1999 DODGE RAM Service Repair Manual

panel. To install, reverse removal procedure.
Fig. 6: Removing Cluster Bezel (Ram Pickup)
Courtesy of Chrysler Corp.
ACCUMULATOR
Removal & Installation
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
clutch cycling pressure switch connector.
2) On Dakota, remove nuts securing cruise control servo
mounting bracket to studs on cowl plenum panel (if equipped). Move
servo far enough to access accumulator refrigerant lines.
3) On all models, disconnect refrigerant lines from A/C
compressor and evaporator. Plug or cover all openings in A/C system.
Loosen support bracket screw. Remove accumulator.
4) To install, reverse removal procedure. Install new "O"
rings. Evacuate and charge A/C system.
BLOWER MOTOR
Removal (Dakota & Durango - Front)
1) Disconnect negative battery cable. Remove and disassemble
A/C-heater assembly. See A/C-HEATER ASSEMBLY. Disconnect blower motor
lead at bottom of housing. Remove 6 screws and blower motor housing
cover.
2) Remove 3 screws and blower motor and fan assembly. Place
reference marks on blower motor and fan for reassembly reference.
Remove blower fan retainer clip. Pull blower motor fan off blower
motor shaft.
Installation
Align reference marks. Press blower fan hub onto blower motor
shaft. Ensure retainer clip ears are indexed over flats of blower
motor shaft and fan hub. To complete installation, reverse removal

procedure.
NOTE: On Durango rear A/C-heater assembly, blower motor and fan are
serviced as an assembly.
Removal (Durango - Rear)
1) Disconnect negative battery cable. Remove headliner from
passenger compartment of vehicle. Remove sun visors and sun visor arm
supports.
2) Remove coat hooks, overhead assist handle and dome light.
If equipped, remove overhead console. Remove air outlet bezel from
rear A/C-assembly. Remove rear blower motor switch. Remove upper
liftgate opening trim. Disengage "A", "B", "C", and "D" pillar trim as
necessary to prevent trim panel interference.
3) Move second and third row seats to cargo position. Move
front seats to full recline position. Remove headliner fasteners.
Carefully bow headliner and remove through lift gate opening.
4) Disconnect "B" pillar drain hoses from "Y" fittings.
Remove lower A/C-heater assembly cover. Disconnect blower motor
harness connector. Remove blower motor and fan assembly. To install,
reverse removal procedure.
Removal (Ram Pickup - Front)
1) Disconnect negative battery cable. Disconnect blower motor
cooling tube. Remove blower motor electrical connector from retainer.
Disconnect electrical connector. See Fig. 5.
2) Remove blower motor and fan assembly mounting screws.
Remove blower motor and fan assembly. Place reference marks on blower
motor and fan for reassembly reference. Remove blower motor fan
retainer clip. Pull blower motor fan off blower motor shaft.
Installation
Align reference marks made during removal. Press blower fan
hub onto blower motor shaft. Ensure retainer clip ears are indexed
over flats of blower motor shaft and fan hub. Ensure blower motor seal
is installed on housing. To complete installation, reverse removal
procedure.
BLOWER MOTOR RESISTOR
Removal & Installation (Dakota & Durango - Front)
Blower motor resistor is located in engine compartment, under
upper right corner of dash panel. Disconnect negative battery cable.
Remove cowl plenum cover to access resistor. Remove blower motor
resistor connector. Remove resistor retaining screws. Remove blower
motor resistor. To install, reverse removal procedure.
Removal & Installation (Durango - Rear)
1) Rear blower motor resistor is located in A/C-heater
assembly. Disconnect negative battery cable. Remove headliner from
passenger compartment of vehicle. Remove sun visors and sun visor arm
supports.
2) Remove coat hooks, overhead assist handle and dome light.
If equipped, remove overhead console. Remove air outlet bezel from
rear A/C-assembly. Remove rear blower motor switch. Remove upper
liftgate opening trim. Disengage "A", "B", "C", and "D" pillar trim as
necessary to prevent trim panel interference.
3) Move second and third row seats to cargo position. Move
front seats to full recline position. Remove headliner fasteners.
Carefully bow headliner and remove through lift gate opening.
4) Disconnect "B" pillar drain hoses from "Y" fittings.
Remove lower A/C-heater assembly cover. Disconnect rear blower motor
resistor connector. Remove screw and rear blower motor resistor. To

install, reverse removal procedure.
Removal & Installation (Ram Pickup - Front)
Blower motor resistor is located under glove box, attached to
blower motor housing. See Fig. 5. Disconnect negative battery cable.
Remove blower motor resistor connector. Remove resistor retaining
screws. Remove blower motor resistor. To install, reverse removal
procedure.
BLOWER MOTOR SWITCH (REAR)
Removal & Installation (Durango)
Disconnect negative battery cable. Pry above indentations at
outer perimeter of rear blower motor switch. Pull rear blower motor
switch and disconnect electrical connector. Remove rear blower motor
switch. To install, reverse removal procedure.
COMPRESSOR
Removal & Installation
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
refrigerant lines and plug or cover all openings in A/C system.
2) Remove drive belt. Disconnect compressor electrical leads.
Remove compressor mounting nuts and bolts. Remove compressor. Drain
oil from compressor, and record amount of oil drained.
3) To install, reverse removal procedure. Using new
refrigerant oil, add to compressor the same amount of oil drained from
it. Evacuate and charge A/C system.
CONDENSER
NOTE: Before removing condenser, note location of radiator and
condenser air seals. If air seals are not installed properly,
A/C and engine cooling systems will not perform properly.
Removal
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
A/C fittings at inlet and outlet of condenser. Plug or cover all
openings in A/C system.
2) On Dakota, remove bolts securing radiator and fan shroud
to inside of upper radiator crossmember. Remove top mounting bolts
securing condenser to upper crossmember. Tilt top of radiator and fan
shroud toward engine.
3) On Ram Pickup (gasoline engine), remove bolts securing
condenser upper mounting brackets to outside of upper radiator
crossmember. Tilt condenser away from engine compartment far enough to
grasp top of condenser with both hands. On Ram Pickup (diesel engine),\
remove bolts securing condenser to charge air cooler. On all models,
lift condenser assembly from vehicle.
Installation
To install, reverse removal procedure. Install new "O" rings
to fittings. Fill cooling system. Evacuate and charge A/C system.
EVAPORATOR CORE & HEATER CORE
Removal & Installation (Dakota & Durango - Front)
Remove instrument panel. See INSTRUMENT PANEL. Remove A/C-
heater assembly. See A/C-HEATER ASSEMBLY. With A/C-heater housing
removed, remove housing cover. Remove evaporator core or heater core

from housing. To install, reverse removal procedure. Install new "O"
rings to A/C fittings. Evacuate and charge A/C system.
Removal & Installation (Durango - Rear Evaporator Core)
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Remove
headliner from passenger compartment of vehicle. Remove sun visors and
sun visor arm supports.
2) Remove coat hooks, overhead assist handle and dome light.
If equipped, remove overhead console. Remove air outlet bezel from
rear A/C-heater assembly. Remove rear blower motor switch. Remove
upper liftgate opening trim. Disengage "A", "B", "C", and "D" pillar
trim as necessary to prevent trim panel interference.
3) Move second and third row seats to cargo position. Move
front seats to full recline position. Remove headliner fasteners.
Carefully bow headliner and remove through lift gate opening.
4) Disconnect "B" pillar drain hoses from "Y" fittings.
Disconnect "B" pillar refrigerant lines and plug or cover all openings
in A/C system. Remove lower A/C-heater assembly cover. Remove screws
securing refrigerant tube and retaining strap to right side of upper
housing cover. Remove evaporator core. To install, reverse removal
procedure. Install new "O" rings to A/C fittings. Evacuate and charge
A/C system.
Removal & Installation (Ram Pickup - Front)
1) Remove and disassemble A/C-heater housing. See
A/C-HEATER ASSEMBLY . Separate halves of A/C-heater housing and remove
top half. Remove evaporator or heater core from housing.
2) To install, reverse removal procedure. Install new "O"
rings to A/C fittings. Evacuate and charge A/C system. Fill cooling
system. On 5.9L diesel engine, engine is equipped with a one-way check
valve. DO NOT run engine while filling cooling system. Fill engine
with engine turned off.
INSTRUMENT PANEL
Removal & Installation (Dakota & Durango)
1) Disconnect negative battery cable. Disable air bag system.
See AIR BAG SYSTEM SAFETY article. Place front wheels in straight-
ahead position. Remove sill trim from both doorways. Remove kick panel
covers from both sides of vehicle. Remove mounting screws for hood
release handle.
2) Remove steering column trim panel and support bracket.
Remove tilt steering column lever (if equipped). Remove upper and
lower shrouds from steering column. Unplug driver's side air bag
module. Loosen multifunction switch wiring harness connector screw and
disconnect from switch. Screw will remain in connector.
3) Disconnect PRNDL cable. Disconnect shift cable from
steering column. Remove steering coupler lock pin. Remove toe plate
retaining screws. Remove steering column mounting bolts and remove
steering column from vehicle.
4) Remove screw from bulkhead wiring harness connector and
disconnect. Disconnect 2 body wiring harness connectors located next
to bulkhead connector. Disconnect 3 wiring harness connectors, from
junction block, located nearest to dash panel. Disconnect brake light
switch connector. Disconnect Rear Wheel Anti-Lock (RWAL) brake module
(if equipped), located near steering column support brackets.
5) Disconnect plastic retainer clip from parking brake
linkage rod, located at back of parking brake release handle. Remove
rod end from parking brake handle. Remove instrument panel center
support bracket. Unplug vacuum harness connector located at left end
of A/C-heater housing. Disconnect Air Bag Control Module (ACM)
connector.

6) Remove glove box. Reach through glove box opening and
disconnect antenna coaxial cable connector. Disconnect blower motor
connector located above glove box opening, near support brace for A/C-
heater housing. Disconnect radio ground strap. Loosen instrument panel
roll down bracket bolts about 2 turns, located at lower corners on
both sides of instrument panel. Remove 5 screws across top of dash
panel at base of windshield, removing center screw last.
7) Roll down instrument panel and install a temporary support
hook that is about 18" (457 mm) in length. Install hook from center
hole in instrument panel to center hole of dash panel. Pull lower
instrument panel outward until both roll down bracket bolts are in
slotted roll down position. Instrument panel should now be supported
and away from firewall.
8) Disconnect 2 door harness connectors, located on a bracket
near right end of instrument panel. Disconnect blower motor resistor.
Disconnect temperature control cable from A/C-heater housing and
remove from housing. See Fig. 5. Disconnect demister duct flexible
hose from A/C-heater housing.
9) Ensure instrument panel is free and clear for removal.
With the aid of an assistant, remove temporary support hook. Lift
instrument panel off of roll down bracket bolts and remove from
vehicle.
10) To install, reverse removal procedure. Ensure all wiring
and hoses are clear and not pinched. Tighten bolts and nuts to
specification. See TORQUE SPECIFICATIONS . Enable air bag system. See
AIR BAG SYSTEM SAFETY article.
Removal & Installation (Ram Pickup)
1) Disable air bag system. See AIR BAG SYSTEM SAFETY article.
Disconnect negative battery cable. Drain cooling system. Remove left
and right kick panel trim. Remove 5 screws and knee bolster/steering
column cover. Remove hood release and parking brake release handle
screws from lower instrument panel support. Remove 6 screws and
instrument panel support. Disconnect air bag connector at lower left
corner of instrument panel.
2) Pull PRNDL cable and twist to remove from position arm.
Push tab on bottom of cable retainer upward, then squeeze sides to
remove retainer from column. Remove tilt lever (tilt column only).
Remove both upper and lower shrouds from column. Remove lower fixed
column shroud. Loosen multifunction switch connector screw. Screw will
remain in connector.
3) Remove remaining steering column electrical connectors.
Remove air bag wiring harness from steering column wiring trough.
Remove wiring trough from steering column. Remove 3 toe plate nuts and
washers.
4) Remove 2 nuts and washers attaching steering column
bracket to instrument panel steering column support bracket. Allow
column to lower and rest on seat. Remove 2 screws from bottom of Air
Bag Control Module (ACM) cover. Remove 4 screws holding ACM to
transmission tunnel.
5) Disconnect wiring at ACM. Disconnect instrument panel left
side wiring connectors. Remove screw holding brake release to bottom
of instrument panel. Disconnect instrument panel right side wiring
connectors, which includes 2 connectors attached to A/C-heater
assembly housing, courtesy light connector, antenna cable and 2 body
connectors. Disconnect vacuum harness from A/C-heater system.
6) Remove 5 screws holding instrument panel to dash. Loosen
lower instrument panel pivot bolts. Roll instrument panel downward.
Remove instrument panel from vehicle.
7) To install, reverse removal procedure. Ensure all wiring
and hoses are clear and not pinched. Tighten bolts and nuts to
specification. See TORQUE SPECIFICATIONS . Enable air bag system. See
AIR BAG SYSTEM SAFETY article.

TEMPERATURE CONTROL CABLE R & I
Removal (Dakota & Durango)
Disconnect negative battery cable. Disconnect but DO NOT
remove instrument panel. See INSTRUMENT PANEL. Disconnect temperature
control cable from A/C-heater control panel. Disconnect temperature
control cable from flag retainer located at top of A/C-heater assembly
housing. See Fig. 7. Remove temperature control cable self-adjuster
clip and temperature control cable.
Installation
1) Before installing temperature control cable, ensure that
self-adjuster clip is positioned as indicated. See Fig. 8.
Measurements must be made with cable end bottomed against flag
retainer on A/C-heater control panel end of cable housing.
2) Measure distance between center of self-adjusting clip and
end of cable flag retainer. If distance is not as specified, adjust
self-adjuster clip. To complete installation, reverse removal
procedure.
Fig. 7: Removing Control Cable Flag From Receiver (Typical)
Courtesy of Chrysler Corp.
Fig. 8: Adjusting Temperature Control Cable (Dakota & Durango)
Courtesy of Chrysler Corp.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
A/C Compressor Mounting Bolts .............................. 20 (27)\
A/C Compressor Suction/Discharge Hose ...................... 17 (23)\
Service Valve-To-Compressor Fitting .................... ( 1) 35 (47)
INCH Lbs. (N.m)
Compressor Oil Filler Plug ................................ 84 (9.5)\
A/C-Heater Housing Mounting Nuts (Front) .................... 60 (7\
)
A/C-Heater Housing Mounting Screws (Rear) ................. 106 (12\
)
( 1) - Wet torque fitting. Lubricate service valve coupling threads and
"O" rings with refrigerant oil.









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VACUUM DIAGRAMS
Fig. 9: Manual A/C-Heater System Vacuum Diagram (Dakota & Durango)
Courtesy of Chrysler Corp.

Fig. 10: Manual A/C-Heater System Vacuum Diagram (Ram Pickup)
Courtesy of Chrysler Corp.
WIRING DIAGRAMS