1999 DODGE RAM clutch

Box (DRB) scan tool with appropriate cartridge for system
diagnosis. Other after-market scan tools may be used for
system diagnosis. The following procedure is for DRB scan
tool usage. Use scan tool manufacturer's instruction for
operating scan tool.
NOTE: Ensure battery is fully charged before proceeding with test.
1) Ensure ignition is off. Connect DRB to Data Link Connector
(DLC) located under driver's side of instrument panel. Using scan
tool, display all Diagnostic Trouble Codes (DTCs). Identify DTCs once
retrieved. See DIAGNOSTIC TROUBLE CODES (DTC) & DRB MESSAGES table.
2) If scan tool will not power up, check for loose cable
connections or faulty cable. If cable connections and cable are okay,
check voltage at DLC terminal No. 16. Voltage should be at least 11
volts. If voltage is not as specified, check wiring circuit and
necessary fuses. See WIRING DIAGRAMS.
3) If scan tool displays an error message, RAM TEST FAILURE,
CARTRIDGE ERROR, KEY PAD TEST FAILURE, or LOW OR HIGH BATTERY, this
indicates a scan tool failure.
4) If DTCs are displayed, perform appropriate test(s). See
DIAGNOSTIC TROUBLE CODES (DTC) & DRB MESSAGES table. If no DTCs are
displayed, see TROUBLE SHOOTING in appropriate AUTOMATIC TRANSMISSION
OVERHAUL article.
DIAGNOSTIC TROUBLE CODES (DTC) & DRB MESSAGES









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DTC DRB-III Scan Tool Message
P0711 .................. TRANS TEMP SENSOR, NO TEMP RISE AFTER START
P0712 ............................. TRANS TEMP SENSOR VOLTAGE TO LOW
P0713 ............................ TRANS TEMP SENSOR VOLTAGE TO HIGH
P0720 ..................... LOW OUTPUT SPEED SENSOR RPM ABOVE 15 MPH
P0740 .................... TORQ CONVERTER CLU, NO RPM DROP AT LOCKUP
P0743 ........ TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CIRCUITS
P0748 ........... GOVERNOR PRESSURE SOL CONTROL/TRANS RELAY CIRCUITS
P0751 ....................... OD SWITCH PRESSED (LO) MORE THAN 5 MIN\
P0753 ................ TRANS 3-4 SHIFT SOLENOID/TRANS RELAY CIRCUITS
P0783 ....................... 3-4 SHIFT SOL, NO RPM DROP @ 3-4 SHIFT
P1740 (1) .......................... TCC OR O/D SOLENOID PERFORMANCE
P1756 .................... GOV PRESS NOT EQUAL TO TARGET @ 15-20 PSI
P1757 ...................... GOV PRES ABOVE 3 PSI IN GEAR WITH 0 MPH
P1762 .................... GOV PRESS SEN OFFSET VOLTS TO LOW OR HIGH
P1763 ....................... GOVERNOR PRESSURE SENSOR VOLTS TO HIGH
P1763B ...................... GOVERNOR PRESSURE SENSOR VOLTS TO HIGH
P1764 ........................ GOVERNOR PRESSURE SENSOR VOLTS TO LOW
P1765 ..................... TRANS 12 VOLT SUPPLY RELAY CNTRL CIRCUIT
P1899 .......................... P/N SWITCH STUCK IN PARK OR ON GEAR
( 1) - BR body only.









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CLEARING DIAGNOSTIC TROUBLE CODES
After repairs have been performed, clear DTCs from PCM memory
using scan tool, following scan tool manufacturer's instructions.
NOTE: If malfunction is no longer present after DTC is stored in
PCM memory, the PCM will erase DTC after ignition has been
cycled at least 50 times. DTC may be cleared by using scan
tool. Follow scan tool manufacturer's instructions. DTCs may
also be cleared by disconnecting negative battery cable for a
period of time, but other vehicle control modules may also be

problem is found, measure resistance between output speed sensor
terminals. If resistance is 300-1200 ohms, go to next step. If
resistance is not as specified, replace output speed sensor.
7) Reconnect output speed sensor. Measure resistance between
ground and output speed sensor ground circuit at PCM harness
connector. If resistance is greater than 5 ohms, go to next step. If
resistance is not as specified, repair output speed sensor ground
circuit for a short to ground.
8) Measure resistance between ground and output speed sensor
signal circuit at PCM harness connector. If resistance is less than 5
ohms, repair output speed sensor signal circuit for a short to ground.
If resistance is not as specified, go to next step.
9) Measure resistance between output speed sensor signal
circuit and ground circuit at PCM harness connector. If resistance is
300-1200 ohms, replace PCM. If resistance is not as specified, go to
next step.
10) Disconnect output speed sensor harness connector. Measure
resistance of output speed sensor signal circuit between output speed
sensor harness connector and PCM harness connector. If resistance is
greater than 5 ohms, repair open in output speed sensor signal
circuit. If resistance is not as specified, repair open in output
speed sensor ground circuit.
11) Turn ignition on. Measure voltage between ground and
speed sensor ground circuit at PCM harness connector. Place gearshift
lever in each gear position and record voltage at each position. If
voltage is greater than one volt in any gear position, repair speed
sensor ground circuit for a short to power. If voltage is not as
specified, go to next step.
12) Raise and support vehicle. Start engine. Place gearshift
lever in "OD" position. Release brakes and allow wheels to rotate.
Using scan tool, monitor output speed sensor. While monitoring output
speed sensor, wiggle harness between output speed sensor and PCM. If
reading dropped towards zero while wiggling harness, repair
intermittent short or open in harness. If reading does not drop
towards zero while wiggling harness, problem is intermittent. See
INACTIVE DTC CONDITION under SELF-DIAGNOSTIC SYSTEM. Testing is
complete.
DTC P0740: TORQ CONV CLU, NO RPM DROP AT LOCKUP
Circuit Description
Circuit is monitored continuously while key is on, and gear
selector is not in Park or Neutral. Code sets if Torque Converter
Clutch (TCC) does not achieve desired drop in RPM when TCC solenoid is\
near maximum duty cycle. A bad test 3 consecutive times is required to
set code.
Possible Causes
* Misfire trouble code set.
* Vehicle stalls (faulty TCC solenoid).
* TCC shaft seal/seal defective.
* Transmission fluid contaminated.
* TCC solenoid wiring harness defective.
* TCC defective.
* TCC hydraulic circuit damaged.
Diagnostic Procedure
1) Using scan tool, read DTCs. On all bodies except AB and WJ
bodies, go to next step. On AB and WJ bodies, if DTC SPECIFIC GOOD
TRIPS counter is not displayed or displayed count is not "0", go to
step 10). If DTC SPECIFIC GOOD TRIPS counter is displayed and
displayed count is "0", indicating DTC still exists, go to next step.

2) If any DTCs listed are present, perform appropriate
test(s). See TORQUE CONVERTOR CLUTCH (TCC) TESTS table. If no DTCs a\
re
present, go to next step.
TORQUE CONVERTOR CLUTCH (TCC) TESTS









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DTC DTC Message
P0122 (1) ................. THROTTLE POSITION SENSOR VOLTAGE TOO LOW
P0123 ( 1) ................ THROTTLE POSITION SENSOR VOLTAGE TOO HIGH
P1696 ( 1) .......................... PCM FAILURE EEPROM WRITE DENIED
P0743 ........ TORQUE CONVERTOR CLUTCH SOLENOID/TRANS RELAY CIRCUITS
( 2) ........................................................ MISFIRE
P0320 ( 1) ......................... NO CRANK REFERENCE SIGNAL AT PCM
( 1) - See appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.
( 2) - Perform appropriate misfire DTC test. See appropriate
SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.









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3) Check transmission fluid for proper level and for any
debris. Fill or repair transmission as necessary. If fluid level and
condition are okay, go to next step.
4) Start engine. Using scan tool, perform TCC SYSTEM TEST. If
vehicle does not stall, go to step 9). If vehicle stalls, go to next
step.
5) Using scan tool, perform GOV and 3-4 SHIFT VALVE SYSTEM
TEST. Select 4th gear. If vehicle stalls, go to next step. If vehicle
does not stall, go to step 7).
6) Turn ignition off. Replace TCC solenoid. Using scan tool,
perform GOV and 3-4 SHIFT VALVE SYSTEM TEST. Select 4th gear. If
vehicle stalls, problem in internal. Check for blocked passage. If
vehicle does not stall, testing is complete.
7) Turn ignition off. Remove oil pump and inspect reaction
shaft, input shaft and input seal. Repair transmission as necessary.
See appropriate AUTOMATIC TRANSMISSION OVERHAUL article. If
transmission is okay, go to next step.
8) Inspect all related wiring and connectors. Repair as
necessary. If wiring and connectors are okay, see INACTIVE DTC
CONDITION under SELF-DIAGNOSTIC SYSTEM. Testing is complete.
9) Turn ignition off. Connect a pressure gauge to
transmission cooler OUT port. Start engine. Using scan tool, perform
TCC SYSTEM TEST. If pressure increases when TCC is actuated, go to
next step. If pressure does not increase, repair leaks or blockage in
hydraulic circuit, or repair valve body as necessary.
10) Turn engine off. Remove oil pump and inspect reaction
shaft, input shaft and input seal. Repair transmission as necessary.
See appropriate AUTOMATIC TRANSMISSION OVERHAUL article. If
transmission is okay, there are no other potential causes remaining.
TCC is assumed to be defective. Replace torque converter.
DTC P0743: TORQUE CONV CLUTCH SOLENOID/TRANS RELAY CKT
NOTE: To test transmission temperature sensor, engine and
transmission temperature must be less than 85F (29C).
Circuit Description
Circuit is monitored continuously while key is on. Code sets
if voltage detected on Torque Converter Clutch (TCC) at the Powertrain\
Control Module (PCM) does not match desired voltage.
Possible Causes

replace PCM and see INACTIVE DTC CONDITION under SELF-DIAGNOSTIC
SYSTEM. Testing is complete.
DTC P0783: 3-4 SHIFT SOL, NO RPM DROP @ 3-4 SHIFT
Circuit Description
Circuit is monitored continuously while key is on and engine
running. Code sets if expected RPM drop does not occur within 4
seconds of requested gear change by PCM. Test must fail 3 times to set
code.
Possible Causes
* Transmission mechanically defective.
* TPS codes set.
* Transmission 3-4 solenoid wiring harness defective.
* Transmission fluid burnt or oil pan has excessive debris.
Diagnostic Procedures
1) Using scan tool, read DTCs. On all bodies except AB and WJ
bodies, go to next step. On AB and WJ bodies, if DTC SPECIFIC GOOD
TRIPS counter is not displayed or displayed count is not "0", go to
step 6). If DTC SPECIFIC GOOD TRIPS counter is displayed and displayed
count is "0", indicating DTC still exists, go to next step.
2) If any DTCs listed are present, perform appropriate
test(s). See 3-4 SHIFT SOLENOID TESTS table. If no DTCs are present,
go to next step.
3-4 SHIFT SOLENOID TESTS









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DTC Message Test
NO CAM SIGNAL AT PCM ..................................... ( 1) P0340
P/N SWITCH STUCK IN PARK OR IN GEAR .......................... P1899
Any Throttle Position Sensor (TPS) DTC ......................... ( 1)
TORQUE CONVERTOR CLUTCH SOLENOID/TRANS RELAY CIRCUITS ........ P0743
TRANS 12-VOLT SUPPLY RELAY CNTRL CIRCUIT ..................... P1765
TRANS 3-4 SHIFT SOLENOID/TRANS RELAY CIRCUITS ................ P0753
( 1) - See appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.









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3) Check transmission fluid for proper level and for any
debris. Fill or repair transmission as necessary. If fluid level and
condition are okay, go to next step.
4) Connect a 0-300 psi (0-21 kg/cm
) pressure gauge to
transmission Overdrive (O/D) clutch pressure test port. Connect a
second 0-300 psi (0-21 kg/cm
) pressure gauge to transmission governor
pressure test port. See appropriate AUTOMATIC TRANSMISSION OVERHAUL
article. Ensure engine and transmission are at normal operating
temperature. With an assistant, test drive vehicle. Using scan tool,
select GOV and 3-4 SHIFT VALVE SYSTEM TEST. Select 4th gear while
monitoring pressure gauge. Governor pressure should rise to greater
than 20 psi (1.4 kg/cm
) and O/D pressure should rise to greater than
40 psi (2.8 kg/cm). If pressures are as specified, go to next step.
If pressures are not as specified, go to step 8).
5) Using wiring diagram as a guide, inspect wiring and
connectors. Repair wiring harness as necessary. If wiring and
connectors are okay, go to next step.
6) Using scan tool, erase DTCs. Start engine. Road test
vehicle at 0-55 MPH with a constant 20 percent throttle. Repeat road
test 4 times. Note if DTC P0783 resets. If DTC P0783 resets, repair
wiring harness as necessary. If DTC P0783 does not reset, go to next

step.
7) Turn engine off. Drain transmission fluid and remove oil
pan. Inspect oil pan for burnt oil and debris. Repair transmission as
necessary. See appropriate AUTOMATIC TRANSMISSION OVERHAUL article. If
transmission is okay, no problem is found at this time, see INACTIVE
DTC CONDITION under SELF-DIAGNOSTIC SYSTEM. Testing is complete.
8) Leave gauges connected. Replace 3-4 shift solenoid.
Replace transmission pan and fill with fluid. Start engine and allow
engine and transmission to reach normal operating temperature. Using
scan tool, select GOV and 3-4 SHIFT VALVE SYSTEM TEST. Select 4th gear
while monitoring pressure gauges. Governor pressure should rise to
greater than 20 psi (1.4 kg/cm
) and O/D pressure should rise to
greater than 40 psi (2.8 kg/cm). If pressures are as specified, no
problem is found at this time. Testing is complete. If pressures are
not as specified, see appropriate AUTOMATIC TRANSMISSION OVERHAUL
article, paying attention to seals and clutches related to O/D clutch.
DTC P1740: TCC OR O/D SOLENOID PERFORMANCE (BR BODY - DIESEL)
Circuit Description
Torque Converter Clutch (TCC) and overdrive clutch are tested\
when Powertrain Control Module (PCM) requests TCC engagement in 3rd
gear and overdrive. Code will set if expected RPM drop is not achieved
while attempting to engage TCC and/or overdrive. Code indicates
malfunctioning torque converter or overdrive clutch.
Possible Causes
* Fluid level or quality problem.
* Transmission wiring and connector defective.
* Transmission mechanically defective.
* Low fuel level.
* Trans temperature below 32
.
* Transfer case is in low range.
* Engine RPM trouble codes set.
* Misfire trouble code set (DTCs P0300-P0306).
* Output shaft speed trouble code set.
* PTO is engaged.
* TPS codes set (DTCs P0121-P0123).
* Torque converter defective.
Diagnostic Procedures
1) Using scan tool, read DTCs. If DTC SPECIFIC GOOD TRIPS
counter is not displayed or displayed count is not "0", go to step
16). If DTC SPECIFIC GOOD TRIPS counter is displayed and displayed
count is "0", go to next step.
2) If any DTCs listed are present, perform appropriate
test(s). See TCC OR O/D SOLENOID TESTS table. If no DTCs are present,
go to next step.
TCC OR O/D SOLENOID TESTS









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DTC Message Test
CAMSHAFT POSITION SENSOR SIGNAL .......................... ( 1) P0341
P/N SWITCH STUCK IN PARK OR IN GEAR .......................... P1899
Any Throttle Position Sensor (TPS) DTC ......................... ( 1)
Any Misfire DTC ................................................ ( 1)
Any Engine RPM DTC ............................................. ( 1)
Any Output Shaft Speed Sensor DTC .............................. ( 1)
TRANS 12-VOLT SUPPLY RELAY CNTRL CIRCUIT ..................... P1765
TORQUE CONVERTOR CLUTCH SOLENOID/TRANS RELAY CIRCUITS ........ P0743
TRANS 3-4 SHIFT SOLENOID/TRANS RELAY CIRCUITS ................ P0753

(1) - See appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.








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3) Ensure fuel tank is at least 1/4 full. If fuel level is
too low, correct fuel level and retest. If fuel level is okay, go to
next step.
4) Ensure transfer case is not in low range. Shift transfer
case out of low range. If transfer case is not in low range, go to
next step.
5) Ensure PTO is not engaged. Disengage PTO. If PTO is not
engaged, go to next step.
6) Ensure transmission fluid temperature is above 32
F (0C).
Warm transmission to normal operating temperature. If transmission
fluid temperature is above 32
F (0C), go to next step.
7) Turn ignition on. Using scan tool, build a custom display
with engine RPM, output shaft SPD, TCC solenoid, O/D solenoid and
throttle position. Set overdrive to off position. Road test vehicle
and reach a steady speed of 55 MPH with a minimum throttle opening
voltage of 1.15 volts for 20 seconds. Note shift patterns while
vehicle is attaining speed. If engine RPM is within 60 RPM of output
shaft speed RPM, go to next step. If engine RPM is not within 60 RPM
of output shaft speed RPM, go to step 15).
8) If output shaft speed RPM is greater than engine RPM, go
to next step. If output shaft speed RPM is equal to or less than
engine RPM, go to step 15).
9) Road test vehicle and reach a steady speed of 55 MPH and
engage overdrive. If engine RPM is 69 percent of output shaft speed,
go to step 15). If engine RPM is not 69 percent of output shaft speed,
go to next step.
10) Connect a 0-300 psi (0-21 kg/cm
) pressure gauge to
transmission Overdrive (O/D) clutch pressure test port. Connect a
second 0-300 psi (0-21 kg/cm
) pressure gauge to transmission governor
pressure test port. See appropriate AUTOMATIC TRANSMISSION OVERHAUL
article. Ensure engine and transmission are at normal operating
temperature. With an assistant, test drive vehicle. Using scan tool,
select GOV and 3-4 SHIFT VALVE SYSTEM TEST. Select 4th gear while
monitoring pressure gauge. Governor pressure should rise to greater
than 20 psi (1.4 kg/cm
) and O/D pressure should rise to greater than
40 psi (2.8 kg/cm). If pressures are as specified, go to next step.
If pressures are not as specified, go to step 13).
11) Check transmission fluid for proper level and for any
debris. Fill or repair transmission as necessary. If fluid level and
condition are okay, go to next step.
12) Drain transmission fluid and remove oil pan. If
transmission fluid is burnt or has excessive debris, repair as
necessary. If transmission fluid is okay, go to step 23).
13) Check transmission fluid for proper level and for any
debris. Fill or repair transmission as necessary. If fluid level and
condition are okay, go to next step.
14) Leave gauges connected. Replace 3-4 shift solenoid. Start
engine and allow engine and transmission to reach normal operating
temperature. Using scan tool, select GOV and 3-4 SHIFT VALVE SYSTEM
TEST. Select 4th gear while monitoring pressure gauges. Governor
pressure should rise to greater than 20 psi (1.4 kg/cm
) and O/D
pressure should rise to greater than 40 psi (2.8 kg/cm). If pressures
are as specified, testing is complete. If pressures are not as
specified, see appropriate AUTOMATIC TRANSMISSION OVERHAUL article,
paying attention to seals and clutches related to O/D clutch.
15) Check transmission fluid for proper level and for any
debris. Fill or repair transmission as necessary. If fluid level and
condition are okay, go to next step.
16) Start engine. Using scan tool, perform TCC SYSTEM TEST.

CLU TC H
1999 D odge P ic ku p R 1500
1998-99 CLUTCHES
CHRY - RWD - Trucks
Dakota, Ram Pickup
DESCRIPTION
Clutches on all models are dry, single-disc design.
Adjustment for wear is not possible. Clutch pedal is connected to
release fork through a hydraulic master cylinder and slave cylinder
and is not adjustable. Pre-lubricated clutch bearing is constant
running type. External adjustments cannot be made.
All models are equipped with a clutch pedal position switch.
The switch completes the circuit to the starter relay and is mounted
on clutch master cylinder push rod. The position switch is an integral
part of clutch master cylinder push rod and cannot be serviced
separately.
TRANSMISSION/TRANSFER CASE APPLICATION









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Transmission Transfer Case
Dakota
AX15, NV1500 & NV3500 .............................. NV231 & NV242
Ram Pickup
NV3500, NV4500, NV4500HD & NV5600 ..... NV231HD, NV241LD & NV241HD









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ADJUSTMENTS
CLUTCH PEDAL FREE PLAY
NOTE: Clutches are a single, dry disc type. Adjustment for wear is
not possible. Clutch is actuated through hydraulic master
cylinder and slave cylinder, and is self-adjusting.
SHIFT LINKAGE ADJUSTMENT
NV231 (Dakota)
1) Shift transfer case into 4H position, and secure shift
lever in shift gate. See Fig. 1. Raise and support vehicle. Loosen
shift rod lock bolt at swivel. Ensure shift rod slides freely in
adjusting swivel.
2) Ensure transfer case range lever is in 4H position. Slide
adjusting swivel forward until shift rod contacts shift gate
crossover, then slide adjusting swivel back, allowing a .11-.20" (3-5
mm) gap between shift lever and shift gate.
3) Center pin on adjusting swivel in shift arm and tighten
lock bolt to 90 INCH lbs. (10 N.m.). Lower vehicle, making sure all
wheels are off floor. Start engine. Shift transfer case through all
ranges to verify correct adjustment.
NV231HD, NV241LD & NV241HD (Ram Pickup)
1) Place shift lever into 2H position. Raise and support
vehicle. Loosen shift rod lock bolt at swivel. See Fig. 2. Ensure
shift rod fits in swivel and does not bind.
2) Ensure transfer case shift lever is in 2H position. Lower
vehicle. Position shift lever in cab so distance between instrument

Fig. 2: Adjusting Transfer Case Shift Linkage (Ram Pickup)
Courtesy of Chrysler Corp.
TROUBLE SHOOTING
NOTE: For trouble shooting not covered in this article, see
appropriate table in TROUBLE SHOOTING article in GENERAL
INFORMATION.
Hydraulic system should not require addition of fluid under
normal circumstances. Reservoir fluid level will increase as normal
clutch wear occurs. Avoid overfilling or removing fluid from
reservoir. This will cause clutch release problems.
TESTING
CLUTCH PEDAL POSITION SWITCH
NOTE: The position switch is an integral part of clutch master
cylinder push rod and cannot be serviced separately.
Disconnect clutch pedal position switch electrical connector.
Depress switch. Using a DVOM, measure continuity between clutch pedal
position switch terminals No. 1 (Yellow/Red wire) and No. 2 (Dark
Blue/Yellow wire). If continuity exists, switch is okay. If continuity
does not exist, replace clutch master cylinder. See CLUTCH MASTER
CYLINDER under REMOVAL & INSTALLATION.