brake DODGE RAM 2003 Service Repair Manual

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
3Differential & Driveline
5Brakes
6Clutch
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 and Transfer Case
22Tires/Wheels
23Body
24Heating & Air Conditioning
25Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)

VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
VIN CODING/LOCATIONS
The Vehicle Identification Number (VIN) plate is
located on the lower windshield fence near the left
a-pillar (Fig. 2). The VIN contains 17 characters that
provide data concerning the vehicle. Refer to the VIN
decoding chart to determine the identification of a
vehicle.
The VIN is also imprinted on the:
²Body Code Plate.
²Equipment Identification Plate.
²Vehicle Safety Certification Label.
²Frame rail.
To protect the consumer from theft and possible
fraud the manufacturer is required to include a
Check Digit at the ninth position of the VIN. The
check digit is used by the manufacturer and govern-
ment agencies to verify the authenticity of the vehi-cle and official documentation. The formula to use
the check digit is not released to the general public.
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = Manufactured By DaimlerChrysler Corporation
3 = Manufactured By DaimlerChrysler De Mexico
2 Make D = Dodge
3 Vehicle Type 2 = Incomplete with Side Airbag
3 = Truck with Side Airbag
6 = Incomplete Less Side Airbag
7 = Truck Less Side Airbag
4 Gross Vehicle Weight Rating G = 5,001-6000 lbs.
H = 6,001-7,000 lbs.
J = 7,001-8,000 lbs.
K = 8,001-9,000 lbs.
L = 9,001-10,000 lbs.
M = 10,001-14,000 lbs.
W = Buses/Incomplete Vehicles with Hydraulic Brakes
5 Vehicle Line A = Ram Pickup 4X2
U = Ram Pickup 4X4
6 Series 1 = 1500
2 = 2500
3 = 3500 Less Dual Rear Wheels
4 = 3500 With Dual Rear Wheels
7 Body Style 6 = Conventional Cab
8 = Quad Cab Full Rear Doors
Fig. 2 VIN LOCATION
1 - DASH PANEL
2 - VIN CODE PLATE
2 INTRODUCTIONDR

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.
FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts (Fig. 6) and (Fig. 7).
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 INTRODUCTIONDR

MAINTENANCE SCHEDULES
DESCRIPTION
Maintenance Schedule Information not included in
this section, is located in the appropriate Owner's
Manual.
There are two maintenance schedules that show
therequiredservice for your vehicle.
First is ScheduleªBº. It is for vehicles that are
operated under the conditions that are listed below
and at the beginning of the schedule.
²Day or night temperatures are below 0É C (32É
F).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 16 km (10 miles).
²More than 50% of your driving is at sustained
high speeds during hot weather, above 32É C (90É F).
²Trailer towing.
²Taxi, police, or delivery service (commercial ser-
vice).
²Off-road or desert operation.
²If equipped for and operating with E-85
(ethanol) fuel.
NOTE: Most vehicles are operated under the condi-
tions listed for Schedule(B(.
Second is ScheduleªAº. It is for vehicles that are
not operated under any of the conditions listed under
Schedule9B9.
Use the schedule that best describes your driving
conditions. Where time and mileage are listed, follow
the interval that occurs first.
CAUTION: Failure to perform the required mainte-
nance items may result in damage to the vehicle.
At Each Stop for Fuel
²Check the engine oil level about 5 minutes after
a fully warmed engine is shut off. Checking the oil
level while the vehicle is on level ground will
improve the accuracy of the oil level reading. Add oil
only when the level is at or below the ADD or MIN
mark.
²Check the windshield washer solvent and add if
required.
Once a Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect the battery and clean and tighten the
terminals as required.
²Check the fluid levels of coolant reservoir, brake
master cylinder, power steering and transmission
and add as needed.
²Check all lights and all other electrical items for
correct operation.
At Each Oil Change
²Change the engine oil filter.
²Inspect the exhaust system.
²Inspect the brake hoses.
²Inspect the CV joints (if equipped) and front sus-
pension components.
²Check the automatic transmission fluid level.
²Check the manual transmission fluid level.
²Check the coolant level, hoses, and clamps.
²Rotate the tires at each oil change interval
shown on Schedule ªAº 10 000 km (6,000 miles) or
every other interval shown on Schedule ªBº 10 000
km (6,000 miles).
Schedule ªBº
Follow schedule ªBº if you usually operate your
vehicle under one or more of the following conditions.
²Day or night temperatures are below 0É C (32É
F).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 16 km (10 miles).
²More than 50% of your driving is at sustained
high speeds during hot weather, above 32É C (90É F).
²Trailer towing.
²Taxi, police, or delivery service (commercial ser-
vice).
²Off-road or desert operation.
²If equipped for and operating with E-85
(ethanol) fuel.
0 - 6 LUBRICATION & MAINTENANCEDR

Miles 3,000 6,000 9,000 12,000 15,000
(Kilometers) (5 000) (10 000) (14 000) (19 000) (24 000)
Change engine oil and engine oil filter.XXXX X
Lubricate outer tie rod ends 2500/3500
(4X4) models only.XX
Change rear axle fluid.X
Change front axle fluid (4X4).X
Inspect brake linings.X
Inspect engine air cleaner filter, replace
if necessary.X
Miles 18,000 21,000 24,000 27,000 30,000
(Kilometers) (29 000) (34 000) (38 000) (43 000) (48 000)
Change engine oil and engine oil filter.XXXX X
Lubricate outer tie rod ends 2500/3500
(4X4) models only.XX X
Change rear axle fluid.X
Change front axle fluid (4X4).X
Inspect brake linings. X
Inspect engine air cleaner filter, replace
if necessary.X
Replace spark plugs.X
Inspect PCV valve, replace as necessary.X*
Drain and refill automatic tranmission fluid,
change filter and adjust bands (46RE/47RE/
48RE).³X
Drain and refill automatic tranmission fluid
and change main sump filter (45RFE/
545RFE only).³X
Miles 33,000 36,000 39, 000 42,000 45,000
(Kilometers) (53 000) (58 000) (62 000) (67 000) (72 000)
Change engine oil and engine oil filter.XXXX X
Lubricate outer tie rod ends 2500/3500
(4X4) models only.XX
Change rear axle fluid.X
Change front axle fluid (4X4).X
Inspect brake linings. X
Inspect engine air cleaner filter, replace
if necessary.X
DRLUBRICATION & MAINTENANCE 0 - 7
MAINTENANCE SCHEDULES (Continued)

Miles 48,000 51,000 54,000 57,000 60,000
(Kilometers) (77 000) (82 000) (86 000) (91 000) (96 000)
Change engine oil and engine oil filter.XXXX X
Lubricate outer tie rod ends 2500/3500
(4X4) models only.XXX
Drain and refill transfer case fluid.X
Change rear axle fluid.X
Change front axle fluid (4X4).X
Inspect brake linings. X X
Inspect engine air cleaner filter, replace
if necessary.X
Replace spark plugs.X
Replace ignition cables (5.7L/5.9L/8.0L).X
Inspect PCV valve, replace as necessary.X*
Drain and refill automatic tranmission fluid,
change filter and adjust bands (46RE/47RE/
48RE).X
Drain and refill automatic tranmission fluid
and change main sump filter (45RFE/
545RFE only).X
Miles 63,000 66,000 69,000 72,000 75,000
(Kilometers) (101 000) (106 000) (110 000) (115 000) (120 000)
Change engine oil and engine oil filter.XXXX
Lubricate outer tie rod ends 2500/3500
(4X4) models only.XX
Inspect engine air cleaner filter.X
Change rear axle fluid.X
Change front axle fluid (4X4).X
Inspect brake linings.X
Inspect auto tension drive belt and replace
if required (3.7L/4.7L/5.7L/5.9L/8.0L).X
0 - 8 LUBRICATION & MAINTENANCEDR
MAINTENANCE SCHEDULES (Continued)

Miles 78,000 81,000 84,000 87,000 90,000
(Kilometers) (125 000) (130 000) (134 000) (139 000) (144 000)
Change engine oil and engine oil filter.XXXX X
Lubricate outer tie rod ends 2500/3500
(4X4) models only.XXX
Change rear axle fluid.X
Change front axle fluid (4X4).X
Inspect brake linings. X
Inspect engine air cleaner filter, replace
if necessary.X
Replace spark plugs.X
Inspect PCV valve, replace as necessary.X*
Inspect auto tension drive belt and replace
if required (3.7L/4.7L/5.7L/5.9L/8.0L).X³
Drain and refill automatic tranmission fluid,
change filter and adjust bands (46RE/47RE/
48RE).X
Drain and refill automatic tranmission fluid
and change main sump and spin-on cooler
return filter (if equipped) [45RFE/545RFE
only].X
Miles 93,000 96,000 99,000 100,000 102,000
(Kilometers) (149 000) (154 000) (158 000) (160 000) (163 000)
Change engine oil and engine oil filter. X X X X
Lubricate outer tie rod ends 2500/3500
(4X4) models only.XX
Flush and replace engine coolant. X
Flush and replace Power Steering Fluid. X
Inspect brake linings. X
DRLUBRICATION & MAINTENANCE 0 - 9
MAINTENANCE SCHEDULES (Continued)

Miles 105,000 108,000 111,000 114,000 117,000 120,000
(Kilometers) (168 000) (173 000) (178 000) (182 000) (187 000) (192 000)
Change engine oil and engine
oil filter.XXXXX X
Lubricate outer tie rod ends
2500/3500 (4X4) models only.XXX
Drain and refill transfer case
fluid.X
Change rear axle fluid. X X
Change front axle fluid (4X4). X X
Inspect brake linings. X X
Inspect engine air cleaner
filter, replace if necessary.XX
Replace spark plugs.X
Replace ignition cables
(5.7L/5.9L/8.0L).X
Inspect PCV valve, replace
as necessary.X*
Inspect auto tension drive belt
and replace if required
(3.7L/4.7L/5.7L/5.9L/8.0L).X³ X³
Drain and refill automatic
tranmission fluid, change filter
and adjust bands (46RE/
47RE/48RE).X
Drain and refill automatic
tranmission fluid and change
main sump filter (45RFE/
545RFE only).X
* This maintenance is recommended by the manu-
facture to the owner but is not required to maintain
the emissions warranty.
³ This maintenance is not required if previously
replaced.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.
0 - 10 LUBRICATION & MAINTENANCEDR
MAINTENANCE SCHEDULES (Continued)

Schedule ªAº
Miles 6,000 12,000 18,000 24,000 30,000
(Kilometers) (10 000) (19 000) (29 000) (38 000) (48 000)
[Months] [6] [12] [18] [24] [30]
Change engine oil and engine oil filter.XXXX X
Check transfer case fluid level.X
Lubricate outer tie rod ends 2500/3500
(4X4) models only.XXXX X
Inspect brake linings. X
Replace engine air cleaner filter.X
Replace spark plugs.X
Miles 36,000 42,000 48,000 54,000 60,000 66,000
(Kilometers) (58 000) (67 000) (77 000) (84 000) (96 000) (106 000)
[Months] [36] [42] [48] [54] [60] [66]
Change engine oil and engine
oil filter.XXXXX
X
Check transfer case fluid
level.X
Lubricate outer tie rod ends
2500/3500 (4X4) models only.XXXXX X
Flush and replace engine
coolant at 60 months,
regardless of mileage.X
Inspect brake linings. X X
Replace engine air cleaner
filter.X
Replace spark plugs.X
Inspect PCV valve, replace
as necessary.X*
Replace ignition cables
(5.7L/5.9L/8.0L).X
DRLUBRICATION & MAINTENANCE 0 - 11
MAINTENANCE SCHEDULES (Continued)

Miles 72,000 78,000 84,000 90,000 96,000 100,000
(Kilometers) (115 000) (125 000) (134 000) (144 000) (154 000) (160 000)
[Months] [72] [78] [84] [90] [96]
Change engine oil and engine oil filter.XXXXX
Lubricate outer tie rod ends 2500/3500
(4X4) models only.XXXXX
Drain and refill transfer case fluid. X
Flush and replace engine coolant, if not
done at 60 mos.X
Flush and replace Power Steering Fluid.X
Inspect brake linings. X X
Replace engine air cleaner filter.X
Replace spark plugs.X
Replace ignition cables (5.7L/5.9L/
8.0L).X
Inspect PCV valve, replace as
necessary.X*
Inspect auto tension drive belt and
replace if required (3.7L/4.7L/5.7L/5.9L/
8.0L).X
Drain and refill automatic tranmission
fluid, change filter and adjust bands
(46RE/47RE/48RE).X
Drain and refill automatic tranmission
fluid and change main sump filter and
spin-on cooler return filter (if equipped)
[45RFE/545RFE only].X
Miles 102,000 108,000 114,000 120,000
(Kilometers) (163 000) (173 000) (182 000) (192 000)
[Months] [102] [108] [114] [120]
Change engine oil and engine oil filter. X X X X
Check transfer case fluid level.X
Lubricate outer tie rod ends 2500/3500 (4X4) models only. X X X X
Inspect brake linings. X
Inspect auto tension drive belt and replace if required
(3.7L/4.7L/5.7L/5.9L/8.0L).X³X³
Replace engine air cleaner filter.X
Replace spark plugs.X
* This maintenance is recommended by the manu-
facture to the owner but is not required to maintain
the emissions warranty.
³ This maintenance is not required if previously
replaced.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.WARNING: You can be badly injured working on or
around a motor vehicle. Do only that service work
for which you have the knowledge and the right
equipment. If you have any doubt about your ability
to perform a service job, take your vehicle to a
competent mechanic.
0 - 12 LUBRICATION & MAINTENANCEDR
MAINTENANCE SCHEDULES (Continued)