1999 DODGE RAM check oil

NOTE: For additional information on fuel pressure and fuel pump
testing procedures, see appropriate NO TROUBLE CODE (NTC)
TEST and NO START (NS) TEST in SELF-DIAGNOSTICS - JEEP,
TRUCKS & RWD VANS article.
Vehicles With Fuel Rail Test Port
1) Disconnect negative battery cable. Release fuel pressure.
See FUEL PRESSURE RELEASE. Install fuel pressure gauge with hose on
fuel pressure test port.
2) Start engine and allow to idle. Fuel pressure should be
44-54 psi (3.1-3.8 kg/cm
). If no fuel pressure exists and engine will
not start, fuel pump relay and control circuit may be defective. See
FUEL PUMP RELAY.
3) If fuel pressure exceeds specification, fuel pump is okay,
but fuel pressure regulator is defective. Replace fuel pressure
regulator. Fuel pressure regulator is incorporated with the fuel
filter. Fuel filter/fuel pressure regulator is located on top of fuel
tank, in fuel pump module. See REMOVAL, OVERHAUL & INSTALLATION -
TRUCKS & RWD VANS - GASOLINE article.
Vehicles Without Fuel Rail Test Port
1) Disconnect negative battery cable. Release fuel pressure.
See FUEL PRESSURE RELEASE. Fuel pressure gauge is installed between
fuel supply line and fuel line fitting on fuel rail.
2) To disconnect fuel supply line from fuel rail, ensure area
around fuel supply line and fuel rail are clean. Note direction of
latch clip installation. Latch clip is located on top of fuel supply
line at fuel rail. See Fig. 1. Using 2 screwdrivers, pry latch clip
upward, and remove from fuel rail.
3) Pull fuel supply line from fuel rail. Install Adapter
(6923) into fuel rail. Ensure adapter is fully seated in fuel rail.
Install latch clip into fuel rail, with latch clip fingers pointing
downward. If latch clip will not fully seat so latch clip fingers
extend downward below fitting on fuel rail, adapter may not be fully
seated in fuel rail.
4) Connect fuel supply line to adapter. Ensure fuel supply
line fully seats in adapter. Remove protective cap from test port, and
install Fuel Pressure Gauge/Hose (5069) at test port.
5) Start engine and allow to idle. Fuel pressure should be
44-54 psi (3.1-3.8 kg/cm
). If no fuel pressure exists and engine will
not start, fuel pump relay and control circuit may be defective. See
FUEL PUMP RELAY.
6) If fuel pressure exceeds specification, fuel pump is okay,
but fuel pressure regulator is defective. Replace fuel pressure
regulator. Fuel pressure regulator is incorporated with the fuel
filter. Fuel filter/fuel pressure regulator is located on top of fuel
tank, in fuel pump module. See REMOVAL, OVERHAUL & INSTALLATION -
TRUCKS & RWD VANS - GASOLINE article.
7) On all models, release fuel pressure. See FUEL PRESSURE
RELEASE. Remove latch clip. Remove test equipment. Before reinstalling
fuel supply line, ensure fuel supply line fitting and fitting on fuel
rail are clean.
8) Lubricate fuel supply line fitting and fitting on fuel
rail with engine oil. Install fuel supply line on fuel rail.
9) Install latch clip into fuel rail, with latch clip fingers
pointing downward. Ensure latch clip is fully seated. Latch clip
fingers should extend downward below fitting on fuel rail when fully
seated.
10) Pull on fuel supply line to ensure fuel supply line is
fully locked on fuel rail. Reinstall negative battery cable. Start
engine and check for fuel leaks.

* ONE GAUGE NOT OPERATING PROPERLY
OVERHEAD CONSOLE CONCERNS
* AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG (CMTC FAILS TO
RESPOND TO INSTRUMENT CLUSTER DIMMING, DISTANCE TO EMPTY
INOPERATIVE OR WRONG, ELAPSED TIME INOPERATIVE/WRONG, SWITCH
ON CMTC INOPERATIVE, TRIP ODOMETER INOPERATIVE/WRONG)
* CMTC DISPLAY SHOWS FAILED
* CMTC SEGMENTS FAIL TO LIGHT UP
* INCORRECT READING BEYOND +/- 5
* REPAIRING "OC" IN CMTC DISPLAY
* REPAIRING "SC" IN CMTC DISPLAY
POWER DOOR LOCK SYSTEM
* DOOR LOCK SWITCH FAILURE (PDL)
* DOOR UNLOCK SWITCH FAILURE (PDL)
* AUTOMATIC (ROLLING) DOOR LOCKS INOPERATIVE
* DOORS LOCK WITH KEY IN IGNITION & LEFT DOOR OPEN
* ONE OR ALL DOORS FAILING TO LOCK FROM ONE SWITCH (ONE OR ALL
DOORS FAILING TO UNLOCK FROM ONE SWITCH)
* REMOTE KEYLESS ENTRY PROBLEM
VEHICLE THEFT/SECURITY SYSTEM
* DOOR DISARM SWITCH FAILURE
* DOOR LOCK SWITCH FAILURE
* DOOR UNLOCK SWITCH FAILURE
* EEPROM CHECKSUM FAILURE
* INTERNAL ROM TEST FAILURE
* IDENTIFYING VTSS PROBLEMS
WINDSHIELD WIPER SYSTEM
* WIPER PARK SWITCH FAILURE
* INTERMITTENT WIPERS INOPERATIVE
* NO WIPER ACTUATION AFTER WASH BUTTON PUSHED
* WIPER SPEED SENSITIVE FEATURE INOPERATIVE
CHIME SYSTEM
CHIME INOPERATIVE WITH EXTREME COOLANT TEMPERATURE
NOTE: For connector terminal identification and wiring diagrams,
see BODY CONTROL COMPUTER - INTRODUCTION article. Perform
VERIFICATION TEST VER-1A after each repair.
CAUTION: Always turn ignition switch to OFF position prior to
disconnecting any module connector.
1) Using scan tool, actuate chime. If chime sounds, go to
next step. If chime does not sound, replace Central Timer Module
(CTM). CTM is located under left side of instrument panel.
2) Using scan tool, read Powertrain Control Module (PCM)
DTCs. If no engine coolant temperature related codes exist, go to next
step. If engine coolant temperature related codes exist, see
appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE section.
3) Due to difficult access of coolant temperature sensor, Oil
Pressure Switch (OPS) will be used to verify CCD bus message from PCM.\
Disconnect OPS connector. OPS is located near bottom of distributor.

circuit.
ONE GAUGE NOT OPERATING PROPERLY
NOTE: For connector terminal identification and wiring diagrams,
see BODY CONTROL COMPUTER - INTRODUCTION article. Perform
VERIFICATION TEST VER-1A after each repair.
CAUTION: Always turn ignition switch to OFF position prior to
disconnecting or connecting any module connector.
1) Push and hold RESET button while cycling ignition key; ON-
OFF-ON. Instrument cluster self-test will start. If inoperative gauge
reached proper calibration point, go to next step. If inoperative
gauge did not reach proper calibration point, replace instrument
cluster.
2) Stop instrument cluster self-test. If problem is with
speedometer, go to next step. If problem is with oil pressure gauge,
go to step 5). If problem is with temperature gauge, go to step 14).
If problem is with fuel level gauge, go to appropriate SELF-
DIAGNOSTICS article in ENGINE PERFORMANCE section and review
powertrain symptoms. If problem is with volt gauge, go to step 16). If
problem is with tachometer, go to step 18).
3) Using scan tool, select BODY, SYSTEMS TESTS then PCM
MONITOR. If scan tool displays PCM ACTIVE ON BUS, go to next step. If
scan tool does not display PCM ACTIVE ON BUS, go to appropriate
VEHICLE COMMUNICATIONS article.
4) Raise and support all wheels. Start engine and place gear
selector in drive. Using scan tool, select MIC, MONITORS then CCD BUS
ENGINE INFO. Read VSS. If vehicle speed on scan tool matches
speedometer, see appropriate ANTI-LOCK BRAKE article. If vehicle speed
on scan tool does not match speedometer, replace instrument cluster
circuit board.
5) Turn ignition on. If CHECK GAUGES light illuminated, go to
next step. If CHECK GAUGES light did not illuminate, go to step 11).
6) Turn ignition off. Inspect oil level. If oil level is
within specification, go to next step. If oil level is not within
specification, adjust oil level and retest.
7) Turn ignition on. Disconnect engine Oil Pressure Switch
(OPS) connector. OPS is located near bottom of distributor. If CHECK
GAUGES light went out, go to next step. If CHECK GAUGES light did not
go out, go to step 10).
8) Remove OPS. Connect mechanical oil pressure gauge to OPS
port. Start engine. If engine oil pressure at idle is 4 psi or more,
go to next step. If engine oil pressure at idle is less than 4 psi,
repair mechanical engine problem.
9) Run engine to reach normal operating temperature. If
engine oil pressure at idle is 4 psi or more, replace OPS. If engine
oil pressure at idle is less than 4 psi, repair mechanical engine
problem.
10) Turn ignition off. Disconnect PCM White connector C2. PCM
is located in engine compartment on right inner fender. Using an
external ohmmeter, measure resistance between ground and PCM Black
connector terminal No. 23 (Gray/Orange wire). If resistance is less
than 5 ohms, repair short to ground in Gray/Orange wire. If resistance
is 5 ohms or more, replace PCM.
11) Disconnect engine Oil Pressure Switch (OPS) connector.
OPS is located near bottom of distributor. Using an external ohmmeter,
measure resistance between ground and OPS connector Black/Light Blue
wire. If resistance is less than 5 ohms, go to next step. If
resistance is 5 ohms or more, repair open Black/Light Blue wire.
Black/Light Blue wire is a common sensor ground. If no other engine
sensors are failed, repair ground between sensor and splice. If

multiple engine sensors have failed, repair ground between splice and
PCM.
12) Connect jumper wire between OPS connector terminals. If
oil pressure warning indicator illuminates, replace OPS. If oil
pressure warning indicator does not illuminate, go to next step.
13) Do not remove jumper wire. Disconnect PCM Black connector
C2. PCM is located in engine compartment on right inner fender. Using
an external ohmmeter, measure resistance between ground and PCM White
connector C2 terminal No. 23 (Gray/Orange wire). If resistance is less\
than 5 ohms, replace PCM. If resistance is 5 ohms or more, repair open
Gray/Orange wire.
14) Check cooling system operation. If cooling system is
operating properly, go to next step. If cooling system is not
operating properly, repair engine cooling problem.
15) Using scan tool, select PCM MONITOR under SYSTEM TESTS.
If scan tool displays PCM ACTIVE ON BUS, system is currently
functioning properly. If scan tool does not display PCM ACTIVE ON BUS,
go to appropriate VEHICLE COMMUNICATIONS article.
16) Using scan tool, select MODULE ENGINE CONTROLLER. Read
PCM DTCs. If scan tool displays any charging system related DTCs, go
to appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE section
and repair DTC as necessary. If scan tool does not display any
charging system related DTCs, go to next step.
17) Check charging system operation. If charging system is
operating properly, replace instrument cluster. If charging system is
not operating properly, repair engine charging problem.
18) Using scan tool, select BODY COMPUTER MONITORS. Read CCD
BUS ENGINE INFO. If scan tool displays engine RPM, replace instrument
cluster. If scan tool does not display engine RPM, replace PCM.
OVERHEAD CONSOLE CONCERNS
AVERAGE MPH/FUEL ECON INOPERATIVE OR WRONG (CMTC FAILS TO
RESPOND TO INSTRUMENT CLUSTER DIMMING, DISTANCE TO EMPTY
INOPERATIVE OR WRONG, ELAPSED TIME INOPERATIVE/WRONG, SWITCH
ON CMTC INOPERATIVE, TRIP ODOMETER INOPERATIVE/WRONG)
NOTE: If any listed symptoms exist, Compass Mini-Trip computer
(CMTC) is defective. Replace CMTC. Perform VERIFICATION TEST
VER- 1A after each repair.
CMTC SHOWS FAILED
NOTE: For connector terminal identification and wiring diagrams,
see BODY CONTROL COMPUTER - INTRODUCTION article. Perform
VERIFICATION TEST VER-1A after each repair.
Using scan tool, perform AUTO SELF TEST. If CMTC shows
failed, replace CMTC. If CMTC does not show failed, system is
currently functioning properly.
CMTC SEGMENTS FAIL TO LIGHT UP
NOTE: For connector terminal identification and wiring diagrams,
see BODY CONTROL COMPUTER - INTRODUCTION article. Perform
VERIFICATION TEST VER-1A after each repair.
Using scan tool, perform AUTO SELF TEST. If CMTC segments
fail to illuminate, replace CMTC. If CMTC segments all illuminate
properly, system is currently functioning properly.
INCORRECT READING BEYOND +/- 5

CAUTION: Clutch disc may contain asbestos fibers which can cause
serious health risk. DO NOT sand clutch components. DO NOT
clean components using compressed air. To clean components,
use a water-dampened cloth.
Removal
With transmission and clutch housing removed, mark pressure
plate and flywheel for reassembly reference. Install clutch aligner in
clutch disc to prevent disc from falling. Loosen pressure plate bolts
evenly and in rotation to avoid warping pressure plate. Remove
pressure plate and disc from flywheel. See Fig. 10.
Inspection
1) Check for oil leakage through engine rear main bearing oil
seal and transaxle input shaft seal. Check flywheel and pressure plate
for burned areas, discoloration, cracks, grooves or ridges. Replace as
necessary.
2) Use medium sandpaper (80-180 grade) to clean flywheel
surface, then wipe with mineral spirits. DO NOT flat-machine flywheel
surface. Check facing surfaces for grease or oil contamination. Check
clutch disc for wear. Clutch disc face-to-rivet head distance should
be at least .008" (.20 mm). Check splines of disc hub and transaxle
input shaft.
3) Using straightedge, check pressure plate. Friction area
should be flat to slightly concave, with the inner diameter about 0-.
0039" (0-0.1 mm) less than outer diameter. Using surface plate, check
clutch cover for flatness. Sections around bolt holes should contact
surface plate within .015" (.38 mm). Ensure cover-to-flywheel dowel
fit is snug. Replace clutch assembly as necessary.
NOTE: Before installing clutch disc, ensure flywheel mating
surface, pilot bearing/bushing and clutch release bearing are
in satisfactory condition. Repair and/or replace components
as necessary.
Installation
To install, reverse removal procedure using clutch aligner.
Ensure reference marks are aligned. Tighten pressure plate retaining
bolts evenly a few threads at a time to prevent warpage. See TORQUE
SPECIFICATIONS table.
Fig. 10: Exploded View Of Clutch Assembly (Typical)
Courtesy of Chrysler Corp.
PILOT BEARING, CLUTCH RELEASE BEARING & FORK

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

(inner) pinion bearing onto pinion until bearing is fully seated.
Install preload shims on pinion. Install pinion in axle housing.
Install front (outer) pinion bearing and slinger (if equipped).
Install pinion flange on pinion.
2) Using holder and Pinion Flange Installer (C-3716), press
pinion flange onto pinion. Install washer and used pinion nut. Tighten
pinion nut to specification. See TORQUE SPECIFICATIONS table.
3) Using INCH-lb. torque wrench, check torque required to
rotate pinion. This is pinion bearing preload. Ensure pinion bearing
preload is within specification. See AXLE ASSEMBLY SPECIFICATIONS.
4) If pinion bearing preload is not within specification,
adjust thickness of preload shims. Decrease shim thickness to increase
pinion bearing preload. Increase shim thickness to decrease pinion
bearing preload.
5) Remove nut and washer from pinion. Using holder and Pinion
Flange Remover (C-452), remove pinion flange from pinion. Ensure oil
seal surface in axle housing is clean.
6) Coat lip of oil seal with gear lube. Using appropriate oil
seal installer and handle, install oil seal.
7) Reinstall pinion flange, washer and NEW pinion nut. DO NOT
reuse pinion nut. Tighten pinion nut to specification. See TORQUE
SPECIFICATIONS table. Recheck pinion preload. Proceed to RING GEAR
BACKLASH.
NOTE: Before performing ring gear backlash, note differential case
zero end play obtained during initial differential bearing
preload. See INITIAL DIFFERENTIAL BEARING PRELOAD.
Ring Gear Backlash
1) Install dummy bearings on each side of differential case
where differential bearings fit. Use Dummy Bearing (D-345) for 216 FBI\
axle, or (D-343) for 248 FBI axle.
2) Install differential case in axle housing. Install bearing
caps on axle housing. Ensure bearing caps are installed in original
location. Install bearing cap bolts.
3) Mount dial indicator on axle housing with stem against
back of ring gear. Ensure pressure exists on stem of dial indicator.
Ensure ring gear and pinion are tightly meshed.
4) Pry between bearing cap and differential case. Pry
differential case as far to right as possible. Zero dial indicator.
5) Pry differential case to the left as far as possible, and
note reading on dial indicator. Repeat procedure several times to
ensure proper reading.
6) Measurement obtained determines preload shim thickness
required to eliminate ring gear backlash. Subtract reading obtained in
step 5) from differential case zero end play obtained during initial
differential bearing preload.
7) This is thickness of preload shims that must be installed
on ring gear side of differential case. These preload shims will be
referred to as the "ring gear backlash preload shims".
8) Remaining preload shims required to equal the differential
case zero end play will be referred as zero end play preload shims.
9) Remove dial indicator, bearing caps and differential case
from axle housing. Remove master bearings from differential case.
Install ring gear backlash preload shims on ring gear side of
differential case.
10) Install differential bearing on ring gear side of
differential case using appropriate bearing installer.
11) Install zero end play preload shims plus an additional .
015" (.38 mm) thick preload shim on differential case (opposite ring
gear side). Using bearing installer, install differential bearing on
differential case.
12) Install bearing races on differential bearings. If

(1) - Approximate drive axle capacity listed. Lubricant level should
be within 1/2" below bottom of oil filler hole in axle housing
cover.
( 2) - Add container of Mopar Gear Oil Friction Modifier when
refilling.









\









\









\









\









\









\









\







FLUID TYPE
Use SAE 80W-90 or SAE 90W hypoid gear lubricant with MIL-L-
2105-B and API GL-5 ratings. Also add a container of Mopar Gear Oil
Friction Modifier when refilling.
FLUID DRAIN & REFILL
1) With lubricant of rear axle assembly at normal operating
temperature, raise and support vehicle so rear wheels are free to
rotate. Clean around axle housing cover. Loosen axle housing cover
bolts. Drain lubricant from axle housing. Remove bolts and axle
housing cover.
2) Position differential so hole in differential case faces
down. Wipe all accessible areas of axle housing. Ensure sealing
surfaces on axle housing and cover are clean. Apply a 1/4" thick bead
of silicone sealant on inside of bolt holes and along sealing surfaces
on axle housing cover.
3) Install axle housing cover, axle identification tag and
retaining bolts. Tighten bolts to 30 ft. lbs. (41 N.m). Remove oil
filler plug. Add a container of Mopar Gear Oil Friction Modifier. Fill
axle with gear lube. Install oil filler plug. Lower vehicle.
TROUBLE SHOOTING
DIFFERENTIAL NOISE
1) Ensure differential lubricant is at normal operating
temperature. Road test vehicle. Note if differential noise exists in
turns, but not during straight-ahead driving. Probable cause is
incorrect or insufficient rear axle lubricant or additive.
2) Drain and refill rear axle. See FLUID DRAIN & REFILL under
LUBRICATION. Road test vehicle and note if noise still exists, it may
be necessary to disassemble rear axle so differential can be repaired.
See RBI FULL-FLOATING AXLES article for removal of differential case.
TESTING
NOTE: Power-Lok differential can be tested without removing
differential carrier from axle housing. Either test can be
used to check drive axle.
TEST I
1) Place blocks under both front wheels. Ensure engine is off
and transmission is in Neutral. Release parking brake. Raise one rear
wheel until it is completely clear of the floor. Remove wheel. Install
Adapter (6790) to wheel studs, and tighten securely.
2) Using torque wrench on adapter, rotate axle, and record
torque required. Repeat procedure for remaining rear wheel position.
If rotational torque for either rear wheel is less than 30 ft. lbs.
(41 N.m) or greater than 200 ft. lbs. (271 N.m), Power-Lok unit must\
be replaced or repaired.