suspension DODGE RAM 2001 Service Repair Manual

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
3Differential & Driveline
5Brakes
7Cooling
8AAudio
8BChime/Buzzer
8EElectronic Control Modules
8FEngine Systems
8GHeated Systems
8HHorn
8IIgnition Control
8JInstrument Cluster
8LLamps
8MMessage Systems
8NPower Systems
8ORestraints
8PSpeed Control
8QVehicle Theft Security
8RWipers/Washers
8WWiring
9Engine
11Exhaust System
13Frame & Bumpers
14Fuel System
19Steering
21Transmission/Transaxle
22Tires/Wheels
23Body
24Heating & Air Conditioning
25Emissions Control Systems
30New Vehicle Preparation
Component and System Index
Service Manual Comment Forms (Rear of Manual)

DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
HOISTING
STANDARD PROCEDURE
Refer to the Owner's Manual for emergency vehicle
lifting procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT (Fig. 9) OR SECURE VEHICLE TO HOIST-
ING DEVICE WHEN THESE CONDITIONS EXIST.
FLOOR JACK
When properly positioned, a floor jack can be used
to lift a vehicle (Fig. 10). Support the vehicle in the
raised position with jack stands at the front and rear
ends of the frame rails (Fig. 9).CAUTION: Do not lift vehicle with a floor jack posi-
tioned under:
²An axle tube.
²A body side sill.
²A steering linkage component.
²A drive shaft.
²The engine or transmission oil pan.
²The fuel tank.
²A front suspension arm.
NOTE: Use the correct frame rail lifting locations
only (Fig. 11).
HOIST
A vehicle can be lifted with:
²A single-post, frame-contact hoist.
²A twin-post, chassis hoist.
²A ramp-type, drive-on hoist.
Fig. 8 Jumper Cable Clamp ConnectionsÐDiesel
Engine
1 - POSITIVE CABLE CONNECTION
2 - BATTERY
3 - NEGATIVE OR GROUND CABLE CONNECTION
Fig. 9 Safety Stands
1 - SAFETY STANDS
0 - 28 LUBRICATION & MAINTENANCEBR/BE
JUMP STARTING (Continued)

SUSPENSION
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT.......................1
FRONT - 2WD............................7FRONT - 4WD...........................14
REAR..................................26
WHEEL ALIGNMENT
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT
DESCRIPTION............................1
OPERATION.............................2
DIAGNOSIS AND TESTING..................2
PRE-ALIGNMENT........................2
STANDARD PROCEDURE...................2ALIGNMENT INDEPENDENT FRONT
SUSPENSION...........................2
CASTER CORRECTION MEASUREMENT.....3
ALIGNMENT LINK/COIL SUSPENSION........5
SPECIFICATIONS.........................6
WHEEL ALIGNMENT
DESCRIPTION
Wheel alignment is the positioning of the wheels in
relation to the vehicle. This is accomplished through
suspension and steering linkage adjustments. An
alignment is essential for efficient steering, good
directional stability and to minimize tire wear. The
most important measurements of an alignment are
caster, camber and toe position (Fig. 1) and (Fig. 2).
CAUTION: Do not attempt to modify any suspen-
sion or steering components by heating and bend-
ing.
NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rub-
ber bushings must never be lubricated. Refer to
Lubrication And Maintenance for the recommended
maintenance schedule.
Fig. 1 Alignment Angles - Independent Front
Suspension
1 - FRONT OF VEHICLE
2 - STEERING AXIS INCLINATION
3 - PIVOT POINT
4 - TOE-IN
BR/BESUSPENSION 2 - 1

OPERATION
²CASTERis the forward or rearward tilt of the
steering knuckle from vertical. Tilting the top of the
knuckle rearward provides positive caster. Tilting the
top of the knuckle forward provides negative caster.
Caster is a directional stability angle which enables
the front wheels to return to a straight ahead posi-
tion after turns.
²CAMBERis the inward or outward tilt of the
wheel relative to the center of the vehicle. Tilting the
top of the wheel inward provides negative camber.
Tilting the top of the wheel outward provides positive
camber. Incorrect camber will cause wear on the
inside or outside edge of the tire.
²WHEEL TOE POSITIONis the difference
between the leading inside edges and trailing inside
edges of the front tires. Incorrect wheel toe position
is the most common cause of unstable steering and
uneven tire wear. The wheel toe position is thefinal
front wheel alignment adjustment.
DIAGNOSIS AND TESTING - PRE-ALIGNMENT
Before starting wheel alignment, the following
inspection and necessary corrections must be com-
pleted. Refer to Suspension and Steering System
Diagnosis Chart for additional information.
(1) Inspect tires for size and tread wear.
(2) Set tire air pressure.
(3) Inspect front wheel bearings for wear.
(4) Inspect front wheels for excessive radial or lat-
eral runout and balance.
(5) Inspect ball studs, linkage pivot points and
steering gear for looseness, roughness or binding.
(6) Inspect suspension components for wear and
noise.
(7) Road test the vehicle.
STANDARD PROCEDURES - ALIGNMENT I.F.S.
Before each alignment reading the vehicle should
be jounced (rear first, then front). Grasp each
bumper at the center and jounce the vehicle up and
Fig. 2 Alignment Angles - Link/Coil
1 - WHEEL CENTERLINE
2 - NEGATIVE CAMBER ANGLE
3 - PIVOT CENTERLINE
4 - SCRUB RADIUS
5 - TRUE VERTICAL6 - KING PIN
7 - VERTICAL
8 - POSITIVE CASTER
2 - 2 WHEEL ALIGNMENTBR/BE
WHEEL ALIGNMENT (Continued)

down several times. Always release the bumper in
the down position.Set the front end alignment to
specifications while the vehicle is in its NOR-
MALLY LOADED CONDITION.
Camber and caster angle adjustments involve
changing the position of the upper suspension arm
pivot bar (Fig. 3). Refer to the Alignment Specifica-
tion Chart for the correct setting.
CASTER:Move the rear position of the pivot bar
in or out. This will change the caster angle signifi-
cantly and camber angle only slightly. To retain cam-
ber move the forward pivot very slightly in the
opposite direction.
NOTE: For example, to increase a positive caster
angle, move the rear position of the pivot bar
inward (toward the engine). Move the front of pivot
bar outward (away from the engine) slightly until
the original camber angle is obtained.CAMBER:Move the forward position of the pivot
bar in or out. This will change the camber angle sig-
nificantly and caster angle only slightly. The camber
angle should be adjusted as close as possible to the
preferred service specification. After adjustment
is made tighten pivot bar nuts to specifications.
TOE POSITION:The wheel toe position adjust-
ment should be the final adjustment.
(1) Start the engine and turn wheels both ways
before straightening the wheels. Center and secure
the steering wheel and turn off engine.
(2) Loosen the tie rod adjustment sleeve clamp
bolts/nuts.
NOTE: Each front wheel should be adjusted for
one-half of the total toe position specification. This
will ensure the steering wheel will be centered
when the wheels are positioned straight-ahead.
(3) Adjust the wheel toe position by turning the tie
rod adjustment sleeves as necessary.
STANDARD PROCEDURES - CASTER
CORRECTION MEASUREMENT
NOTE: To determine the correct caster alignment
angle for Cab-Chassis vehicles the following proce-
dure must be performed.
NOTE: 4x2 11000 GVW has a solid front axle and
uses a 4x4 frame.
(1) Take a height measurement to the center of the
front gauge hole in the frame. Take another measure-
ment to the center of the rear spring hanger bolt
(Fig. 4). Take these measurements on both sides of
the vehicle.
(2) Subtract the front measurement from the rear
measurement and use the average between the right
and left side. Use this number (caster correlation
valve) with the Corrected Caster Chart to obtain the
preferred caster angle.
Fig. 3 Caster Camber Adjustment Location
1 - PIVOT BAR
2 - UPPER SUSPENSION ARM
3 - SUSPENSION ARM FRAME MOUNT
4 - ADJUSTMENT SLOTS
BR/BEWHEEL ALIGNMENT 2 - 3
WHEEL ALIGNMENT (Continued)

CORRECTED CASTER CHART-CAB CHASSIS
Caster
Correlation
Value
(inches)4x2 8800
lb. GVW
134.7 in.
wheel
base4x4 8800
lb. GVW
4x2 & 4x4
11000 lb.
GVW
134.7 &
138.7 in.
wheel
base4x2 & 4x4
11000 lb.
GVW 162.7
in. wheel
base
Caster61
deg.Caster61
deg.Caster61
deg.
þ5.00 4.27É 3.77É 3.81É
þ4.75 4.39É 3.89É 3.91É
þ4.50 4.51É 4.01É 4.01É
þ4.25 4.64É 4.14É 4.11É
þ4.00 4.76É 4.26É 4.21É
þ3.75 4.88É 4.38É 4.31É
þ3.50 5.00É 4.50É 4.41É
þ3.25 5.12É 4.62É 4.51É
þ3.00 5.25É 4.75É 4.61É
þ2.75 5.37É 4.87É 4.71É
þ2.50 5.49É 4.99É 4.81É
þ2.25 5.61É 5.11É 4.91É
þ2.00 5.74É 5.24É 5.01É
þ1.75 5.86É 5.36É 5.11É
þ1.50 5.98É 5.48É 5.21É
þ1.25 6.10É 5.60É 5.31É
þ1.00 6.23É 5.73É 5.41É
þ0.75 6.33É 5.83É 5.51É
þ0.50 6.47É 5.97É 5.61É
þ0.25 6.59É 6.09É 5.71É
0.00 6.71É 6.21É 5.81É
STANDARD PROCEDURES - ALIGNMENT
LINK/COIL SUSPENSION
Before each alignment reading the vehicle should
be jounced (rear first, then front). Grasp each
bumper at the center and jounce the vehicle up and
down several times. Always release the bumper in
the down position.Set the front end alignment to
specifications while the vehicle is in its NOR-
MALLY LOADED CONDITION.
CAMBER:The wheel camber angle is preset and
is not adjustable.
CASTER:Check the caster of the front axle for
correct angle. Be sure the axle is not bent or twisted.Road test the vehicle and make left and right turn.
Observe the steering wheel return-to-center position.
Low caster will cause poor steering wheel returnabil-
ity.
Caster can be adjusted by rotating the cams on the
lower suspension arm (Fig. 5). (Refer to 2 - SUSPEN-
SION/WHEEL ALIGNMENT - STANDARD PROCE-
DURE).
TOE POSITION:The wheel toe position adjust-
ment should be the final adjustment.
(1) Start the engine and turn wheels both ways
before straightening the wheels. Center and Secure
the steering wheel and turn off engine.
(2) Loosen the adjustment sleeve clamp bolts.
(3) Adjust the right wheel toe position with the
drag link. Turn the sleeve until the right wheel is at
the correct TOE-IN position. Position clamp bolts to
their original position and tighten to specifications.
Make sure the toe setting does not change dur-
ing clamp tightening.
(4) Adjust left wheel toe position with tie rod at
left knuckle. Turn the sleeve until the left wheel is at
the correct TOE-IN position. Position clamp bolts to
their original position and tighten to specifications.
Make sure the toe setting does not change dur-
ing clamp tightening.
(5) Verify the right toe setting.
Fig. 5 Adjustment Cam
1 - ADJUSTMENT CAM
2 - AXLE BRACKET
3 - BRACKET REINFORCEMENT
4 - LOWER SUSPENSION ARM
BR/BEWHEEL ALIGNMENT 2 - 5
WHEEL ALIGNMENT (Continued)

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
CASTER61.00ÉPREFERRED
CAMBER60.50É
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 2.86É Not Set
4 x 4 6,400 134.7 3.04É Not Set
4 x 4 6,600 138.7 3.19É Not Set
4 x 4 6,600 154.7 3.37É Not Set
4 x 4 8,800 134.7 2.68É Not Set
4 x 4 8,800 138.7 2.74É Not Set
4 x 4 8,800 154.7 2.88É Not Set
4 x 4 10,500 134.7 2.48É Not Set
4 x 4 10,500 154.7 2.63É Not Set
CAB-CHASSIS VEHICLES
4x2/4x48,800 134.7
Caster Correction
MeasurementNot Set
*4x2/4x4 11,000 138.7 Not Set
*4x2/4x4 11,000 162.7 Not Set
Preferred Total Toe-In 0.10É (60.10É)
Preferred Cross Caster 0É (60.5É)
Preferred Cross Camber 0É (60.5É)
Thrust Angle 0É (60.4É)
2 - 6 WHEEL ALIGNMENTBR/BE
WHEEL ALIGNMENT (Continued)

FRONT - 2WD
TABLE OF CONTENTS
page page
FRONT - 2WD
DESCRIPTION............................7
SPECIFICATIONS.........................8
SPECIAL TOOLS..........................9
HUB / BEARING
REMOVAL...............................9
INSTALLATION............................9
JOUNCE BUMPER
DESCRIPTION............................9
OPERATION.............................9
KNUCKLE
DESCRIPTION............................9
OPERATION.............................10
REMOVAL..............................10
INSTALLATION...........................10
LOWER BALL JOINT
DIAGNOSIS AND TESTING.................10
LOWER BALL JOINT....................10
LOWER CONTROL ARM
REMOVAL..............................10
INSTALLATION...........................10
SHOCK
DESCRIPTION...........................11OPERATION.............................11
DIAGNOSIS AND TESTING.................11
SHOCK...............................11
REMOVAL..............................11
INSTALLATION...........................11
SPRING
DESCRIPTION...........................11
OPERATION.............................11
REMOVAL..............................11
INSTALLATION...........................12
STABILIZER BAR
DESCRIPTION...........................12
OPERATION.............................12
REMOVAL..............................12
INSTALLATION...........................12
UPPER BALL JOINT
DIAGNOSIS AND TESTING.................12
UPPER BALL JOINT.....................12
UPPER CONTROL ARM
REMOVAL..............................13
INSTALLATION...........................13
FRONT - 2WD
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
²Hub/Bearing
²Ball Joints
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 betightened 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
LD Ball Joint Nut129 95 Ð
Lower Suspension Arm
HD 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
LD 1500 Nut251 185 Ð
Hub Bearing
HD 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.
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.
(3) Install thenewhub/bearing nut and tighten
to:
²LD 1500: 251N´m (185 ft. lbs.)
²HD 2500/3500: 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:
²LD 1500: 176 N´m (130 ft lbs.)
²HD 2500/3500: 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.
JOUNCE BUMPER
DESCRIPTION
The jounce bumpers are mounted under the coil
spring bracket.
OPERATION
The jounce bumpers are used to limit suspension
travel in compression.
KNUCKLE
DESCRIPTION
The knuckles are a single casting with legs
machined for the upper and lower ball joints. The
knuckles also has machined mounting locations for
the front brake calipers adapters and hub bearing
assembly.
Remover, Tie Rod End MB-990635
Puller Tie Rod C-3894-A
Fig. 3 Caliper Adapter Assembly
1 - HUB/BEARING
2 - SPINDLE
BR/BEFRONT - 2WD 2 - 9
FRONT - 2WD (Continued)