1999 DODGE RAM clutch

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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CRUIS E C O NTR O L S YSTE M

1999 D odge P ic ku p R 1500
1999 ACCESSORIES & EQUIPMENT
CHRY - Cruise Control Systems
Dakota, Durango, Ram Pickup, Ram Van & Ram Wagon
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.
DESCRIPTION
The speed (cruise) control system is electronically
controlled and vacuum operated. The electronic control is integrated
into the Powertrain Control Module (PCM). System consists of the
following components: Powertrain Control Module (PCM), servo, speed
control switches, vacuum reservoir, vehicle speed sensor, speed
control relay and brake switch.
System controls are located on each side of steering wheel
air bag module and consist of ON/OFF, SET, RESUME/ACCEL, CANCEL AND
COAST buttons. System is designed to operate at speeds above 30 MPH.
OPERATION
SYSTEM CONTROLS
To Set Speed Control
Press ON/OFF button to turn speed control system on.
Accelerate to desired speed (minimum of 35 MPH) and press SET/COAST
button. Vehicle speed will be maintained.
NOTE: Speed control system will automatically disengage when
vehicle speed decreases to less than 35 MPH or increases to
more than 85 MPH.
To Disengage Speed Control
Press brake pedal. Press clutch pedal (M/T). Press CANCEL
button. Press ON/OFF button. If ON/OFF button is used, set speed will
be erased from memory.
To Resume Previous Speed
If set speed has not been erased from memory and vehicle
speed is more than 35 MPH, press RES/ACCEL button.
To Increase Speed
With speed control system on, increase set speed by rapidly
pressing and releasing RES/ACCEL button. Each pressing of button will
cause speed increase of 2 MPH. For example, pressing button 3 times
will increase speed by 6 MPH. To increase speed gradually, hold
RES/ACCEL button down until desired speed is reached. When button is
released, new set speed will be maintained.
To Decrease Speed
With speed control system on, decrease set speed by pressing
SET/COAST button. Vehicle speed will gradually decrease. Releasing
button will set a new speed as long as vehicle speed is still more
than 35 MPH.


DRIV E A XLE S - P O W ER -L O K

1999 D odge P ic ku p R 1500
1998-99 DRIVE AXLES
CHRY - Power-Lok
Ram Pickup
IDENTIFICATION
POWER-LOK DIFFERENTIAL APPLICATION








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Application Axle Ring Axle
Model Gear Size Ratio
Ram Pickup ........ Rear Axle ... 10.5" (266.7 mm) ..... 267 RBI\









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NOTE: For rear axles with limited-slip differentials, see TRAC-LOK
article.
DESCRIPTION & OPERATION
A Rear Beam-Design Iron (RBI) axle is an iron casting axle
and differential housing with axle shaft tubes extending from either
side. Tubes are pressed to form a one-piece full-floating axle
housing.
Power-Lok differential assembly is optional equipment. The
differential assembly is a limited-slip type differential. It is
similar in operation to a conventional type differential, except for 2
clutch packs located at the side gears in the differential case. See
Fig. 1 . Clutch packs provide differential action when required for
turning corners, and transmit equal torque to both wheels when driving
straight ahead.
AXLE RATIO & IDENTIFICATION
Axle ratio can be identified by axle identification tag
attached to axle housing cover. See AXLE RATIO SPECIFICATIONS table.
AXLE RATIO SPECIFICATIONS









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Application Ratio
Ram Pickup ......................................... 3.54:1 & 4.10:1









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WARNING: Whenever rotating wheels, DO NOT use engine to rotate
individual wheels unless both rear wheels are off ground and
vehicle is securely supported.
LUBRICATION
CAPACITY
DRIVE AXLE CAPACITY ( 1)








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Application Pts. (L)\
Ram Pickup ........................................... ( 2) 7.0 (3.3)

TEST II
1) Drive vehicle until differential lubricant is at normal
operating temperature. Place a piece of Kraft paper over a smooth
Formica board. Place Formica board with Kraft paper under one rear
wheel. Rear wheel should be centered on board on level surface.
2) Block one front tire with a 2" high by 3" wide wooden
block. Start vehicle. With gradual throttle pressure, attempt to
slowly drive vehicle over wooden block.
3) If Kraft paper slips out from under rear wheel before
vehicle drives over wooden block, move Formica board and Kraft paper
under the other rear wheel.
4) With gradual throttle pressure, attempt to slowly drive
vehicle over wooden block again. If vehicle drives over wooden block
with Formica and Kraft paper under either rear wheel, drive axle is
functioning properly.
REMOVAL & INSTALLATION
Servicing procedure is same as that used for a standard
differential. See appropriate RBI FULL-FLOATING AXLES article for
servicing procedures.
OVERHAUL
DIFFERENTIAL CARRIER
CAUTION: Mark all component locations for reassembly reference. Note
position of clutch pack components before removal. Install
clutch pack components in correct order and original
locations.
Disassembly
1) Place reference mark on differential case lower half and
upper half for reassembly reference. Also place reference mark on
pinion cross shaft and differential case lower half for reassembly
reference.
2) Remove differential case half retaining bolts. Remove
differential case upper half. Remove components from differential case
lower half. See Fig. 1.
Fig. 1: Exploded View Of Power-Lok Differential
Courtesy of Chrysler Corp.
Cleaning & Inspection
Clean components with solvent, and dry with compressed air.

Inspect clutch components for scoring, wear or damage. Replace
components if necessary.
NOTE: If any clutch pack components are defective, replace both
clutch packs.
NOTE: Ensure axle shaft is positioned in vise so splines on axle
shaft extend approximately 3.00" (76.2 mm) above top of
vise.
Reassembly
1) Place axle shaft that was removed from differential in
soft-jaw vise with splines facing upward to serve as an alignment
device for component assembly.
2) Lubricate all components with gear lube. Assemble
components on axle shaft. Ensure all clutch plates are saturated with
gear lube. Install all clutch components and clutch ring on each side
gear. Ensure components are installed in proper sequence and in
original location. See Fig. 1.
3) Align all tabs on clutch plates, and secure with retaining
clips. Remove clutch component/side gear assembly from axle shaft.
Install assembly in differential case lower half. Ensure clutch is
fully seated in differential case lower half.
4) Install pinion cross shaft and pinion gears is
differential case lower half. Ensure reference marks on pinion cross
shaft and differential case lower half are aligned.
5) Install remaining clutch components and side gear on
differential case lower half. Install differential case upper half on
differential case lower half with reference marks aligned.
6) Install differential case half retaining bolts finger
tight. Place differential case assembly on axle shaft mounted in vise.
Ensure splines on axle shaft engage with side gear splines.
7) Install other axle shaft through differential case upper
half and into side gear. Ensure splines on axle shaft engage with side
gear splines. This must be done to ensure proper alignment of all
components.
NOTE: Different grade differential case half retaining bolts may be
used. Note number of radial lines on head of the bolt before
tightening bolts, as different torque specifications are
used.
8) Ensure both axle shafts are fully engaged. Tighten
differential case half bolts evenly in alternating pattern to
specification. See TORQUE SPECIFICATIONS table.
9) Remove axle shaft. Remove differential case assembly from
axle shaft in vise. Ensure pinion cross shaft is relatively tight on
its ramp. Clearance should not exceed .010" (.25 mm) and should be
equal at all 4 areas.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Applications Ft. Lbs. (N.m)\
Axle Housing Cover Bolt .................................... 30 (41)\
Differential Case Half Bolt
7 Radial Lines Or No. 180 Stamp ................. 90-100 (122-136)\
All Others ......................................... 65-70 (88-95)\









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DRIV E A XLE - R BI F U LL F LO ATIN G A XLE

1999 D odge P ic ku p R 1500
1998-99 DRIVE AXLES
CHRY - RBI Full-Floating Axles
Ram Pickup, Ram Van/Wagon
IDENTIFICATION
REAR DRIVE AXLE APPLICATION








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Application Axle Ring Axle
Model Gear Size Ratio
Ram Pickup ....... 248 RBI .......... 9.75" ... 3.55:1 Or 4.10:1
Ram Pickup ....... 267 RBI ......... 10.50" ... 3.54:1 Or 4.10:1
Ram Pickup ....... 286 RBI ......... 11.00" ... 3.54:1 Or 4.10:1
Ram Van/Wagon .... 248 RBI .......... 9.75" ... 3.55:1 Or 4.10:1









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DESCRIPTION & OPERATION
The Rear Beam-Design Iron (RBI) axle is an iron center
casting (differential housing) with axle shaft tubes extending from
both sides. The tubes are pressed in to form a one-piece axle housing.
Axle contains an integral carrier with hypoid-type ring gear
and pinion with a solid full-floating axle shaft splined into side
gear. Vehicle weight is supported on tubes of axle housing. Axle
shafts may be serviced without disturbing wheel bearings. On vehicles
equipped with Rear Wheel Anti-Lock (RWAL) brakes, a brake sensor is
mounted on top of axle housing and an exciter ring is mounted on ring
gear.
Axles may be equipped with limited-slip differential. Models
248 and 286 RBI use a Trac-Lok differential and Model 267 RBI uses a
Power-Lok differential as optional equipment. Trac-Lok differential
uses a one-piece case. Power-Lok differential uses a 2-piece case.
Both differentials use same internal components as a standard
differential, except 2 clutch packs are used in the differential case.
NOTE: For servicing of limited-slip differential components in
differential case, see appropriate POWER-LOK or TRAC-LOK
article.
AXLE RATIO & IDENTIFICATION
NOTE: Axle ratio can be identified by axle identification tag
attached to axle housing cover. For axle ratio, see REAR
DRIVE AXLE APPLICATION table at beginning of article.
LUBRICATION
CAPACITY
DRIVE AXLE CAPACITY ( 1)








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Application Pts. (L)\
Ram Pickup
248 RBI ................................................ 6.3 (3.0)\


DRIV E A XLE - T R AC -L O K

1999 D odge P ic ku p R 1500
1998-99 DRIVE AXLES
CHRY - Trac-Lok
Dakota, Ram Pickup, Ram Van/Wagon
IDENTIFICATION
TRAC-LOK DIFFERENTIAL APPLICATION (REAR AXLE)








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Model Ring Gear Axle
Size Model
Dakota .................... 8 1/4" ........................... ( 1)
Ram Pickup ............ 9 3/4" ....................... 248 RBI
10 3/4" ....................... 267 RBI
11" ....................... 286 RBI
Ram Van/Wagon ............. 9 3/4" ....................... 248 RBI
( 1) - Manufacturer does not designate axle model.









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NOTE: For rear axles with limited-slip differentials, see POWER-LOK
- RAM PICKUP article.
DESCRIPTION & OPERATION
A Rear Beam-Design Iron (RBI) axle is an iron casting axle
and differential housing with axle shaft tubes extending from either
side. Tubes are pressed in to form a one-piece full-floating axle
housing.
Trac-Lok differential assembly is optional equipment. The
Trac-Lok differential assembly is a limited-slip type differential. It
is similar in operation to a conventional type differential, except
for 2 clutch packs located at the side gears in the differential case.
See Fig. 1 . Clutch packs provide differential action when required for
turning corners, and transmit equal torque to both wheels when driving
straight ahead.
AXLE RATIO & IDENTIFICATION
Axle ratio can be identified by axle identification tag
attached to axle housing cover. See AXLE RATIO SPECIFICATIONS table.
AXLE RATIO SPECIFICATIONS









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Application Ratio
Dakota ..................................... 3.21:1, 3.55:1 & 3.92:1
Ram Pickup
248 RBI .......................................... 3.55:1 & 4.10:1
267 & 286 RBI .................................... 3.54:1 & 4.10:1
Ram Van/Wagon ...................................... 3.55:1 & 4.10:1









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WARNING: Whenever rotating wheels, DO NOT use engine to rotate wheels
unless both rear wheels are off the ground and vehicle is
securely supported.

TESTING
NOTE: Trac-Lok differential can be tested without removing
differential case from axle housing.
1) Place blocks under both front wheels. Ensure engine is off
and transmission is in Neutral. Release parking brake. Raise one rear
wheel until it is completely clear of the floor. Remove wheel. Install
Adapter (6790) to wheel studs and tighten securely.
2) Using torque wrench on adapter, rotate axle and record
torque required. Repeat procedure for remaining rear wheel position.
If rotational torque for either rear wheel is less than 30 ft. lbs.
(40.1 N.m) or greater than 200 ft. lbs. (271 N.m), Trac-Lok unit mus\
t
be replaced or repaired.
REMOVAL & INSTALLATION
Servicing procedure is same as that used for standard
differential. See RBI FULL FLOATING AXLES article for servicing
procedures.
OVERHAUL
DIFFERENTIAL CARRIER
Disassembly
1) Place appropriate side gear holding tool in soft-jaw vise.
Position differential carrier on holding tool. Remove ring gear, if
necessary. Ring gear removal is only necessary when ring gear is being
replaced.
2) Remove roll pin holding pinion mate shaft into housing.
Remove pinion gear mate shaft. A drift and hammer can be used if
necessary. See Fig. 1.
3) Install appropriate Step Plate on lower side gear. Install
appropriate threaded forcing screw into upper side gear. See Fig. 2.
4) Thread Forcing Screw into threaded adapter disc until
forcing screw is centered in threaded adapter disc. Perform STEP 1
shown in illustration. See Fig. 2.
5) Place small screwdriver in slot of threaded adapter disc
to prevent disc from rotating. Tighten forcing screw to relieve
tension from clutch pack.
6) Remove pinion gear thrust washers. Loosen forcing screw to
release pressure from clutch pack. Install appropriate turning bar in
hole on side of differential case. Perform STEP 2 shown in
illustration. See Fig. 2.
7) Using turning bar, rotate differential case until pinion
gears can be removed. Remove pinion gears. Remove turning bar, forcing
screw, step plate, and threaded adapter disc from differential case.
8) Remove upper side gear and clutch pack. See Fig. 1. Remove
differential case from axle shaft. Remove remaining side gear and
clutch pack from differential case.
CAUTION: Mark clutch pack location for reassembly reference. Note
position of clutch pack components before removing clutch
pack retainers. Clutch packs must be assembled in correct
order and installed in original location.
9) Remove clutch pack retainers from clutch pack. Keeping
clutch pack components in correct order, disassemble clutch pack.