bumper DODGE RAM 2003 Service User Guide

JOUNCE BUMPER
REMOVAL
(1) Remove the two bolts securing the jounce
bumper to the bracket (Fig. 1).
(2) Remove the jounce bumper.
INSTALLATION
(1) Install the jounce bumper.
(2) Install the two bolts securing the jounce
bumper to the bracket. Tighten the bolts to 40 N´m
(30 ft. lbs.).
AUXILIARY SPRING BUMPERS
(3500)
REMOVAL
(1) Remove the nut securing the auxiliary spring
bumper to the bracket (Fig. 2).
(2) Remove the auxiliary spring bumper.
INSTALLATION
(1) Install the auxiliary spring bumper.
(2) Install the nut securing the auxiliary spring
bumper to the bracket (Fig. 2). Tighten the nut to 61
N´m (45 ft. lbs.).
SHOCK
REMOVAL
(1) Raise vehicle and support the axle.
(2) Remove the upper shock bolt and nut (Fig. 3).
(3) Remove the lower shock bolt and nut.
(4)
Remove the rear shock absorber from the vehicle.
INSTALLATION
(1) Position the shock absorber in the brackets.
(2) Install the bolts through the brackets and the
shock. Install the flag nut on the top bolt and nut on
lower bolt.
(3) Tighten the upper and lower bolt/nuts Tighten
to 135 N.m (100 ft. lbs.)
(4) Remove the support and lower the vehicle.
Fig. 1 JOUNCE BUMPER
1 - MOUNTING BOLTS
2 - JOUNCE BUMPER
Fig. 2 AUXILIARY SPRING BUMPER (3500)
1 - NUTS
2 - AUXILIARY SPRING BUMPERS
Fig. 3 SHOCK ABSORBER
1 - NUT
2 - AXLE
3 - SHOCK ABSORBER
2 - 40 REARDR

HALF SHAFT
TABLE OF CONTENTS
page page
HALF SHAFT
CAUTION.............................11
DIAGNOSIS AND TESTING................11
REMOVAL.............................11
INSTALLATION.........................12
SPECIFICATIONS.......................12
SPECIAL TOOLS.......................12CV JOINT-OUTER
REMOVAL.............................13
INSTALLATION.........................13
CV JOINT-INNER
REMOVAL.............................16
INSTALLATION.........................16
HALF SHAFT
CAUTION
CAUTION:: Never grasp half shaft assembly by the
boots. This may cause the boot to pucker or crease
and reduce the service life of the boot.
Avoid over angulating or stroking the C/V joints
when handling the half shaft.
Half shafts exposed to battery acid, transmission
fluid, brake fluid, differential fluid or gasoline may
cause the boots to deteriorate.
DIAGNOSIS AND TESTING
Check for grease at the inboard and outboard C/V
joint. This is a sign of boot or boot clamp damage.
NOISE/VIBRATION IN TURNS
A clicking noise or a vibration in turns could be
caused by a damaged outer C/V or inner tripod joint
seal boot or seal boot clamps. This will result in the
loss/contamination of the joint grease, resulting in
inadequate lubrication of the joint. Noise could also
be caused by another component of the vehicle com-
ing in contact with the half shafts.
CLUNKING NOISE DURING ACCELERATION
This noise may be a result of a damaged or worn
C/V joint. A torn boot or loose/missing clamp on the
inner/outer joint which has allowed the grease to be
lost will damage the C/V joint.
SHUDDER/VIBRATION DURING ACCELERATION
This problem could be a result of a worn/damaged
inner tripod joint or a sticking tripod joint. Improper
wheel alignment may also cause a shudder or vibra-
tion.
VIBRATION AT HIGHWAY SPEEDS
This problem could be a result of out of balance
front tires or tire/wheel runout. Foreign material
(mud, etc.) packed on the backside of the wheel(s)
will also cause a vibration.
REMOVAL
(1) Loosen lug nuts and hub nut while the with
the vehicle brakes applied.
(2) Raise and support the vehicle.
(3) Remove wheel and tire assembly
(4) Remove half shaft hub nut.
(5) Remove brake caliper and rotor.
(6) Position hydraulic jack under lower suspension
arm and raise jack to unload rebound bumper.
(7) Remove lower shock absorber bolt.
(8) Remove upper ball joint nut and seperate ball
with Remover 8677 (Fig. 1).
Fig. 1 UPPER BALL JOINT SEPARATION
1 - UPPER CONTROL ARM
2 - REMOVER
3 - STEERING KNUCKLE
DRHALF SHAFT 3 - 11

FOG LAMP
REMOVAL
NOTE: The fog lamps are serviced from the rear-
ward side of the front bumper.
(1) Disconnect and isolate the battery negative
cable.
(2) Disengage fog lamp harness connector.
(3) Remove the bolts attaching the fog lamp to the
bumper (Fig. 6).
(4) Separate fog lamp from bumper.
INSTALLATION
(1) Position fog lamp in bumper.
(2) Install the bolts attaching the fog lamp to the
bumper.
(3) Connect fog lamp harness connector.
(4) Connect the battery negative cable.
(5) Check for proper operation and beam align-
ment.
FOG LAMP RELAY
DESCRIPTION
The front fog lamp relay is located in the Power
Distribution Center (PDC) in the engine compart-
ment of the vehicle. The front fog lamp relay is a
conventional International Standards Organization
Fig. 5 CLEARANCE LAMP
1 - NUT
2 - CAB ROOF
3 - BULB SOCKET
4 - CLEARANCE LAMP
5 - SCREW
6 - BULB
Fig. 6 Fog Lamp
1 - SCREW
2 - FOG LAMP UNIT
3 - CONNECTOR
Fig. 7 ISO Micro Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
DRLAMPS/LIGHTING - EXTERIOR 8L - 11
CAB CLEARANCE LAMP (Continued)

(4) Install the cluster bezel onto the instrument
panel (Fig. 9).
(5) Connect the battery negative cable.
HEADLAMP UNIT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the push pins attaching the seal to the
fender.
(3) Remove the bolts attaching the headlamp unit
to the fender (Fig. 10).
(4) Remove the bulb sockets from the headlamp
unit
(5) Separate headlamp unit from vehicle.
INSTALLATION
CAUTION: Do not touch the bulb glass with fingers
or other oily surfaces. Reduced bulb life will result.
(1) Install the bulb sockets for the front park/turn
signal and headlamp.
(2) Position headlamp unit in inner fender panel.
(3) Install the bolts attaching headlamp unit to the
fender (Fig. 10).
(4) Align the seal and install the push pins.
(5) Connect the battery negative cable.
ADJUSTMENTS
Headlamps can be aligned using the screen method
provided in this section. Alignment Tool C-4466-A or
equivalent can also be used. Refer to instructions
provided with the tool for proper procedures.
LAMP ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 7.62 meters (25 ft) away from front
of headlamp lens (Fig. 11).
(2) If necessary, tape a line on the floor 7.62
meters (25 ft) away from and parallel to the wall.
(3) Up 1.27 meters (5 feet) from the floor, tape a
line on the wall at the centerline of the vehicle. Sight
along the centerline of the vehicle (from rear of vehi-
cle forward) to verify accuracy of the line placement.
(4) Rock vehicle side-to-side three times to allow
suspension to stabilize.
(5) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(6) Measure the distance from the center of head-
lamp lens to the floor. Transfer measurement to the
alignment screen (with tape). Use this line for
up/down adjustment reference.
(7) Measure distance from the centerline of the
vehicle to the center of each headlamp being aligned.
Transfer measurements to screen (with tape) to each
side of vehicle centerline. Use these lines for left/
right adjustment reference.
VEHICLE PREPARATION FOR HEADLAMP
ALIGNMENT
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Correct defective components that could hinder
proper headlamp alignment.
(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is not heavily loaded.
(6) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
HEADLAMP ALIGNMENT
A properly aimed low beam headlamp will project
top edge of high intensity pattern on screen from 50
mm (2 in.) above to 50 mm (2 in.) below headlamp
centerline. The side-to-side outboard edge of high
intensity pattern should be from 50 mm (2 in.) left to
50 mm (2 in.) right of headlamp centerline (Fig. 11).
The preferred headlamp alignment is 1(down
for the up/down adjustment and 0 for the left/
right adjustment.The high beam pattern should be
correct when the low beams are aligned properly.
To adjust low beam headlamp, rotate alignment
screws to achieve the specified aim.
Fig. 10 HEADLAMP Ð TYPICAL
1 - SEAL
2 - PUSH PIN
3 - SCREW
4 - HEADLAMP UNIT
DRLAMPS/LIGHTING - EXTERIOR 8L - 15
HEADLAMP SWITCH (Continued)

LICENSE PLATE LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Grasp license plate bulb socket and 1/4 turn
left to release from the license plate lamp unit.
(3) Pull bulb from license plate lamp socket.
INSTALLATION
(1) Install the bulb in the socket.
(2) Install the socket in to the license plate lamp
unit and 1/4 turn to lock.
(3) Connect the battery negative cable.
LICENSE PLATE LAMP UNIT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Disconnect the harness connector.
(3) Remove the retaining clip. (Fig. 12).
(4) Separate license plate lamp from vehicle.
INSTALLATION
(1) Position license plate lamp on the bumper.
(2) Install the clip.
(3) Reconnect the harness connector.
(4) Connect the battery negative cable.
MARKER LAMP UNIT
REMOVAL
REMOVAL
(1) Grasp the lens assembly firmly and pushing
rearward, remove the lens assembly from the fender.
(2) Quarter turn the bulb socket counterclockwise
and remove it from lens assembly.
REMOVAL
(1) Remove the lens mounting screws.
(2) Quarter twist counterclockwise the tailgate
marker lamp bulb sockets and remove lamp housing.
Fig. 11 Headlamp Alignment ScreenÐTypical
1 - CENTER OF VEHICLE
2 - CENTER OF HEADLAMP3 - 7.62 METERS (25 FT.)
4 - FRONT OF HEADLAMP
8L - 16 LAMPS/LIGHTING - EXTERIORDR
HEADLAMP UNIT (Continued)

INSTALLATION
INSTALLATION
(1) Quarter twist the bulb socket into the lamp
assembly
(2) Position the lamp assembly against the fender,
using firm pressure insert the lens into the fender.
(Fig. 13)
INSTALLATION
(1) Position the tailgate marker bulb harness to
the lens and quarter twist each bulb assembly clock-
wise to seat bulb sockets.
(2) Position the tailgate marker lens to the tailgate
and install the retaining screws. (Fig. 14)
MULTI-FUNCTION SWITCH
DESCRIPTION - TURN SIGNAL SYSTEM
The multi-function switch is a resistive MUX
switch that is monitored by the Instrument Cluster.
The turn signals are actuated with the lever on
Multi-Function Switch. The signals are automatically
turned off by a canceling cam (two lobes molded to
the back of the clock spring mechanism). The cam
comes in contact with the cancel actuator on the turn
signal (multi-function) switch assembly. Either cam
Fig. 12 License Plate Lamp Panel
1 - REAR BUMPER
2 - WIRING CONNECTOR
3 - CLIP
4 - LICENSE PLATE LAMP UNIT
Fig. 13 FENDER EXTENSION AND MARKER LAMP
ASSEMBLY
1 - WIRING HARNESS
2 - MARKER LAMP
Fig. 14 Tailgate Marker Lamp Housing
1 - Nut
2 - Tailgate
3 - Bulb Harness
4 - Screw
5 - Lens
DRLAMPS/LIGHTING - EXTERIOR 8L - 17
MARKER LAMP UNIT (Continued)

TRAILER TOW WIRING
DESCRIPTION
Vehicles equipped with an optional factory-in-
stalled trailer towing package have a rear body wire
harness that includes an integral trailer tow wiring
take out that connects to a heavy duty, sealed, 7-pin
trailer tow connector located in the rear bumper (Fig.20). This harness includes an adapter harness that
adapts the 7-pin trailer tow connector to a standard,
light-duty, 4-pin trailer tow connector. Refer to the
appropriate wiring information.
TURN LAMP
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the tail lamp unit (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL
LAMP UNIT - REMOVAL).
(3) Remove the bulb back plate from the tail lamp
unit.
(4) Separate the bulb from the lamp bar.
INSTALLATION
(1) Install the bulb into the back plate.
(2) Install the bulb back plate to the tail lamp
unit.
(3) Install the tail lamp unit (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL
LAMP UNIT - INSTALLATION).
(4) Connect the negative battery cable.
UNDERHOOD LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Insert a small flat blade in the access slot
between the lamp base and lamp lens.
(3) Pry the lamp lens upward and remove the
lamp lens (Fig. 21).
(4) Depress the bulb terminal inward (Fig. 22) to
release the bulb.
INSTALLATION
(1) Engage the replacement bulb wire loop to the
terminal closest to the lamp base wire connector (Fig.
22).
(2) Depress the opposite terminal inward and
engage the remaining bulb wire loop.
(3) Position the lamp lens on the lamp base and
press into place (Fig. 21).
(4) Connect the battery negative cable.
UNDERHOOD LAMP UNIT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
Fig. 19 TAIL LAMP UNIT
1 - SCREW
2 - ELECTRICAL CONNECTOR
3 - TAILLAMP UNIT
Fig. 20 Trailer Tow Wiring
1 - RETAINER CLIP (4)
2 - REAR BODY HARNESS (TRAILER TOW TAKE OUT)
3 - RETAINER CLIP (2)
4 - WIRE HARNESS CONNECTOR
8L - 22 LAMPS/LIGHTING - EXTERIORDR
TAIL LAMP UNIT (Continued)

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Headlamp-Right BL At Headlamp 1, 25, 29
Heated Seat Cushion - Driver BL Under Driver Seat N/S
Heated Seat Cushion - Passenger BL Under Passenger Seat N/S
Heated Seat Switch-Driver RD Center of Instrument Panel 35, 37, 38
Heated Seat Switch-Passenger BL Center of Instrument Panel 35, 37, 38
Horn Switch WT In Steering Wheel N/S
Horn-High Note BK Left Front Fender 26, 30, 31
Horn-Low Note BK Left Front Fender 26, 31
Idle Air Control Motor BK On Throttle Body 4, 8
Ignition Coil GY Left Rear of Engine 7, 17
Ignition Coil - Left (8.0L) BK Right Side Engine 9
Ignition Coil - Right (8.0L) BK Right Side Engine 9
Ignition Switch BK Steering Column 33
Inlet Air Temperature/Manifold
Absolute Pressure SensorBK Right Side Engine 10
Input Speed Sensor BK At Transmission 14, 15
Instrument Cluster C1 GY Rear of Instrument Cluster 37
Instrument Cluster C2 GY Rear of Instrument Cluster 37
Instrument Cluster C3 WT Rear of Instrument Cluster 39
Intake Air Heater Relay Right Engine Compartment 2
Intake Air Temperature/Manifold
Absolute Temperature Sensor
(Diesel)BK Left rear Engine N/S
Intake Air Temperature Sensor BK On Intake Manifold 4, 7, 9
Integrated Power Module C1 BK Left Front Fender 29, 30
Integrated Power Module C2 WT Left Front Fender 29, 30
Integrated Power Module C3 GR Left Front Fender 29, 30
Integrated Power Module C4 WT Left Front Fender 29, 30
Integrated Power Module C5 BK Left Front Fender 29, 30
Integrated Power Module C6 BK Left Front Fender 28, 29, 30
Integrated Power Module C7 GY Left Front Fender 29, 30
Integrated Power Module FCM BK In IPM N/S
Knock Sensor BK Left Rear of Engine 5, 6, 17
Leak Detection Pump (Except 8.0L) BK Left Middle of Chassis 48
Leak Detection Pump (8.0L) BK Left Transmission 13
License Lamp-Left BK At Rear Bumper 48, 49
License Lamp-Right BK At Rear Bumper 48, 49
Lift Pump Motor BK Near T/O for WIF Sensor N/S
Line Pressure Sensor BK Right Rear of Transmission 14, 18, 19
Lumbar Motor-Driver DK GY At Driver Seat N/S
Lumbar Motor-Passenger BK At Passenger Seat N/S
Manifold Absolute Pressure Sensor
(4.7L)GY Left Front of Intake Manifold 4
DR8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 5
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

Fig. 1 RIGHT SIDE FRONT LIGHTING
Fig. 2 LEFT FRONT BUMPER AND RIGHT BATTERY TRAY
DR8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 13
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

Fig. 51 REAR BUMPER
DR8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 61
CONNECTOR/GROUND/SPLICE LOCATION (Continued)