1999 DODGE RAM clutch

panel. To install, reverse removal procedure.
Fig. 6: Removing Cluster Bezel (Ram Pickup)
Courtesy of Chrysler Corp.
ACCUMULATOR
Removal & Installation
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
clutch cycling pressure switch connector.
2) On Dakota, remove nuts securing cruise control servo
mounting bracket to studs on cowl plenum panel (if equipped). Move
servo far enough to access accumulator refrigerant lines.
3) On all models, disconnect refrigerant lines from A/C
compressor and evaporator. Plug or cover all openings in A/C system.
Loosen support bracket screw. Remove accumulator.
4) To install, reverse removal procedure. Install new "O"
rings. Evacuate and charge A/C system.
BLOWER MOTOR
Removal (Dakota & Durango - Front)
1) Disconnect negative battery cable. Remove and disassemble
A/C-heater assembly. See A/C-HEATER ASSEMBLY. Disconnect blower motor
lead at bottom of housing. Remove 6 screws and blower motor housing
cover.
2) Remove 3 screws and blower motor and fan assembly. Place
reference marks on blower motor and fan for reassembly reference.
Remove blower fan retainer clip. Pull blower motor fan off blower
motor shaft.
Installation
Align reference marks. Press blower fan hub onto blower motor
shaft. Ensure retainer clip ears are indexed over flats of blower
motor shaft and fan hub. To complete installation, reverse removal


A/C -H EA TE R S YSTE M T R O UBLE S H O OTIN G

1999 D odge P ic ku p R 1500
1999 MANUAL A/C-HEATER SYSTEMS
Trouble Shooting - Cars & Trucks
CHRYSLER
Avenger, Breeze, Caravan, Cirrus, Concorde, Dakota, Durango,
Intrepid, LHS, Neon, Ram Pickup, Ram Van/Wagon, Sebring Convertible,
Sebring Coupe, Stratus, Town & Country, Voyager, 300M
A/C SYSTEM DIAGNOSIS
RAPID COMPRESSOR CLUTCH CYCLING
Some possible causes of rapid compressor clutch cycling,
clutch cycles 10 or more times per minute, include:
* Low refrigerant system charge.
* Faulty low pressure cycling clutch switch.
* Faulty PCM.
COMPRESSOR WILL NOT ENGAGE
Some possible causes of compressor not engaging with high and
low side system pressures equal include:
* No refrigerant in system.
* Faulty fuse.
* Faulty compressor clutch coil.
* Faulty compressor clutch relay.
* Faulty electronic cycling clutch switch.
* Improperly installed or faulty low pressure cycling clutch
switch.
* Faulty low pressure cut-off switch.
* Faulty high pressure cut-off switch.
* Faulty PCM.
* Faulty A/C-heater control panel.
TEMPERATURE IS TOO HIGH WITH A/C ON
Some possible causes of high temperature output at center
panel when A/C system pressure is normal include:
* Excessive oil charge in refrigerant.
* Temperature control cable improperly installed or faulty.
* Blend-air door inoperative, obstructed or sealing
improperly.
* Blend door actuator not calibrated.
LOW SIDE PRESSURE IS LOW-TO-NORMAL & HIGH SIDE PRESSURE IS
LOW
Some possible causes of low side system pressure being lower-
to-normal and high side system pressure being too low include:
* Low refrigerant system charge.
* Refrigerant flow through accumulator is restricted.
* Refrigerant flow through evaporator is restricted.
* Faulty compressor.
LOW SIDE PRESSURE IS HIGH-TO-NORMAL & HIGH SIDE PRESSURE IS

Fig. 5: A/C Compressor & Compressor Clutch Diagnosis (1 Of 2)
Courtesy of Chrysler Corp.

Fig. 6: A/C Compressor & Compressor Clutch Diagnosis (2 Of 2)
Courtesy of Chrysler Corp.

SERVICE VALVE LOCATIONS
For service valve locations, see SERVICE VALVE LOCATIONS
(CARS) or SERVICE VALVE LOCATIONS (TRUCKS & VANS) table.
SERVICE VALVE LOCATIONS (CARS)









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Vehicle High Low
Chrysler Corp.
Avenger & Sebring Coupe .................... ( 1) ........... ( 2)
Concorde, Intrepid, LHS & 300M
2.7L ...................................... ( 3) ........... ( 4)
3.2L & 3.5L ............................... ( 5) ........... ( 6)
Breeze, Cirrus & Stratus ................... ( 7) ........... ( 4)
Neon ....................................... ( 7) ........... ( 4)
Sebring Convertible ........................ ( 7) ........... ( 4)
Ford Motor Co.
Continental ................................ ( 9) .......... ( 10)
Contour, Cougar & Mystique
2.0L Engine ............................... ( 7) .......... ( 11)
2.5L Engine ............................... ( 7) .......... ( 12)
Crown Victoria, Grand Marquis & Town Car ... ( 7) .......... ( 13)
Escort & Tracer ............................ ( 14) ......... ( 10)
Mustang .................................... ( 7) .......... ( 12)
Sable & Taurus ............................. ( 8) .......... ( 11)
General Motors
"C" Body ................................... ( 3) .......... ( 15)
"E" & "K" Bodies ........................... ( 3) .......... ( 15)
"F" Body ................................... ( 9) ........... ( 4)
"G" Body ................................... ( 3) .......... ( 15)
"H" Body ................................... ( 7) .......... ( 12)
"J" Body ................................... ( 7) .......... ( 12)
"M" Body ................................... ( 9) ........... ( 4)
"N" Body ................................... ( 9) ........... ( 4)
"S" Body ................................... ( 9) ........... ( 4)
"V" Body ................................... ( 9) ........... ( 4)
"W" Body ................................... ( 9) ........... ( 4)
"Y" Body ................................... ( 3) .......... ( 12)
"Z" Body ................................... ( 7) .......... ( 15)
( 1) - On high-side liquid line, between receiver-drier and evaporator.
( 2) - On low-side hose between evaporator and compressor.
( 3) - On high-side liquid line.
( 4) - On low-side suction line.
( 5) - On top of compressor manifold.
( 6) - On compressor manifold, closest to compressor clutch.
( 7) - On high-side line, between compressor and condenser.
( 8) - On extension of high-side line, between condenser and
evaporator.
( 9) - On high-side line (or extension), near condenser.
( 10 ) - On low-side line (or extension), near accumulator.
( 11 ) - On low-side line, between the evaporator and
accumulator/receiver-drier.
( 12 ) - On low-side line, between acumulator/receiver-dryer and
compressor.
( 13 ) - On acumulator/receiver-drier.
( 14 ) - On high-side line, near condenser.
( 15 ) - On low-side line, between orifice tube and evaporator.









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SERVICE VALVE LOCATIONS (TRUCKS & VANS)

vacuum reading of 26 in. Hg or more. Close all valves and turn vacuum
pump off. Observe vacuum gauge, go to next step.
2) If A/C system maintains specified vacuum for 5 minutes,
open low-side and high-side valves, restart vacuum pump and operate
for an additional 10 minutes. Close all valves. Turn vacuum pump off
and disconnect pump.
3) If A/C system cannot get to or maintain specified vacuum,
check for a defective vacuum pump or leak in A/C system or gauge set.
See LEAK TESTING. Repair or replace components as necessary.
CHARGING A/C SYSTEM
* PLEASE READ THIS FIRST *
CAUTION: During charging of A/C system, refrigerant container must be
in an upright position. If refrigerant container is
upside down, compressor may be damaged by liquid refrigerant
drawn into A/C system.
CHRYSLER CORP.
Avenger 2.0L & Sebring Coupe 2.0L
1) Ensure A/C system has no leaks and has been evacuated. See
EVACUATING A/C SYSTEM and LEAK TESTING. Locate sight glass on
receiver-drier and ensure it is clean. Close low-pressure adapter
valve and remove from manifold gauge set.
2) Connect low-pressure adapter valve to refrigerant
container and open container valve. Ensure Blue charging hose is
properly connected to vehicle low-pressure service valve. Open adapter
valve.
3) If refrigerant is not drawn in, fully close adapter valve
and check for hose connection leaks. If leak is detected, retighten
connections and repeat A/C system evacuation. See EVACUATING A/C
SYSTEM.
4) If refrigerant is drawn in, start engine. Turn A/C on and
set temperature control to maximum cold and blower motor to low speed.
Operate engine at 1500 RPM. As refrigerant is drawn into system, foam
or bubbles will appear in sight glass.
5) System charge will be close to full when sight glass is
clear, compressor clutch is engaged, and compressor suction and
discharge line temperatures are similar. System charge will be
complete when sight glass is clear, compressor clutch is engaged,
compressor discharge line is warm and suction line is cool.
6) When proper amount of refrigerant has been added, stop
engine. Close refrigerant container and adapter valve, and disconnect
gauge set.
Breeze, Cirrus, Concorde, Intrepid, LHS, Stratus & 300M (Scan
Tool Method)
1) Attach Diagnostic Readout Box (DRB) to Data Link Connecto\
r
(DLC). Set DRB (scan tool) to PARTIAL CHARGE TEST. Attach clamp-on
Thermocouple (80PK-1A) to liquid line, as close to condenser outlet as\
possible.
2) Set parking brake, and place transaxle in Park position.
Start engine and allow to idle. Set A/C controls to outside air, panel
mode, full cool, and high blower speed. Turn A/C on, and open vehicle
windows. Operate A/C system for a few minutes to allow system to
stabilize.
3) Place cardboard over front grille area, to block airflow
through part of condenser, to set A/C system pressure to 260 psi (18.3
kg/cm
). This will stop cooling fans from alternating speeds and
maintain constant pressure.

Fig. 24: Electronic Leak Detector
PREPARATION FOR LEAK TESTING
Connect manifold gauge set to air conditioning system. Ensure
low-side and high-side gauge set valves are closed. Check system
pressure. It should be at least 50 psi (3.5 kg/cm
). If system is
empty, evacuate A/C system and apply 28 in. Hg of vacuum. If system
holds vacuum for 15 minutes there most likely are no leaks present. If
low, add just enough refrigerant (about 10 ounces) to bring system to
50 psi (3.5 kg/cm
).
Ensure all joints, connections, and fittings are free of oil
dirt and other contaminants. Using a refrigerant leak detector, check
all refrigerant line connections for leaks. Check condenser and
compressor seal area.
Start engine and allow to idle. Operate A/C system for about
5 minutes. Set A/C controls to outside air, and high blower speed.
Turn A/C on, and open vehicle windows. Turn engine off and wait 2-7
minutes. Refrigerant is heavier than air. Always check for leaks at
bottom of refrigerant lines and components. Refrigerant oil will leak
with refrigerant. Visually check all connections and compressor clutch
area for oil stains. If compressor shaft seal is leaking, a fresh oil
streak will normally be seen on underside of hood, above compressor
clutch.
Always perform leak testing after A/C service. Move
refrigerant leak detector slowly to check for leaks, as leaks will not

Governor pressure is monitored electronically and is used to
control transmission shifting. Electronic control system consists of
Powertrain Control Module (PCM), governor pressure solenoid, governor
pressure sensor, transmission fluid temperature sensor, OD (Overdrive)\
OFF switch, Throttle Position (TP) sensor and output shaft speed
sensor.
NOTE: Governor pressure sensor may also be referred to as governor
pressure transducer. Transmission fluid temperature sensor
may also be referred to as transmission fluid temperature
thermistor. Output shaft speed sensor may also be referred to
as transmission shaft speed sensor or shaft speed sensor.
Transmission shifting is controlled by throttle pressure and
governor pressure. Governor pressure is generated by electronic
components through control of line pressure. Transmission will not
upshift into 4th gear under the following conditions:
* 3rd gear upshift is not complete.
* OD OFF switch is in OFF position.
* Throttle is at 3/4 to WOT position.
* Vehicle speed is too low for 3-4 upshift.
* Transmission fluid temperature is less than 50
F (10C) or
greater than 250F (121C).
* Battery temperature is less than 5F (-15C).
OPERATION
POWERTRAIN CONTROL MODULE (PCM)
The PCM controls Torque Converter Clutch (TCC) operation,
overdrive clutch operation and the governor pressure solenoid. The PCM
determines shift points and TCC operation based on input signals
received from transmission fluid temperature sensor, output shaft
speed sensor, Crankshaft Position (CKP) sensor, Vehicle Speed Sensor
(VSS), Throttle Position (TP) sensor and battery temperature sensor.\
There are 4 governor pressure curves programmed into the PCM.
Governor pressure curves allow the PCM to adjust governor pressure for
varying conditions. One governor pressure curve is used for operation
when transmission fluid temperature is at or less than 30
F (1C). The
second governor pressure curve is used for operation when transmission
fluid temperature is at or greater than 30
F (1C) during normal city
operation or highway driving. The third governor pressure curve is
used for operation during wide open throttle (WOT). The fourth
governor pressure curve is used for operation when transfer case is in
low range.
The PCM controls TCC operation by operating the lock-up
solenoid located on the valve body. Lock-up solenoid may be referred
to as TCC solenoid. If OD switch is in the ON position, the TCC will
lock-up once transmission is in 4th gear with vehicle speed greater
than 45 MPH. If OD switch is in the OFF position, the TCC will lock-up
once transmission is in 3rd gear with vehicle speed greater than 35
MPH at light throttle application. When OD switch is in the OFF
position, the OD light on instrument panel will be illuminated.
The PCM prevents TCC operation and overdrive operation when
transmission fluid temperature is less than 50
F (10C). If
transmission fluid temperature exceeds 260F (126C), the PCM will
cause a 4-3 downshift and engage the TCC. The OD light will be
illuminated when the downshift occurs. Transmission will not upshift
until transmission fluid temperature decreases to approximately 230
F
(110F).