1999 DODGE RAM wheel bolts

Fig. 6: Compressor Components (Sanden MSC90-C Scroll)
Courtesy of chrysler corp.
SANDEN SD-7H15 7-CYLINDER
NOTE: On Cherokee, Dakota, Durango, Ram Pickup and Wrangler,
compressor clutch can be serviced in vehicle, without
discharging A/C system.
CLUTCH ASSEMBLY
Removal (Cherokee, Dakota, Durango, Ram Pickup & Wrangler)
1) Disconnect and isolate negative battery cable. Remove
serpentine drive belt. Disconnect clutch coil harness connector.
Without disconnecting refrigerant lines, remove A/C compressor from
mounting bracket. Support compressor in engine compartment.
2) Using spanner wrench, hold clutch plate and remove
compressor shaft nut. See Fig. 1. Using a steering wheel puller,
remove clutch plate, compressor shaft key and shims. Remove external
front housing snap ring.
3) Install jaws of Rotor Puller (C-6141-1) into pulley snap
ring groove. Install Shaft Protector (C-6141-2) over compressor shaft.\
Install puller flange plate on jaws. Install Puller Through-Bolts (C-
6461) through puller flange plate into jaws and hand tighten. Tighten
pulley center bolt clockwise and remove pulley from compressor.
4) Remove clutch coil wire harness retainer from compressor
housing. Remove clutch coil snap ring and clutch coil.

Installation (Cherokee & Wrangler)
1) Install clutch coil and clutch coil snap ring. Install
clutch coil wire harness to compressor housing. Align pulley and
bearing assembly on front compressor housing hub. Using Installer (C-
6871), press pulley and bearing assembly onto compressor housing hub.
Thread installer on compressor shaft and tighten nut until pulley
assembly is seated.
2) Install external front snap ring with beveled side facing
outward. Ensure snap ring is properly seated. Install compressor shaft
key and original shims. Using a plastic mallet and Driver (C-6463),
install clutch plate on compressor shaft. Tighten compressor shaft nut
to 10 ft. lbs. (14 N.m).
3) Using feeler gauge, measure air gap between clutch plate
and pulley assembly in several areas. Air gap should be 0.016-0.031"
(0.41-0.79 mm). If air gap is not within specification, adjust shim
thickness as necessary. If air gap is not consistent around clutch
plate, lightly pry up or tap down on clutch plate to make corrections.
To complete installation, reverse removal procedure.
Installation (Dakota, Durango & Ram Pickup)
1) Install clutch coil and clutch coil snap ring. Install
clutch coil wire harness to compressor housing. Align pulley and
bearing assembly on front compressor housing hub.
2) Install Handle (6464) and Driver (6143) into pulley
assembly bearing cavity. Ensure outer edge of driver rests firmly on
inner race of bearing. Using hammer, install pulley and bearing
assembly. While tapping on handle, guide pulley and bearing assembly
to prevent binding. Ensure pulley assembly bottoms against compressor
housing. Install external snap ring.
3) Install original shim(s) and compressor shaft key. Use a
hammer and Shaft Protector (6141-2) to install clutch plate on
compressor shaft. Ensure clutch plate bottoms out on clutch shims.
Replace compressor shaft nut and tighten compressor shaft nut to 10
ft. lbs. (14 N.m).
4) Measure air gap between clutch plate and pulley assembly
in several areas. Air gap should be 0.016-0.031" (0.41-0.79 mm). If
air gap is not within specification, adjust shim thickness as
necessary. If air gap is not consistent around clutch plate, lightly
pry up or tap down on clutch plate to make corrections. To complete
installation, reverse removal procedure. Ensure A/C system operates
properly.
5) After completing compressor clutch installation, start
engine. Set A/C-heater control to recirculated air mode and high
blower motor speed. Set engine speed to 1500-2000 RPM. Cycle
compressor on for 5 seconds and off for 5 seconds, about 20 times to
break-in clutch.
Removal (Ford "F" Series Super Duty Pickup)
1) Disconnect and isolate negative battery cable. Discharge
A/C system, using approved refrigerant recovery/recycling equipment.
Disconnect clutch coil harness connector and remove compressor. Drain
oil from compressor, and measure amount drained.
2) Using Spanner Wrench (T70P-4067-A), hold clutch plate and\
remove compressor shaft nut. See Fig. 1. If necessary, use a steering
wheel puller to remove clutch plate and shim(s).
3) Using a flat-blade screwdriver, remove pulley assembly
bearing dust cover. Remove compressor shaft key and internal bearing
snap ring. Remove external front housing snap ring.
4) Install jaws of rotor puller into pulley assembly internal
bearing snap ring groove. Install shaft protector over compressor
shaft. Install puller flange plate on jaws. Install 2 puller bolts
through puller flange plate into jaws and hand tighten. Tighten pulley
center bolt clockwise and remove pulley assembly from compressor.

from housing. To install, reverse removal procedure. Install new "O"
rings to A/C fittings. Evacuate and charge A/C system.
Removal & Installation (Durango - Rear Evaporator Core)
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Remove
headliner from passenger compartment of vehicle. Remove sun visors and
sun visor arm supports.
2) Remove coat hooks, overhead assist handle and dome light.
If equipped, remove overhead console. Remove air outlet bezel from
rear A/C-heater assembly. Remove rear blower motor switch. Remove
upper liftgate opening trim. Disengage "A", "B", "C", and "D" pillar
trim as necessary to prevent trim panel interference.
3) Move second and third row seats to cargo position. Move
front seats to full recline position. Remove headliner fasteners.
Carefully bow headliner and remove through lift gate opening.
4) Disconnect "B" pillar drain hoses from "Y" fittings.
Disconnect "B" pillar refrigerant lines and plug or cover all openings
in A/C system. Remove lower A/C-heater assembly cover. Remove screws
securing refrigerant tube and retaining strap to right side of upper
housing cover. Remove evaporator core. To install, reverse removal
procedure. Install new "O" rings to A/C fittings. Evacuate and charge
A/C system.
Removal & Installation (Ram Pickup - Front)
1) Remove and disassemble A/C-heater housing. See
A/C-HEATER ASSEMBLY . Separate halves of A/C-heater housing and remove
top half. Remove evaporator or heater core from housing.
2) To install, reverse removal procedure. Install new "O"
rings to A/C fittings. Evacuate and charge A/C system. Fill cooling
system. On 5.9L diesel engine, engine is equipped with a one-way check
valve. DO NOT run engine while filling cooling system. Fill engine
with engine turned off.
INSTRUMENT PANEL
Removal & Installation (Dakota & Durango)
1) Disconnect negative battery cable. Disable air bag system.
See AIR BAG SYSTEM SAFETY article. Place front wheels in straight-
ahead position. Remove sill trim from both doorways. Remove kick panel
covers from both sides of vehicle. Remove mounting screws for hood
release handle.
2) Remove steering column trim panel and support bracket.
Remove tilt steering column lever (if equipped). Remove upper and
lower shrouds from steering column. Unplug driver's side air bag
module. Loosen multifunction switch wiring harness connector screw and
disconnect from switch. Screw will remain in connector.
3) Disconnect PRNDL cable. Disconnect shift cable from
steering column. Remove steering coupler lock pin. Remove toe plate
retaining screws. Remove steering column mounting bolts and remove
steering column from vehicle.
4) Remove screw from bulkhead wiring harness connector and
disconnect. Disconnect 2 body wiring harness connectors located next
to bulkhead connector. Disconnect 3 wiring harness connectors, from
junction block, located nearest to dash panel. Disconnect brake light
switch connector. Disconnect Rear Wheel Anti-Lock (RWAL) brake module
(if equipped), located near steering column support brackets.
5) Disconnect plastic retainer clip from parking brake
linkage rod, located at back of parking brake release handle. Remove
rod end from parking brake handle. Remove instrument panel center
support bracket. Unplug vacuum harness connector located at left end
of A/C-heater housing. Disconnect Air Bag Control Module (ACM)
connector.

CALIPER
CAUTION: DO NOT allow caliper to hang by brake hose. Damage to brake
hose could result.
Removal
Raise and support vehicle. Remove front wheels. Remove
caliper guide pins from steering knuckle or mounting bolts from
caliper adapter. Rotate lower end of caliper away from rotor. Slide
upper end of caliper from steering knuckle or caliper adapter. Remove
outer pad from caliper. Remove inner pad from caliper piston. See
Fig. 2 . Support caliper aside. Remove rotor. See ROTOR.
Fig. 2: Exploded View Of Single-Piston (75 mm) Sliding Caliper
(Typical)
Courtesy of Chrysler Corp.
Installation
1) Clean caliper and adapter slide surfaces using wire brush.
Lubricate with multipurpose grease. Remove protective paper from noise
suppression gasket on inner and outer pads (if equipped). Install
anti-rattle clip on top of adapter (if equipped). Install inner pad in\
caliper piston. Install outer pad in caliper. Install rotor. Install
caliper assembly. Install and tighten caliper guide pins (or mounting
bolts) to specification. See TORQUE SPECIFICATIONS table.
2) If caliper overhaul was necessary, install brake hose.
Bleed brake system. See BLEEDING BRAKE SYSTEM. Install wheels. Fill
master cylinder to proper level. Slowly pump brake pedal until firm.
Check master cylinder fluid level. Road test vehicle.

pads at this time. On models with removable hub, install hub on rotor.
Install wheel and tire assembly. Tighten lug nuts so they are snug,
but DO NOT tighten to final torque specifications.
3) While rotating wheel, tighten adjuster nut sufficiently to
seat bearing. Loosen nut and retighten while still rotating wheel.
Back off adjuster nut to completely release bearing preload torque.
Ensure endplay of .001-.003" (.025-.076 mm). Install lock nut and NEW
cotter pin. If necessary, tighten lock nut slightly to align cotter
pin hole. Install grease cap. Tighten caliper bolts and lug nuts to
specification. See TORQUE SPECIFICATIONS table. To complete
installation, reverse remove procedure.
Removal (Ram Pickup With 8 Studs)
1) Raise and support vehicle. Remove wheel. Remove hub
extension, if equipped. Remove brake caliper. Support caliper aside.
2) On models with removable adapter hub, remove hub from
rotor. On models with one-piece hub and rotor assembly, remove cotter
pin from rotor hub nut. Remove nut. Disconnect ABS wheel speed sensor
wire (if equipped), and remove from frame and steering knuckle. Remove\
bolts securing hub to steering knuckle from inboard side of steering
knuckle. Remove rotor and hub assembly.
Installation
1) Apply anti-seize compound to drive shaft splines. Replace
grease seal in steering knuckle, if necessary. Insert 2 rearmost top
and bottom rotor hub bolts in steering knuckle so they extend through
back of knuckle. Install hub spacer, ensuring flat on space is
positioned to rear. Use chassis grease to hold spacer in position, if
necessary.
NOTE: If equipped with wheel speed sensor, brake shield must be
positioned on hub bearing, and sensor wire must be at top of
knuckle.
2) Align rotor hub with drive shaft and install hub assembly.
Align bolt holes in hub flange with bolts previously installed. Start
nuts on flange bolts sufficiently to hold assembly in place. Install
remaining bolts, and tighten all bolts to specification. See TORQUE
SPECIFICATIONS table.
3) Install washer and hub nut. Tighten nut securely. Install
NEW cotter pin. Install grease cap. Install caliper. Tighten caliper
bolts and lug nuts to specification. See TORQUE SPECIFICATIONS table.
To complete installation, reverse remove procedure.
REAR BRAKE SHOES
WARNING: Use water or brake cleaner to clean brake parts. DO NOT use
compressed air to remove dirt and dust.
Removal (Dakota & Ram Van)
1) Remove wheel and drum. Note how secondary spring overlaps
primary return spring. Using spring remover, remove brake shoe return
springs. Slide automatic adjuster cable off anchor. Disconnect cable
from adjusting lever.
2) Remove cable, cable guide and anchor plate. See Figs. 3,
4, and 5. Disconnect adjusting lever return spring from lever. Remove
lever and return spring from pivot pin. Remove shoe-to-shoe spring.
Spread shoes, and remove adjustment star wheel.
3) Remove shoe retainers, springs and pins. Remove parking
brake lever from secondary shoe. Remove shoes and parking brake strut
with spring.

threads. Right side assembly has right-hand threads.
Installation
1) Lubricate and assemble adjustment star wheel. Apply thin
film of multipurpose grease to shoe contact pads on support plate.
Assemble lower shoe-to-shoe spring, adjustment star wheel and both
shoes. Position shoe assembly on support plate.
2) Attach parking brake cable to lever using NEW "U" clip or
"E" clip. Install shoe hold-down pins, springs and retainers. Install
upper shoe-to-shoe spring. Position adjusting lever return spring on
pivot. Install adjusting lever. Route cable, and connect it to
adjuster. Install drum assembly and wheel. Adjust brakes. See REAR
BRAKE SHOES under ADJUSTMENTS.
WHEEL CYLINDERS
Removal & Installation
1) Remove wheel, drum and brake shoes. Inspect boots for
damage and signs of leakage. Disconnect and plug hydraulic brakeline
from wheel cylinder. Remove attaching bolts, and remove cylinder. See
Fig. 5 .
2) Apply silicone sealant to cylinder mounting surface, and
position cylinder on support plate. Start brakeline fitting in wheel
cylinder. Install and tighten mounting bolts. Tighten brakeline
fitting. To complete installation, reverse removal procedure. Fill
brake fluid reservoir, and bleed hydraulic system. See BLEEDING
PROCEDURES under BLEEDING BRAKE SYSTEM.
Fig. 5: Exploded View Of Rear Wheel Cylinder (Typical)
Courtesy of Chrysler Corp.
MASTER CYLINDER & RESERVOIR
NOTE: Manufacturer does not recommend overhaul of master cylinder.
Removal and replacement of reservoir and grommets are the
only recommended service procedures. Replace master cylinder
if faulty.

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)\

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.