1999 DODGE RAM wheel

Dakota & Ram Van ..................................... .004 (.102)\
Ram Pickup ........................................... .005 (.127)\
Parallelism
Dakota & Ram Van .................................... .0005 (.013)\
Ram Pickup ........................................... .001 (.025)\
Original Thickness
Dakota & Ram Van ............................................. (1)
Ram Pickup
1/2 Ton ............................................... 1.26 (32)\
3/4 & 1 Ton ........................................... 1.50 (38)\
Minimum Refinish Thickness ..................................... ( 1)
Dakota ............................................... .890 (22.6)\
Ram Van ................................................ 1.18 (30)\
Ram Pickup
1/2 Ton ............................................ 1.22 (31.00)\
3/4 Ton ............................................ 1.27 (32.26)\
1 Ton .............................................. 1.52 (38.61)\
Discard Thickness .............................................. ( 2)
( 1) - Information is not available from manufacturer.
( 2) - Discard thickness is marked on rotor hub.









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DRUM BRAKE SPECIFICATIONS
DRUM BRAKE SPECIFICATIONS








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Application In. (mm)\
9" Drum
Drum Width ........................................... 2.50 (63.5)\
Maximum Allowable Diameter ........................ 9.060 (230.12)\
Wheel Cylinder Diameter ............................. .750 (19.05)\
10" Drum
Drum Width ........................................... 2.50 (63.5)\
Maximum Allowable Diameter ....................... 10.060 (255.52)\
Wheel Cylinder Diameter ............................. .810 (20.57)\
11" Drum
Drum Width
Ram Pickup (1/2 Ton) ................................ 2.00 (51.0\
)
Ram Van (1/2 & 3/4 Ton) ............................ 2.25 (57.15\
)
Maximum Allowable Diameter ....................... 11.060 (280.92)\
Wheel Cylinder Diameter ............................. .940 (23.88)\
12" Drum
Drum Width
Ram Van (1 Ton) ..................................... 3.50 (88.9\
)
Maximum Allowable Diameter ....................... 12.060 (306.32)\
Wheel Cylinder Diameter
Ram Van
3/4 Ton .......................................... .940 (23.88)\
1 Ton ........................................... 1.060 (27.00)\
13" Drum
Drum Width
Ram Pickup
3/4 Ton ........................................... 2.50 (63.5)\
1 Ton ............................................. 3.50 (89.0)\
Maximum Allowable Diameter ....................... 13.060 (331.72)\
Wheel Cylinder Diameter
Ram Pickup
3/4 Ton .......................................... .940 (23.88)\
1 Ton ............................................. 1.06 (27.0)\









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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Axle Adjustment Nut .............................. 120-140 (163-190)\
Axle Shaft Flange Or Support Plate Mounting Nuts
Dakota .................................................. 47 (64)\
Ram Pickup ........................................ 35-50 (48-68)\
Ram Van ................................................ 85 (115)\
Bearing/Hub Assembly Mounting Bolts ...................... 125 (170)\
Brake Booster Mounting Nuts
Dakota & Ram Pickup ...................................... 21 (29)\
Ram Van .................................................. 13 (18)\
Brake Hose Front Bolt (Dakota) ............................. 21 (29\
)
Brake Hose Front Fitting (Dakota) .......................... 12 (16\
)
Brake Hose Rear Fitting (Dakota) ........................... 14 (19\
)
Brakeline Fittings Combination Valve
Dakota ................................................... 14 (19)\
Ram Pickup ......................................... 14-17 (19-23)\
Brakeline Fittings Master Cylinder
Dakota ................................................... 14 (19)\
Ram Pickup ......................................... 14-17 (19-23)\
Brakeline Fittings Wheel Cylinder
Dakota ................................................... 12 (16)\
Ram Pickup ............................................... 10 (14)\
Brake Pedal Shaft Nut (Ram Van) ............................ 40 (54\
)
Caliper Adapter Bolts (Ram Van)
1/2 Ton ................................................ 130 (176)\
3/4 & 1 Ton ............................................ 210 (285)\
Caliper Mounting Bolts
Dakota (Guide Pins) ...................................... 22 (30\
)
Ram Pickup ............................................... 38 (52)\
Ram Van .................................................. 24 (33)\
Combination Valve Mounting Bolt (Ram Pickup) ............... 17 (23\
)
Diesel Hydraulic Booster Hoses (Ram Pickup) ................ 23 (31\
)
Diesel Hydraulic Booster Lines (Ram Pickup) ................ 21 (29\
)
Diesel Hydraulic Booster Mounting Bolts (Ram Pickup) ....... 21 (29\
)
Drive Flange Lock Nuts (4WD) ............................... 65 (88\
)
Master Cylinder Nuts
Dakota
1998 .................................................... 21 (29)\
1999 .................................................... 13 (18)\
Ram Pickup ............................................... 21 (29)\
Ram Van .................................................. 17 (23)\
Park Brake Pedal Assembly Mounting Bolts/Nuts
Ram Pickup ............................................... 21 (29)\
Ram Van .................................................. 40 (54)\
Pivot Pin .................................................. 30 (41)\
Power Booster Lock Nuts
Dakota & Ram Pickup ...................................... 21 (29)\
Ram Van .................................................. 13 (18)\
Proportioning Valve Brake Hose (Ram Pickup) ................ 23 (31\
)
Proportioning Valve Brakelines (Ram Pickup) .......... 14-17 (19-23\
)
Proportioning Valve Mounting Nuts (Ram Pickup) ............. 25 (34\
)
Wheel Bearing Outer Lock Nut (4WD) ......................... 65 (88\
)
Wheel Cylinder Mounting Bolts
1/4" Bolts (Dakota) ...................................... 11 (15\
)
5/16" Bolts (Dakota) ..................................... 16 (22\
)
Ram Pickup & Ram Van ..................................... 15 (20)\

Wheel Lug Nuts
Dakota .......................................... 85-115 (115-156)\
Ram Pickup
5-Stud Wheel ........................................... 95 (129)\
8-Stud Wheel
Single Wheel ........................................ 135 (183)\
Dual Wheel .......................................... 145 (197)\
Ram Van
15" Wheel (5 Stud) ............................. 80-110 (109-149\
)
16" Wheel (8 Stud) ............................ 120-150 (163-203\
)
INCH Lbs. (N.m)
Locking Hub Allen Screws ........................... 35-45 (4.0-5.0)\









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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

panel and 2H position dot in shift lever insert is 5.75" (14.6 cm).
Make measurement parallel to floor of vehicle.
3) Tighten shift rod lock bolt to 90 INCH lbs. (10 N.m).
Start engine. Shift transfer case through all ranges to verify proper
operation.
NV242 (Dakota)
1) Put shift lever into 4FT position and secure. Raise
vehicle. Loosen shift rod lock bolt at swivel. See Fig. 1. Ensure
shift rod slides freely in adjusting swivel.
2) Ensure transfer case shift lever is in 4FT position. Slide
adjusting swivel forward until shift lever contacts shifter gate
crossover then slide adjusting swivel back, allowing a 0.11-0.20" (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 wheels
are off floor. Start engine. Shift transfer case through all ranges to
verify correct adjustment.
Fig. 1: Adjusting Transfer Case Shift Linkage (Dakota)
Courtesy of Chrysler Corp.

CLUTCH HOUSING (RAM PICKUP)
NOTE: Only NV4500 clutch housing can be checked using the following
bore and face runout procedures. The NV1500, NV3500 and
NV5600 clutch housings are an integral part of transmission
front case and can only be checked off vehicle.
Clutch Housing Bore Runout (NV4500)
1) Remove clutch housing. Remove clutch cover and disc. See
CLUTCH ASSEMBLY under REMOVAL & INSTALLATION. Replace one flywheel
bolt with a threaded rod. See Fig. 2. Remove release fork from clutch
housing. Reinstall clutch housing. Tighten housing bolts nearest
alignment dowels first. Mount dial indicator on threaded rod and
position indicator plunger on surface of clutch housing bore. See
Fig. 4 .
2) Rotate crankshaft until indicator plunger is at top center
of housing bore. Zero dial indicator. Rotate crankshaft and record
indicator readings at 8 points, 45 degrees apart, around bore. See
Fig. 5 .
3) Repeat measurement at least twice. Subtract each reading
from one 180 degrees opposite to determine magnitude and direction of
runout. For example: 0.000" minus (-0.007") = 0.007", 0.002" minus (-\
0.010") = 0.01", 0.004" minus (-0.005") = 0.009" or -0.001" minus (0\
.
001") = -0.002" which will be 0.002". In this example, largest
difference is 0.012" (total indicator reading). This means housing
bore is offset from crankshaft centerline by 0.006" (1/2 of 0.012").
4) On gas engines, acceptable total indicator reading is 0.
010". If measured total indicator reading is more than 0.010", bore
runout will have to be corrected using offset dowels. Offset dowels
are available in 0.007", 0.014" and 0.021". See DOWEL SELECTION table.
If total indicator reading is 0.053" or greater, replace clutch
housing. If dial indicator reads positive when plunger moves inward
(toward indicator) and negative when moves outward away from
indicator), lowest or most negative reading determines direction of
housing bore offset (runout).
5) On diesel engines, offset dowels are not available to
correct runout. If total indicator reading exceeds bore runout of 0.
015", replace either clutch housing, or transmission adapter plate. On
gas engines, if bore is offset, remove housing and original dowels,
install new offset dowels in direction need to center bore with
crankshaft centerline. Install new dowels with slotted side facing
out. Using a screwdriver, rotate dowels until total indicator reading
is less than 0.010". Ensure clutch housing face runout is within
specification.
DOWEL SELECTION









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Application - In. (mm) Offset Dowel - In. (mm\
)
0.011-0.021 (0.2794-0.5334) ......................... 0.007 (0.1778\
)
0.022-0.035 (0.5588-0.8890) ......................... 0.014 (0.3556\
)
0.036-0.052 (0.9144-1.3208) ......................... 0.021 (0.5334\
)









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Fig. 3: Manufactured Stud Or Threaded Rod
Courtesy of Chrysler Corp.

CAUTION: Clutch disc may contain asbestos fibers which can cause
serious health risk. DO NOT sand clutch components. DO NOT
clean components using compressed air. To clean components,
use a water-dampened cloth.
Removal
With transmission and clutch housing removed, mark pressure
plate and flywheel for reassembly reference. Install clutch aligner in
clutch disc to prevent disc from falling. Loosen pressure plate bolts
evenly and in rotation to avoid warping pressure plate. Remove
pressure plate and disc from flywheel. See Fig. 10.
Inspection
1) Check for oil leakage through engine rear main bearing oil
seal and transaxle input shaft seal. Check flywheel and pressure plate
for burned areas, discoloration, cracks, grooves or ridges. Replace as
necessary.
2) Use medium sandpaper (80-180 grade) to clean flywheel
surface, then wipe with mineral spirits. DO NOT flat-machine flywheel
surface. Check facing surfaces for grease or oil contamination. Check
clutch disc for wear. Clutch disc face-to-rivet head distance should
be at least .008" (.20 mm). Check splines of disc hub and transaxle
input shaft.
3) Using straightedge, check pressure plate. Friction area
should be flat to slightly concave, with the inner diameter about 0-.
0039" (0-0.1 mm) less than outer diameter. Using surface plate, check
clutch cover for flatness. Sections around bolt holes should contact
surface plate within .015" (.38 mm). Ensure cover-to-flywheel dowel
fit is snug. Replace clutch assembly as necessary.
NOTE: Before installing clutch disc, ensure flywheel mating
surface, pilot bearing/bushing and clutch release bearing are
in satisfactory condition. Repair and/or replace components
as necessary.
Installation
To install, reverse removal procedure using clutch aligner.
Ensure reference marks are aligned. Tighten pressure plate retaining
bolts evenly a few threads at a time to prevent warpage. See TORQUE
SPECIFICATIONS table.
Fig. 10: Exploded View Of Clutch Assembly (Typical)
Courtesy of Chrysler Corp.
PILOT BEARING, CLUTCH RELEASE BEARING & FORK

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Clutch Master Cylinder Nuts ................................ 40 (54)\
Clutch Slave Cylinder Nuts ................................. 17 (23)\
Crossmember-To-Frame Bolts
AX15 & NV3500 (Dakota) ..................................... 30 (41\
)
NV3500 (Ram Pickup) ........................................ 50 (68\
)
Crossmember-To-Transmission Insulator Nuts
2WD (NV3500 - Ram Pickup) ................................ 50 (68\
)
4WD (NV3500 - Ram Pickup) .......................... 40-45 (54-61\
)
Flywheel Bolts
Dakota 2.5L ................................................ 70 (95)\
Dakota V6 & V8 ............................................. 55 (75)\
Pressure Plate Bolts
5/16" .................................................... 17 (23)\
3/8" ..................................................... 30 (41)\
Transfer Case To Transmission Nuts
AX15 ................................................. 26 (35 N.m)\
NV3500, NV4500, NV4500HD & NV5600
5/16" ............................................. 22-30 (30-41)\
3/8" .............................................. 30-35 (41-47)\
Transmission-To-Clutch Housing Bolts
AX15 ..................................................... 27 (37)\
NV3500 (Ram Pickup) & NV5600 ....................... 40-45 (54-61\
)
NV1500, NV3500 (Dakota), NV4500 & NV 4500HD ............. 80 (108\
)
"U" Joint Clamp Bolts ...................................... 14 (19)\
INCH Lbs. (N.m)
Shift Tower Bolts (NV3500) ............................ 62-89 (7-10\
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