1999 DODGE RAM Service Repair Manual

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

NOTE: Clutch release bearing is packed with grease. DO NOT use
cleaning solvent to clean release bearing.
Removal
1) Remove transmission and clutch housing. See TRANSMISSION
(DAKOTA) or TRANSMISSION (RAM PICKUP). Disconnect release bearing fr\
om
fork, and remove bearing. See Fig. 11. Remove release fork.
2) Inspect bearing. Bearing should turn smoothly under a
light thrust load. Inspect release fork and fork ball pivot for
distortion and wear.
Installation
1) Lubricate crankshaft pilot bearing, input shaft splines,
bearing retainer slide surface, fork pivot and release fork pivot
surface with high-temperature bearing grease.
2) Install release fork and release bearing. Ensure fork and
bearing are properly secured. Install transmission and clutch housing.
Fig. 11: Exploded View Of RWD Clutch Release Bearing Assembly
Courtesy of Chrysler Corp.
CLUTCH MASTER CYLINDER
Removal
1) Disconnect clutch pedal interlock switch wires. Remove
locating clip from clutch master cylinder mounting bracket. Remove
retaining clip, flat washer and wave washer that attach clutch master
cylinder push rod to clutch pedal. Slide clutch master cylinder push
rod off pedal pin. Ensure cap on clutch master cylinder reservoir is
tight.
2) Remove clutch fluid reservoir. Rotate clutch master
cylinder 45 degrees counterclockwise to unlock it. Remove cylinder
from dash panel. Remove clutch master cylinder rubber seal from dash
panel.
Installation
Lubricate cylinder seal with liquid soap to ease
installation. Seat seal in dash and around cylinder. To install,
reverse removal procedure.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Clutch Master Cylinder Nuts ................................ 40 (54)\
Clutch Slave Cylinder Nuts ................................. 17 (23)\
Crossmember-To-Frame Bolts
AX15 & NV3500 (Dakota) ..................................... 30 (41\
)
NV3500 (Ram Pickup) ........................................ 50 (68\
)
Crossmember-To-Transmission Insulator Nuts
2WD (NV3500 - Ram Pickup) ................................ 50 (68\
)
4WD (NV3500 - Ram Pickup) .......................... 40-45 (54-61\
)
Flywheel Bolts
Dakota 2.5L ................................................ 70 (95)\
Dakota V6 & V8 ............................................. 55 (75)\
Pressure Plate Bolts
5/16" .................................................... 17 (23)\
3/8" ..................................................... 30 (41)\
Transfer Case To Transmission Nuts
AX15 ................................................. 26 (35 N.m)\
NV3500, NV4500, NV4500HD & NV5600
5/16" ............................................. 22-30 (30-41)\
3/8" .............................................. 30-35 (41-47)\
Transmission-To-Clutch Housing Bolts
AX15 ..................................................... 27 (37)\
NV3500 (Ram Pickup) & NV5600 ....................... 40-45 (54-61\
)
NV1500, NV3500 (Dakota), NV4500 & NV 4500HD ............. 80 (108\
)
"U" Joint Clamp Bolts ...................................... 14 (19)\
INCH Lbs. (N.m)
Shift Tower Bolts (NV3500) ............................ 62-89 (7-10\
)









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CO M PU TE R R ELE A R N P R O CED URES

1999 D odge P ic ku p R 1500
GENERAL INFORMATION
DaimlerChrysler Computer Relearn Procedures
INTRODUCTION
Vehicles equipped with engine or transmission/transaxle
computers may require a computer relearn procedure after the vehicle
battery is disconnected. Vehicle computers memorize and store vehicle
operation patterns for optimum driveability and performance. When the
vehicle battery is disconnected, this memory is lost, resulting in a
driveability problem. Depending on the vehicle and how it is equipped,
the following driveability problems may exist:
* Rough or unstable idle.
* Hesitation or stumble.
* Rich or lean running.
* Poor fuel mileage.
* Harsh or poor transmission/transaxle shift quality.
Default data is used until NEW data from each key start is
stored. As the computer restores its memory from each new key start,
driveability is restored.
Driveability problems may occur during the computer relearn
stage. To accelerate computer relearn process after battery removal
and installation, specified computer relearn procedures should be
performed. See appropriate procedures under specified manufacturer.
COMPUTER RELEARN PROCEDURES
ALL MODELS
NOTE: Read all procedures listed to determine why each procedure is
to be performed before proceeding.
Vehicle Driveability Computer Relearn Procedure
Manufacturer does not provide a specified computer relearn
procedure for obtaining proper driveability. If vehicle battery was
disconnected or Powertrain Control Module (PCM) was replaced, driving
the vehicle will enable the PCM to perform a computer relearn
procedure for obtaining proper driveability. Inform customer that
driveability may differ from what they are accustomed to until the PCM
completes the computer relearn procedure.
NOTE: If Powertrain Control Module (PCM) was replaced, the correct
vehicle mileage and Vehicle Identification Number (VIN) must
be programmed into the PCM to prevent Diagnostic Trouble
Codes (DTCs) from being set in the Anti-Lock Brake System
(ABS) module and Supplemental Restraint System (SRS) module\
.
To program PCM and clear DTCs from ABS and SRS modules,
proceed to appropriate procedure listed. If replacing
Powertrain Control Module (PCM) on models equipped with a
Smart Key Immobilizer Module (SKIM), the secret key data must\
also be updated to enable engine starting. To update secret
key data, proceed to appropriate procedure listed.
Programming PCM & Clearing DTCs From ABS & SRS Modules
Connect scan tool to Data Link Connector (DLC) below driver's\
side of instrument panel. Using scan tool, enter correct VIN and
mileage into PCM. Using scan tool manufacturer's instructions, clear

DTCs from ABS and SRS modules.
Updating Secret Key Data
Connect scan tool to Data Link Connector (DLC) below driver's\
side of instrument panel. Go to ENGINE, then MISC menu on scan tool.
Place the SKIM in SECURED ACCESS MODE by using the appropriate
Personal Identification Number (PIN) for this vehicle. PIN may be
obtained from the owner, vehicle's invoice, or from the manufacturer.
Select UPDATE THE SECRET KEY DATA. The data will be transferred from
Smart Key Immobilizer Module (SKIM) to the PCM.
NOTE: If 3 attempts are made to enter the SECURED ACCESS MODE using
the incorrect Personal Identification Number (PIN), the
SECURED ACCESS MODE will be locked out for one hour. To exit
this locked-out mode, leave ignition switch in the ON
position for one hour with all accessories turned off. It may
be necessary to monitor battery state and connect a battery
charger.
FWD CARS & FWD VANS
Transaxle Shift Quality Quick Learn Procedure (All FWD Cars
Except Avenger & Sebring Coupe, & All FWD Vans)
1) Transaxle shift quality quick learn procedure must be
performed to provide proper transaxle operation if any of the
following have been done:
* Vehicle battery was disconnected.
* Transaxle assembly was replaced.
* Transmission Control Module (TCM) was replaced.
* Solenoid assembly was replaced.
* Valve body was reconditioned or replaced.
2) Transaxle shift quality quick learn procedure must be
performed using Chrysler's Diagnostic Readout Box III (DRB-III) scan
tool. Following conditions must be met when performing transaxle shift
quality quick learn procedure:
* Brakes must be applied.
* Engine speed must be greater than 500 RPM.
* Throttle position sensor angle must be less than 3 degrees.
* Shift lever must remain in designated position until prompted
to shift to overdrive.
* Shift lever must remain in overdrive after the shift to
overdrive until scan tool indicates procedure is complete.
* Calculated oil temperature must be within 60-200
F
(16-93C).
3) Connect scan tool to Data Link Connector (DLC) below
driver's side of instrument panel. For DLC location, see appropriate
SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.
4) Go to TRANSMISSION display on scan tool. Go to
MISCELLANEOUS display on scan tool. Select QUICK LEARN PROCEDURE
display on scan tool. Follow instructions displayed on scan tool to
perform transaxle shift quality quick learn procedure. Remove scan
tool.
Transaxle Shift Quality Quick Learn Procedure (Avenger &
Sebring Coupe)
1) Transaxle shift quality quick learn procedure must be
performed to provide proper transaxle operation after replacing or
overhauling transaxle. After transaxle work is completed, clear any
Diagnostic Trouble Codes (DTCs) as necessary. Connect Chrysler's

Diagnostic Readout Box III (DRB-III) scan tool to Data Link Connector
(DLC) below driver's side of instrument panel. For DLC location, see
appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.
2) Select SPECIAL FUNCTION on scan tool. Set scan tool to
QUICK LEARN mode. Follow scan tool manufacturer's instructions to
perform transaxle shift quality quick learn procedure. Remove scan
tool.
Pinion Factor Procedure (All FWD Cars Except Avenger &
Sebring Coupe, & All FWD Vans)
1) Electronic pinion factor procedure must be performed to
provide proper speedometer operation if Transmission Control Module
(TCM) is replaced. If pinion factor procedure is not performed,
improper speedometer readings may exist or speedometer may not
operate. Pinion factor procedure must be performed using Chrysler's
Diagnostic Readout Box (DRB-III) scan tool.
2) Connect scan tool to Data Link Connector (DLC) below
driver's side of instrument panel. For DLC location, see appropriate
SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.
3) Select TRANSMISSION system, MISCELLANEOUS functions, then
PINION FACTOR. Scan tool will now display tire size. If tire size is
incorrect, press ENTER key and select correct size. Press PAGE BACK
key to exit procedure.
Pinion Factor Procedure (Avenger & Sebring Coupe)
1) Transaxle uses rotation speed of output shaft to calculate
vehicle speed and cumulative distance travelled. Therefore, it is
necessary to input or update tire size into TCM memory after TCM has
been replaced or tire size has been changed.
2) Select SPECIAL FUNCTION on Chrysler's Diagnostic Readout
Box (DRB-III) scan tool. Set scan tool to PINION FACTOR mode. Input
tire size into TCM memory.
NOTE: New TCMs do not have tire size input into memory. TCM may
also be referred to as EATX module.

CRUIS E C O NTR O L S YSTE M

1999 D odge P ic ku p R 1500
1999 ACCESSORIES & EQUIPMENT
CHRY - Cruise Control Systems
Dakota, Durango, Ram Pickup, Ram Van & Ram Wagon
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
COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION
before disconnecting battery.
DESCRIPTION
The speed (cruise) control system is electronically
controlled and vacuum operated. The electronic control is integrated
into the Powertrain Control Module (PCM). System consists of the
following components: Powertrain Control Module (PCM), servo, speed
control switches, vacuum reservoir, vehicle speed sensor, speed
control relay and brake switch.
System controls are located on each side of steering wheel
air bag module and consist of ON/OFF, SET, RESUME/ACCEL, CANCEL AND
COAST buttons. System is designed to operate at speeds above 30 MPH.
OPERATION
SYSTEM CONTROLS
To Set Speed Control
Press ON/OFF button to turn speed control system on.
Accelerate to desired speed (minimum of 35 MPH) and press SET/COAST
button. Vehicle speed will be maintained.
NOTE: Speed control system will automatically disengage when
vehicle speed decreases to less than 35 MPH or increases to
more than 85 MPH.
To Disengage Speed Control
Press brake pedal. Press clutch pedal (M/T). Press CANCEL
button. Press ON/OFF button. If ON/OFF button is used, set speed will
be erased from memory.
To Resume Previous Speed
If set speed has not been erased from memory and vehicle
speed is more than 35 MPH, press RES/ACCEL button.
To Increase Speed
With speed control system on, increase set speed by rapidly
pressing and releasing RES/ACCEL button. Each pressing of button will
cause speed increase of 2 MPH. For example, pressing button 3 times
will increase speed by 6 MPH. To increase speed gradually, hold
RES/ACCEL button down until desired speed is reached. When button is
released, new set speed will be maintained.
To Decrease Speed
With speed control system on, decrease set speed by pressing
SET/COAST button. Vehicle speed will gradually decrease. Releasing
button will set a new speed as long as vehicle speed is still more
than 35 MPH.

COMPONENT LOCATIONS
COMPONENT LOCATIONS








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Component Location
ABS Control Module
Ram Pickup ....................... Left Side Of Engine Compartment
Ram Van/Wagon ...................................... Under Battery
Data Link Connector (DLC) ...... Lower Left Side Of Instrument Panel\
Output Shaft Speed Sensor (OSS) .......... Left Side Of Transmission\
Park/Neutral Position (PNP) Switch ....... Left Side Of Transmission\
Powertrain Control Module (PCM)
Dakota & Durango ............... Right Front Of Engine Compartment
Ram Pickup ............... Right Rear Corner Of Engine Compartment
Ram Van/Wagon ..................... Under Hood Next To Wiper Motor
Vehicle Speed Sensor (VSS) ........ On Transmission Or Transfer Case\
Extension Housing









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TROUBLE SHOOTING
ROAD TEST
Perform a road test to verify speed control malfunctions.
Ensure speedometer operation is smooth without flutter at all speeds.
Speedometer fluttering may cause surging in speed control system. For
speedometer diagnosis, see appropriate INSTRUMENT PANELS article. If
road test verifies a surge following speed control set and speedometer
operates smoothly, see OVERSHOOT/UNDERSHOOT FOLLOWING SPEED CONTROL
SET.
If road test verifies an inoperative system, and speedometer
operates smoothly, check for:
* Diagnostic Trouble Codes (DTCs). See SELF-DIAGNOSTIC
SYSTEM.
* Misadjusted brake switch. See BRAKE SWITCH under REMOVAL &
INSTALLATION.
* Poor electrical connections at servo.
* Leaking vacuum reservoir, check valve, hoses or connections.
See VACUUM SUPPLY under COMPONENT TESTS.
* Secure attachments of S/C servo cable.
* Smooth operation of throttle linkage.
* Defective PCM or wiring.
* Defective servo. See SPEED CONTROL SERVO under COMPONENT
TESTS.
To verify a speed control electronic malfunction, use scan
tool to check for DTCs. See SELF-DIAGNOSTIC SYSTEM. A speed control
malfunction may occur without setting a FTC. If no DTCs are stored, go
to CHECKING SPEED CONTROL OPERATION under SYSTEM TESTS.
OVERSHOOT/UNDERSHOOT FOLLOWING SPEED CONTROL SET
If operator repeatedly presses and releases set button with
their foot off accelerator (lift foot set) to begin speed control
operation, vehicle may accelerate and exceed desired set speed by 5
MPH and then decelerate to less than desired set speed before
achieving desired set speed.
Speed Control (S/C) has as adaptive strategy that compensates\
for variations in S/C cable lengths. When S/C is set with vehicle