331 DODGE RAM 2003 Service Repair Manual

8W-70 SPLICE INFORMATION
Component PageS101................................8W-15-7
S102...............................8W-10-36
S103................................8W-70-2
S104...............................8W-10-38
S105................................8W-15-2
S106...............................8W-10-36
S107...............................8W-10-38
S108................................8W-33-6
S109...............................8W-10-38
S110 ...............................8W-10-33
S111 ................................8W-20-2
S112 ...............................8W-10-23
S114 ...............................8W-10-30
S117 ................................8W-34-2
S119 ...............................8W-10-54
S120...............................8W-10-52
S121................................8W-33-6
S122...............................8W-10-39
S123................................8W-21-4
S124................................8W-21-4
S125.............................8W-10-27, 29
S126...............................8W-10-41
S127...............................8W-30-82
S129...............................8W-30-82
S130..........................8W-70-3, 4, 5, 6, 8
S131..............................8W-70-3, 4
S132..........................8W-70-3, 4, 5, 6, 8
S133.............................8W-30-20, 21
S134...........................8W-31-6, 14, 49
S135...............................8W-10-18
S136.............................8W-10-43, 44
S137...............................8W-10-21
S138...............................8W-10-25
S139...............................8W-10-25
S140...............................8W-10-58
S141...............................8W-10-21
S142...............................8W-10-24
S143.............................8W-10-21, 23
S144........................8W-70-3, 4, 5, 6, 7, 8
S145...............................8W-10-32
S146...............................8W-10-46
S147...............................8W-10-24
S148...............................8W-10-22
S149...............................8W-10-22
S150..............................8W-70-10, 9
S152...............................8W-30-23
S154...............................8W-30-55
S155.............................8W-10-19, 58
S156...............................8W-10-43
S157...............................8W-30-72
S158...............................8W-30-68
S159...............................8W-30-67
S160.............................8W-10-20, 67
S162...............................8W-10-19
S163.............................8W-10-20, 65
S164...............................8W-15-11
S165................................8W-20-4
S166................................8W-20-4
S168...............................8W-30-45
S169...............................8W-30-47
S170...............................8W-30-69
S171...............................8W-30-67
S172...............................8W-70-12
S173.............................8W-70-11, 68
S174...............................8W-30-69
S175...............................8W-30-69
S176...............................8W-15-11
S178...............................8W-30-17
S179................................8W-31-9
S181...............................8W-30-16Component PageS182...............................8W-10-25
S183..............................8W-15-9, 16
S184...............................8W-30-16
S186...............................8W-10-44
S191...............................8W-10-49
S201...............................8W-10-42
S202................................8W-44-2
S204...............................8W-10-32
S205...............................8W-10-45
S206..............................8W-33-3, 4
S207..............................8W-33-3, 4
S208...............................8W-15-15
S209................................8W-63-5
S210...............................8W-40-13
S212...............................8W-10-50
S213...............................8W-10-33
S214................................8W-33-6
S216................................8W-63-5
S217................................8W-47-4
S218................................8W-47-4
S219................................8W-47-7
S220................................8W-47-7
S221...............................8W-10-33
S222...............................8W-10-46
S224................................8W-42-2
S225...............................8W-10-46
S226..............................8W-42-5, 6
S228...........................8W-33-4, 18, 90
S230................................8W-18-4
S231..............................8W-18-5, 6
S301...............................8W-10-42
S302................................8W-44-2
S304...............................8W-10-45
S305..............................8W-18-5, 6
S306...............................8W-15-21
S307...............................8W-15-15
S308................................8W-15-3
S309.............................8W-15-3, 4, 6
S310...............................8W-15-18
S311 ...............................8W-15-20
S312...............................8W-15-19
S313...............................8W-15-19
S314...............................8W-15-22
S315...............................8W-15-22
S316..............................8W-63-2, 30
S317............................8W-63-3, 4, 21
S318...............................8W-10-30
S319...............................8W-15-21
S320................................8W-40-2
S321................................8W-40-7
S322................................8W-61-4
S323..............................8W-61-4, 8
S324...............................8W-10-36
S325...............................8W-10-52
S326...............................8W-10-37
S327...............................8W-10-36
S328...............................8W-10-34
S329................................8W-63-6
S330...............................8W-10-35
S331...............................8W-10-35
S332................................8W-62-2
S333................................8W-60-4
S334..............................8W-62-3, 47
S335...............................8W-10-46
S336..............................8W-50-6, 37
S337..............................8W-50-6, 16
S340................................8W-15-3
S341................................8W-15-3
S342...............................8W-10-37
S343...............................8W-10-37
DR8W-70 SPLICE INFORMATION 8W - 70 - 1

SPLICE
NUMBERLOCATION FIG.
S316 At Driver Seat N/S
S317 At Passenger Seat N/S
S318 At Passenger Seat N/S
S319 Left Front Door 42
S320 Center of Body 44
S321 Left Front Body N/S
S322 Left Front Body N/S
S323 Left Front Body 45
S324 Left Rear Chassis 48, 49
S325 Left Rear Chassis 48, 49
S326 Left Rear Chassis 48, 49
S327 Left Rear Chassis 48, 49
S328 At Driver Seat N/S
S329 At Driver Seat N/S
S330 Center Rear of Chassis 49
S331 Center Rear of Chassis 49
S332 Left Front Door 42
S333 Left Front Body 45
S334 Left Front Body 41, 44, 45
S335 Left Front Body 41, 44, 45
S338 Left Rear Fender 50
S339 Left Rear Fender 50
8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONDR
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
Both the intake and exhaust valves are made of
steel. The intake valve is 48.768 mm (1.92 inches) in
diameter and the exhaust valve is 41.148 mm (1.62
inches) in diameter and has a 2.032 mm (0.080 inch)
wafer interia welded to the tip for durability. These
valves are not splayed.
STANDARD PROCEDUREÐVALVES, GUIDES
AND SPRINGS
VALVE CLEANING
Clean valves thoroughly. Discard burned, warped,
or cracked valves.
Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
VALVE GUIDES
Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 in.), replace the valve.
Measure valve stem guide clearance as follows:
(1) Install Valve Guide Sleeve Tool C-3973 over
valve stem and install valve (Fig. 10). The special
sleeve places the valve at the correct height for
checking with a dial indicator.(2) Attach dial indicator Tool C-3339 to cylinder
head and set it at right angles to valve stem being
measured (Fig. 11).
(3) Move valve to and from the indicator. The total
dial indicator reading should not exceed 0.432 mm
(0.017 in.). Ream the guides for valves with oversize
stems if dial indicator reading is excessive or if the
stems are scuffed or scored.
VALVE GUIDES
Service valves with oversize stems are available.
Refer to REAMER SIZES CHART
REAMER SIZES CHART
REAMER O/S VALVE GUIDE SIZE
0.076 mm 8.026 - 8.052 mm
(0.003 in.) (0.316 - 0.317 in.)
0.381 mm 8.331 - 8.357 mm
(0.015 in.) (0.328 - 0.329 in.)
(1) Slowly turn reamer by hand and clean guide
thoroughly before installing new valve.Ream the
valve guides from standard to 0.381 mm (0.015
in.). Use a two step procedure so the valve
guides are reamed true in relation to the valve
seat:
²Step 1ÐReam to 0.0763 mm (0.003 inch).
²Step 2ÐReam to 0.381 mm (0.015 inch).
Fig. 10 Positioning Valve with Tool C-3973
1 - VALVE
2 - SPACER TOOL
Fig. 11 Measuring Valve Guide Wear
1 - VALVE
2 - SPECIAL TOOL C-3339
9 - 246 ENGINE - 5.9LDR

CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................323
INSTALLATION........................324
CRANKSHAFT OIL SEAL - REAR
REMOVAL............................325
INSTALLATION........................325
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL............................326
INSTALLATION........................326
SOLID LIFTERS/TAPPETS
REMOVAL............................327
CLEANING...........................328
INSPECTION.........................328
INSTALLATION........................328
PISTON & CONNECTING ROD
DESCRIPTION........................329
STANDARD PROCEDURE - HEAD GASKET
SELECTION.........................330
REMOVAL............................330
CLEANINGÐPISTON AND CONNECTING
ROD ..............................331
INSPECTION
INSPECTIONÐPISTONS...............331
INSPECTIONÐCONNECTING ROD.......332
INSTALLATION........................332
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING............................333
VIBRATION DAMPER
REMOVAL............................335
INSPECTION.........................335
INSTALLATION........................335
FRONT MOUNT
REMOVAL............................335
INSTALLATION........................335
REAR MOUNT
REMOVAL............................337
INSTALLATION........................337
LUBRICATION
DESCRIPTION........................337
OPERATION..........................337
DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE.........................338
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL
LEVEL.............................341STANDARD PROCEDURE - ENGINE OIL
SERVICE...........................341
OIL COOLER & LINES
CLEANING
CLEANING AND INSPECTION...........342
OIL FILTER
REMOVAL............................342
INSTALLATION........................342
OIL PAN
REMOVAL............................342
CLEANING...........................342
INSPECTION.........................342
INSTALLATION........................342
OIL PRESSURE RELIEF VALVE
REMOVAL............................343
CLEANING...........................343
INSPECTION.........................343
INSTALLATION........................343
OIL PRESSURE SENSOR/SWITCH
REMOVAL............................343
INSTALLATION........................343
OIL PUMP
REMOVAL............................343
CLEANING...........................344
INSPECTION.........................344
INSTALLATION........................344
INTAKE MANIFOLD
REMOVAL............................345
CLEANING...........................346
INSPECTION.........................346
INSTALLATION........................346
EXHAUST MANIFOLD
REMOVAL............................347
CLEANING...........................347
INSPECTION.........................347
INSTALLATION........................347
VALVE TIMING
STANDARD PROCEDURE - TIMING
VERIFICATION.......................348
GEAR HOUSING
REMOVAL............................348
INSTALLATION........................349
GEAR HOUSING COVER
REMOVAL............................349
INSTALLATION........................350
DRENGINE 5.9L DIESEL 9 - 281

(11) Use a hammer handle or similar object to
push the piston and connecting rod through the cyl-
inder bore.
(12) Store the piston/rod assemblies in a rack.
CLEANINGÐPISTON AND CONNECTING ROD
CAUTION: DO NOT use bead blast to clean the pis-
tons. DO NOT clean the pistons and rods in an acid
tank.
PISTON
Clean the pistons and pins in a suitable solvent,
rinse in hot water and blow dry with compressed air.
Soaking the pistons over night will loosen most of the
carbon build up. De-carbon the ring grooves with a
broken piston ring and again clean the pistons in sol-
vent. Rinse in hot water and blow dry with com-
pressed air.
CONNECTING ROD
Clean the connecting rods in a suitable solvent,
rinse in hot water and blow dry with compressed air.
INSPECTION
INSPECTIONÐPISTONS
Inspect the pistons for damage and excessive wear.
Check top of the piston, ring grooves, skirt and pin
bore. Measure the piston skirt diameter (Fig. 90). If
the piston is out of limits, replace the piston.The upper groove only needs to be inspected for
damage. Use a new piston ring to measure the clear-
ance in the intermediate ring groove (Fig. 91). Mini-
mum clearance is 0.045 mm (0.0018 inch), maximum
clearance is 0.095 mm (.0037 inch). If the clearance
of the intermediate ring exceeds specifications,
replace the piston.
Use a new oil ring to measure the clearance in the
oil groove (Fig. 91). Minimum clearance is 0.040 mm
(0.0016 inch), maximum clearance is 0.085 mm
(.0033 inch). If the clearance exceeds specifications,
replace the piston.
Measure the pin bore (Fig. 92). The maximum
diameter is 40.012 mm (1.5753 inch), Minimum is
40.006 mm (1.575 inch). If the bore is over limits,
replace the piston.
Fig. 90 Piston Skirt Diameter
PISTON SKIRT DIAMETER (MIN.)
101.887 mm (4.011 in. )
Fig. 91 Intermediate and Oil Ring Clearances
1 - FEELER GAUGE
2 - RING
3 - PISTON
Fig. 92 Piston Pin Bore
1 - PISTON
2 - PIN BORE
DRENGINE 5.9L DIESEL 9 - 331
PISTON & CONNECTING ROD (Continued)

INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The valves (Fig. 13) are arranged in-line and
inclined 18É. The rocker pivot support and the valve
guides are cast integral with the heads.
STANDARD PROCEDURE
VALVE SERVICE
VALVE GUIDES
Measure valve stem guide clearance as follows:
(1) Install Black Valve Guide Sleeve Tool C-6819
over valve stem for theINTAKEvalve and install
valve (Fig. 14). The special sleeve places the valve at
the correct height for checking with a dial indicator.
(2) Install Silver Valve Guide Sleeve Tool C-6818
over valve stem for theEXHAUSTvalve and install
valve. The special sleeve places the valve at the cor-
rect height for checking with a dial indicator.
(3) Attach Dial Indicator Tool C-3339 to cylinder
head and set it at right angle of valve stem being
measured (Fig. 15).
(4) Move valve to and from the indicator. The total
dial indicator reading should not exceed 0.432 mm
(0.017 inch). Ream the guides for valves with over-
size stems if dial indicator reading is excessive or if
the stems are scuffed or scored.
Service valves with oversize stems are available as
shown below
REAMER SIZE CHART
REAMER O/S VALVE GUIDE SIZE
0.076 mm 8.026 - 8.052 mm
(0.003 in.) (0.316 - 0.317 in.)
0.381 mm 8.331 - 8.357 mm
(0.015 in.) (0.316 - 0.329 in.)
(5) Slowly turn reamer by hand and clean guide
thoroughly before installing new valve.Ream the
valve guides from standard to 0.381 mm (0.015
inch). Use a 2 step procedure so the valve
guides are reamed true in relation to the valve
seat:
²Step 1ÐReam to 0.0763 mm (0.003 inch).
²Step 2ÐReam to 0.381 mm (0.015 inch).
Fig. 13 Intake and Exhaust ValvesÐ8.0L Engine
1 - MARGIN
2 - VALVE SPRING RETAINER LOCK GROOVE
3 - STEM
4-FACE
Fig. 14 Positioning Valve Spacer Tool (Typical)
1 - VALVE
2 - SPACER TOOL
Fig. 15 Measuring Valve Guide Wear
1 - VALVE
2 - SPECIAL TOOL C-3339
DRENGINE 8.0L 9 - 375

(4) Position lower housing separator plate on
transfer plate (Fig. 329).
(5) Install lower housing on assembled transfer
plate and upper housing (Fig. 330).
(6) Install and start all valve body screws by hand
except for the screws to hold the boost valve tube
brace. Save those screws for later installation. Then
tighten screws evenly to 4 N´m (35 in. lbs.) torque.
Start at center and work out to sides when tighten-
ing screws (Fig. 330).UPPER HOUSING VALVE AND PLUG
Refer to (Fig. 331), (Fig. 332) and (Fig. 333) to per-
form the following steps.
(1) Lubricate valves, plugs, springs with clean
transmission fluid.
(2) Assemble regulator valve line pressure plug,
sleeve, throttle plug and spring. Insert assembly in
upper housing and install cover plate. Tighten cover
plate screws to 4 N´m (35 in. lbs.) torque.
(3) Install 1-2 and 2-3 shift valves and springs.
(4) Install 1-2 shift control valve and spring.
(5) Install retainer, spring, limit valve, and 2-3
throttle plug from limit valve housing.
(6) Install limit valve housing and cover plate.
Tighten screws to 4 N´m (35 in. lbs.).
(7) Install shuttle valve as follows:
(a) Insert plastic guides in shuttle valve second-
ary spring and install spring on end of valve.
(b) Install shuttle valve into housing.
(c) Hold shuttle valve in place.
(d) Compress secondary spring and install E-clip
in groove at end of shuttle valve.
(e) Verify that spring and E-clip are properly
seated before proceeding.
(8) Install shuttle valve cover plate. Tighten cover
plate screws to 4 N´m (35 in. lbs.) torque.
(9) Install 1-2 and 2-3 valve governor plugs in
valve body.
(10) Install shuttle valve primary spring and
throttle plug.
(11) Align and install governor plug cover. Tighten
cover screws to 4 N´m (35 in. lbs.) torque.
Fig. 329 Lower Housing Separator Plate
1 - BE SURE TO ALIGN BORES
2 - TRANSFER PLATE
3 - LOWER HOUSING (OVERDRIVE) SEPARATOR PLATE
Fig. 330 Installing Lower Housing On Transfer Plate
And Upper Housing
1 - VALVE BODY SCREWS (13)
2 - LOWER HOUSING
3 - UPPER HOUSING
4 - TRANSFER PLATE
DRAUTOMATIC TRANSMISSION - 46RE 21 - 301
VALVE BODY (Continued)

Fig. 331 Shuttle and Boost Valve Locations
1 - SPRING 8 - SHUTTLE VALVE COVER
2 - RETAINER 9 - SHUTTLE VALVE
3 - BOOST VALVE 10 - SHUTTLE VALVE PRIMARY SPRING
4 - BOOST VALVE PLUG 11 - GOVERNOR PLUG COVER
5 - SPRING GUIDES 12 - THROTTLE PLUG
6 - E-CLIP 13 - UPPER HOUSING
7 - SHUTTLE VALVE SECONDARY SPRING 14 - BOOST VALVE COVER
21 - 302 AUTOMATIC TRANSMISSION - 46REDR
VALVE BODY (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
GROWLING, GRATING OR
SCRAPING NOISES1. Drive Plate Broken. 1. Replace.
2. Torque Converter Bolts Hitting
Dust Shield.2. Dust shield bent. Replace or repair.
3. Planetary Gear Set Broken/
Seized.3. Check for debris in oil pan and repair as
required.
4. Overrunning Clutch Worn/Broken. 4. Inspect and check for debris in oil pan.
Repair as required.
5. Oil Pump Components Scored/
Binding.5. Remove, inspect and repair as required.
6. Output Shaft Bearing or Bushing
Damaged.6. Remove, inspect and repair as required.
7. Clutch Operation Faulty. 7. Perform air pressure check and repair as
required.
8. Front and Rear Bands Mis-
adjusted.8. Adjust bands.
DRAGS OR LOCKS UP 1. Fluid Level Low. 1. Check and adjust level.
2. Clutch Dragging/Failed 2. Air pressure check clutch operation and
repair as required.
3. Front or Rear Band Mis-adjusted. 3. Adjust bands.
4. Case Leaks Internally. 4. Check for leakage between passages in
case.
5. Servo Band or Linkage
Malfunction.5. Air pressure check servo operation and
repair as required.
6. Overrunning Clutch Worn. 6. Remove and inspect clutch. Repair as
required.
7. Planetary Gears Broken. 7. Remove, inspect and repair as required
(look for debris in oil pan).
8. Converter Clutch Dragging. 8. Check for plugged cooler. Inspect pump
for excessive side clearance. Replace
pump as required.
NO 4-3 DOWNSHIFT 1. Circuit Wiring and/or Connectors
Shorted.1. Test wiring and connectors with test lamp
and volt/ohmmeter. Repair wiring as
necessary. Replace connectors and/or
harnesses as required.
2. PCM Malfunction. 2. Check PCM operation with DRBTscan
tool. Replace PCM only if faulty.
3. TPS Malfunction 3. Check TPS with DRBTscan tool at PCM.
4. Lockup Solenoid Not Venting. 4. Remove valve body and replace solenoid
assembly if plugged or shorted.
5. Overdrive Solenoid Not Venting. 5. Remove valve body and replace solenoid
if plugged or shorted.
6. Valve Body Valve Sticking. 6. Repair stuck 3-4 shift valve or lockup
timing valve.
DRAUTOMATIC TRANSMISSION - 48RE 21 - 331
AUTOMATIC TRANSMISSION - 48RE (Continued)

(15) Check and adjust front and rear bands if nec-
essary.
(16) Connect solenoid case connector wires.
(17) Install the transmission range sensor.
(18) Install oil pan and new gasket. Tighten pan
bolts to 17 N´m (13 ft. lbs.) torque.
(19) Lower vehicle and fill transmission with
MopartATF +4, Automatic Transmission fluid.
(20) Check and adjust gearshift and throttle valve
cables, if necessary.
ADJUSTMENTS - VALVE BODY
CONTROL PRESSURE ADJUSTMENTS
There are two control pressure adjustments on the
valve body;
²Line Pressure
²Throttle Pressure
Line and throttle pressures are interdependent
because each affects shift quality and timing. As a
result, both adjustments must be performed properly
and in the correct sequence. Adjust line pressure first
and throttle pressure last.
LINE PRESSURE ADJUSTMENT
Measure distance from the valve body to the inner
edge of the adjusting screw with an accurate steel
scale (Fig. 331).
Distance should be 33.4 mm (1-5/16 in.).
If adjustment is required, turn the adjusting screw
in, or out, to obtain required distance setting.
NOTE: The 33.4 mm (1-5/16 in.) setting is an
approximate setting. Manufacturing tolerances may
make it necessary to vary from this dimension to
obtain desired pressure.
One complete turn of the adjusting screw changes
line pressure approximately 1-2/3 psi (9 kPa).Turning the adjusting screw counterclockwise
increases pressure while turning the screw clockwise
decreases pressure.
THROTTLE PRESSURE ADJUSTMENT
Insert Gauge Tool C-3763 between the throttle
lever cam and the kickdown valve stem (Fig. 332).
Push the gauge tool inward to compress the kick-
down valve against the spring and bottom the throt-
tle valve.
Maintain pressure against kickdown valve spring.
Turn throttle lever stop screw until the screw head
touches throttle lever tang and the throttle lever cam
touches gauge tool.
NOTE: The kickdown valve spring must be fully
compressed and the kickdown valve completely
bottomed to obtain correct adjustment.
Fig. 330 Manual Lever Shaft Seal
1 - 15/1688SOCKET
2 - SEAL
Fig. 331 Line Pressure Adjustment
1 - WRENCH
2 - 1±5/16 INCH
Fig. 332 Throttle Pressure Adjustment
1 - HEX WRENCH (IN THROTTLE LEVER ADJUSTING SCREW)
2 - SPECIAL TOOL C-3763 (POSITIONED BETWEEN THROTTLE
LEVER AND KICKDOWN VALVE)
DRAUTOMATIC TRANSMISSION - 48RE 21 - 487
VALVE BODY (Continued)