1999 DODGE RAM Service Repair Manual


A/C C O M PR ESSO R S ER VIC IN G
1999 D odge P ic ku p R 1500
1999 GENERAL SERVICING
A/C Compressor Servicing
All Models
* PLEASE READ THIS FIRST *
NOTE: Always refer to underhood A/C specification label in engine
compartment or A/C compressor label while servicing A/C
system. If A/C specification label and A/C COMPRESSOR
SERVICING article specifications differ, use underhood label
specifications.
BODY DESIGNATIONS
BODY DESIGNATIONS (CHRYSLER CORP. CARS)








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Model ( 1) Body Designation
Avenger & Sebring Coupe ................................ "FJ22" Body
Breeze, Cirrus & Stratus ................................. "JA" Body
Concorde, Intrepid, LHS & 300M ........................... "LH" Body
Neon ..................................................... "PL" Body
Sebring Convertible ...................................... "JX" Body
( 1) - Body codes are determined by fifth character of VIN code.









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BODY DESIGNATIONS (CHRYSLER CORP. LIGHT TRUCKS & VANS)








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Model Body Designation
Caravan, Town & Country, & Voyager ..................... "NS" Series
Dakota ................................................. "AN" Series
Durango ................................................ "DN" Series
Ram Pickup .......................................... "BR/BE" Series
Ram Van/Wagon .......................................... "AB" Series









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BODY DESIGNATIONS (FORD MOTOR CO. LIGHT TRUCKS & VANS)








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Model Body Designation
Explorer & Mountaineer .................................. "U" Series
Pickup .................................................. "F" Series
Ranger .................................................. "R" Series
Van ..................................................... "E" Series









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BODY DESIGNATIONS (GENERAL MOTORS CARS)








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Model ( 1) Body Designation
Alero, Cutlass, Grand Am & Malibu ......................... "N" Body
Aurora & Riviera .......................................... "G" Body
Bonneville, Eighty Eight, LeSabre & LSS ................... "H" Body
Camaro & Firebird ......................................... "F" Body
Catera .................................................... "V" Body
Cavalier & Sunfire ........................................ "J" Body

Century, Grand Prix, Intrigue, Lumina, Monte Carlo &
Regal .................................................... "W" Body
DeVille & Seville ......................................... "K" Body
Corvette .................................................. "Y" Body
Eldorado .................................................. "E" Body
Metro ..................................................... "M" Body
Park Avenue ............................................... "C" Body
Prizm ..................................................... "S" Body
Saturn .................................................... "Z" Body
(1) - Body codes are determined by fourth character of VIN code.









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BODY DESIGNATIONS (GENERAL MOTORS LIGHT TRUCKS & VANS)








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Model ( 1) Body Designation
Astro & Safari
2WD ................................................... "M" Series
4WD ................................................... "L" Series
Blazer, Bravada, Envoy, Jimmy, Pickup & Sonoma
2WD ................................................... "S" Series
4WD ................................................... "T" Series
Commercial Chassis & Motorhome .......................... "P" Series
Escalade, Pickup, Sierra, Silverado, Suburban, Tahoe & Yukon
2WD ................................................... "C" Series
4WD ................................................... "K" Series
Express & Savana ........................................ "G" Series
Tracker ................................................. "J" Series
Montana, Silhouette & Venture ........................... "U" Series
( 1) - Series codes are determined by fifth character of VIN code.









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BODY DESIGNATIONS (JEEP LIGHT TRUCKS)








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Model ( 1) Body Designation
Cherokee ............................................... "XJ" Series
Grand Cherokee ......................................... "WJ" Series
Wrangler ............................................... "TJ" Series
( 1) - Series codes are determined by fifth character of VIN code.









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COMPRESSOR APPLICATIONS
COMPRESSOR APPLICATIONS (CARS)








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Application Compressor
Chrysler Corp.
Avenger & Sebring Coupe
2.0L (DOHC) ........................ Nippondenso 10PA17C 10-Cyl.\
2.5L (SOHC) .............................. Sanden MSC90-C Scroll\
Breeze, Cirrus & Stratus .................... Sanden TRS-90 Scroll
Concorde, Intrepid, LHS & 300M ........ Nippondenso 10PA17 10-Cyl.
Neon .................................. Nippondenso 10PA17 10-Cyl.
Sebring Convertible ......................... Sanden TRS-90 Scroll
Ford Motor Co.
Except Taurus 3.4L SHO ........................ Ford FS-10 10-Cyl.
Taurus 3.4L SHO .................................... Sanden Scroll

General Motors (1)
"C" Body ...................................... Harrison V5 5-Cyl.
"E" Body ................................. Harrison HD6/HT6 6-Cyl.
"F" Body
3.8L Engine ................................. Harrison V5 5-Cyl.
5.7L Engine ................................. Harrison V7 7-Cyl.
"G" Body
Aurora ................................. Harrison HD6/HT6 6-Cyl.
Riviera ..................................... Harrison V5 5-Cyl.
"H" Body ...................................... Harrison V5 5-Cyl.
"J" Body ...................................... Harrison V5 5-Cyl.
"K" Body ................................. Harrison HD6/HT6 6-Cyl.
"M" Body ..................................... Nippondenso 10-Cyl.
"N" Body ...................................... Harrison V5 5-Cyl.
"S" Body ...................................... Harrison V5 5-Cyl.
"V" Body ...................................... Harrison V5 5-Cyl.
"W" Body ...................................... Harrison V5 5-Cyl.
"Y" Body ...................................... Harrison V7 7-Cyl.
"Z" Body ....................................... Zexel Rotary Vane
( 1) - Body codes are determined by fourth character of VIN code.









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COMPRESSOR APPLICATIONS (LIGHT TRUCKS & VANS)








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Application Compressor
Chrysler Corp.
Dakota & Ram Pickup ........................ Sanden SD-7H15 7-Cyl.
Durango .................................... Sanden SD-7H15 7-Cyl.
Caravan, Town & Country, & Voyager .... Nippondenso 10PA17 10-Cyl.
Ram Van/Wagon ............................... Sanden TR-105 Scroll
Ford Motor Co.
"E" Series Van ................................ Ford FS-10 10-Cyl.
Expedition & Navigator ........................ Ford FS-10 10-Cyl.
Explorer & Mountaineer ........................ Ford FS-10 10-Cyl.
"F" Series Pickup
Except Super Duty ........................... Ford FS-10 10-Cyl.
Super Duty ............................... Sanden SD-7H15 7 Cyl.
Ranger ........................................ Ford FS-10 10-Cyl.
Villager ........................................... FS-10 10-Cyl.
Windstar ...................................... Ford FS-10 10-Cyl.
General Motors ( 1)
"C" & "K" Series ......................... Harrison HD6/HT6 6-Cyl.
"G" Series .................................... Harrison V5 5-Cyl.
"J" Series ................................... Nippondenso 10-Cyl.
"L" & "M" Series ......................... Harrison HD6/HT6 6-Cyl.
"P" Series ............................... Harrison HD6/HT6 6-Cyl.
"S" & "T" Series
2.2L ........................................ Harrison V7 7-Cyl.
4.3L ................................... Harrison HD6/HT6 6-Cyl.
"U" Series .................................... Harrison V5 5-Cyl.
Jeep
Cherokee ................................... Sanden SD-7H15 7-Cyl.
Grand Cherokee ........................ Nippondenso 10PA17 10-Cyl.
Wrangler ................................... Sanden SD-7H15 7-Cyl.
( 1) - Series codes are determined by fifth character of VIN code.









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FORD FS-10 10-CYLINDER

CLUTCH ASSEMBLY
Removal
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Remove A/C compressor. Using a spanner
wrench or clutch holder, remove clutch plate bolt. Discard bolt.
Thread an 8-mm bolt into clutch plate, and remove clutch plate and
shims.
2) Remove pulley outside snap ring. Remove pulley assembly.
See Fig. 1 . Disconnect clutch coil lead. Install Shaft Protector
(T89P-19623-FH) over compressor shaft. Install 2-jaw puller on
compressor. Carefully tighten puller to remove clutch coil from
compressor. DO NOT use air-powered tools when removing clutch coil.
Installation
1) Ensure clutch coil mounting surface is clean. Install
clutch coil. Ensure electrical connection is correctly positioned.
Position Coil Replacer (T91L-19623-CH) onto coil and Coil Pressing
Adapter (T89P-19623-EH) onto coil replacer.
2) Install 2-jaw puller on compressor and coil replacer.
Engage jaws on puller with compressor front mounts. Carefully tighten
puller until clutch coil bottoms completely against compressor. DO NOT
use air-powered tools when installing clutch coil.
3) Carefully install pulley assembly onto compressor,
ensuring that it is properly aligned. Install pulley assembly snap
ring with beveled side out. Install shim(s) and clutch plate. Install
a new clutch plate bolt, and tighten it to 98-123 INCH lbs. (11-14 N.
m).
4) Using a feeler gauge, measure air gap between clutch plate
and pulley assembly mating surfaces in 3 places. Air gap should be 0.
014-0.033" (0.36-0.84 mm). If air gap is not as specified, add or
remove shims as necessary.
Fig. 1: Exploded View Of Compressor Clutch Assembly (Ford FS-10;
Sanden Is Similar)
Courtesy of ford motor co.
SHAFT SEAL

Removal
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Remove compressor. Using a spanner
wrench or clutch holder, remove clutch plate bolt. Discard bolt.
Thread an 8-mm bolt into clutch plate and remove clutch plate and
shims.
2) Remove shaft felt seal. Using low pressure compressed air
and a lint-free cloth, thoroughly clean seal inside and outside of
compressor nose area. Using Snap Ring Remover (T89P-19623-DH), rotate
eye of snap ring. Pull up snap ring while holding snap ring at an
angle.
3) Position Shaft Seal Remover (T89P-19623-BH) over
compressor shaft. Push shaft seal remover downward against seal.
Ensure end of shaft seal remover engages inside of seal.
4) Rotate shaft seal remover handle clockwise to expand
remover tip inside seal. Pull shaft seal from compressor.
Installation
1) Lubricate shaft seal protector and shaft seal with
refrigerant oil. Replacement Seal Kit (19D665) includes Shaft Seal
Protector (T94P-19623-F).
2) Coat shaft seal and protector with clean refrigerant oil.
Install shaft seal on shaft seal protector so lip of seal is toward
large end of shaft seal protector. Install shaft seal protector onto
compressor shaft.
3) Using Shaft Seal Replacer (T89P-19623-AH), slowly push
shaft seal down until it is seated. Remove shaft seal installer and
protector. Install new shaft seal snap ring. Rotate compressor shaft
about 10 revolutions and leak test shaft seal installation.
4) Install new shaft seal felt. Install clutch plate. Install
new clutch plate bolt, and tighten it to 98-123 INCH lbs. (11-14 N.m).\
5) Using a feeler gauge, measure air gap (in 3 places)
between clutch plate and pulley assembly mating surface. Air gap
should be 0.014-0.033" (0.36-0.84 mm). If air gap is not as specified,\
add or remove shims as necessary.
HARRISON HD6/HT6 & HD6/HR-6HE 6-CYL., V5 5-CYL. & V7 7-CYL.
CLUTCH ASSEMBLY
CAUTION: DO NOT hammer on compressor shaft to remove clutch plate, as
compressor damage will result.
Removal
1) Remove compressor from vehicle. Place compressor in
Holding Fixture (HD6/HT6 and HD6/HR-6HE compressor use J-33026; on V5
or V7 compressor use J-34992 or J-41790). On V5 or V7 compressor,
remove dust cover (if equipped). Use Clutch Plate Spanner (J-33027-A)\
to hold clutch plate and remove compressor shaft nut using Shaft Nut
Socket (J-33022). See Fig. 2 or 3.
2) On all compressors, using Clutch Plate Remover/Installer
(J-33013-B), remove compressor clutch plate and hub. See Fig. 2 or 3.
Hold remover body and turn center screw into remover body to remove
clutch plate and hub. Ensure forcing tip on remover/installer center
screw is flat or end of shaft/axial plate will be damaged. Remove
shaft key.
3) Remove snap ring. Install Puller Guide (J-33023-A) on
front head. Position Pulley and Bearing Puller (J-41552 for HD6/HT6
and HD6/HR-6HE or J-33020 for V5 or V7 compressor) into inner circle
of slots on pulley assembly. Turn puller clockwise in slots. Tighten
puller and remove pulley assembly.

4) If bearing is to be removed, remove forcing screw from
puller. With puller still engaged in pulley slots, invert assembly
onto a solid flat surface. Use a hammer and Bearing Remover (J-9398-A)\
to drive bearing from pulley. See Fig. 2 or 3.
NOTE: It is not necessary to remove staking in front of bearing
before removing bearing.
5) Disconnect clutch coil lead. Scribe marks on compressor
and clutch coil for installation reference. Remove clutch coil using
Puller Adapter (J-33023-A) and 2-jaw puller.
Installation
1) Align reference marks made during removal. Using Puller
Adapter (J-33024) and Puller Bar (J-8433-1), press clutch coil onto
compressor. Ensure clutch coil and installer stay lined up during
installation. Using a 1/8" punch, stake clutch coil inner ring in 3
places, 120 degrees apart. Stake size should be 1/2 the area of punch
tip and 0.010-0.015" (0.28-0.38 mm) deep.
NOTE: To ensure proper bearing clearance, it is necessary to remove
old stake metal before installing new bearing.
2) To install pulley bearing, place pulley on Support (J-
21352-A). DO NOT support pulley rim on flat surface, or pulley will be
damaged. Install bearing in pulley using hammer, Bearing Installer (J-
9481-A) and Handle (J-29886).
3) With pulley on support, use Bearing Staking Guide (J-
33019-1) and Bearing Staking Pin (J-33019-2) to stake pulley in 3
places, 120 degrees apart. Reposition pulley on support to ensure full
support under staking pin. Metal stake should be similar to original
stake (down to, but not touching bearing). Position pulley on
compressor.
4) Place Bearing Installer (J-33017) and Puller Guide (J-
33023-A) over inner race of bearing. Using puller, press pulley onto
compressor. Install snap ring. Install shaft key in clutch plate,
allowing key to protrude about 1/8" from rear of clutch plate.
5) Install clutch plate on compressor shaft. Using clutch
plate remover/installer, press clutch plate onto compressor. Ensure
shaft key is still in keyway before installing clutch assembly.
6) Air gap between friction surfaces for HD6/HT6 and HD6/HR-
6HE compressor is 0.020-0.030" (0.51-0.76 mm); for V5 and V7
compressor air gap is 0.015-0.020" (0.38-0.51 mm). On V5 and V7
compressor, using clutch plate spanner, install compressor shaft nut.
Tighten shaft nut to 12.5 ft. lbs. (17 N.m). Check components for
proper rotation.

Fig. 2: Compressor Components (Harrison HD6/HT6 & HD6/HR-6HE
6-Cylinder)
Courtesy of general motors corp.

Fig. 3: Compressor Components (Harrison V5 5-Cylinder Shown;
V7 7-Cylinder Is Similar)
Courtesy of general motors corp.
SHAFT SEAL