1999 DODGE RAM clutch

Fig. 2: Removing Differential Case Components
Courtesy of Chrysler Corp.
NOTE: If any clutch pack components are defective, both clutch
packs must be replaced.

Cleaning & Inspection
1) Clean components with solvent and dry with compressed air.
Inspect plates in clutch pack for scoring, wear or damage.
2) Inspect remaining components for damage or wear. Replace
components if necessary.
Reassembly
1) Lubricate clutch pack components with gear lube.
Reassemble clutch packs. Ensure components are installed in correct
sequence and in original location. See Fig. 1. Install clutch pack
retainers on clutch packs.
2) Install clutch packs on respective side gears. Install
differential case on axle shaft. Install clutch pack and lower side
gear in differential case.
3) Install step plate on lower side gear. Install upper side
gear and clutch pack in differential case. Install threaded adapter
disc into upper side gear. Install forcing screw.
4) Tighten forcing screw to compress clutch packs. Install
pinion gears on side gears. Using turning bar, rotate differential
case until hole in differential case is aligned with pinion gears.
Remove turning bar.
5) Lubricate pinion gear thrust washers with gear lube.
Install pinion gear thrust washers. It may be necessary to tighten
forcing screw until pinion gear thrust washers can be installed.
6) Remove forcing screw, step plate and threaded adapter
disc. Using soft-face hammer, tap pinion shaft into differential case.
Install snap rings on pinion shaft (if equipped).
7) Install NEW roll pin. Stake differential case in 2 areas
to retain roll pin. Remove differential case from axle shaft. Install
ring gear on differential case. Install NEW ring gear bolts. DO NOT
reuse bolts. Tighten ring gear bolts evenly in alternating pattern to
specification. See TORQUE SPECIFICATIONS table.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Applications Ft. Lbs. (N.m)\
Axle Housing Cover Bolt .............................. 30-35 (41-47)\
Ring Gear Bolt
Dakota ................................................... 70 (95)\
All Others ..................................... 120-140 (163-190)\









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* 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

Bracket corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Bracket cracked, affecting
performance ............ A .. Require repair or replacement.
Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket loose, affecting
performance ............ A .. Require repair or replacement.
Bracket loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket missing ......... C ............ Require replacement.
Broken .................. A ............ Require replacement.
Cracked ................. A .. Require repair or replacement.
Disconnected ............ A .. Require repair or replacement.
Frayed .................. A ............ Require replacement.
Kinked .................. A .. Require repair or replacement.
Melted .................. A ........... (1) Require repair or
replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Out of adjustment ....... B ........... ( 2) Require repair or
replacement.
Routed incorrectly ...... 2 ................. Suggest repair.
Seized .................. A .. Require repair or replacement.
Self-adjuster
inoperative ............ A .. Require repair or replacement
of self-adjuster.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Cable replacement is required if it cannot be adjusted
within specifications.









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CARRIER BEARINGS
See INTERMEDIATE SHAFT SUPPORT BEARINGS .
CLUTCH CABLES AND CABLE HOUSINGS
CLUTCH CABLE AND CABLE HOUSING INSPECTION








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Condition Code Procedure
Broken .................. A ............ Require replacement.
Cable bent .............. A ............ Require replacement.
Cable binding ........... A .. Require repair or replacement.
Cable mounting loose .... B .. Require repair or replacement.
Cable out of adjustment . B .. Require repair or replacement.
Frayed .................. B ............ Require replacement.
Housing heat-damaged .... 1 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Seized .................. A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Worn, affecting
performance ............ A ............ Require replacement.









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CLUTCH DISCS (MANUAL TRANSMISSION)
CLUTCH DISC (MANUAL TRANSMISSION) INSPECTION








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Condition Code Procedure
Backing plate cracked ... A ............ Require replacement.
Broken .................. A ............ Require replacement.
Contaminated with oil ... A ............ Require replacement.
Damper cushion broken ... A ............ Require replacement.
Damper cushion
collapsed .............. A ............ Require replacement.
Damper spring collapsed . A ............ Require replacement.
Damper spring missing .. C ........ ( 1) Require replacement.
Friction material cracked
through ................ B ............ Require replacement.
Friction material flaking
or chunking ............ B ............ Require replacement.
Friction material surface
cracking ............... B ......... No service suggested or
required.
Grooved ................. B ......... No service suggested or
required unless the pressure
plate or flywheel is being
resurfaced or replaced. In this
case, replacement of clutch
disc is required.
Ridged .................. B ......... No service suggested or
required unless the pressure
plate or flywheel is being
resurfaced or replaced. In this
case, replacement of clutch
disc is required.
Splines worn, affecting
performance ............ A ............ Require replacement.
Warped .................. A ............ Require replacement.
Wear exceeds
specifications (where
applicable) ............ B ............ Require replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.
( 1) - Not all clutch discs have springs in all spring
chambers on the disc.









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CLUTCH FORKS
CLUTCH FORK INSPECTION








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Condition Code Procedure
Bent .................... B ............ Require replacement.
Broken .................. A .. Require repair or replacement.
Cracked ................. B .. Require repair or replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.









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CLUTCH LINKAGES (MECHANICAL)
See LINKAGES (EXTERNAL) .
CLUTCH MASTER CYLINDERS
CLUTCH MASTER CYLINDER INSPECTION








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Condition Code Procedure
Cover gasket distorted .. A .... Require replacement of cover
gasket.
Cover gasket gummy ...... A .... Require replacement of cover
gasket.
Cylinder leaking fluid
from rear of bore ...... A .. Require repair or replacement.
Cylinder leaking fluid
internally ............. A ............ Require replacement.
Dust boot missing ....... C ..... Require replacement of dust
boot.
Dust boot punctured ..... A ..... Require replacement of dust
boot.
Dust boot torn .......... A ..... Require replacement of dust
boot.
Fluid level incorrect ... B . Require fluid level adjustment.
Housing damaged, affecting
performance ............ A .. Require repair or replacement.
Master cylinder has
residue in reservoir
(make parallel w/brakes
when they are done) .... 2 .......... ( 1) Further inspection
required.
Threads damaged ......... A ...... Require repair replacement
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - DO NOT replace master cylinder unless it exhibits
conditions listed for replacement. You may suggest fluid
change according to OEM service intervals.









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CLUTCH PEDALS
CLUTCH PEDAL INSPECTION








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Condition Code Procedure
Bent, affecting
performance ............ A .. Require repair or replacement.
Broken .................. A .. Require repair or replacement.
Pedal pad missing ....... C .......... Require replacement of
pedal pad.
Pivot bushings worn,
affecting performance .. A .... Require replacement of pivot
bushings.









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CLUTCH PIVOTS
CLUTCH PIVOT INSPECTION








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Condition Code Procedure
Bent .................... A ............ Require replacement.
Broken .................. A .. Require repair or replacement.
Cracked ................. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.









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CLUTCH PRESSURE PLATES
See PRESSURE PLATES .
CLUTCH RELEASE BEARINGS
CLUTCH RELEASE BEARING INSPECTION








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Condition Code Procedure
Collar broken ........... A ............ Require replacement.
Cracked ................. A ............ Require replacement.
Rough when rotated as an
assembly ............... B ............ Require replacement.
Seized .................. A ............ Require replacement.
Wear exceeds
specifications ......... B ............ Require replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.









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CLUTCH SLAVE CYLINDERS (CONCENTRIC)
CLUTCH SLAVE CYLINDER (CONCENTRIC) INSPECTION








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Condition Code Procedure
Bearing rough when rotated
as an assembly ......... B ............ Require replacement.
Bearing seized .......... A ............ Require replacement.
Bleeder pipe leaks ...... A .. Require repair or replacement.
Carrier assembly worn,
affecting performance .. A ........... Require replacement.
Collar broken ........... A ............ Require replacement.
Cracked ................. A ............ Require replacement.
Housing leaks ........... A ............ Require replacement.
Inoperative ............. A ............ Require replacement.
Release binding ......... A ............ Require replacement.
Spring broken ........... A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Worn, affecting
performance ............ A ............ Require replacement.









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CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)
CLUTCH SLAVE CYLINDER (CONVENTIONAL OR EXTERNAL) INSPECTION








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Condition Code Procedure
Binding ................. A .. Require repair or replacement.
Bleeder port damaged (not
repairable) ............ A ........ ( 1) Require replacement.
Bleeder port damaged
(repairable) ........... A ............. ( 1) Require repair.
Bleeder screw broken off
in slave cylinder ...... A ........ ( 1) Require replacement.
Bleeder screw seized .... A ........ ( 2) Require replacement.
Bore corroded (pitted) .. B ............ Require replacement.
Bore grooved ............ A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Only required if the hydraulic system must be opened.
( 2) - Seized is defined as a bleeder screw that cannot be
removed after a practical attempt at removing it has
been made.









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COMPANION FLANGES
See YOKES AND SLIP YOKES .
CONNECTORS
See WIRING HARNESSES AND CONNECTORS .
COOLER BYPASS VALVES
COOLER BYPASS VALVE INSPECTION








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Condition Code Procedure
Inoperative ............. A ............ Require replacement.
Installed incorrectly ... A ................. Require repair.
Leaking ................. A .. Require repair or replacement.
Restricted .............. A .. Require repair or replacement.









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COOLER LINES
COOLER LINE INSPECTION








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Condition Code Procedure
Abrasion damage, affecting
structural integrity ... A .. Require repair or replacement.
Abrasion damage, not
affecting structural
integrity .............. .. ........ No service suggested or
required.
Application incorrect ... B ............ Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.