1999 DODGE RAM brake sensor


DRIV E A XLE - 8 .2 5" & 9 .2 5" R IN G G EA R

1999 D odge P ic ku p R 1500
1998-99 DRIVE AXLES
CHRY - 8 1/4" & 9 1/4" Ring Gears
Dakota, Ram Pickup, Ram Van/Wagon
NOTE: For models using full-floating axles in which vehicle weight
is supported by axle housing tubes, see RBI FULL-FLOATING
AXLES article.
DESCRIPTION & OPERATION
Drive axle contains a solid semi-floating axle shaft splined
into the side gear. On semi-floating axle shafts, vehicle weight is
supported on axle shaft and bearing. Drive shaft rotates the pinion
which drives the ring gear. Power is transferred from ring gear
through side gears to the axle shafts (hypoid gear type).
On rear axles used in vehicles with Rear Wheel Anti-Lock
(RWAL) brakes, a brake sensor is mounted on top of axle housing, and
an exciter ring is mounted on the differential carrier. See Fig. 1.
Fig. 1: Exploded View Of Drive Axle
Courtesy of Chrysler Corp.
AXLE RATIO & IDENTIFICATION

from axle housing clips. Disconnect electrical connector from brake
sensor mounted on top of axle housing (if equipped).
4) Disconnect parking brake cables. Scribe mark on drive
shaft and pinion flange for reassembly reference. Remove bolts and "U"
joint straps at pinion flange. Support drive shaft aside to prevent
damage to rear "U" joint.
5) Remove shock absorber from axle housing. Support axle
housing with floor jack. Remove "U" bolt nuts. Remove "U" bolts and
spring brackets. Lower axle housing from vehicle.
Installation
1) To install, reverse removal procedure. Ensure rear spring
center bolts align with holes in spring pads on axle housing.
2) Ensure reference mark on drive shaft and pinion flange are
aligned. Tighten bolt/nuts to proper specification. See TORQUE
SPECIFICATIONS. Bleed and adjust brakes.
DIFFERENTIAL ASSEMBLY
NOTE: Differential assembly consists of differential carrier and
components mounted in axle housing. For differential assembly
servicing, see DIFFERENTIAL ASSEMBLY under OVERHAUL.
OVERHAUL
DIFFERENTIAL ASSEMBLY
NOTE: Check pinion bearing preload, side play and then ring gear
runout, in this order, before disassembling differential
assembly.
Disassembly
1) Remove axle shafts. See AXLE SHAFT & BEARING under REMOVAL
& INSTALLATION. 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 if front pinion
bearing will be replaced.
2) To check side play, place pry bar between differential
carrier and axle housing. Pry differential carrier to one side and
note if any side play exists. No side play should exist. If side play
exists, remove bolt and adjuster lock. See Fig. 1. Using Adjuster
Rotator (C-4164), tighten adjuster to eliminate side play.
3) To check ring gear runout, install dial indicator on axle
housing at 90 degree angle to ring gear, with stem resting against
flat side of ring gear, opposite gear teeth. Rotate ring gear, and
note ring gear runout.
NOTE: Ring gear must be removed from differential carrier before
checking differential carrier flange runout. Differential
carrier and bearings must be reinstalled in axle housing to
check differential carrier flange runout.
4) Mark ring gear and differential carrier at point of
maximum ring gear runout for reassembly reference. If ring gear runout
does not exceed .005" (.13 mm), differential carrier and ring gear are\
okay. If ring gear runout exceeds .005" (.13 mm), check differential
carrier flange runout once ring gear is removed.
5) Remove brake sensor from top of axle housing (if
equipped). Mark bearing caps and axle housing for reassembly
reference.
CAUTION: Mark all bearing races and adjusters in relation to their

side gear clearance does not exceed .005" (.13 mm), determine if axle
shaft is contacting pinion shaft with feeler gauges installed. If axle
shaft is not contacting pinion shaft, side gear clearance is correct.
5) If side gear clearance exceeds .005" (.13 mm) and axle
shaft is not contacting pinion, record side gear clearance. Remove
pinion shaft, pinion gears, thrust washers, side gear and side gear
thrust washer. Measure thickness of side gear thrust washer.
6) Add thickness of side gear thrust washer to side gear
clearance measurement. This is required thickness of replacement side
gear thrust washer.
7) For example, if side gear clearance was .007" (.18 mm) an\
d
side gear thrust washer thickness is .033" (.84 mm), replacement side
gear thrust washer thickness is .040" (1.02 mm). Install replacement
side gear thrust washer and recheck side gear clearance.
8) If no side gear clearance exists, remove clip and axle
shaft. Remove pinion shaft, pinion gears, thrust washers, side gear
and side gear thrust washer. Measure and record thickness of side gear
thrust washer.
9) Reassemble side gear and components in differential
carrier. Install axle shaft in side gear. DO NOT install clip. Recheck
side gear clearance. If side gear clearance is now less than .012" (.
30 mm), add this measurement to thickness of side gear thrust washer
thickness. This is thickness of replacement side gear thrust washer.
10) If side gear clearance in step 9) is .012" (.30 mm) or
more, both side gears must be replaced and side gear clearance
rechecked. If side gear clearance is still .012" (.30 mm) or more with\
replacement side gears, replace differential carrier.
AXLE ASSEMBLY SPECIFICATIONS
AXLE ASSEMBLY SPECIFICATIONS








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Application In. (mm)\
Maximum Differential Carrier Flange Runout .............. .003 (.08)\
Maximum Ring Gear Runout ................................ .005 (.13)\
Ring Gear Backlash ............................. .005-.008 (.13-.20)\
Ring Gear Backlash Variation ( 1) ........................ .003 (.08)
INCH Lbs. (N.m.)
Pinion Bearing Preload
New Bearings ......................................... 10-20 (1-2)\
Used Rear & New Front Bearing ............................. ( 2) 10
( 1) - This is amount of variation in ring gear backlash from reading
obtained at minimum point on ring gear. If ring gear backlash is
.005" (.13 mm) at minimum point, ring gear backlash should not
exceed .008" (.20 mm) anywhere on ring gear.
( 2) - Maximum increase over original pinion bearing preload before
disassembly.









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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Axle Housing Cover Bolt .................................... 35 (47)\
Bearing Cap Bolt ......................................... 100 (136)\
Brake Sensor ............................................... 18 (24)\

VEHICLE SPEED SENSORS
VENTS
VIBRATION DAMPERS
WHEEL ATTACHMENT HARDWARE
WHEEL SPEED SENSORS
WIRING HARNESSES AND CONNECTORS
YOKES AND SLIP YOKES
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
(1) a Pledge of Assurance to their Customers and (2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection were recently published.
Further, revisions to all of these inspection communication standards
are continually republished. In addition to these, standards for Drive
Train and Transmissions have recently been promulgated. Participating
shops utilize these Uniform Inspection & Communication Standards as
part of the inspection process and for communicating their findings to
their customers.
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
(and their representatives), concerned with auto repair and/or
consumer protection, are conducted. Feedback from these sessions is
brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not
satisfied with a repair transaction, the Motorist Assurance Program
offers mediation and arbitration through MAP/BBB-CARE and other non-
profit organizations. MAP conducted pilot programs in twelve states
before announcing the program nationally in October, 1998. During the
pilots, participating repair shops demonstrated their adherence to the
Pledge and Standards and agreed to follow the UICS in communicating
the results of their inspection to their customers. To put some
"teeth" in the program, an accreditation requirement for shops was
initiated. The requirements are stringent, and a self-policing method


* E LE C TR IC AL S YSTE M U NIF O RM IN SPEC TIO N G UID ELIN ES *

1 999 D odge P ic ku p R 1500
GENERAL INFORMATION
Electrical System Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
ACTUATOR MOTORS (SOLENOIDS) (ELECTRIC)
ACTUATOR MOTORS (VACUUM)
AIR BAGS
ALTERNATORS AND GENERATORS
AMPLIFIERS
ANTENNAS
BATTERIES
BATTERY CABLES
BATTERY CABLES
BATTERY HOLD DOWN HARDWARE
BATTERY TRAYS AND HOLD DOWN HARDWARE
BATTERY WIRES
BELTS
BULB SOCKETS
BULBS, SEALED BEAMS AND LEDS
CD PLAYERS
CIGARETTE LIGHTER ASSEMBLIES
CIRCUIT BREAKERS
CLUTCH SWITCHES
CONNECTORS
CONTROL MODULES
CRUISE CONTROL BRAKE SWITCHES
CRUISE CONTROL CABLES
CRUISE CONTROL CLUTCH SWITCHES
CRUISE CONTROL LINKAGES AND CABLES
CRUISE CONTROL RESERVOIRS
CRUISE CONTROL TUBES
CRUISE CONTROL VACUUM DUMP RELEASE VALVES
CRUISE CONTROL VACUUM HOSES, TUBES AND RESERVOIRS
CRUISE CONTROL VEHICLE SPEED SENSORS
DEFOGGERS
DEFROSTERS
DELAYS
DIMMERS
ELECTRIC HEATERS
EQUALIZERS
FUSE BLOCKS
FUSE BOXES AND BLOCKS
FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS
FUSIBLE LINKS
GAUGES
GENERATORS
GROUND CABLES AND STRAPS
GROUND STRAPS
HEADLIGHT ADJUSTERS
HEATING ELEMENTS (DEFROSTERS, DEFOGGERS, ELECTRIC HEATERS AND SEATS)
HORNS AND SIRENS

components, reverse removal procedure.
Removal (Dakota 4WD & Durango 4WD)
1) Disconnect negative battery cable. Remove oil dipstick.
Drain engine oil. Remove exhaust pipe crossover and lower transmission
cover.
2) Remove front drive axle for access to oil pan. For front
drive axle removal, loosen wheel lug nuts. Remove cotter pin, lock nut
and spring washer. Loosen axle shaft nut with vehicle on floor and
brakes applied. Raise and support vehicle.
CAUTION: DO NOT pull on rubber boot during axle shaft removal. Pull on
outer CV joint only.
3) Remove wheels and skid plate. Remove axle shaft nut.
Remove axle shaft-to-differential flange bolts at front drive axle.
Support axle shaft, and separate axle splines from wheel hub by
pulling inward at outer CV joint.
4) Remove remaining axle shaft. Mark front drive shaft and
transfer case yoke for installation reference. Remove front drive
shaft from transfer case. Disconnect vacuum hoses from shift motor and
electrical connections at shift indicator switch.
5) Support front drive axle using a floor jack. Remove front
drive axle and shift motor bolts. Lower floor jack, and remove front
drive axle with drive shaft. Remove transmission lower cover. Remove
bolts, oil pan and gasket.
Installation
1) To install, reverse removal procedure. Before installing
oil pan, apply RTV sealant where front cover contacts cylinder block,
oil pan side gaskets meet end seals and end seals contact cylinder
block. See Fig. 14.
2) To facilitate oil pan installation, fabricate 4 alignment
dowels from 1 1/2" x 5/16" bolts. See Fig. 15. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table.
3) To install remaining components, reverse removal
procedure. When installing front drive axle, loosely install all bolts
before tightening to specification. Tighten axle shaft nut to
specification with vehicle on ground. See TORQUE SPECIFICATIONS table.
Ensure reference marks on transfer case yoke and front drive shaft are
aligned.
Removal (Ram Pickup & Ram Van/Wagon - 3.9L)
1) Disconnect negative battery cable. Remove oil dipstick. On
Ram Van/Wagon, remove engine cover. On all models, remove air cleaner
and engine controller. Raise and support vehicle. Drain engine oil.
2) Remove left engine-to-transmission strut. Loosen exhaust
pipe support bracket. Disconnect exhaust pipe. On Ram Pickup, remove
oil pan and gasket.
3) On Ram Van/Wagon, remove starter, transmission dust
shield, oxygen sensor and air injection tube. On all models, remove
right engine mount nut. Loosen, but DO NOT remove, left engine mount
nut.
4) Support right side of engine using jackstand. Remove
transmission mount through-bolt, and support transmission using
jackstand. Raise engine and transmission enough for oil pan removal.
Remove bolts, oil pan and gasket.
Installation
1) To install, reverse removal procedure. Before installing
oil pan, apply RTV sealant where front cover contacts cylinder block,
oil pan side gaskets meet end seals and end seals contact cylinder
block. See Fig. 14.

SUPER CHARGERS
SWITCHES
THERMAL VACUUM VALVES
THERMOSTATIC AIR DOOR ASSEMBLIES
THERMOSTATS AND HOUSINGS
THROTTLE BODIES
THROTTLE CABLES
THROTTLE LINKAGES AND CABLES
THROTTLE POSITION SENSORS
THROTTLE POSITION SWITCHES
TIMING BELT SPROCKETS
TIMING BELTS
TORQUE STRUTS
TRANSMISSION RANGE SWITCHES
TUBE CLAMPS
TUBE CONNECTORS
TUBE COUPLERS
TUBES
TURBO CHARGERS
VACUUM CONNECTIONS
VACUUM HOSES, TUBES AND CONNECTIONS (NON-METALLIC)
VACUUM REGULATOR SOLENOIDS
VACUUM TUBES
VEHICLE SPEED SENSORS
VOLUME AIR FLOW SENSORS
WASTE GATE CONTROL SOLENOIDS
WASTE GATES AND BOOST CONTROL MECHANISMS
WATER PUMPS (ELECTRIC)
WATER PUMPS (NON-ELECTRIC)
WIRING HARNESSES AND CONNECTORS
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
(1) a Pledge of Assurance to their Customers and (2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards
are continually re-published. In addition to these, standards for
Drive Train and Transmissions have recently been promulgated.
Participating shops utilize these Uniform Inspection & Communication

WIRING DIAGRAM COMPONENT LOCATIONS
When trying to locate a component in a wiring diagram and you
don't know the specific system where it is located, use this handy
component locator to find the system wiring diagram in which the
component is located. Then, go to that system and locate the component
within the wiring diagram.
For example, if you don't know the specific system in which
the ignition switch is located, look up ignition switch in the wiring
diagram component location tables and go to the appropriate wiring
diagram(s) which contain either full or partial views of the ignition
switch. The full view of the ignition switch is located in Power
Distribution.
The first listing for the component will be the full or most
complete view of the component. Additional listings will be partial
views of the component. Not all components are used on all models.
All components will have a partial view in Ground
Distribution and Power Distribution. Data Link Connectors show
connecting circuits between modules. Alternate names for components
may be listed in wiring diagram component locations tables.
WIRING DIAGRAM COMPONENT LOCATIONS TABLE









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Component Wiring Diagram
ABS Electronic Control Unit ....................... Anti-Lock Brakes
Data Link Connectors
ABS Hydraulic Unit ................................ Anti-Lock Brakes
Acceleration Sensor ............................... Anti-Lock Brakes
Accessory Delay Relay ................................ Power Windows
A/C Compressor Clutch Relay ..................... Engine Performance
A/C Sensor ...................................... Engine Performance
A/C Pressure Switch ............................. Engine Performance
Adaptive Lamp Control Module ....................... Exterior Lights
Air Bag(s) ................................ Air Bag Restraint System\
Air Bag Module ............................ Air Bag Restraint System
Air Bag Sensor(s) ......................... Air Bag Restraint System\
Air Injection Pump Relay ........................ Engine Performance
Air Temperature Sensor ............................ Overhead Console
Alternator (Generator) ..................... Generators & Regulators\
Anti-Theft Control Module ........................ Anti-Theft System
Starters
Autolamp Control Relay ........................... Headlight Systems
Daytime Running Lights
Automatic Shutdown (ASD) Relay .................. Engine Performance\
Generators & Regulators
Autostick Switch ................................ Engine Performance
Auxiliary Battery Relay .................... Generators & Regulators
Back-Up Lights ...................................... Back-Up Lights
Exterior Lights
Barometric (BARO) Pressure Sensor ............... Engine Performance\
Battery ......................................... Power Distribution
Battery Temperature Sensor ...................... Engine Performance
Body Control Module .......................... Body Control Computer
Anti-Theft System
Daytime Running Lights
Engine Performance
Headlight Systems
Warning Systems
Boost Control Solenoid .......................... Engine Performance
Boost Sensor .................................... Engine Performance
Brake Fluid Level Switch .................. Analog Instrument Panels