1999 DODGE RAM service


TR AN SM IS SIO N S ER VIC IN G - M /T

1999 D odge P ic ku p R 1500
1998-99 TRANSMISSION SERVICING
CHRY - Manual Transmission - Trucks
Dakota, Ram Pickup
APPLICATION
MANUAL TRANSMISSION APPLICATIONS (TRUCKS)








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Model Designation
Dakota
2.5L & 3.9L .............................. AX15/AS82 & ( 1) NV1500
5.2L ...................................................... NV3500
Ram Pickup
3.9L & 5.2L ............................................... NV3500
5.2L & 5.9L (Gasoline) ......................... NV4500 & NV4500HD\
5.9L Diesel & 8.0L ..................... NV4500, NV4500HD & NV5600
( 1) - NV1500 is available on 4-cylinder 2WD models only.









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TRANSFER CASE APPLICATIONS (TRUCKS)








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Model Designation
Dakota
3.9L ....................................................... NV231
5.2L ........................................ NV231HD Or ( 1) NV242HD
5.9L ........................................ NV231HD Or ( 1) NV242HD
Ram Pickup
1500 ..................................................... NV231HD
2500 & 3500 ..................................... NV241 Or NV241HD
( 1) - NV242HD is used on automatic transmission only.









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IDENTIFICATION
TRANSMISSION
AX-15 identification numbers are located on bottom surface of
intermediate plate. NV1500 consists of 2 aluminum housings and a
removable clutch housing. NV1500 is available on 4-cylinder 2WD
models. NV3500 consists of 2 aluminum housings and a non-removable
clutch housing. NV4500 identification tag is attached to driver's side
PTO cover. NV5600 is equipped with 2 identification tags attached to
driver's side of clutch housing.
TRANSFER CASE
Transfer case identification tag is located on rear of
transfer case housing.
LUBRICATION
SERVICE INTERVALS

Transmission (Dakota)
Check transmission fluid level when performing other
underhood services. Under normal service conditions, change
transmission fluid at 30 months or 37,500 miles. Under severe service
conditions, change transmission fluid at 18,000 miles. Severe service
are conditions such as long periods of engine idling, trailer towing,
off-highway operation, snow removal, or operating in dusty or
excessively hot conditions.
Transmission (Ram Pickup)
Check transmission fluid level when performing other
underhood services. Fluid change service interval information is not
available from manufacturer.
Transfer Case
Check transfer case fluid level when performing other
underhood services. On Dakota and Light-Duty Pickup, change transfer
case fluid at 37,500 miles or 30 months. On Medium-Duty and Heavy-Duty
Pickup, change transfer case fluid at 36,000 miles or 36 months.
CHECKING FLUID LEVEL
Transmission (Dakota)
1) Park vehicle on level surface. Remove transmission fill
plug from side of transmission. On AX-15 transmission, transmission
fill plug is located on driver's side of transmission. On NV3500
transmission, transmission fill plug is located near front of
transmission on passenger's side of transmission.
2) On all transmissions, fluid level should even with bottom
of fill plug hole on side of transmission. Add appropriate type of
transmission fluid if necessary. See RECOMMENDED FLUID. Install and
tighten transaxle fill plug to specification. See TORQUE
SPECIFICATIONS.
Transmission (Ram Pickup)
1) Park vehicle on level surface. Remove transmission fill
plug from side of transmission. On NV3500 transmissions, transmission
fill plug is located near front of transmission on passenger's side of
transmission. On NV4500 transmissions, transmission fill plug is
located near rear of transmission on passenger's side of transmission.
2) On all transmissions, fluid level should even with bottom
of fill plug hole on side of transmission. Add appropriate type of
transmission fluid if necessary. See RECOMMENDED FLUID. Install and
tighten transaxle fill plug to specification. See TORQUE
SPECIFICATIONS.
Transfer Case
Park vehicle on level surface. Remove transfer case fill plug
from rear of transfer case. Fluid level should even with bottom of
transfer case fill plug hole on rear of transfer case. Add appropriate
type of transfer case fluid if necessary. See RECOMMENDED FLUID.
Install and tighten transfer case fill plug to specification. See
TORQUE SPECIFICATIONS.
RECOMMENDED FLUID
Transmission (Dakota)
On AX-15 transmissions, use API 75W-90 GL-3 gear oil. On
NV1500 and NV3500 transmissions, use ONLY Mopar M/T Lube Part No.
4761526.
Transmission (Ram Pickup)

Junction block is on left side of instrument panel. If fuse is open,
go to next step. If fuse is okay, go to step 6).
2) Using external voltmeter, measure voltage between ground
and voltage input side of fuse No. 19 socket. If voltage is 10 volts
or less, repair open ignition switch output circuit (Dark Blue wire
between ignition switch and junction block). If voltage is more than
10 volts, go to next step.
3) Turn ignition off and wait 2 minutes. Using external
ohmmeter, measure resistance between ground and fused ignition switch
output run/start terminal (Light Green/Yellow wire) on fuse No. 19
socket. If resistance is less than 5 ohms, go to next step. If
resistance is 5 ohms or more, go to step 5).
4) Disconnect Air Bag Control Module (ACM) connector. ACM is\
located under center of instrument panel. Turn ignition on. Measure
resistance between ground and fused ignition switch output run/start
terminal (Light Green/Yellow wire) on fuse No. 19 socket. If
resistance is less than 5 ohms, repair Light Green/Yellow wire for
short to ground. Replace fuse No. 19. If resistance is 5 ohms or more,
replace air bag control module and fuse No. 19.
5) Turn ignition off and wait 2 minutes. Disconnect Air Bag
Control Module (ACM) connector. ACM is located under center of
instrument panel. Using external ohmmeter, measure resistance of Light
Green/Yellow wire between ACM connector terminal No. 14 and fused
ignition switch output run/start terminal on fuse No. 19 socket. If
resistance is less than 5 ohms, connect ACM connector. Turn ignition
on. Replace fuse No. 19 in junction block. Go to appropriate AIR BAG
SERVICE & REPAIR, DOMESTIC CARS, LIGHT TRUCKS & VANS for further
testing. If resistance is 5 ohms or more, repair open Light
Green/Yellow wire. Replace fuse No. 19.
6) Using external voltmeter, measure voltage between ground
and voltage input side of fuse No. 19 socket. If voltage is 10 volts
or less, repair open ignition switch output circuit (Dark Blue wire
between ignition switch and junction block). If voltage is more than
10 volts, go to next step.
7) Turn ignition off and wait 2 minutes. Install fuse No. 19.
Disconnect Air Bag Control Module (ACM) connector. ACM is located
under center of instrument panel. Turn ignition on. Using external
voltmeter, measure voltage between ground and ACM connector terminal
No. 14 (Light Green/Yellow wire). If voltage is 10 volts or less,
repair open Light Green/Yellow wire. If voltage is more than 10 volts,
go to next step.
8) Turn ignition off. Using external ohmmeter, measure
resistance between ground and ACM connector terminal No. 4
(Black/Pink). If resistance is 5 ohms or more, repair open Black/Pink
wire. If resistance is less than 5 ohms, go to next step.
9) Turn ignition on. Using external voltmeter, measure
voltage between ground and ACM connector terminal No. 21 (Violet/Brown
wire). If voltage is not 1.8-2.6 volts, repair open Violet/Brown wire.
If voltage is 1.8-2.6 volts, go to next step.
10) Turn ignition off. Using external ohmmeter, measure
resistance between ground and ACM connector terminal No. 4 (Black/Pink
wire). If resistance is 5 ohms or more, repair open Black/Pink wire.
If resistance is less than 5 ohms, go to next step.
11) Using external voltmeter, measure voltage between ground
and ACM connector terminal No. 22 (White/Black wire). If voltage is
not 1.8- 2.6 volts, repair open White/Black wire. If voltage is 1.8-2.
6 volts, replace ACM.
NO RESPONSE CENTRAL TIMER MODULE
NOTE: For connector terminal identification and wiring diagrams,
see BODY CONTROL COMPUTER - INTRODUCTION article. Perform
VERIFICATION TEST VER-1 after each repair.

Application Front - In. (mm) Rear - In. (mm\
)
Gas Engine With
14" & 15" Wheels (1) ....... 29.04-29.82
(737.5-757.5) .......... 29.76-30.54\
(756.0-776.0)\
Gas Engine With 15",
16" & 17" Wheels ( 2) ....... 29.27-30.05
(743.5-765.5) ........... 30.0-30.78\
(762.0-782.0)\
CNG & Electric Vehicles ..... 30.46-31.24
(783.5-803.5) ........... 31.2-31.98\
(792.5-812.5)\
( 1) - With tire sizes P205/75R 15 and P215/65R 15.
( 2) - With tire sizes P215/70R 15, P215/65R 16 and 215/65R 17.









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HOIST
CAUTION: On Ram Van/Wagon, ensure there is adequate drive shaft
clearance while raising vehicle. DO NOT raise vehicle by
hoisting or jacking against front lower control arms. If rear
axle, fuel tank, spare tire and liftgate will be removed for
service, place additional weight on rear end of vehicle. This
will prevent tipping as center of gravity changes.
Caravan, Ram Van/Wagon, Town & Country, & Voyager
To raise vehicle on single and twin post type hoists, ensure
hoist pads contact vehicle frame behind front control arm pivots and
inside rear wheels on rear axle housing. Always use hoist adapters.
See Fig. 2 or 5.
Dakota & Ram Pickup
Vehicle may be raised on single or twin post swiveling arm,
or ramp-type drive hoists. If using swiveling arm hoist, ensure
lifting arms, pads or ramps are positioned evenly on frame rails, and
adequate clearance is maintained for transfer case (4WD models) or
skid plate. All hoists must be equipped with adapters to properly
support vehicle. See Fig. 3.
WHEEL ALIGNMENT PROCEDURES
FRONT WHEEL CAMBER & CASTER ADJUSTMENT
CAUTION: DO NOT adjust caster by heating or bending suspension
components. If caster angle is incorrect, replace
component(s) causing incorrect angle.
Caravan, Town & Country, & Voyager
1) Caster is factory preset and cannot be adjusted. Camber is
factory preset, but can be adjusted with a camber service kit. Raise
and support vehicle. While holding lower strut attaching bolts
stationary, loosen attaching nuts. See Fig. 6. Remove upper attaching
nut and bolt. Install camber service kit attaching/adjusting bolt and
nut. While holding bolt stationary, lightly tighten nut. Repeat
procedure for lower attaching nut and bolt.
2) Lower vehicle until vehicle weight is supported by
suspension. Bounce vehicle several times and allow suspension to
settle. Rotate new cam bolt to move top of wheel in or out to
specified camber. See WHEEL ALIGNMENT SPECIFICATIONS table. Tighten
through-bolt nuts to specification. See TORQUE SPECIFICATIONS table.

subtracted by the width measured at the front of the tires at about
spindle height. A positive figure would indicate toe-in and a negative
figure would indicate toe-out. If the distance between the front and
rear of the tires is the same, toe measurement would be zero. To
adjust:
1) Measure toe-in with front wheels in straight ahead
position and steering wheel centered. To adjust toe-in, loosen clamps
and turn adjusting sleeve or adjustable end on right and left tie
rods. See Figs. 2 and 5.
2) Turn equally and in opposite directions to maintain
steering wheel in centered position. Face of tie rod end must be
parallel with machined surface of steering rod end to prevent binding.
3) When tightening clamps, make certain that clamp bolts are
positioned so there will be no interference with other parts
throughout the entire travel of linkage.
Fig. 5: Wheel Toe-In (Dimension A Less Dimension B)
TOE-OUT ON TURNS
1) Toe-out on turns (turning radius) is a check for bent or
damaged parts, and not a service adjustment. With caster, camber, and
toe-in properly adjusted, check toe-out with weight of vehicle on
wheels.
2) Use a full floating turntable under each wheel, repeating
test with each wheel positioned for right and left turns. Incorrect
toe-out generally indicates a bent steering arm. Replace arm, if
necessary, and recheck wheel alignment.

STEERING AXIS INCLINATION
1) Steering axis inclination is a check for bent or damaged
parts, and not a service adjustment. Vehicle must be level and camber
should be properly adjusted. See Fig. 6.
2) If camber cannot be brought within limits and steering
axis inclination is correct, steering knuckle is bent. If camber and
steering axis inclination are both incorrect by approximately the same
amount, the upper and lower control arms are bent.
Fig. 6: Checking Steering Axis Inclination

POWER WINDOW MOTOR
NOTE: On Dakota, window motor and regulator are serviced as an
assembly.
1) Remove door trim panel. See DOOR TRIM PANEL under REMOVAL
& INSTALLATION. Disconnect window motor connector. Using jumper wires,
apply battery voltage to window motor terminals. Motor should operate,
unless window is already at maximum travel.
2) Reverse jumper wires. Window should move in opposite
direction. If window does not move in either direction, replace window
motor.
3) If motor operates in one direction only, replace motor.
See POWER WINDOW MOTOR under REMOVAL & INSTALLATION. If motor grunts
and does not move, disconnect window glass from regulator plate. Check
window glass, tracks and regulator for sticking, binding or improper
adjustment. Repair as necessary and recheck system operation.
POWER WINDOW SWITCH
1) Remove window switch from door trim panel. See POWER
WINDOW SWITCH under REMOVAL & INSTALLATION. Using an ohmmeter, check
switch continuity. See appropriate WINDOW SWITCH CONTINUITY table.
Replace power window switch as necessary. See appropriate
illustration. See Figs. 1 - 6.
2) Vehicles equipped with Auto Down feature have electronic
components in switch to actuate Auto Down. To test, check switch
continuity, reconnect switch, turn ignition on and test feature. If
Auto Down does not work, replace switch.
Fig. 1: Identifying Driver's Window Switch Terminals (Caravan,
Durango, Town & Country, & Voyager)
Courtesy of Chrysler Corp.
Fig. 2: Identifying Passenger's Window Switch & Vent Switch
Terminals (Caravan, Town & Country, & Voyager)