise jaws.
Disassembly
1) Clamp front drive shaft in a soft-jaw vise. If required,
disassemble "U" joint from yoke to access yoke-to-drive shaft
retaining bolt. Scribe mark yoke or slip joint to drive shaft for
reassembly reference. Slide yoke or slip joint off shaft splines.
2) Remove and retain center bearing support bracket and
retainer. (Service replacement assembly may not come with these items.
) Remove rubber insulator from bearing housing. See Fig. 10.
3) Bend slinger away from center bearing to provide clearance
for bearing puller. Using bearing puller, remove center bearing from
drive shaft. On some applications, outer bearing cover/cage and balls
must be removed to attach puller to bearing race.
Reassembly & Installation
Install NEW slinger to shaft. Install/press bearing onto
shaft using appropriate tool or tube until bearing is seated to shaft
shoulder. To complete installation, reverse disassembly and removal
procedures. Ensure support bracket angle adjustment shims are
reinstalled (if removed).
OVERHAUL
NOTE: Manufacturer recommends replacing "U" joint(s) whenever "U"
joint is disassembled from yoke. ALWAYS replace complete "U"
joint whenever extreme external lubrication leakage or
bearing cap damage exists.
Before disassembly, mark flange/yoke to drive shaft for
reassembly reference, and remove "U" joint lube fitting(s). If joints
are rusted or corroded, apply penetrating oil before pressing bearing
caps out of yoke or off "U" joint trunnion pin.
SINGLE CARDAN "U" JOINTS
Other than adding grease, "U" joint assembly items are not
individually serviceable or repairable. If needle bearings, seals,
spider, or bearing caps are found to be defective, damaged or
excessively worn, complete "U" joint must be replaced.
NOTE: Saturate bearing caps and yokes with penetrating oil before
removal.
Removal
Raise and support vehicle. Remove drive shaft. Remove inner
or outer type bearing cap retainer clips. See Fig. 11. Press bearing
caps from yokes. Remove bearings, seals and spider from yoke bore, and
discard.
Cleaning
Clean yoke bores using solvent and wire brush or crocus
cloth. Remove rust, corrosion and foreign matter from yoke bores.
Installation
1) Apply multipurpose lubricant (NLGI grade 2 EP) to yoke
bores and into needle bearings of each bearing cap. Position spider in
yoke bores.
2) Install seals onto spider trunnions or bearing caps.
Lightly tap bearing caps into yoke bore far enough to retain spider in
place.

CAUTION: DO NOT clamp drive shaft tube or slip joint tube in a vise.
Clamp only forged portion of each yoke in vise. To avoid
distorting yoke, DO NOT overtighten vise jaws.
3) Using vise or press, push bearing caps into yoke bores,
keeping spider aligned in center of bearing caps. Using socket with
diameter slightly smaller than bearing cap, continue pressing caps
inward until retainer clips can be installed. Install inner or outer
type bearing cap retainer clips.
4) Install lube fitting, and lube "U" joint. Install drive
shaft. Tighten "U" joint clamp bolts to 14 ft. lbs. (19 N.m). Lower
vehicle.
Fig. 11: Exploded View Of Single Cardan "U" Joint
Courtesy of Chrysler Corp.
DOUBLE CARDAN CONSTANT VELOCITY (CV) JOINT (4WD)
NOTE: Other than adding grease, "U" joint assembly items are not
individually serviceable or repairable. If needle bearings,
seals, spider, or bearing caps are found to be defective,
damaged or excessively worn, complete "U" joint assembly must
be replaced.
CAUTION: DO NOT allow pinion flange end of front drive shaft to hang
free or bend at sharp angle from CV joint.
Removal & Disassembly (Dakota & Ram Pickup)
1) Mark drive shaft yoke-to-front pinion flange position and
transfer case flange-to-CV joint flange position for installation
reference. Remove CV joint flange-to-transfer case flange bolts first,
then remove pinion flange bolts. Remove front drive shaft from
vehicle. DO NOT bend shaft at sharp angle from CV joint.
2) Mark CV joint components for reassembly reference. Remove
all inner or outer type bearing cap retaining clips. See Fig. 12.
3) Set joint in arbor press or vise and place a socket on
upper bearing cap. Partially press one bearing cap from outer side of

FLYWHEEL INSPECTION








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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Cracked (other than
mounting area) ......... A ...... (1) Require resurfacing or
replacement.
Cracks in mounting area . B ............ Require replacement.
Hard spots .............. B .. Require repair or replacement.
Ring gear broken ........ A ..... Require replacement of ring
gear.
Ring gear teeth worn,
affecting performance .. A ..... Require replacement of ring
gear.
Runout exceeds
specifications ......... B .. Require repair or replacement.
Scored .................. B .. Require repair or replacement.
Surface cracks after
resurfacing to
manufacturer's minimum
specifications ......... B ............ Require replacement.
Wear exceeds
specifications ......... B ............ Require replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Some manufacturers allow slight surface cracking in the
friction surface.









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FORCE MOTORS
See ACTUATORS (ELECTRICAL) .
GUIDES
See DOWEL PINS, GUIDES AND PILOT HOLES .
HALF SHAFTS
See DRIVE SHAFTS AND HALF SHAFTS .
HOSES, LINES AND TUBES
HOSE, LINE AND TUBE INSPECTION








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Condition Code Procedure