DODGE RAM 2002 Service Owner's Guide

SPECIFICATIONS
ALIGNMENT
NOTE: *4x211,000 GVW has a solid front axle with
link/coil suspension system.
DESCRIPTION SPECIFICATION
4x2&4x4GROSS VEHICLE
WEIGHT lbs.WHEEL BASE
inchesPREFERRED
CASTER   1.00ÉPREFERRED
CAMBER   0.50É
4 x 2 6,400 118.7 3.66É 0.50É
4 x 2 6,400 134.7 3.89É 0.50É
4 x 2 6,400 138.7 3.99É 0.50É
4 x 2 6,400 154.7 4.17É 0.50É
4 x 2 8,800 134.7 3.53É 0.50É
4 x 2 8,800 138.7 3.59É 0.50É
4 x 2 8,800 154.7 3.78É 0.50É
4 x 2 10,500 134.7 3.33É 0.50É
4 x 2 10,500 154.7 3.58É 0.50É
4 x 4 6,400 118.7 2.86É0.50É
Non Adjustable
4 x 4 6,400 134.7 3.04É0.50É
Non Adjustable
4 x 4 6,600 138.7 3.19É0.50É
Non Adjustable
4 x 4 6,600 154.7 3.37É0.50É
Non Adjustable
4 x 4 8,800 134.7 2.68É0.50É
Non Adjustable
4 x 4 8,800 138.7 2.74É0.50É
Non Adjustable
4 x 4 8,800 154.7 2.88É0.50É
Non Adjustable
4 x 4 10,500 134.7 2.48É0.50É
Non Adjustable
4 x 4 10,500 154.7 2.63É0.50É
Non Adjustable
CAB-CHASSIS VEHICLES
4x2/4x48,800 134.7
Caster Correction
Measurement0.50É
Non Adjustable
*4x2/4x4 11,000 138.70.50É
Non Adjustable
*4x2/4x4 11,000 162.70.50É
Non Adjustable
Preferred Total Toe-In 0.10É (  0.10É)
Preferred Cross Caster 0É (  0.5É)
Preferred Cross Camber 0É (  0.5É)
Thrust Angle 0É (  0.4É)
2 - 6 WHEEL ALIGNMENTBR/BE
WHEEL ALIGNMENT (Continued)

FRONT - 2WD
TABLE OF CONTENTS
page page
FRONT - 2WD
DESCRIPTION
DESCRIPTION........................7
DESCRIPTION........................8
SPECIFICATIONS
TORQUE CHART......................8
SPECIAL TOOLS
INDEPENDENT FRONT SUSPENSION......9
HUB / BEARING
REMOVAL.............................9
INSTALLATION..........................9
KNUCKLE
REMOVAL.............................10
INSTALLATION.........................10
LOWER BALL JOINT
DIAGNOSIS AND TESTING - LOWER BALL
JOINT..............................10
LOWER CONTROL ARM
REMOVAL.............................10INSTALLATION.........................10
SHOCK
DIAGNOSIS AND TESTING - SHOCK........11
REMOVAL.............................11
INSTALLATION.........................11
SPRING
REMOVAL.............................11
INSTALLATION.........................12
STABILIZER BAR
REMOVAL.............................12
INSTALLATION.........................12
UPPER BALL JOINT
DIAGNOSIS AND TESTING - UPPER BALL
JOINT..............................12
UPPER CONTROL ARM
REMOVAL.............................13
INSTALLATION.........................13
FRONT - 2WD
DESCRIPTION
DESCRIPTION
The independent front suspension (IFS) is com-
prised of (Fig. 1) and (Fig. 2):
²Shock absorbers
²Coil springs
²Upper and lower suspension arms
²Stabilizer bar
²Steering Knuckles
²Jounce Bumpers
CAUTION: Components attached with a nut and cot-
ter pin must be torqued to specification. Then if the
slot in the nut does not line up with the cotter pin
hole, tighten nut until it is aligned. Never loosen the
nut to align the cotter pin hole.
Fig. 1 Independent Front Suspension
1 - KNUCKLE
2 - SUSPENSION ARM
3 - COIL SPRING
4 - STABILIZER BAR
5 - SUSPENSION ARM
6 - LINK
BR/BEFRONT - 2WD 2 - 7

CAUTION: Suspension components with rubber/ure-
thane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur.
DESCRIPTION
The upper suspension arm bolts on frame brackets
through the arm pivot shaft. The frame brackets
have slotted holes which allow the arms to be
adjusted for caster and camber. Pivot shaft bushings
are not replaceable.
The lower suspension arms bolt to the lower frame
brackets and pivot through bushings, these bushings
are not replaceable.
The suspension arms have lube for life riveted ball
studs.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Shock Absorber
Upper Nut54 40 Ð
Shock Absorber
Lower Bolt142 105 Ð
Lower Suspension Arm
Frame Nuts169 125 Ð
Lower Suspension Arm
Ball Joint Nut149 110 Ð
Upper Suspension Arm
Pivot Bar Nuts169 125 Ð
Upper Suspension Arm
Ball Joint Nut81 60 Ð
Stabilizer Bar
Clamp Bolt54 40 Ð
Stabilizer Bar
Link Nuts37 27 Ð
Hub Bearing
2500/3500 Nut380 280 Ð
Fig. 2 Independent Front Suspension
1 - SHOCK
2 - JOUNCE BUMPER
2 - 8 FRONT - 2WDBR/BE
FRONT - 2WD (Continued)

SPECIAL TOOLS
INDEPENDENT FRONT SUSPENSION
HUB / BEARING
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the caliper adapter bolts from the
steering knuckle and remove caliper adapter assem-
bly (Refer to 5 - BRAKES/HYDRAULIC/MECHANI-
CAL/DISC BRAKE CALIPERS - REMOVAL).
NOTE: Do not allow brake hose to support caliper
adapter assembly.
(4) Remove the rotor from the hub/bearing wheel
studs.
(5) Remove the hub/bearing nut (Fig. 3) and slide
the hub/bearing off the spindle.On 3500 HD models
the hub spindle shaft must removed (Fig. 4).
CAUTION: The hub/bearing nut can not be re-used.
INSTALLATION
(1) On models with all-wheel antilock system
(ABS), check condition of tone wheel on hub/bearing.
If teeth on wheel are damaged, hub/bearing assembly
will have to be replaced (tone wheel is not serviced
separately).
(2) Slide the hub/bearing onto the spindle.On 3500
HD slide the spindle stub shaft into the hub/bearing
and tighten.(3) Install thenewhub/bearing nut and tighten
to:
²2500/3500: 380 N´m (280 ft lbs.)
(4) Install the rotor onto hub/bearing wheel studs.
(5) Install the caliper adapter assembly (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION), and tighten
adapter bolts to:
²2500/3500: 285 N´m (210 ft lbs.)
(6) Install the wheel and tire assembly and lower
the vehicle, (Refer to 22 - TIRES/WHEELS/WHEELS
- STANDARD PROCEDURE).
(7) Apply brakes several times to seat brake shoes.
Be sure to obtain firm pedal before moving vehicle.
Remover, Tie Rod End MB-990635
Puller Tie Rod C-3894-A
Fig. 3 Caliper Adapter Assembly
1 - HUB/BEARING
2 - SPINDLE
Fig. 4 SPINDLE STUB SHAFT
1 - Hub/Bearing
2 - Knuckle
3 - Spindle Stub Shaft
BR/BEFRONT - 2WD 2 - 9
FRONT - 2WD (Continued)

KNUCKLE
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the brake caliper and rotor, (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).
(4) Remove the cotter pin and nut from the tie-rod
end. Remove the tie rod end from the knuckle with
Puller C-3894-A.
(5) Remove the cotter pins and nuts from the
upper and lower ball joints. Separate upper ball joint
from knuckle with remover MD-990635. Separate
lower ball joint with remover C-4150A and remove
knuckle.
INSTALLATION
(1) Position the knuckle on the ball joints and
install the ball joint nuts.
(2) Tighten the upper ball joint nut to 81 N´m (60
ft. lbs.) and install cotter pin.
(3) Tighten the lower ball joint nut to:
²149 N´m (110 ft. lbs.) Install the cotter pin.
(4) Install the tie rod end on the steering knuckle
and tighten the nut to 108 N´m (80 ft. lbs.). Install
cotter pin.
(5) Install the brake rotor and caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION).
(6) Install wheel and tire assembly (Refer to 22 -
TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(7) Remove support and lower vehicle.
LOWER BALL JOINT
DIAGNOSIS AND TESTING - LOWER BALL
JOINT
(1) Raise the front of the vehicle. Place safety floor
stands under both lower suspension arms as far out-
board as possible. Lower the vehicle to allow the
stands to support some or all of the vehicle weight.
NOTE: The upper suspension arms must not be in
maximum rebound position.
(2) Remove the tire and wheel assembly.
(3) Mount a dial indicator solidly under the lower
suspension arm.
(4) Position indicator plunger against the bottom
of the steering knuckle lower ball joint boss.NOTE: The dial Indicator plunger must be perpen-
dicular to the machined surface of the steering
knuckle lower ball joint boss.
(5) Position a pry bar over the top of the upper
suspension arm and under the pivot bar of the upper
suspension arm. Pry down on the upper suspension
arm and then zero the dial indicator.
(6) Reposition the pry bar under the upper suspen-
sion arm and on top of the frame rail. Pry up on the
upper suspension arm and record the dial indicator
reading.
(7) If the travel exceeds 0.8 mm (0.030 in.) replace
the suspension arm.
LOWER CONTROL ARM
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the brake caliper assembly and rotor,
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTORS - REMOVAL).
(4) Remove the cotter pin and nut from the tie rod.
Remove the tie rod end from the steering knuckle
with Puller C-3894-A.
(5) Remove the stabilizer bar link from lower sus-
pension arm.
(6) Support the lower suspension arm outboard
end with jack. Place a jack under the arm in the
front of the shock mount.
(7) Remove the cotter pin and nut from the lower
ball joint. Separate the ball joint with Remover
C-4150A.
(8) Remove the lower shock bolt from the suspen-
sion arm.
(9) Lower the jack and suspension arm until
spring tension is relieved. Remove spring and rubber
isolator (Fig. 6).
(10) Remove bolts mounting suspension arm to
crossmember and remove arm.
INSTALLATION
(1) Position the suspension arm on the crossmem-
ber and install the bolts and nuts snug.
(2) Install the rubber isolator on top of the spring.
Position the spring into upper spring seat.
(3) Raise the lower suspension arm with a jack
and position the spring into the lower suspension
arm mount.
(4) Install the lower shock bolt and tighten to 142
N´m (105 ft. lbs.).
(5) Install the steering knuckle on the lower ball
joint. Install the lower ball joint nut and tighten to:
2 - 10 FRONT - 2WDBR/BE

²136 N´m (110 ft. lbs.) Install the lower ball joint
cotter pin.
(6) Install the stabilizer bar link on the lower sus-
pension arm. Install the grommet, retainer and nut
and tighten to 37 N´m (27 ft. lbs.).
(7) Install the tie rod end on the steering knuckle
and tighten nut to 108 N´m (80 ft. lbs.). Install cotter
pin.
(8) Install the brake rotor and caliper assembly,
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTORS - INSTALLATION).
(9) Install the tire and wheel assembly, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(10) Remove the support and lower the vehicle.
(11) Tighten the suspension arm crossmember
nuts to 169 N´m (125 ft. lbs.).
SHOCK
DIAGNOSIS AND TESTING - SHOCK
A knocking or rattling noise from a shock absorber
may be caused by movement between mounting
bushings and metal brackets or attaching compo-
nents. These noises can usually be stopped by tight-
ening the attaching nuts. If the noise persists,
inspect for damaged and worn bushings, and attach-
ing components. Repair as necessary if any of these
conditions exist.
A squeaking noise from the shock absorber may be
caused by the hydraulic valving and may be intermit-
tent. This condition is not repairable and the shock
absorber must be replaced.
The shock absorbers are not refillable or adjust-
able. If a malfunction occurs, the shock absorber
must be replaced. To test a shock absorber, hold it in
an upright position and force the piston in and out of
the cylinder four or five times. The action throughout
each stroke should be smooth and even.
The shock absorber bushings do not require any
type of lubrication. Do not attempt to stop bushing
noise by lubricating them. Grease and mineral oil-
base lubricants will deteriorate the bushing.
REMOVAL
(1) Raise and support vehicle.
(2) Remove shock upper nut and remove retainer
and grommet.
(3) Remove lower mounting bolt from suspension
arm and remove shock (Fig. 5).
INSTALLATION
(1) Extend shock fully, install retainer and grom-
met on top of shock absorber. Check grommets and
retainer for wear.(2) Guide shock up through upper suspension arm
bracket. Install top grommet, retainer and nut.
Tighten nut to 54 N´m (40 ft. lbs.).
(3) Align bottom end of shock into lower suspen-
sion arm and install mounting bolt. Tighten bolt to
142 N´m (105 ft. lbs.).
(4) Remove support and lower vehicle.
SPRING
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the brake caliper assembly and rotor,
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTORS - REMOVAL).
(4) Remove the cotter pin and nut from the tie rod.
Remove the tie rod end from the steering knuckle
with Puller C-3894-A.
(5) Remove the stabilizer bar link from the lower
suspension arm.
(6) Support the lower suspension arm outboard
end with a jack. Place a jack under the arm in front
of the shock mount.
(7) Remove the cotter pin and nut from the lower
ball joint. Separate the ball joint with Remover
C-4150A.
(8) Remove the lower shock bolt from the suspen-
sion arm.
(9) Lower the jack and suspension arm until
spring tension is relieved. Remove spring and rubber
isolator (Fig. 6).
Fig. 5 Shock
1 - SHOCK
2 - JOUNCE BUMPER
BR/BEFRONT - 2WD 2 - 11
LOWER CONTROL ARM (Continued)

INSTALLATION
(1) Install the rubber isolator on top of the spring.
Position the spring into the upper spring seat.
(2) Raise the lower suspension arm with a jack
and position the spring into the lower suspension
arm mount.
(3) Install the lower shock bolt and tighten to 142
N´m (105 ft. lbs.).
(4) Install the steering knuckle on the lower ball
joint. Install the lower ball joint nut and tighten to:
²136 N´m (110 ft. lbs.) Install the lower ball joint
cotter pin.
(5) Install the stabilizer bar link on the lower sus-
pension arm. Install the grommet, retainer and nut
and tighten to 37 N´m (27 ft. lbs.).
(6) Install the tie rod end on the steering knuckle
and tighten nut to 108 N´m (80 ft. lbs.). Install cotter
pin.
(7) Install the brake rotor and caliper assembly,
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTORS - INSTALLATION).
(8) Install the tire and wheel assembly, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(9) Remove the support and lower the vehicle.
STABILIZER BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the link nuts, retainers and grommets
from lower suspension arm and stabilizer bar (Fig.
7).
(3) Remove the stabilizer bar clamps from the
frame rails. Remove the stabilizer bar.
INSTALLATION
(1) Position the stabilizer bar on the frame rail
and install the clamps and bolts. Ensure the bar is
centered with equal spacing on both sides. Tighten
the bolts to 54 N´m (40 ft. lbs.).
(2) Install links on stabilizer bar and lower sus-
pension arm. Install grommets, retainers and nuts.
Tighten nuts to 37 N´m (27 ft. lbs.).
(3) Remove the supports and lower the vehicle.
UPPER BALL JOINT
DIAGNOSIS AND TESTING - UPPER BALL
JOINT
(1) Position a floor jack under the lower suspen-
sion arm. Raise the wheel and allow the tire to
lightly contact the floor (vehicle weight relieved from
the tire).
(2) Mount a dial indicator solidly on the upper sus-
pension arm.
(3) Position the indicator plunger against the
upper ball stud boss of the steering knuckle.
(4) Grasp the top of the tire and apply force in and
out. Look for movement at the ball joint between the
upper suspension arm and steering knuckle.
(5) If lateral movement is greater than 0.8 mm
(0.030 in.), replace the suspension arm.
Fig. 6 Coil Spring
1 - COIL SPRING
2 - RUBBER ISOLATER
Fig. 7 STABILIZER BAR
1 - STABILIZER BAR
2 - GROMMET
3 - GROMMET
4 - LINK
2 - 12 FRONT - 2WDBR/BE
SPRING (Continued)

UPPER CONTROL ARM
REMOVAL
(1) Raise and support vehicle.
(2) Remove tire and wheel assembly.
(3) Support lower suspension arm at outboard end
with jack stand.
(4) Remove upper ball joint cotter pin and nut.
(5) Separate ball joint from knuckle with remover
MB-990635.
(6) Remove pivot bar bolts from upper suspension
arm bracket and remove arm from vehicle (Fig. 8).
INSTALLATION
(1) Position the upper suspension arm on the
bracket and install the pivot bar bolts. Tighten to
169 N´m (125 ft. lbs.).
(2) Install the ball joint in the knuckle. Install the
nut and tighten to 81 N´m (60 ft. lbs.) and replace-
ment the cotter pin.
(3) Remove the jack from the lower suspension
arm.
(4) Install the tire and wheel assembly, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(5) Remove the support and lower the vehicle.(6) Align the front suspension, (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
Fig. 8 Upper Suspension Arm
1 - PIVOT BAR
2 - UPPER SUSPENSION ARM
3 - SUSPENSION ARM FRAME MOUNT
4 - ADJUSTMENT SLOTS
BR/BEFRONT - 2WD 2 - 13

FRONT - 4WD
TABLE OF CONTENTS
page page
FRONT - 4WD
DESCRIPTION
DESCRIPTION........................14
DESCRIPTION........................15
SPECIFICATIONS
TORQUE CHART......................15
SPECIAL TOOLS
LINK/COIL SUSPENSION...............16
HUB / BEARING
REMOVAL.............................16
INSTALLATION.........................17
KNUCKLE
REMOVAL.............................19
INSTALLATION.........................19
UPPER CONTROL ARM
REMOVAL.............................19
INSTALLATION.........................19
UPPER BALL JOINT
REMOVAL - DANA 44 & 60................19
INSTALLATION
INSTALLATION - DANA 44 AXLE..........20
INSTALLATION - DANA 60 AXLE..........20
LOWER CONTROL ARM
REMOVAL.............................20INSTALLATION.........................20
LOWER BALL JOINT
REMOVAL
REMOVAL - DANA 44 AXLE..............21
REMOVAL - DANA 60 AXLE..............21
INSTALLATION
INSTALLATION - DANA 44 AXLE..........21
INSTALLATION - DANA 60 AXLE..........22
SHOCK
DIAGNOSIS AND TESTING - SHOCK........22
REMOVAL.............................22
INSTALLATION.........................22
SPRING
REMOVAL.............................23
INSTALLATION.........................23
STABILIZER BAR
REMOVAL.............................23
INSTALLATION.........................23
TRACK BAR
DIAGNOSIS AND TESTING - TRACK BAR....24
REMOVAL.............................24
INSTALLATION.........................24
FRONT - 4WD
DESCRIPTION
DESCRIPTION
The link/coil suspension allows each wheel to adapt
to different road surfaces. The suspension is com-
prised of (Fig. 1) :
²Shock absorbers
²Coil springs
²Upper and lower suspension arms
²Stabilizer bar
²Track bar
²Steering Knuckles
²Jounce Bumper
Fig. 1 Link/Coil Suspension
1 - STABILIZER BAR
2 - SHOCK ABSORBER
3 - COIL SPRING
4 - UPPER SUSPENSION ARM
5 - LOWER SUSPENSION ARM
6 - TRACK BAR
2 - 14 FRONT - 4WDBR/BE

CAUTION: Components attached with a nut and cot-
ter pin must be torqued to specification. Then if the
slot in the nut does not line up with the cotter pin
hole, tighten nut until it is aligned. Never loosen the
nut to align the cotter pin hole.
CAUTION: Suspension components with rubber
bushings (except stabilizer bar) should be tightened
with the vehicle at normal height. It is important to
have the springs supporting the weight of the vehi-
cle when the fasteners are torqued. If springs arenot at their normal ride position, vehicle ride com-
fort could be affected and premature bushing wear
may occur.
DESCRIPTION
The upper and lower suspension arms use bush-
ings to isolate road noise. The suspension arms are
bolted to the frame and axle through the rubber
bushings. The lower suspension arm uses cam bolts
at the axle to allow for caster and pinion angle
adjustment.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Shock Absorber
Upper Nut47 35 Ð
Shock Absorber
Lower Bolt135 100 Ð
Shock Absorber
Bracket75 55 Ð
Suspension Arm Lower
Axle Nut190 140 Ð
Suspension Arm Lower
Frame Nut190 140 Ð
Suspension Arm Upper
Axle Nut163 120 Ð
Suspension Arm Upper
Frame Nut163 120 Ð
Stabilizer Bar
Clamp Bolt54 40 Ð
Stabilizer Bar
Link Upper Nut37 27 Ð
Stabilizer Bar
Link Lower Nut47 35 Ð
Track Bar
Ball Stud Nut95 70 Ð
Track Bar
Axle Bracket Bolt176 130 Ð
Hub/Bearing
Nut245 180 Ð
Hub/Bearing
Bolts166 122 Ð
BR/BEFRONT - 4WD 2 - 15
FRONT - 4WD (Continued)