1999 DODGE RAM brake sensor

ON-VEHICLE TESTING
CAUTION: When battery is disconnected, vehicle computer and memory
systems may lose memory data. Driveability problems may exist
until computer systems have completed a relearn cycle. See
COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION
before disconnecting battery.
DISABLING/ENABLING IGNITION & FUEL SYSTEMS
WARNING: To prevent engine from starting while performing tests,
always disable ignition and fuel systems.
Disabling Ignition & Fuel Systems
Remove Automatic Shutdown Relay (ASD) located in Power
Distribution Center (PDC). Refer to PDC cover for proper relay
location. PDC is located in engine compartment. On 5.9L diesel
engines, also disconnect fuel shutdown solenoid connector. Solenoid is
located behind upper intake manifold. See appropriate SYSTEM &
COMPONENT TESTING article in ENGINE PERFORMANCE section.
Enabling Ignition & Fuel Systems
When testing and/or repairs have been completed, verify
battery condition. Recharge battery as necessary, after starter tests
have been completed. Disconnect all test equipment. Install ASD relay.
On 5.9L diesel engines, reconnect fuel shutdown relay connector. On
all models, start engine several times to verify malfunction has been
corrected.
CRANKING TEST
NOTE: Ensure engine is at normal operating temperature. High
viscosity oil, extreme cold temperatures, or tight engine
will increase amperage draw.
1) Using a battery load tester, connect positive and negative
leads to battery. Connect inductive ammeter pick-up to positive
battery cable. Disable ignition and fuel systems. See
DISABLING/ENABLING IGNITION & FUEL SYSTEMS.
2) Ensure all lights and accessories are off. Place A/T in
Park position or M/T in Neutral position. Apply parking brake. Crank
engine and observe voltmeter reading. If voltage is more than 9.6
volts and cranking amperage draw is more than specified amps, proceed
to CIRCUIT RESISTANCE TESTS. See STARTER SPECIFICATIONS - CARS or
STARTER SPECIFICATIONS - TRUCKS.
3) If voltage is 12.5 volts or more and cranking amperage
draw is less than specified, check starter circuit components in the
following order:
starter solenoid, starter relay, starter relay circuit, park/neutral
position switch or transmission range sensor (A/T), clutch pedal
position switch (M/T), ignition switch, wiring harness and
connections.
CIRCUIT RESISTANCE TESTS
NOTE: If excessive resistance is not found in circuits being
tested, remove starter and proceed to BENCH TESTING.
Battery Connection Resistance Test
1) Disable vehicle ignition and fuel systems. See
DISABLING/ENABLING IGNITION & FUEL SYSTEMS. A voltmeter accurate to
one tenth of a volt will be needed for the following tests.


STE ER IN G K NUCKLE S - 4 W D

1999 D odge P ic ku p R 1500
1998-99 DRIVE AXLES
CHRY - 4WD Steering Knuckles
Ram Pickup
DESCRIPTION
Open type steering knuckles are used on all models. Open type
knuckles provide sharper turning angle, decreasing turning radius.
Axle shafts are free floating. Steering knuckles are attached to axle
housing by ball joints.
REMOVAL & INSTALLATION
REMOVAL
1) Raise and support vehicle. Remove wheels. Remove brake
caliper, and support aside. DO NOT allow caliper to hang by brake
hose. On one ton models, remove adapter hub bolts and hub from rotor
and hub assembly. On all models, remove cotter pin from rotor and hub
nut.
2) Remove rotor and hub nut. Remove bolts securing rotor and
hub assembly to steering knuckle. Bolts are accessible from inboard
side of steering knuckle. Remove rotor and hub assembly. Remove hub
spacer from steering knuckle. Note spacer position for installation
reference.
3) Disconnect tie rod end and drag link studs. Remove anti-
lock brake sensor from steering knuckle. Remove ball joint cotter pins
and nuts. Discard lower nut. Using a soft-face hammer, tap steering
knuckle to free it from ball joints.
4) Clean all components with solvent, and dry with compressed
air. Inspect all parts for burrs, chips, wear, flat spots or cracks.
Replace all damaged or worn parts.
INSTALLATION
NOTE: When aligning upper ball joint nut to install cotter pin,
always tighten nut to align holes. Never loosen nut to align
holes.
1) Position steering knuckle on ball joints, and install NEW
lower ball joint nut. Tighten nut to specification. See TORQUE
SPECIFICATIONS. Install upper ball joint nut, and tighten to
specification. Tighten, DO NOT loosen, nut to install NEW cotter pin.
2) Install hub bearing and axle shaft. Connect drag link stud
to steering knuckle arm. Install retaining nut, and tighten to
specification. Install NEW cotter pin. Connect tie rod end stud to
steering knuckle arm. Install retaining nut and tighten to
specification. Install NEW cotter pin. Install anti-lock brake sensor
to steering knuckle.
3) Apply anti-seize compound to splines of front drive axle.
Inspect hub grease seal and wheel bearing. Replace as necessary. From
rear of steering knuckle, install 2 rearward rotor and hub assembly
bolts in steering knuckle.
4) Apply chassis grease to hub spacer to secure on steering
knuckle. Position spacer on rotor and hub assembly bolts. Ensure
spacer is installed with flat edge toward rear of vehicle. Apply
Loctite to rotor and hub assembly bolt threads. Install rotor and hub

assembly to steering knuckle. Finger tighten bolts. Install 2
remaining rotor and hub assembly bolts. Tighten all bolts to
specification.
5) Install rotor and hub nut. Tighten nut to specification.
See TORQUE SPECIFICATIONS. Install cotter pin. On one ton models,
install adapter hub bolts and hub to rotor and hub assembly. Install
brake caliper, and tighten bolts to specification. Install wheels, and
tighten lug nuts to specification.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application (1) Ft. Lbs. (N.m)
ABS Sensor Bolt ............................................ 15 (11)\
Brake Caliper Bolt ......................................... 38 (52)\
Drag Link Nut .............................................. 65 (88)\
Hub-To-Steering Knuckle Bolt ..................... 125-160 (170-217)\
Lower Ball Joint Nut
216 FBI ................................................. 80 (108)\
248 FBI ........................................ 140-160 (190-217)\
Rotor & Hub Nut .................................. 160-200 (217-271)\
Shock Absorber Lower Bolt ................................ 100 (136)\
Stabilizer Bar Bolt ........................................ 27 (37)\
Tie Rod-To-Steering Knuckle Nut ............................ 65 (88)\
Upper Ball Joint Nut
216 FBI ................................................. 75 (102)\
248 FBI .................................................. 70 (94)\
Wheel Lug Nuts .................................... 95-145 (130-195)\
( 1) - Front axles can be identified by differential cover. The 216 FBI
has rounded edges, the 248 FBI has flat angled edges.









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1) Raise and support vehicle. Remove cotter pin and nut from
ball joint stud at end of frame rail bracket. See Fig. 4. Remove ball
stud from bracket with Puller C-4150A.
2) Remove bolt and flag nut from axle bracket. Remove track
bar. To install, reverse removal procedure. Tighten nuts and bolts to
specification. See TORQUE SPECIFICATIONS table.
Fig. 4: Removing Track Bar Assembly
Courtesy of Chrysler Corp.
WHEEL BEARINGS & HUB ASSEMBLY (5 STUDS)
Removal & Installation
1) Raise and support vehicle. Remove wheel. Remove caliper
and rotor. Remove ABS sensor (if equipped). Remove cotter pin and axle\
hub nut.
2) Remove wheel bearing and hub assembly hub-to-knuckle
bolts. Remove wheel bearing and hub assembly from steering knuckle and
axle shaft. Remove brake dust shield and spacer. To install, reverse
removal procedure. Tighten retaining nuts and bolts to specification.
See TORQUE SPECIFICATIONS table.
WHEEL BEARINGS & HUB ASSEMBLY (8 STUDS)
Removal & Installation
1) Raise and support vehicle. Remove wheel. Remove caliper
and rotor. Remove hub extension mounting nuts and remove extension
rotor (if equipped).

2) Remove brake caliper. Remove cotter pin and axle hub nut.
3) Disconnect ABS speed sensor wire. Remove sensor wire from
frame and steering knuckle (if equipped).
4) Remove wheel bearing and hub assembly hub-to-knuckle
bolts. Remove wheel bearing and hub assembly from steering knuckle and
axle shaft. Remove brake dust shield and spacer.
5) Press out wheel studs/hub extension studs and separate
rotor from hub. Remove wheel speed sensor from hub bearing (if
equipped). To install, reverse removal procedure. Tighten retaining
nuts and bolts to specification. See TORQUE SPECIFICATIONS table.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Anti-Rattle Springs & Clips ................................ 15 (20)\
Axle Nut ................................................. 175 (237)\
Ball Joint Nut
Model 44
Lower .................................................. 80 (108)\
Upper .................................................. 75 (102)\
Model 60
Lower ......................................... 140-160 (190-217)\
Upper ................................................... 70 (95)\
Cam Adjustment Nut ....................................... 170 (230)\
Control Arm
Lower
At Axle Bracket ........................................ 95 (129)\
At Frame Bracket ...................................... 125 (169)\
Upper
At Axle Bracket ........................................ 89 (121)\
At Frame Bracket ....................................... 80 (108)\
Drag Link-To-Pitman Arm .................................... 65 (88)\
Shock Absorber
Bracket Nut .............................................. 55 (75)\
Lower Mounting Bolt .................................... 100 (135)\
Upper Mounting Nuts ...................................... 35 (47)\
Stabilizer Bar
Bar-To-Link .............................................. 50 (68)\
Link-To-Axle Nut (1988 Models) ........................... 27 (37\
)
Link-To-Axle Nut (1999 Models) ........................... 35 (47\
)
Frame Bracket ............................................ 40 (54)\
Steering Knuckle Arm Nut ................................... 55 (75)\
Track Bar
Axle End ............................................... 130 (176)\
Frame End ................................................ 70 (95)\
Wheel Bearing & Hub Assembly-To-Knuckle Bolt ............. 125 (169)\
Wheel Lug Nuts
5 Stud Wheel
1998 Models ............................................ 95 (129)\
1999 Models .................................... 80-110 (108-149)\
8 Stud Wheel
1998 Models ........................................... 135 (183)\
1999 Models ................................... 120-150 (163-203)\
8 Stud Dual Wheel ...................................... 145 (196)\









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See TRANSMISSION under MISCELLANEOUS CONTROLS.
Transmission Speed Sensor (A/T Models)
See TRANSMISSION under MISCELLANEOUS CONTROLS.
Transmission Temperature Sensor (A/T Models)
See TRANSMISSION under MISCELLANEOUS CONTROLS.
Water-In-Fuel (WIF) Sensor
Water-in-fuel sensor is located in bottom of fuel
filter/water separator. Testing information not available from
manufacturer.
SWITCHES
Brake Switch
1) Remove lower panel for access to brake switch. Brake
switch is located on bracket, near top of brake pedal. Disconnect
electrical connector from brake switch. Pull plunger on brake switch
fully outward. See Fig. 2.
2) Using ohmmeter, check for continuity between terminals No.
5 and 6 on brake switch. See Fig. 2. Continuity should exist. If
continuity exists, go to next step. If continuity does not exist,
replace brake switch.
3) Push plunger on brake switch fully inward. Using ohmmeter,
check for continuity between terminals No. 1 and 2, and 3 and 4 on
brake switch. See Fig. 2. Continuity should exist. If continuity does
not exist, replace brake switch.
Fig. 2: Identifying Brake Switch Terminals
Courtesy of Chrysler Corp.
Park/Neutral Switch (A/T Models)
See TRANSMISSION under MISCELLANEOUS CONTROLS.

located in power distribution center at driver's side front corner of
engine compartment, near the battery. Automatic Shutdown (ASD) relay
may also be referred to as Auto Shutdown (ASD) relay.
Battery Temperature Sensor
Battery temperature sensor delivers input signal to
Powertrain Control Module (PCM) to indicate the battery temperature.
PCM uses battery temperature input to modify rate of output from the
charging system. Battery temperature sensor is snapped into battery
tray below driver's side battery.
Battery Voltage
Battery voltage input signal provides operating voltage to
Powertrain Control Module (PCM). This input signal keeps PCM memory
alive and informs PCM what generator output voltage is when engine is
running. PCM memory is used to store Diagnostic Trouble Codes (DTCs),
store APPS sensor voltages from previous key cycles and provide a
speed control adaptive memory.
Brake Switch
Brake switch delivers input signal to Powertrain Control
Module (PCM) to indicate when brakes are applied. PCM uses input
signal for controlling cruise control system and transmission torque
converter clutch operation on A/T models. Brake switch is located near
top of brake pedal and may also be referred to as brakelight switch.
CKP Sensor
Crankshaft Position (CKP) sensor delivers input signal (35
tooth wheel with gap) to Engine Control Module (ECM) to indicate
engine speed and crankshaft position. ECM uses CKP signal along with
other input signals for controlling injector firing sequence and
timing. Sensor is located below fuel transfer pump, on side of engine
block. See Fig. 2.
Cruise Control System Switches
Cruise control system functions, controlled by momentary
contact switches, are monitored through multiplexed input signal to
Powertrain Control Module (PCM). Resistance monitored at this input
signal, in conjunction with the length of time the PCM measures the
resistance, determines which switch feature has been selected.
Data Link Connector (DLC)
Data Link Connector (DLC) provides an input signal to
Powertrain Control Module (PCM) when using scan tool to retrieve
Diagnostic Trouble Codes (DTCs) from PCM. Input signal may also be
used when performing various tests on the PCM and electronic control
system. DLC is a 16-pin connector located at lower edge of driver's
side of instrument panel, just above accelerator pedal.
Fuel Level Sensor
The Powertrain Control Module (PCM) sends a 5-volt signal to
the fuel level sensor. The fuel level sensor will return a signal to
PCM. This signal is used for fuel gauge operation and to prevent
setting a false misfire or fuel system trouble codes. If fuel level is
less than 15 percent, PCM will not set code.
Ignition Sense
Ignition switch position input to Powertrain Control Module
(PCM). PCM uses input to determine proper output functions, including
cruise control, generator output, sensor supply and transmission
functions.
Transmission Speed Sensor (A/T Models)

Transmission speed sensor may also be referred to as
transmission output shaft speed sensor. Transmission speed sensor is
located on overdrive case at rear of transmission. Transmission speed
sensor delivers input signal to Powertrain Control Module (PCM) to
indicate transmission output shaft speed.
Overdrive Switch (A/T Models)
Transmission overdrive switch may be referred to as
overdrive/override switch, OD switch or overdrive off switch.
Transmission overdrive switch is located on end of gearshift lever.
When vehicle operator depresses transmission overdrive switch, an
input signal is delivered to the Powertrain Control Module (PCM). The
PCM uses input signal for controlling transmission overdrive shifts by
use of transmission overdrive solenoid on transmission valve body.
Transmission overdrive switch is normally in the ON position, allowing
transmission overdrive operation. If transmission overdrive switch is
depressed once, switch is in OFF position, allowing no transmission
overdrive upshift. If transmission overdrive switch is depressed
again, switch returns to the ON position, allowing transmission
overdrive operation.
Park/Neutral Switch (A/T Models)
Park/neutral switch delivers input signal to Powertrain
Control Module (PCM) to indicate if transmission is in Park, Neutral
or Drive. PCM uses input signal for controlling cruise control system,
transmission torque converter clutch operation and transmission
overdrive solenoid. When park/neutral switch is in Park or Neutral,
switch also provides a ground circuit for the engine starting system.
Park/neutral switch is located on the driver's side of transmission,
near shift linkage.
Transmission Governor Pressure Sensor (A/T Models)
Transmission governor pressure sensor delivers input signal
to Powertrain Control Module (PCM) to indicate transmission governor
pressure. PCM uses input signal for controlling governor pressure by
use of governor pressure solenoid on transmission valve body.
Transmission Temperature Sensor (A/T Models)
Transmission temperature sensor monitors transmission fluid
temperature and delivers input signal to Powertrain Control Module
(PCM). PCM uses input signal for controlling transmission torque
converter clutch operation, transmission overdrive shifts and governor
pressure. Transmission temperature sensor is located on transmission
valve body, incorporated into governor pressure sensor.
PCM prevents torque converter clutch engagement and
transmission overdrive operation when transmission fluid temperature
is less than 50
F (10C). If transmission fluid temperature is more
than 260F (126C), PCM forces a 4-3 downshift and engages torque
converter clutch until transmission fluid cools down. Once
transmission fluid cools to less than 230
F (110C), PCM allows a 3-4
shift again.
Vehicle Speed & Distance
Vehicle speed sensor is no longer used. The vehicle speed and
distance traveled are determined by rear wheel speed sensor. Rear
wheel speed sensor is mounted on top of rear axle housing, above the
ring gear. Rear wheel speed sensor delivers an input signal to
Controller Anti-Lock Brake (CAB) to indicate vehicle speed and
distance traveled. The CAB then delivers input signal to Powertrain
Control Module (PCM) to indicate vehicle speed and distance traveled.
PCM uses input signal for controlling control cruise control system
and fuel system. The CAB is mounted on top of the hydraulic control
unit. Hydraulic control unit contains the pump assembly that