1999 DODGE RAM length

6) Remove glove box. Reach through glove box opening and
disconnect antenna coaxial cable connector. Disconnect blower motor
connector located above glove box opening, near support brace for A/C-
heater housing. Disconnect radio ground strap. Loosen instrument panel
roll down bracket bolts about 2 turns, located at lower corners on
both sides of instrument panel. Remove 5 screws across top of dash
panel at base of windshield, removing center screw last.
7) Roll down instrument panel and install a temporary support
hook that is about 18" (457 mm) in length. Install hook from center
hole in instrument panel to center hole of dash panel. Pull lower
instrument panel outward until both roll down bracket bolts are in
slotted roll down position. Instrument panel should now be supported
and away from firewall.
8) Disconnect 2 door harness connectors, located on a bracket
near right end of instrument panel. Disconnect blower motor resistor.
Disconnect temperature control cable from A/C-heater housing and
remove from housing. See Fig. 5. Disconnect demister duct flexible
hose from A/C-heater housing.
9) Ensure instrument panel is free and clear for removal.
With the aid of an assistant, remove temporary support hook. Lift
instrument panel off of roll down bracket bolts and remove from
vehicle.
10) To install, reverse removal procedure. Ensure all wiring
and hoses are clear and not pinched. Tighten bolts and nuts to
specification. See TORQUE SPECIFICATIONS . Enable air bag system. See
AIR BAG SYSTEM SAFETY article.
Removal & Installation (Ram Pickup)
1) Disable air bag system. See AIR BAG SYSTEM SAFETY article.
Disconnect negative battery cable. Drain cooling system. Remove left
and right kick panel trim. Remove 5 screws and knee bolster/steering
column cover. Remove hood release and parking brake release handle
screws from lower instrument panel support. Remove 6 screws and
instrument panel support. Disconnect air bag connector at lower left
corner of instrument panel.
2) Pull PRNDL cable and twist to remove from position arm.
Push tab on bottom of cable retainer upward, then squeeze sides to
remove retainer from column. Remove tilt lever (tilt column only).
Remove both upper and lower shrouds from column. Remove lower fixed
column shroud. Loosen multifunction switch connector screw. Screw will
remain in connector.
3) Remove remaining steering column electrical connectors.
Remove air bag wiring harness from steering column wiring trough.
Remove wiring trough from steering column. Remove 3 toe plate nuts and
washers.
4) Remove 2 nuts and washers attaching steering column
bracket to instrument panel steering column support bracket. Allow
column to lower and rest on seat. Remove 2 screws from bottom of Air
Bag Control Module (ACM) cover. Remove 4 screws holding ACM to
transmission tunnel.
5) Disconnect wiring at ACM. Disconnect instrument panel left
side wiring connectors. Remove screw holding brake release to bottom
of instrument panel. Disconnect instrument panel right side wiring
connectors, which includes 2 connectors attached to A/C-heater
assembly housing, courtesy light connector, antenna cable and 2 body
connectors. Disconnect vacuum harness from A/C-heater system.
6) Remove 5 screws holding instrument panel to dash. Loosen
lower instrument panel pivot bolts. Roll instrument panel downward.
Remove instrument panel from vehicle.
7) To install, reverse removal procedure. Ensure all wiring
and hoses are clear and not pinched. Tighten bolts and nuts to
specification. See TORQUE SPECIFICATIONS . Enable air bag system. See
AIR BAG SYSTEM SAFETY article.

Because R-134a is not interchangeable with R-12, separate
sets of hoses, gauges, and recovery/recycling equipment are required
to service vehicles. This is necessary to avoid cross-contamination
and damaging system.
All equipment used to service systems using R-134a must meet
SAE standard J2210. The service hoses on the manifold gauge set must
have manual (turn wheel) or automatic back-flow valves at the service
port connector ends. This will prevent refrigerant from being released
into the atmosphere.
For identification purposes, R-134a service hoses must have a
Black stripe along their length and be clearly labeled SAE J2196/134a.
The low pressure test hose is Blue with a Black stripe. The high-side
test hose is Red with a Black stripe. The center test hose is Yellow,
or White, with a Black stripe.
NOTE: Refrigerant R-12 service hoses will ONLY be labeled SAE
J2196.
All R-134a manifold gauge sets can be identified by one or
all of the following:
* Labeled FOR USE WITH R-134a on set.
* Labeled HFC-134 or R-134a on gauge face.
* Light Blue color on gauge face. In addition,
pressure/temperature scales on R-134a gauge sets are
different from R-12 manifold gauge sets.
MANIFOLD GAUGE SET
A manifold gauge set is used to determine the system's high-
side and low-side pressures, correct refrigerant charge, and operating
efficiency. High (discharge) and low (suction) pressures must be
compared to determine system operation. Manifold gauge sets for the 2
refrigerant types are basically the same except for fittings at ends
of hoses. Fittings are different to ensure connection only to
appropriate refrigerant system.
Low-Side Gauge
Low-side gauge, which may have a Blue identifying feature, is
used to measure low-side (suction) pressure. Low-side gauge is also
called a compound gauge because it can measure pressure and vacuum.
Pressure scale ranges from 0 to 150 psi; vacuum scale ranges from 0 to
30 in. Hg.
High-Side Gauge
High-side gauge, which may have a Red identifying feature, is
used to measure high-side (discharge) pressure. Gauge scale ranges
from 0 to 500 psi.
CONNECTING GAUGE SET
NOTE: R-134a quick disconnect service couplings are connected in
the same sequence as Schrader-type service valves.
Schrader-Type Valves
1) Put on safety goggles, and cover vehicle's fender. Slowly
remove protective caps from Schrader valves to check for leaky valves.
CAUTION: Ensure hand valves on manifold gauge set and the hose-end
shutoff valves are closed before attaching test hoses to
Schrader valves.

1) Manufacturer recommends flushing contaminated system using
one gallon of Ford A/C System Flushing Solvent (F4AZ-19579-A), a
Filter (FL-1A), an A/C Flusher Fitting Kit (014-00992). DO NOT reuse\
flushing solvent and filter, they are intended to be used on one
vehicle only.
2) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Flush specified A/C components using A/C
System Flusher (014-00991), according to manufacturer's operating
instructions.
3) If an A/C system flusher is not available to clean A/C
system, an in-line filter kit can be used. Filter kit is installed
before replacement compressor, accumulator/receiver-drier, muffler,
and thermal expansion valve/fixed orifice tube have been installed.
4) Filter kits are used with either a rubber lined suction
hose or with a nylon lined suction hose located between compressor and
evaporator. Rubber lined hose has a wall thickness of 1/4" and nylon
lined hose has a wall thickness of 1/8". See Fig. 22.
5) The filter kit for either type hose has 2 filters. A
temporary pancake filter and a permanent in-line suction filter.
Pancake filter is temporarily installed between condenser and
condenser-to-evaporator line. See Fig. 23. Permanent filter is
installed in suction line between accumulator and compressor.
6) Install replacement components (compressor, accumulator
and fixed orifice) with correct amount of refrigerant oil. See
COMPRESSOR REFRIGERANT OIL CHECKING article.
7) Cut suction hose between compressor and accumulator
(closer to compressor). Remove a length of suction hose to accommodate\
suction filter. Measure side wall of suction hose and install
appropriate filter with "O" rings and filter clamps. If side wall is
1/4", use in-line filter labeled USE WITH RUBBER INNER LINED HOSE. If
side wall is 1/8", use in-line filter labeled USE WITH NYLON INNER
LINED HOSE. Ensure arrow on filter is pointing in direction of
refrigerant flow. Tighten hose clamps to 54 INCH lbs. (6 N.m). See
Fig. 22 .
8) Install pancake filter in liquid line between condenser
and condenser-to-evaporator line. Ensure filter inlet (label) is
toward condenser. Evacuate, charge, and leak test A/C system. See
EVACUATING A/C SYSTEM, CHARGING A/C SYSTEM and LEAK TESTING. Check
filters and hoses for clearance from other engine components. Use tie
straps if necessary.
9) Place an external cooling fan in front of radiator. Select
MAX A/C operation and set blower motor speed to maximum. Start engine
and allow to idle. Ensure A/C is operating properly. Slowly increase
engine speed to 800 RPM, then 1000 RPM, and then to 1200 RPM. With
engine speed set to 1200 RPM, operate engine for one hour with A/C
system operating.
10) Stop engine. Discharge A/C system, using approved
refrigerant recovery/recycling equipment. Remove pancake filter, hoses
and fittings. Discard pancake filter. Reconnect liquid line, evacuate,
charge, and leak test A/C system. Ensure A/C system is operating
properly.

COMPONENT LOCATIONS
COMPONENT LOCATIONS








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Component Location
ABS Control Module
Ram Pickup ....................... Left Side Of Engine Compartment
Ram Van/Wagon ...................................... Under Battery
Data Link Connector (DLC) ...... Lower Left Side Of Instrument Panel\
Output Shaft Speed Sensor (OSS) .......... Left Side Of Transmission\
Park/Neutral Position (PNP) Switch ....... Left Side Of Transmission\
Powertrain Control Module (PCM)
Dakota & Durango ............... Right Front Of Engine Compartment
Ram Pickup ............... Right Rear Corner Of Engine Compartment
Ram Van/Wagon ..................... Under Hood Next To Wiper Motor
Vehicle Speed Sensor (VSS) ........ On Transmission Or Transfer Case\
Extension Housing









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TROUBLE SHOOTING
ROAD TEST
Perform a road test to verify speed control malfunctions.
Ensure speedometer operation is smooth without flutter at all speeds.
Speedometer fluttering may cause surging in speed control system. For
speedometer diagnosis, see appropriate INSTRUMENT PANELS article. If
road test verifies a surge following speed control set and speedometer
operates smoothly, see OVERSHOOT/UNDERSHOOT FOLLOWING SPEED CONTROL
SET.
If road test verifies an inoperative system, and speedometer
operates smoothly, check for:
* Diagnostic Trouble Codes (DTCs). See SELF-DIAGNOSTIC
SYSTEM.
* Misadjusted brake switch. See BRAKE SWITCH under REMOVAL &
INSTALLATION.
* Poor electrical connections at servo.
* Leaking vacuum reservoir, check valve, hoses or connections.
See VACUUM SUPPLY under COMPONENT TESTS.
* Secure attachments of S/C servo cable.
* Smooth operation of throttle linkage.
* Defective PCM or wiring.
* Defective servo. See SPEED CONTROL SERVO under COMPONENT
TESTS.
To verify a speed control electronic malfunction, use scan
tool to check for DTCs. See SELF-DIAGNOSTIC SYSTEM. A speed control
malfunction may occur without setting a FTC. If no DTCs are stored, go
to CHECKING SPEED CONTROL OPERATION under SYSTEM TESTS.
OVERSHOOT/UNDERSHOOT FOLLOWING SPEED CONTROL SET
If operator repeatedly presses and releases set button with
their foot off accelerator (lift foot set) to begin speed control
operation, vehicle may accelerate and exceed desired set speed by 5
MPH and then decelerate to less than desired set speed before
achieving desired set speed.
Speed Control (S/C) has as adaptive strategy that compensates\
for variations in S/C cable lengths. When S/C is set with vehicle

DRIV E S H AFTS & " U " J O IN TS - R W D

1999 D odge P ic ku p R 1500
1998-99 Drive Axles
CHRY - Drive Shafts & "U" Joints - RWD Trucks
Dakota, Ram Pickup, Ram Van/Wagon
DESCRIPTION
Drive shafts are balanced, tubular shafts with "U" joints
attached at each end. Flanges or yokes are used to connect drive shaft
"U" joints to rear differential pinion flange or to transmission
output shaft. "U" joint bearing caps are bolted to shaft flanges, or
are pressed into shaft yokes. Drive shafts can be steel or aluminum.
Number of drive shafts used by vehicle depends on vehicle
length and 4WD capability. Long wheel base vehicles use 2 rear drive
shafts with a center bearing support assembly. See Fig. 1. 4WD
applications use a double cardan constant velocity joint on front axle
drive shaft for correct drive shaft-to-front axle alignment. See
Fig. 12 .
Locations of slip joints and splined shafts vary with model
application. Single tube type drive shaft has slip joint on outside of
"U" joint flange/yoke. This slip joint slides in and out on
transmission's splined main shaft.
Fig. 1: Identifying Common Drive Shaft Combinations
Courtesy of Chrysler Corp.
LUBRICATION

1) On drive shafts greater than 30" in length, measure runout
3" from transmission flange/yoke, center bearing yoke and pinion
flange using dial indicator. Maximum runout for Ram Pickup is .030" (.
76 mm) at front and rear end of drive shaft and .035" (.89 mm) at
center of drive shaft. Maximum runout for all other models is .010" (.
25 mm) at front and rear end of drive shaft and .015" (.38 mm) at
center of drive shaft.
2) For drive shafts less than 30" in length, maximum runout
for Pickup is .030" (.76 mm). Maximum runout for all other models is .\
020" (.51 mm). Replace drive shaft if maximum runout is exceeded.
BALANCING DRIVE SHAFT
1) Perform following procedure only after inspecting all
other possible causes of vibration. See INSPECTION. Drive shaft
imbalance may often be cured by disconnecting shaft, rotating it 180
degrees and reconnecting shaft to flange. Test drive to check results.
NOTE: DO NOT run engine for prolonged periods without forced
airflow across radiator. Engine or transmission may
overheat.
2) To balance drive shaft(s), begin by raising rear wheels
off ground and turning drive shaft with engine. Balance testing may be
done by marking drive shaft in 4 positions, 90 degrees apart around
shaft. Place marks about 6" forward of rear flange/yoke weld. Number
marks 1-4.
3) Install large diameter screw-type hose clamp around drive
shaft so clamp's head is in No. 1 position. Spin drive shaft with
engine and note vibrations. If there is little or no change in
vibration intensity, move clamp head to No. 2 position, and repeat
test.
4) Continue procedure until vibration is at lowest level. If
no difference is noted with clamp head moved to all 4 positions,
vibrations may not be due to drive shaft imbalance.
5) If vibration decreases but is not completely eliminated,
place a second clamp at same position, and repeat test. Combined
weight of both clamps in one position may increase vibration. If so,
rotate clamps 1/2" apart, above and below lowest vibration level
position, and repeat test.
6) Continue to rotate clamps, as necessary, until vibration
is at lowest point. If vibration can be eliminated or reduced to
acceptable level, bend back slack end of clamp so screw cannot loosen.
If vibration level is still unacceptable, leave rear clamp(s) in
place, and repeat procedure at front end of drive shaft. Road test
vehicle. On 4WD models, perform procedure on each shaft.
CHECKING VERTICAL ANGLE
One-Piece Drive Shafts
1) Raise and support vehicle so rear wheels can be rotated.
Rotate drive shaft so a pinion flange bearing cap faces downward.
Attach Inclinometer (C-4224) magnet to bearing cap, and measure drive
shaft vertical angle. See Fig. 4. Remove inclinometer.
2) Rotate drive shaft 90 degrees until drive shaft rear yoke
bearing cap faces downward. Attach inclinometer magnet to bearing cap,
and measure drive shaft vertical angle. Difference between 2 measured
angles is drive shaft rear angle. See Fig. 5. Remove inclinometer.
3) Rotate drive shaft until a slip joint yoke bearing cap
faces downward. Attach inclinometer magnet to bearing cap, and note
angle. Remove inclinometer. Rotate drive shaft 90 degrees until drive
shaft front yoke bearing cap faces downward. Attach inclinometer
magnet to bearing cap, and note angle. Remove inclinometer.

CYLINDER HEAD
Cylinder Head
Check cylinder head warpage. Repair or replace cylinder head
if warpage exceeds specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS.
Valve Springs
1) Check valve spring free length, out-of-square and
pressure. Replace valve spring if not within specification. See VALVES
& VALVE SPRINGS table under ENGINE SPECIFICATIONS.
2) Measure valve spring installed height from bottom of
spring seat (cylinder head surface) to bottom of spring retainer. If
spacers are installed, measure from top of spacer.
3) If height exceeds 1.687" (42.86 mm), install a .066" (1.\
58
mm) thick spacer in cylinder head counterbore to obtain correct
installed spring height. See VALVES & VALVE SPRINGS table.
Valve Stem Oil Seals
Cup-type oil seals are used on all valves. Ensure oversize
valve stem oil seals are used when oversize valves are installed. When
installing valves, DO NOT overcompress valve springs, or damage to
valve stem oil seal may result.
NOTE: DO NOT ream valve guides from standard to maximum oversize in
one step. Ream valve guides to oversize in gradual steps so
guides are reamed true in relation to valve seat. After
reaming valve guides, valve seat runout must be checked.
Valve Guides
Check valve stem oil clearance. Ensure valve stem diameter is
within specification. Valve guide must be reamed for valve with
oversize valve stem if oil clearance exceeds specification. See
CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valves are available
with stems of .015" (.38 mm) and .030" (.76 mm) oversize.
Valve Seat
Check valve seat width and runout. Grind valve seat if not
within specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS.
Valves
Ensure valve margin, head diameter and stem diameter are
within specification. See VALVES & VALVE SPRINGS table under ENGINE
SPECIFICATIONS. Valves are available with stems of .015" (.38 mm) and
.030" (.76 mm) oversize.
Valve Seat Correction Angles
Use a 15-degree stone to lower valve seat, and a 60-degree
stone to raise valve seat.
VALVE TRAIN
Rocker Arms & Pivots
Remove rocker arms and pivots. Inspect for wear. Replace as
necessary.
NOTE: Cylinder block must be marked to indicate oversize valve
lifters. See SPECIAL ENGINE MARKS.
Valve Lifters
Measure valve lifter diameter and bore diameter in cylinder

Remove bolts and oil pump from rear main bearing cap.
2) Remove cotter pin. Drill a 1/8" (3.17 mm) hole into relie\
f
valve retainer cap and insert a self-tapping sheet metal screw into
cap. Clamp screw into vise. While supporting pump, remove retainer cap
by tapping pump body using soft-face hammer.
3) Discard retainer cap, and remove spring and relief valve.
Remove pump cover and discard oil seal ring. Remove inner rotor and
shaft and outer rotor. See Fig. 19.
Fig. 19: Exploded View Of Oil Pump Assembly
Courtesy of Chrysler Corp.
Inspection
1) Inspect components for damage. Using feeler gauge and
straightedge, check pump cover flatness. Measure thickness of inner
and outer rotors. Measure outer rotor outside diameter. Replace rotors
if not to specification. See OIL PUMP SPECIFICATIONS table.
2) Install outer rotor into pump body. Press outer rotor to
one side, and measure clearance between outer rotor and pump body.
Replace oil pump assembly if clearance exceeds specification. See OIL
PUMP SPECIFICATIONS table.
3) With outer rotor installed in pump body, install inner
rotor and shaft into pump body. Measure rotor tip clearance between
inner and outer rotors. Replace rotors if clearance exceeds
specification. See OIL PUMP SPECIFICATIONS table.
4) With rotors installed in pump body, place a straightedge
(between bolt holes) across face of pump body. Measure rotor end
clearance between rotors and straightedge. Replace oil pump assembly
if clearance exceeds specification. See OIL PUMP SPECIFICATIONS table.
5) Ensure relief valve slides freely in bore. Check free
length and tension of relief valve spring. Replace spring if not
within specification. See OIL PUMP SPECIFICATIONS table.