torque DODGE RAM 2001 Service Repair Manual

INTRODUCTION
TABLE OF CONTENTS
page page
BODY CODE PLATE
DESCRIPTION............................1
FASTENER IDENTIFICATION
DESCRIPTION............................3
FASTENER USAGE
DESCRIPTION............................6
INTERNATIONAL VEHICLE CONTROL &
DISPLAY SYMBOLS
DESCRIPTION............................6
METRIC SYSTEM
DESCRIPTION............................6TORQUE REFERENCES
DESCRIPTION............................9
VECI LABEL
DESCRIPTION...........................10
OPERATION.............................10
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION...........................10
VEHICLE SAFETY CERTIFICATION LABEL
DESCRIPTION...........................12
EQUIPMENT IDENTIFICATION PLATE
DESCRIPTION...........................12
BODY CODE PLATE
DESCRIPTION
The Body Code Plate (Fig. 1) is located on the floor
pan under the passenger seat or attached to the front
face of the radiator closure panel. There are seven
lines of information on the body code plate. Lines 5,
6, and 7 are not used to define service information.
Information reads from left to right, starting with
line 4 in the center of the plate to line 1 at the bot-
tom of the plate.
The last code imprinted on a vehicle code plate will
be followed by the imprinted word END. When two
vehicle code plates are required, the last available
spaces on the first plate will be imprinted with the
letters CTD (for continued).
When a second vehicle code plate is necessary, the
first four spaces on each row will not be used because
of the plate overlap.
BODY CODE PLATEÐLINE 4
DIGITS 1 THROUGH 12
Vehicle Order Number
DIGITS 13, 14, AND 15
Transmission Codes
²DGP = 4±speed Automatic (47RE)
²DGT = 4±speed Automatic (46RE)
²DGK = 4±speed Automatic (42RE)
²DDP = 5±speed Manual (NVG-4500)
²DDX = 5±speed Manual (NVG-4500 Heavy Duty)
²DDC = 5±speed Manual (NVG-3500)
²DEE = 6±speed Manual (NVG-5600)DIGITS 16, 17, AND 18
Car Line Shell
²BR1=15004X2
²BE1=15004X2
²BR6=15004X4
Fig. 1 Body Code Plate
1 - PRIMARY PAINT
2 - SECONDARY PAINT
3 - TRANSMISSION CODE
4 - VEHICLE MODEL NUMBER
5 - ENGINE CODE
6 - INTERIOR TRIM CODE
7 - VEHICLE IDENTIFICATION NUMBER
8 - TAILGATE CODE
9 - CARGO BOX CODE
10 - TAILGATE TRIM CODE
11 - BODY-IN-WHITE SEQUENCE
12 - MARKET CODE
13 - SPECIES CODE
14 - PAINT PROCEDURE
15 - VEHICLE ORDER NUMBER
BR/BEINTRODUCTION 1

FASTENER USAGE
DESCRIPTION - FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Figure art, specifications and torque references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
DESCRIPTION - THREADED HOLE REPAIR
Most stripped threaded holes can be repaired using
a Helicoilt. Follow the manufactures recommenda-
tions for application and repair procedures.
INTERNATIONAL VEHICLE
CONTROL & DISPLAY
SYMBOLS
DESCRIPTION - INTERNATIONAL SYMBOLS
The graphic symbols illustrated in the following
International Control and Display Symbols Chart are
used to identify various instrument controls. The
symbols correspond to the controls and displays that
are located on the instrument panel.
METRIC SYSTEM
DESCRIPTION - METRIC SYSTEM
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million .
The following chart will assist in converting metric
units to equivalent English and SAE units, or vise
versa.
International Symbols
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
6 INTRODUCTIONBR/BE

CONVERSION FORMULAS AND EQUIVALENT VALUES
MULTIPLY BY TO GET MULTIPLY BY TO GET
in-lbs x 0.11298 = Newton Meters (N´m) N´m x 8.851 = in-lbs
ft-lbs x 1.3558 = Newton Meters (N´m) N´m x 0.7376 = ft-lbs
Inches Hg
(60É F)x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters M x 1.0936 = Yards
mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph
Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/
Hr. (Km/h)x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr.
(Km/h)
COMMON METRIC EQUIVALENTS
1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters
1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers
Refer to the Metric Conversion Chart to convert
torque values listed in metric Newton- meters (N´m).Also, use the chart to convert between millimeters
(mm) and inches (in.)
BR/BEINTRODUCTION 7
METRIC SYSTEM (Continued)

TORQUE REFERENCES
DESCRIPTION
Individual Torque Charts appear at the end of
many Groups. Refer to the Standard Torque Specifi-cations Chart for torque references not listed in the
individual torque charts.
Torque Specifications
BR/BEINTRODUCTION 9

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)

FRONT - 4WD
TABLE OF CONTENTS
page page
FRONT - 4WD
DESCRIPTION...........................14
SPECIFICATIONS........................15
SPECIAL TOOLS.........................16
HUB / BEARING
REMOVAL..............................16
INSTALLATION...........................18
KNUCKLE
DESCRIPTION...........................20
OPERATION.............................20
REMOVAL..............................20
INSTALLATION...........................20
LOWER CONTROL ARM
REMOVAL..............................20
INSTALLATION...........................20
SHOCK
DESCRIPTION...........................21
OPERATION.............................21
DIAGNOSIS AND TESTING.................21
SHOCK..............................21
REMOVAL..............................21
INSTALLATION...........................21
SPRING
DESCRIPTION...........................22OPERATION.............................22
REMOVAL..............................22
INSTALLATION...........................22
STABILIZER BAR
DESCRIPTION...........................22
OPERATION.............................22
REMOVAL..............................22
INSTALLATION...........................23
TRACK BAR
DESCRIPTION...........................23
OPERATION.............................23
DIAGNOSIS AND TESTING.................23
TRACK BAR...........................23
REMOVAL..............................23
INSTALLATION...........................23
UPPER CONTROL ARM
REMOVAL..............................23
INSTALLATION...........................24
LOWER BALL JOINT
REMOVAL..............................24
INSTALLATION...........................25
UPPER BALL JOINT
REMOVAL..............................25
INSTALLATION...........................25
FRONT - 4WD
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
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.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 are
not 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.
2 - 14 FRONT - 4WDBR/BE

SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Shock Absorber Upper Nut 47 35 Ð
Shock Absorber Lower Bolt 135 100 Ð
Shock Absorber Bracket 75 55 Ð
Suspension Arm Lower Axle Nut 190 140 Ð
Suspension Arm Lower Frame Nut 190 140 Ð
Suspension Arm Upper Axle Nut 163 120 Ð
Suspension Arm Upper Frame Nut 163 120 Ð
Stabilizer Bar Clamp Bolt 54 40 Ð
Stabilizer Bar Link Upper Nut 37 27 Ð
Stabilizer Bar Link Lower Nut 47 35 Ð
Track Bar Ball Stud Nut 95 70 Ð
Track Bar Axle Bracket Bolt 176 130 Ð
Hub/Bearing Nut 245 180 Ð
Hub/Bearing Bolts 166 122 Ð
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
BR/BEFRONT - 4WD 2 - 15
FRONT - 4WD (Continued)

(8) Install a new cotter pin in hub nut. Tighten the
nut as needed to align cotter pin hole in shaft with
the opening in the nut.
(9) Install the rotor, brake caliper with adapter,
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DISC BRAKE CALIPERS - INSTALLATION).
(10) Install the ABS wheel speed sensor if
equipped, (Refer to 5 - BRAKES/ELECTRICAL/
FRONT WHEEL SPEED SENSOR - INSTALLA-
TION).
(11) Install the wheel and tire assemblies, (Refer
to 22 - TIRES/WHEELS/WHEELS - STANDARD
PROCEDURE).
(12) Remove the support and lower the vehicle.
(13) Apply the brakes several times to seat the
brake shoes and the caliper piston. Do not move the
vehicle until a firm brake pedal is obtained.
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.
OPERATION
The steering knuckles pivots between the upper
and lower ball joints. The steering linkage is
attached to the knuckles controls vehicle steering.
REMOVAL
(1) Remove hub bearing and axle shaft.
(2) Remove tie-rod or drag link end from the steer-
ing knuckle arm.
(3) Remove the ABS sensor wire and bracket from
knuckle.
(4) Remove the cotter pin from the upper ball stud
nut. Remove the upper and lower ball stud nuts.
(5) Strike the steering knuckle with a brass ham-
mer to loosen. Remove knuckle from axle tube yokes.
REMOVAL
(1) Remove hub bearing and axle shaft.
(2) Remove tie-rod or drag link end from the steer-
ing knuckle arm.
(3) Remove the ABS sensor wire and bracket from
knuckle. Refer to Brakes, for proper procedures.
(4) Remove the cotter pin from the upper ball stud
nut. Remove the upper and lower ball stud nuts.
(5) Strike the steering knuckle with a brass ham-
mer to loosen.
(6) Remove knuckle from axle tube yokes.
INSTALLATION
(1) Position the steering knuckle on the ball studs.
(2) Install and tighten lower ball stud nut to 108
N´m (80 ft. lbs.) torque. Advance nut to next slot to
line up hole and install new cotter pin.
(3) Install and tighten upper ball stud nut to 101
N´m (75 ft. lbs.) torque. Advance nut to next slot to
line up hole and install new cotter pin.
(4) Install the hub bearing and axle shaft.
(5) Install tie-rod or drag link end onto the steer-
ing knuckle arm.
(6) Install the ABS sensor wire and bracket to the
knuckle. Refer to Brakes, for proper procedures.
INSTALLATION
(1) Position the steering knuckle on the ball studs.
(2) Install and tighten lower ball stud nut to 47
N´m (35 ft. lbs.) torque. Do not install cotter pin at
this time.
(3) Install and tighten upper ball stud nut to 94
N´m (70 ft. lbs.) torque. Advance nut to next slot to
line up hole and install new cotter pin.
(4) Retorque lower ball stud nut to 190±217 N´m
(140±160 ft. lbs.) torque. Advance nut to next slot to
line up hole and install new cotter pin.
(5) Install the hub bearing and axle shaft.
(6) Install tie-rod or drag link end onto the steer-
ing knuckle arm.
(7) Install the ABS sensor wire and bracket to the
knuckle. Refer to Brakes, for proper procedure.
LOWER CONTROL ARM
REMOVAL
(1) Raise and support the vehicle.
(2) Paint or scribe alignment marks on the cam
adjusters and suspension arm for installation refer-
ence (Fig. 15).
(3) Remove the lower suspension arm nut, cam
and cam bolt from the axle.
(4) Remove the nut and bolt from the frame rail
bracket and remove the lower suspension arm (Fig.
22).
INSTALLATION
(1) Position the lower suspension arm at the axle
bracket and frame rail bracket.
(2) Install the rear bolt and finger tighten the nut.
(3) Install the cam bolt, cam and nut in the axle
and align the reference marks.
(4) Remove support and lower the vehicle.
(5) Tighten cam nut at the axle bracket to 190
N´m (140 ft. lbs.). Tighten rear nut at the frame
bracket to 190 N´m (140 ft. lbs.).
2 - 20 FRONT - 4WDBR/BE
HUB / BEARING (Continued)

REAR
TABLE OF CONTENTS
page page
REAR
DESCRIPTION...........................26
DIAGNOSIS AND TESTING.................26
SPRING AND SHOCK....................26
SPECIFICATIONS........................27
SPECIAL TOOLS.........................28
BUSHINGS
REMOVAL..............................28
INSTALLATION...........................28
JOUNCE BUMPER
DESCRIPTION...........................28
OPERATION.............................28
SHOCK
DESCRIPTION...........................28OPERATION.............................28
REMOVAL..............................28
INSTALLATION...........................28
SPRING
DESCRIPTION...........................28
OPERATION.............................28
REMOVAL..............................28
INSTALLATION...........................29
STABILIZER BAR
DESCRIPTION...........................30
OPERATION.............................30
REMOVAL..............................30
INSTALLATION...........................30
REAR
DESCRIPTION
The rear suspension is comprised of:
²Shock Absorbers
²Jounce Bumpers
²Stabilizer Bar (optional)
²Leaf Springs
²Drive Axle
CAUTION: A vehicle should always be loaded so
the vehicle weight center-line is located immedi-
ately forward of the rear axle. Correct vehicle load-
ing provides proper front tire-to-road contact. This
results in maximum vehicle handling stability and
safety. Incorrect vehicle weight distribution can
cause excessive tire tread wear, spring fatigue or
failure, and erratic steering.
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.
DIAGNOSIS AND TESTING - SPRING AND
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 spring eye and shock absorber bushings do not
require any type of lubrication. Do not attempt to
stop spring bushing noise by lubricating them.
Grease and mineral oil-base lubricants will deterio-
rate the bushing rubber.
If the vehicle is used for severe, off-road operation,
the springs should be examined periodically. Check
for broken and shifted leafs, loose and missing clips,
and broken center bolts. Refer to Spring and Shock
Absorber Diagnosis chart for additional information.
2 - 26 REARBR/BE