1999 DODGE RAM Service Repair Manual

horizontally, and clamp straightedge to yoke in a horizontal plane.
Repeat procedure with drive pinion flange. Ensure flange/yokes are
horizontal by checking angle of straightedge using a machinist spirit
level.
4) Measure distance "X" at each side. See Fig. 9. If
measurements are not within 1/16" (1.6 mm) of each other, transmission\
flange is horizontally misaligned.
5) Measure distance "Y" (edge of straightedge to axle shaft
center line) at each side. If measurements are not within 1/8" (3.2
mm) of each other, axle housing is misaligned. Measure distance "W" at
each side. If measurements are not within 1/16" (1.6 mm) of each
other, pinion flange is horizontally misaligned.
ADJUSTING HORIZONTAL ALIGNMENT
NOTE: Excessive difference in measurements may indicate frame
damage. DO NOT attempt to use following correction procedure
if more than slight horizontal misalignment exists.
Minor adjustment of drive shaft horizontal alignment may be
made by loosening axle housing "U" bolts and moving either side of
axle housing forward or backward. If frame is not bent, slight axle
movement should make "W" measurements equal. See Fig. 9.
REMOVAL & INSTALLATION
CENTER BEARING SUPPORT ASSEMBLY
Removal
1) With transmission in neutral and parking brake off, raise
vehicle. Scribe alignment marks on all flange/yokes and slip joints to
be disassembled or disconnected. Remove drive shaft from pinion
flange/yoke.
2) Slide rear drive shaft slip joint from front drive shaft
splines. See Fig. 10. Support drive shaft(s) while removing center
bearing support bracket mounting bolts. Pull to remove front drive
shaft slip joint from transmission extension housing shaft.
Fig. 10: Identifying Center Bearing Support Assembly Components
Courtesy of Chrysler Corp.
CAUTION: DO NOT clamp drive shaft tube or slip joint tube in a vise.
Clamp only forged portion of each yoke in vise. To avoid

distorting yoke, DO NOT overtighten vise jaws.
Disassembly
1) Clamp front drive shaft in a soft-jaw vise. If required,
disassemble "U" joint from yoke to access yoke-to-drive shaft
retaining bolt. Scribe mark yoke or slip joint to drive shaft for
reassembly reference. Slide yoke or slip joint off shaft splines.
2) Remove and retain center bearing support bracket and
retainer. (Service replacement assembly may not come with these items.
) Remove rubber insulator from bearing housing. See Fig. 10.
3) Bend slinger away from center bearing to provide clearance
for bearing puller. Using bearing puller, remove center bearing from
drive shaft. On some applications, outer bearing cover/cage and balls
must be removed to attach puller to bearing race.
Reassembly & Installation
Install NEW slinger to shaft. Install/press bearing onto
shaft using appropriate tool or tube until bearing is seated to shaft
shoulder. To complete installation, reverse disassembly and removal
procedures. Ensure support bracket angle adjustment shims are
reinstalled (if removed).
OVERHAUL
NOTE: Manufacturer recommends replacing "U" joint(s) whenever "U"
joint is disassembled from yoke. ALWAYS replace complete "U"
joint whenever extreme external lubrication leakage or
bearing cap damage exists.
Before disassembly, mark flange/yoke to drive shaft for
reassembly reference, and remove "U" joint lube fitting(s). If joints
are rusted or corroded, apply penetrating oil before pressing bearing
caps out of yoke or off "U" joint trunnion pin.
SINGLE CARDAN "U" JOINTS
Other than adding grease, "U" joint assembly items are not
individually serviceable or repairable. If needle bearings, seals,
spider, or bearing caps are found to be defective, damaged or
excessively worn, complete "U" joint must be replaced.
NOTE: Saturate bearing caps and yokes with penetrating oil before
removal.
Removal
Raise and support vehicle. Remove drive shaft. Remove inner
or outer type bearing cap retainer clips. See Fig. 11. Press bearing
caps from yokes. Remove bearings, seals and spider from yoke bore, and
discard.
Cleaning
Clean yoke bores using solvent and wire brush or crocus
cloth. Remove rust, corrosion and foreign matter from yoke bores.
Installation
1) Apply multipurpose lubricant (NLGI grade 2 EP) to yoke
bores and into needle bearings of each bearing cap. Position spider in
yoke bores.
2) Install seals onto spider trunnions or bearing caps.
Lightly tap bearing caps into yoke bore far enough to retain spider in
place.

CAUTION: DO NOT clamp drive shaft tube or slip joint tube in a vise.
Clamp only forged portion of each yoke in vise. To avoid
distorting yoke, DO NOT overtighten vise jaws.
3) Using vise or press, push bearing caps into yoke bores,
keeping spider aligned in center of bearing caps. Using socket with
diameter slightly smaller than bearing cap, continue pressing caps
inward until retainer clips can be installed. Install inner or outer
type bearing cap retainer clips.
4) Install lube fitting, and lube "U" joint. Install drive
shaft. Tighten "U" joint clamp bolts to 14 ft. lbs. (19 N.m). Lower
vehicle.
Fig. 11: Exploded View Of Single Cardan "U" Joint
Courtesy of Chrysler Corp.
DOUBLE CARDAN CONSTANT VELOCITY (CV) JOINT (4WD)
NOTE: Other than adding grease, "U" joint assembly items are not
individually serviceable or repairable. If needle bearings,
seals, spider, or bearing caps are found to be defective,
damaged or excessively worn, complete "U" joint assembly must
be replaced.
CAUTION: DO NOT allow pinion flange end of front drive shaft to hang
free or bend at sharp angle from CV joint.
Removal & Disassembly (Dakota & Ram Pickup)
1) Mark drive shaft yoke-to-front pinion flange position and
transfer case flange-to-CV joint flange position for installation
reference. Remove CV joint flange-to-transfer case flange bolts first,
then remove pinion flange bolts. Remove front drive shaft from
vehicle. DO NOT bend shaft at sharp angle from CV joint.
2) Mark CV joint components for reassembly reference. Remove
all inner or outer type bearing cap retaining clips. See Fig. 12.
3) Set joint in arbor press or vise and place a socket on
upper bearing cap. Partially press one bearing cap from outer side of

link yoke enough to grasp bearing cap with vise jaws. Remove grease
fittings that interfere with removal.
4) Grasp protruding bearing in vise jaws. Tap link yoke with
mallet and drift to dislodge bearing cap from yoke.
5) Flip assembly and repeat steps 3 and 4 to remove opposite
bearing cap. Remove cross centering kit assembly and spring.
6) Press remaining bearing caps out other end of link yoke to
complete disassembly.
Reassembly & Installation
1) Clean dirt and rust from all contact areas. Apply
multipurpose lubricant (NLGI grade 2 EP) to yoke bores and into needle\
bearings of each bearing cap. Lube center socket yoke and needle
bearings. See Fig. 12.
2) Position spider in drive shaft yoke bore. Reassemble
components in reverse order of disassembly, ensuring reference marks
align. Install drive shaft in vehicle, and tighten flange bolts to
specification. See TORQUE SPECIFICATIONS table.
Installation
1) Before installing drive shaft, clean mating flange, and
inspect machined surface for scratches, nicks and burrs. Support drive
shaft during installation to prevent bending shaft at sharp angle to
CV joint and causing damage to "U" joints.
2) Aligning reference marks, install CV joint flange to
transfer case flange first, then install shaft to pinion flange.
Attach 2 clamps to pinion flange, and tighten attaching bolts to
specification. Install and tighten 4 bolts to CV joint at transfer
case flange.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








\









\









\









\









\









\









\








Application Ft. Lbs. (N.m)\
Center Bearing Support Bracket-To-Upper Bracket Bolts ...... 50 (68)\
Center Bearing Upper Bracket-To-Frame Bolts ................ 50 (68)\
Spring "U" Bolt Nuts
Dakota
2WD ..................................................... 65 (88)\
4WD ................................................... 110 (149)\
Ram Pickup ............................................. 110 (149)\
Ram Van/Wagon
B150 & B250 ............................................. 45 (61)\
B350 .................................................. 110 (149)\
Transfer Case Flange-To-CV Joint Flange Bolts
Dakota ................................................... 20 (27)\
Ram Pickup ............................................... 65 (88)\
"U" Joint Clamp-To-Pinion Flange Bolts
1/4" ..................................................... 14 (19)\
5/16" .................................................... 25 (34)\
Wheel Lug Nuts
Dakota .......................................... 85-115 (115-156)\
Ram Pickup
5-Lug .................................................. 95 (129)\
8-Lug (Single Wheel) .................................. 135 (183\
)
8-Lug (Dual Wheel) .................................... 145 (196\
)
Ram Van/Wagon
5-Lug .......................................... 80-110 (108-149)\
8-Lug ......................................... 120-150 (163-203)\









\









\









\









\









\









\









\








Fig. 12: Double Cardan Constant Velocity (CV) "U" Joint (Dakota &
Ram Pickup)
Courtesy of Chrysler Corp.


* D RIV ETR AIN S YSTE M S U NIF O RM IN SPEC TIO N G UID ELIN ES *

1 999 D odge P ic ku p R 1500
GENERAL INFORMATION
Drivetrain/Transmission 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
Drive/Power Train Assemblies
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLIES
DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES
MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES
TRANSFER CASE ASSEMBLIES
Drive/Power Train Components
ACTUATORS (ELECTRICAL)
ACTUATORS (VACUUM)
AXLES
BEARINGS AND RACES
BELL CRANKS
BELL HOUSINGS
BUSHINGS (EXTERNAL)
CABLES (SPEEDOMETER)
CABLES (TV, DETENT AND SHIFT)
CARRIER BEARINGS
CLUTCH CABLES AND CABLE HOUSINGS
CLUTCH DISCS (MANUAL TRANSMISSION)
CLUTCH FORKS
CLUTCH LINKAGES (MECHANICAL)
CLUTCH MASTER CYLINDERS
CLUTCH PEDALS
CLUTCH PIVOTS
CLUTCH PRESSURE PLATES
CLUTCH RELEASE BEARINGS
CLUTCH SLAVE CYLINDERS (CONCENTRIC)
CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)
COMPANION FLANGES
CONNECTORS
COOLER BYPASS VALVES
COOLER LINES
COOLERS
CV JOINTS
DIP STICK TUBES
DIP STICKS (FLUID LEVEL INDICATORS)
DOWEL PINS, GUIDES AND PILOT HOLES
DRIVE SHAFT FLANGES
DRIVE SHAFTS AND HALF SHAFTS
DUST BOOTS
ENGINE MOUNTS
EXCITER RINGS
FILLER TUBES
FILTERS AND SCREENS

FLANGES
FLEX PLATES
FLUID LEVEL INDICATORS
FLUIDS AND LUBRICANTS
FLYWHEELS
FORCE MOTORS
GUIDES
HALF SHAFTS
HOSES, LINES AND TUBES
HOUSINGS (BELL, CASE, TAIL (EXTENSION) AND AUXILIARY)
INTERMEDIATE SHAFT SUPPORT BEARINGS
KEY INTERLOCK SYSTEMS
LIMITED SLIPS
LINES
LINKAGES (EXTERNAL)
LOCKING HUB ASSEMBLIES
LOCKING HUB CONTROL KNOBS
LUBRICANTS
METAL-CLAD SEALS
METALASTIC JOINTS
MODULATOR PINS
MODULATORS
MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION)
ODOMETER DRIVES (MECHANICAL)
ODOMETER HEADS (MECHANICAL)
OIL PANS
PANS
PILOT HOLES
PRESSURE PLATES
PRESSURE SWITCHES
RACES
RUBBER JOINTS (METALASTIC)
SCREENS
SEALS
SEALS (METAL-CLAD)
SELECTOR INTERLOCK SYSTEMS
SERVOS
SHIFT INTERLOCK SYSTEMS (SELECTOR AND KEY INTERLOCK SYSTEMS)
SENSORS
SIDE COVERS
SLIP YOKES
SOLENOIDS
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)
SPEEDOMETER-DRIVEN GEAR HOUSINGS
SPEEDOMETER/ODOMETER DRIVES (MECHANICAL)
SPEEDOMETER/ODOMETER HEADS (MECHANICAL)
SPEEDOMETERS AND ODOMETERS (ELECTRONIC)
SWITCHES
TONE WHEELS
TOOTHED RINGS (TONE WHEELS)
TORQUE CONVERTERS
TRANSAXLE MOUNTS
TRANSDUCERS (TRANSMISSION)
TRANSMISSION COOLERS
TRANSMISSION MOUNTS
TRANSMISSION PANS
TRANSMISSION RANGE INDICATORS (PRNDL)
TUBES
UNIVERSAL JOINTS (CARDON OR CROSS TYPE)
VACUUM CONTROLS
VACUUM HOSES
VACUUM MOTORS
VACUUM-OPERATED SWITCHES

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