1999 DODGE RAM Service Repair Manual

or bungie cord to secure transfer case shift lever in 2H position.
2) Raise and support vehicle. Loosen lock bolt at adjusting
swivel on shift rod. See Fig. 8. Ensure shift rod slides freely in
adjusting swivel. If shift rod fails to slide freely in adjusting
swivel, lubricate shift rod as necessary.
3) Ensure shift lever on transfer case is still in 2H
position. Tighten lock bolt. With all wheels off floor, start engine
and shift transfer case through all ranges to ensure proper operation.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Kickdown Band Adjusting Screw Lock Nut ..................... 30 (41)\
Low-Reverse Band Adjusting Screw Lock Nut .................. 25 (34)\
Oil Pan Bolt ............................................... 12 (16)\
PTO Adapter Drain Plug (Ram Pickup) ........................ 40 (54\
)
PTO Adapter Fill Plug (Ram Pickup) ......................... 40 (54\
)
Transfer Case Drain Plug ................................... 40 (54)\
Transfer Case Fill Plug .................................... 40 (54)\
INCH Lbs. (N.m)
Oil Filter Bolt ........................................... 35 (4.0)\









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TR AN SM IS SIO N S ER VIC IN G - M /T

1999 D odge P ic ku p R 1500
1998-99 TRANSMISSION SERVICING
CHRY - Manual Transmission - Trucks
Dakota, Ram Pickup
APPLICATION
MANUAL TRANSMISSION APPLICATIONS (TRUCKS)








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Model Designation
Dakota
2.5L & 3.9L .............................. AX15/AS82 & ( 1) NV1500
5.2L ...................................................... NV3500
Ram Pickup
3.9L & 5.2L ............................................... NV3500
5.2L & 5.9L (Gasoline) ......................... NV4500 & NV4500HD\
5.9L Diesel & 8.0L ..................... NV4500, NV4500HD & NV5600
( 1) - NV1500 is available on 4-cylinder 2WD models only.









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TRANSFER CASE APPLICATIONS (TRUCKS)








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Model Designation
Dakota
3.9L ....................................................... NV231
5.2L ........................................ NV231HD Or ( 1) NV242HD
5.9L ........................................ NV231HD Or ( 1) NV242HD
Ram Pickup
1500 ..................................................... NV231HD
2500 & 3500 ..................................... NV241 Or NV241HD
( 1) - NV242HD is used on automatic transmission only.









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IDENTIFICATION
TRANSMISSION
AX-15 identification numbers are located on bottom surface of
intermediate plate. NV1500 consists of 2 aluminum housings and a
removable clutch housing. NV1500 is available on 4-cylinder 2WD
models. NV3500 consists of 2 aluminum housings and a non-removable
clutch housing. NV4500 identification tag is attached to driver's side
PTO cover. NV5600 is equipped with 2 identification tags attached to
driver's side of clutch housing.
TRANSFER CASE
Transfer case identification tag is located on rear of
transfer case housing.
LUBRICATION
SERVICE INTERVALS

Transmission (Dakota)
Check transmission fluid level when performing other
underhood services. Under normal service conditions, change
transmission fluid at 30 months or 37,500 miles. Under severe service
conditions, change transmission fluid at 18,000 miles. Severe service
are conditions such as long periods of engine idling, trailer towing,
off-highway operation, snow removal, or operating in dusty or
excessively hot conditions.
Transmission (Ram Pickup)
Check transmission fluid level when performing other
underhood services. Fluid change service interval information is not
available from manufacturer.
Transfer Case
Check transfer case fluid level when performing other
underhood services. On Dakota and Light-Duty Pickup, change transfer
case fluid at 37,500 miles or 30 months. On Medium-Duty and Heavy-Duty
Pickup, change transfer case fluid at 36,000 miles or 36 months.
CHECKING FLUID LEVEL
Transmission (Dakota)
1) Park vehicle on level surface. Remove transmission fill
plug from side of transmission. On AX-15 transmission, transmission
fill plug is located on driver's side of transmission. On NV3500
transmission, transmission fill plug is located near front of
transmission on passenger's side of transmission.
2) On all transmissions, fluid level should even with bottom
of fill plug hole on side of transmission. Add appropriate type of
transmission fluid if necessary. See RECOMMENDED FLUID. Install and
tighten transaxle fill plug to specification. See TORQUE
SPECIFICATIONS.
Transmission (Ram Pickup)
1) Park vehicle on level surface. Remove transmission fill
plug from side of transmission. On NV3500 transmissions, transmission
fill plug is located near front of transmission on passenger's side of
transmission. On NV4500 transmissions, transmission fill plug is
located near rear of transmission on passenger's side of transmission.
2) On all transmissions, fluid level should even with bottom
of fill plug hole on side of transmission. Add appropriate type of
transmission fluid if necessary. See RECOMMENDED FLUID. Install and
tighten transaxle fill plug to specification. See TORQUE
SPECIFICATIONS.
Transfer Case
Park vehicle on level surface. Remove transfer case fill plug
from rear of transfer case. Fluid level should even with bottom of
transfer case fill plug hole on rear of transfer case. Add appropriate
type of transfer case fluid if necessary. See RECOMMENDED FLUID.
Install and tighten transfer case fill plug to specification. See
TORQUE SPECIFICATIONS.
RECOMMENDED FLUID
Transmission (Dakota)
On AX-15 transmissions, use API 75W-90 GL-3 gear oil. On
NV1500 and NV3500 transmissions, use ONLY Mopar M/T Lube Part No.
4761526.
Transmission (Ram Pickup)

On NV3500 and NV5600, use ONLY Mopar M/T Lube Part No.
4761526. On NV4500, use ONLY Mopar M/T Lube Part No. 4874459.
Transfer Case
Manufacturer recommends using Dexron II or Mopar ATF Plus
Type 7176.
FLUID CAPACITIES
TRANSMISSION REFILL CAPACITIES ( 1)








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Application Pts. (L)\
Dakota
AX-15 .................................................. 6.6 (3.1)\
NV1500HD ............................................... 4.7 (2.2)\
NV3500 ................................................. 4.2 (1.9)\
Ram Pickup
NV3500 ................................................. 4.2 (1.9)\
NV4500 & NV4500HD ...................................... 8.0 (3.8)\
NV5600 ................................................. 9.5 (4.5)\
(1) - Approximate quantity listed.









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TRANSFER CASE REFILL CAPACITIES ( 1)








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Application Pts. (L)\
Dakota ................................................... 2.5 (1.2)\
Ram Pickup
NV231HD ................................................ 2.5 (1.2)\
NV241 .................................................. 5.0 (2.7)\
NV241HD ................................................ 6.5 (3.1)\
NV241HD With Power Take-Off (PTO) Adapter .............. 9.0 (4.3\
)
(1) - Approximate quantity listed.









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DRAINING & FILLING
Transmission (Dakota)
1) Park vehicle on level surface. Remove transmission drain
plug and allow fluid to drain from transmission. On AX-15
transmission, drain plug is located on passenger's side of
transmission. On NV3500 transmission, drain plug is located on bottom
of transmission housing, at center of transmission housing.
2) On all transmissions, install and tighten transmission
drain plug to specification. See TORQUE SPECIFICATIONS.
3) Remove transmission fill plug from side of transmission.
On AX-15 transmission, fill plug is located on driver's side of
transmission. On NV3500 transmission, fill plug is located near front
of transmission on passenger's side of transmission.
4) On all transmissions, fill transmission with appropriate
type of transmission fluid until fluid level is even with bottom of
fill plug hole on transmission. See RECOMMENDED FLUID. Install and
tighten transmission fill plug to specification. See TORQUE
SPECIFICATIONS.
Transmission (Ram Pickup With NV3500)
1) Park vehicle on level surface. Remove transmission drain
plug and allow fluid to drain from transmission. Transmission drain
plug is located on bottom of transmission housing, at center of

transmission housing.
2) Install and tighten transmission drain plug to
specification. See TORQUE SPECIFICATIONS.
3) Remove transmission fill plug from side of transmission.
Transmission fill plug is located near front of transmission on
passenger's side of transmission. Fill transmission with appropriate
type of transmission fluid until fluid level is even with bottom of
fill plug hole on transmission. See RECOMMENDED FLUID. Install and
tighten transmission fill plug to specification. See TORQUE
SPECIFICATIONS.
Transmission (Ram Pickup With NV4500 Or NV5600)
1) Park vehicle on level surface. Remove bottom bolt from
Power Take-Off (PTO) cover on passenger's side of transmission. Allow
fluid to drain.
2) Install and tighten PTO cover bolt to specification. See
TORQUE SPECIFICATIONS. Remove transmission fill plug from side of
transmission. Transmission fill plug is located near rear of
transmission on passenger's side of transmission.
3) Fill transmission with appropriate type of transmission
fluid until fluid level is even with bottom of fill plug hole on
transmission. See RECOMMENDED FLUID. Install and tighten transmission
fill plug to specification. See TORQUE SPECIFICATIONS.
Transfer Case
1) Ensure vehicle is parked on level surface. Remove transfer
case drain plug. Transfer case drain plug is located on rear of
transfer case at driver's side corner of transfer case. Allow fluid to
drain from transfer case.
2) Reinstall transfer case drain plug. Tighten transfer case
drain plug to specification. See TORQUE SPECIFICATIONS. Remove
transfer case fill plug fill plug from rear of transfer case. Transfer
case fill plug is located on rear of transfer case, just below
identification tag.
3) Fill transfer case with appropriate type of transfer case
fluid until fluid level is even with bottom of fill plug hole on
transfer case. See RECOMMENDED FLUID. Install and tighten transfer
case fill plug to specification. See TORQUE SPECIFICATIONS.
ADJUSTMENTS
TRANSFER CASE SHIFT LINKAGE
Dakota
1) On NV231, place transfer case lever in 4H position. On
NV242, place transfer case lever in 4FT position. On all models, use
wire or tape to hold lever in position. Raise and support vehicle.
Loosen shifter rod lock bolt at adjusting swivel. Ensure shift rod
slides freely in adjusting swivel.
2) Ensure shift lever on transfer case is in 4H position.
Slide adjusting swivel forward until shift lever touches shifter gate
crossover. Slide adjusting swivel slightly rearward to provide a 3-5
mm gap between shift lever shifter gate.
3) Center pin on adjusting swivel in shift arm and tighten
lock bolt to 90 INCH lbs. (10 N.m). Lower vehicle enough to enter
vehicle. Ensure wheels are off floor. Start engine and shift
transmission into gear. Operate transfer case to verify correct
adjustment.

Fig. 1: Identifying Typical Transfer Case Shift Linkage Components
Courtesy of Chrysler Corp.
Ram Pickup
1) Place transfer case shift lever in 2H position. Use wire
or bungie cord to secure transfer case shift lever in 2H position.
2) Raise and support vehicle. Loosen lock bolt at adjusting
swivel on shift rod. See Fig. 1. Ensure shift rod slides freely in
adjusting swivel. If shift rod fails to slide freely in adjusting
swivel, lubricate shift rod as necessary.
3) Ensure shift lever on transfer case is still in 2H
position. Lower vehicle. Position shift lever so that distance from
instrument panel to 2H position dot in shift lever insert is 5.75 in.
(146.000 mm). Tighten lock bolt to 90 INCH lbs. (10 N.m). Check shif\
t
linkage operation.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs.
PTO Cover Bolt
Ram Pickup ............................................... 30 (40)\
Transfer Case Drain Plug & Fill Plug ....................... 40 (54)\
Dakota ............................................. 15-25 (20-25)\
Ram Pickup ........................................... 30-40 (40-54)\
Transmission Drain Plug & Fill Plug
Dakota
AX-15 ................................................... 33 (44)\
NV1500 .................................................. 25 (34)\
NV3500 ............................................ 14-20 (19-27)\
Ram Pickup
NV3500 ............................................ 14-20 (19-27)\
NV4500 ............................................ 25-35 (34-47)\
NV5600 .................................................. 22 (30)\









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M - V A C UUM D IA G RAM S
1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Vacuum Diagrams - Trucks
Caravan, Dakota, Durango, Ram Pickup, Ram Van, Ram Wagon,
Town & Country, Voyager
INTRODUCTION
This article contains underhood views or schematics of vacuum
hose routing. Use these vacuum diagrams during the visual inspection
in appropriate BASIC DIAGNOSTIC PROCEDURES article. This will assist
in identifying improperly routed vacuum hoses, which may cause
driveability and/or computer-indicated malfunctions.
VACUUM DIAGRAMS
NOTE: References to California models apply to California emission
vehicles, which may be verified by underhood Emission Control
label. California emissions may be available in other
states.
NOTE: Vacuum diagrams for applications not shown were not available
at time of publication. See underhood Emission Control
label.
Fig. 1: Vacuum Hose Diagram (Caravan & Voyager - 2.4L - Calif.)
Courtesy of Chrysler Corp.