1999 DODGE RAM lock

Fig. 8: Removing Lock Cylinder
Courtesy of Chrysler Corp.
MULTIFUNCTION SWITCH
Removal & Installation
Disconnect negative battery cable. On tilt columns, remove
tilt lever. On all models, remove upper and lower steering column
covers. Remove tamper-proof Torx screws. Pull switch away from column,
and loosen connector screw (screw remains in connector). Remove
switch. To install, reverse removal procedure. Tighten screws to
specification. See TORQUE SPECIFICATIONS.


STE ER IN G K NUCKLE S - 4 W D

1999 D odge P ic ku p R 1500
1998-99 DRIVE AXLES
CHRY - 4WD Steering Knuckles
Ram Pickup
DESCRIPTION
Open type steering knuckles are used on all models. Open type
knuckles provide sharper turning angle, decreasing turning radius.
Axle shafts are free floating. Steering knuckles are attached to axle
housing by ball joints.
REMOVAL & INSTALLATION
REMOVAL
1) Raise and support vehicle. Remove wheels. Remove brake
caliper, and support aside. DO NOT allow caliper to hang by brake
hose. On one ton models, remove adapter hub bolts and hub from rotor
and hub assembly. On all models, remove cotter pin from rotor and hub
nut.
2) Remove rotor and hub nut. Remove bolts securing rotor and
hub assembly to steering knuckle. Bolts are accessible from inboard
side of steering knuckle. Remove rotor and hub assembly. Remove hub
spacer from steering knuckle. Note spacer position for installation
reference.
3) Disconnect tie rod end and drag link studs. Remove anti-
lock brake sensor from steering knuckle. Remove ball joint cotter pins
and nuts. Discard lower nut. Using a soft-face hammer, tap steering
knuckle to free it from ball joints.
4) Clean all components with solvent, and dry with compressed
air. Inspect all parts for burrs, chips, wear, flat spots or cracks.
Replace all damaged or worn parts.
INSTALLATION
NOTE: When aligning upper ball joint nut to install cotter pin,
always tighten nut to align holes. Never loosen nut to align
holes.
1) Position steering knuckle on ball joints, and install NEW
lower ball joint nut. Tighten nut to specification. See TORQUE
SPECIFICATIONS. Install upper ball joint nut, and tighten to
specification. Tighten, DO NOT loosen, nut to install NEW cotter pin.
2) Install hub bearing and axle shaft. Connect drag link stud
to steering knuckle arm. Install retaining nut, and tighten to
specification. Install NEW cotter pin. Connect tie rod end stud to
steering knuckle arm. Install retaining nut and tighten to
specification. Install NEW cotter pin. Install anti-lock brake sensor
to steering knuckle.
3) Apply anti-seize compound to splines of front drive axle.
Inspect hub grease seal and wheel bearing. Replace as necessary. From
rear of steering knuckle, install 2 rearward rotor and hub assembly
bolts in steering knuckle.
4) Apply chassis grease to hub spacer to secure on steering
knuckle. Position spacer on rotor and hub assembly bolts. Ensure
spacer is installed with flat edge toward rear of vehicle. Apply
Loctite to rotor and hub assembly bolt threads. Install rotor and hub

After pulley installation, run the engine until warm. See
PUMP PULLEY under REMOVAL & INSTALLATION. If drive belt chirps, move
pulley outward approximately .020" (0.5 mm). If noise increases, press\
pulley inward .040" (1.0 mm). Ensure pulley does not contact mounting
bolts.
THRUST BEARING PRELOAD
NOTE: Manufacturer recommends removing steering gear from vehicle
before performing any adjustments.
1) Remove steering gear from vehicle. See STEERING GEAR under
REMOVAL & INSTALLATION. Ensure steering gear is empty of hydraulic
fluid. Rotate steering from stop-to-stop several times to drain fluid.
Loosen lock nut on adjuster plug. See Fig. 3. Using spanner wrench,
rotate adjuster plug clockwise until plug is seated in housing. Torque
will be approximately 20 ft. lbs. (27 N.m).
Fig. 3: Measuring Thrust Bearing Preload
Courtesy of Chrysler Corp.
2) Place reference mark on steering gear housing adjacent to
one hole in adjuster plug. Measure counterclockwise about 1/2" (13 mm)\

from reference mark and place a second reference mark on steering gear
housing.
3) Rotate adjuster plug counterclockwise until hole in
adjuster plug aligns with second mark on steering gear housing.
Tighten lock nut on adjuster plug to 80 ft. lbs. (108 N.m). Ensure
adjuster plug does not move while tightening lock nut.
OVER-CENTER PRELOAD
CAUTION: Thrust bearing preload must be adjusted before adjusting
over-center preload.
1) Loosen lock nut on sector shaft adjuster screw. See Fig. 4
. Rotate stub shaft and count turns required to go from stop-to-stop.
Turn stub shaft back 1/2 number of turns to center steering gear.
Fig. 4: Adjusting Over-Center Preload
Courtesy of Chrysler Corp.
2) Rotate sector shaft adjuster screw counterclockwise until
fully extended, then turn clockwise one full turn. Attach INCH-lb.
torque wrench to end of stub shaft. Position torque wrench handle in a
vertical position. Rotate stub shaft 45 degrees from vertical position
in each direction, and record highest reading. See Fig. 4.
3) Turn adjuster in until torque required to turn stub shaft
is 6-10 INCH lbs. (0.7-1.1 N.m) more than reading in step 2). Hold
adjuster screw, and tighten lock nut to 20 ft. lbs. (27 N.m).

REMOVAL & INSTALLATION
CAUTION: When battery is disconnected, vehicle computer and memory
systems may lose memory data. Driveability problems may exist
until computer systems have completed a relearn cycle. See
the COMPUTER RELEARN PROCEDURES article in GENERAL
INFORMATION before disconnecting battery.
POWER STEERING PUMP (GASOLINE)
WARNING: DO NOT attempt to remove power steering pump without removing
power steering pump belt. Personal injury or pulley damage
could result.
Removal
1) Disconnect and isolate negative battery cable. To remove
serpentine belt, rotate tensioner clockwise and hold in place, slide
belt from tensioner pulley. Place drain pan under pump. Disconnect and
cap hoses.
2) Remove bracket-to-engine block bolts. Remove pump, pulley
and mounting bracket as an assembly. To allow access to pump screws,
remove pump pulley. See PUMP PULLEY. Remove bracket-to-pump screws.
Installation
To install pump, reverse removal procedure. Fill and bleed
system. See HYDRAULIC SYSTEM BLEEDING under LUBRICATION.
VACUUM/POWER STEERING PUMP (DIESEL)
Removal
1) Disconnect negative battery cable. Place drip pan under
vacuum/power steering pump. Disconnect and cap power brake booster
hose at vacuum pump and hydraulic lines at power steering pump.
Disconnect oil pressure sending unit electrical connector. Remove
sending unit from engine block and plug hole in block. Disconnect and
cap oil feed line from bottom of vacuum pump.
2) Remove vacuum/power steering pump-to-engine block nuts and
bolts, and mounting bracket. Remove upper pump bolt and remove pump.
Drain fluid from steering pump reservoir. Remove gaskets from mounting
surfaces.
CAUTION: DO NOT damage internal vacuum pump oil seal when separating
steering pump from vacuum pump. See Fig. 5.
3) Remove steering pump-to-vacuum pump bracket bolts.
Carefully slide steering pump from bracket. Remove 2 pump body
spacers. See Fig. 5.
NOTE: Steering pump housing and spacers must mate completely with
vacuum pump bracket.
Installation
1) Install 2 pump body spacers and rotate drive gear until
steering pump and vacuum pump drive splines align. See Fig. 5.
Carefully install steering pump on vacuum pump bracket to prevent
damaging oil seal.

Fig. 5: Installing Power Steering Pump (Diesel)
Courtesy of Chrysler Corp.
2) Install 3 vacuum pump bracket-to-steering pump nuts and
tighten to 18 ft. lbs. (24 N.m). Using silicone sealer if needed,
position NEW gaskets on mounting surfaces.
3) Ensuring steering pump stud is inserted into block
bracket, align and install pump assembly. Tighten pump assembly-to-
engine block bolts to 57 ft. lbs. (77 N.m). Install steering pump-to-
bracket nut. Tighten nut to 18 ft. lbs. (24 N.m).
4) Remove plug from engine block and install oil sending
unit. Tighten sending unit to 60 INCH lbs. (7 N.m) and install
electrical connector. Install oil feed line to vacuum pump and tighten
to 60 INCH lbs. (7 N.m). To complete installation, reverse removal
procedure. Fill and bleed system. See HYDRAULIC SYSTEM BLEEDING under
LUBRICATION. Start engine. Ensure brakes are operating properly.
PUMP PULLEY
CAUTION: Examine exposed end of rotor drive shaft before removal. If
it is corroded, clean surface with crocus cloth to prevent
damage to shaft bushing during removal.
Removal & Installation (Gasoline)
Remove power steering pump from vehicle if necessary. See
POWER STEERING PUMP (GASOLINE). Using Puller (C-4333), remove pump
pulley. See Fig. 6. Replace pulley if bent, cracked or loose. Using
Installer (C-4063-B), press pulley until flush with end of shaft. If
drive belt chirps after engine starts, see POWER STEERING PUMP PULLEY

Removal
1) Place wheels in straight-ahead position. Place drain pan
under steering gear assembly. Disconnect and cap pressure and return
hoses from steering gear. Disconnect steering column shaft coupling
from steering gear stub shaft.
2) Raise and support vehicle. Disconnect steering linkage
(center link) from pitman arm. See Fig. 9. Disconnect stabilizer bar
(if necessary). Place reference mark on pitman arm and sector shaft.
Remove nut and pitman arm from sector shaft. Remove steering gear-to-
frame bolts. Remove steering gear.
Installation
1) Install steering gear with bolts finger tight. Center
steering gear and align stub shaft with steering column. Install
steering column shaft coupling bolt and tighten to specification. See
TORQUE SPECIFICATIONS.
CAUTION: Stake pitman arm nut against pitman arm to ensure proper
retention.
2) Reposition steering gear to eliminate binding, and tighten
bolts to specification. Install pitman arm on sector shaft with
reference marks aligned. Install lock washer and nut. Tighten nut to
specification.
3) To install remaining components, reverse removal
procedure. Fill pump reservoir. Bleed air from hydraulic system. See
HYDRAULIC SYSTEM BLEEDING under LUBRICATION.
SECTOR SHAFT OIL SEAL
Removal
1) Raise and support vehicle. Place wheels in straight-ahead
position. Disconnect steering linkage (center link) from pitman arm.
Disconnect stabilizer bar (if necessary).
2) Place reference mark on pitman arm and sector shaft.
Remove nut and pitman arm from sector shaft. Place drain pan under
steering gear. Remove retaining ring and steel washer. See Fig. 1.
CAUTION: DO NOT hold steering wheel in left-turn position for more
than 2 seconds.
3) Start engine and momentarily hold steering wheel in
extreme left-turn position. When pressure develops, this should force
upper oil seal, steel washer and lower oil seal from steering gear
housing. Stop engine and remove seals.
Installation
1) Ensure seal bore of steering gear is free of burrs and
sector shaft is free of pitting or roughness. Lubricate replacement
seals and steel washers with power steering fluid.
2) Wrap sector shaft with plastic tape or .005" (.13 mm)
thick shim stock. Install upper oil seal (single lip seal) and steel
washer first. Oil seal must be installed only deep enough to allow for
remaining oil seal, steel washer and retaining ring.
CAUTION: DO NOT install upper oil seal against inner bore surface of
steering gear housing. Oil seals must be installed so each
oil seal is separately seated in shaft bore.
3) Install lower oil seal (double lip seal) and steel washer\
.
Oil seal must be installed only deep enough to allow for steel washer
and retaining ring. Remove tape or shim stock and install retaining
ring.

CAUTION: Stake pitman arm nut against pitman arm to ensure proper
retention.
4) Install pitman arm on sector shaft with reference marks
aligned. Install lock washer and nut. Tighten nut to specification.
See TORQUE SPECIFICATIONS.
5) To install remaining components, reverse removal
procedure. Fill pump reservoir. Allow engine to idle for at least 3
minutes. DO NOT turn wheels during this time. Rotate wheels both
directions and check for leaks. Refill pump reservoir.
CENTER LINK
Removal & Installation
Separate tie rods, idler arm, steering and drag link (if
equipped) from center link. Remove center link. To install, reverse
removal procedure. Tighten nuts to specification.
Fig. 9: Exploded View Of Steering Linkage
Courtesy of Chrysler Corp.
DRAG LINK
Removal & Installation
Remove cotter pins and drag link nuts. Using Separator (C-
4150), separate drag link from steering knuckle or center link and