Dodge Ram 1500-2500-3500 Pickup Truck 1999-2009 Workshop Repair & Service Manual (1.3 GB PDF, COMPLETE & INFORMATIVE for DIY REPAIR) ☆ ☆ ☆ ☆ ☆
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This highly detailed workshop service repair manual for download contains virtually everything you will ever need to repair, maintain, rebuild, refurbish or restore Dodge Ram 1500-2500-3500 Pickup Truck 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009. All diagnostic and repair procedures and gives you access to the same information that professional technicians and mechanics have. You can view and print out the complete repair procedures with this workshop service repair manual Download - you do not need to be skilled with a computer.
GROUP TAB LOCATOR
0 Lubrication & Maintenance
3 Differential & Driveline
4 Vehicle Quick Reference
8E Electronic Control Modules
8F Engine Systems
8G Heated Systems
8I Ignition Control
8J Instrument Cluster
8M Message Systems
8N Power Systems
8P Speed Control
8Q Vehicle Theft Security
11 Exhaust System
13 Frame & Bumpers
14 Fuel System
21 Transmission and Transfer Case
24 Heating & Air Conditioning
25 Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)
Vehicles with a gasoline engine are equipped with a single 12-volt battery. All of the components of the battery system are located within the engine compartment.
The battery system for this vehicle, covers the following related components:
*). Battery (2) - The storage battery provides a reliable means of storing a renewable source of electrical energy within the vehicle.
*). Positive Battery cable (1) - The positive battery cable connects the battery positive terminal post to the vehicle electrical system, starter and alternator.
*). Negative Battery Cable (3) - The negative battery cable connects the battery negative terminal post to the vehicle electrical system through body, chassis and engine grounding points.
*). Battery Thermal Guard (5) - A thermal guard wraps around the battery case to enclose the sides of the battery. The thermal guard consists of a heavy black plastic outer skin and two lighter plies of plastic that have been formed into a sheet with hundreds of small air pockets entrapped between them.
*). Battery Holddown - The battery holddown hardware secures the battery in the battery tray in the engine compartment.
*). Battery Tray - The battery tray provides a secure mounting location in the vehicle for the battery and an anchor point for the battery holddown hardware.
Vehicles with a diesel engine utilize two 12-volt batteries connected in parallel. All of the components of the battery system are located within the engine compartment. The battery system for this vehicle, covers the following related components:
*). Left Battery (3) - The Left storage battery provides a reliable means of storing a renewable source of electrical energy within the vehicle.
*). Right Battery (5) - The Right storage battery provides a reliable means of storing a renewable source of electrical energy within the vehicle as well as the additional required electrical energy due to high demands of the diesel system.
*). Positive Battery cables (2 & 6) - The positive battery cables connect the battery positive terminal
posts to the vehicle electrical system, starter and alternator as well as connecting the two batteries together.
*). Negative Battery Cables (1 & 4) - The negative battery cables connect the battery negative terminal posts to the vehicle electrical system through body, chassis and engine grounding points.
*). Battery Thermal Guard - A thermal guard wraps around the battery case to enclose the sides of the battery. The thermal guard consists of a heavy black plastic outer skin and two lighter plies of plastic that have been formed into a sheet with hundreds of small air pockets entrapped between them.
DIFFERENTIAL CASE BEARING PRELOAD AND GEAR BACKLASH
Backlash is adjusted by moving the adjusters in and out or both. By moving the adjusters the case/ring gear will move closer or further away from the pinion.
In most cases this adjustment can be used to achieve the correct gear tooth pattern and set the case bearing
1. Remove adjuster lock bolts (3) and adjuster locks (2).
2. Loosen the differential bearing cap bolts (4).
3. Slide differential case (1) toward the pinion gear until the gears make contact/zero backlash. If zero backlash cannot be obtained, turn the pinion side adjuster until zero backlash is obtained.
4. Holding the differential case (2) toward the pinion gear, turn bearing adjusters with Adjuster Wrench 8883 (1) until they make contact with the differential bearings/cups.
5. Back off the ring gear side adjuster 4 holes, to obtain initial ring gear backlash.
6. Install ring gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time.
7. Tighten pinion gear side adjuster firmly against the differential case bearing cup.
8. Rotate the pinion several times to seat the deferential bearings.
9. Loosen pinion gear side adjuster until it is no longer in contact with the bearing cup, then tighten it until it makes contact.
10. Tighten pinion gear side adjuster an additional:
*). New Bearings: 6 Adjuster Holes
*). Original Bearings: 4 Adjuster Holes
11. Install pinion gear side adjuster lock and bolt.
12. Tighten bearing cap bolts to 165 N·m (122 ft. lbs.).
13. Tighten adjuster lock bolts to 25 N·m (18 ft. lbs.).
14. Measure ring gear (2) backlash with a Dial Indicator C-3339 (1) and Pilot Stud L-4438 at eight points around the drive side of the ring gear. The backlash should be 0.08-0.25 mm (0.003-0.010 in) with a preferred backlash of 0.13-0.18 mm (0.005-0.007 in).