maintenance DODGE RAM 2003 Service User Guide

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)

JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN THE BATTERY SYSTEM SEC-
TION OF THE SERVICE MANUAL. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/BATTERY - STAN-
DARD PROCEDURE)
²DO NOT JUMP START A FROZEN BATTERY,
PERSONAL INJURY CAN RESULT.
²IF EQUIPPED, DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR.
²DO NOT JUMP START A VEHICLE WHEN THE
BATTERY FLUID IS BELOW THE TOP OF LEAD
PLATES.
²DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
²DO NOT USE OPEN FLAME NEAR BATTERY.
²REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT.
²WHEN USING A HIGH OUTPUT BOOSTING
DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO
EXCEED 16 VOLTS. REFER TO INSTRUCTIONS
PROVIDED WITH DEVICE BEING USED.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN PERSONAL INJURY.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Yellow or bright color test indicator, if equipped.
²Low battery fluid level.
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible.
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
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.
DRLUBRICATION & MAINTENANCE 0 - 13

HOISTING
STANDARD PROCEDURE - HOISTING
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. 5) 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. 6). Support the vehicle in the
raised position with jack stands at the front and rear
ends of the frame rails (Fig. 5).
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. 7) and (Fig. 8).
HOIST
A vehicle can be lifted with:
²A single-post, frame-contact hoist.
²A twin-post, chassis hoist.
²A ramp-type, drive-on hoist.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly
(Fig. 6). The forward lifting pads should be posi-
tioned against the forward flange of the transmis-
sion crossmember brackets at the bottom of the
frame rail (Fig. 7). The real lifting pads should be
wedged between the forward flange of the leaf
spring bracket and the frame rail (Fig. 8). Safety
stands should be placed under the frame rails at
the front and rear ends (Fig. 5).
Fig. 5 Safety Stands
1 - SAFETY STANDS
Fig. 6 Vehicle Lifting Locations
0 - 14 LUBRICATION & MAINTENANCEDR

TOWING
STANDARD PROCEDURE - TOWING
A vehicle equipped with SAE approved sling-type
towing equipment can be used to tow all vehicles.
When towing a 4WD vehicle using a wheel-lift towing
device, use tow dollies under the opposite end of the
vehicle. A vehicle with flat-bed device can also be
used to transport a disabled vehicle (Fig. 9).
A wooden crossbeam may be required for proper
connection when using the sling-type, front-end tow-
ing method.
SAFETY PRECAUTIONS
CAUTION: The following safety precautions must be
observed when towing a vehicle:
²Secure loose and protruding parts.
²Always use a safety chain system that is inde-
pendent of the lifting and towing equipment.
²Do not allow towing equipment to contact the
disabled vehicle's fuel tank.
²Do not allow anyone under the disabled vehicle
while it is lifted by the towing device.
²Do not allow passengers to ride in a vehicle
being towed.
²Always observe state and local laws regarding
towing regulations.
²Do not tow a vehicle in a manner that could
jeopardize the safety of the operator, pedestrians or
other motorists.
²Do not attach tow chains, T-hooks, J-hooks, or a
tow sling to a bumper, steering linkage, drive shafts
or a non-reinforced frame hole.
²Do not tow a heavily loaded vehicle. Damage to
the cab, cargo box or frame may result. Use a flatbed
device to transport a loaded vehicle.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums or rotors.
Fig. 7 FRONT LIFT PAD LOCATION
1 - BODY MOUNT BRACKET
2 - FRONT LIFT PAD
3 - TRANSMISSION CROSSMEMBER BRACKET
4 - FRAME RAIL
Fig. 8 REAR LIFT PAD LOCATION
1 - FRAME RAIL
2 - REAR LIFT PAD
3 - LEAF SPRING MOUNTING BRACKET
4 - BOX MOUNTING BRACKET
Fig. 9 Tow Vehicles With Approved Equipment
1 - SLING TYPE2 - WHEEL LIFT3 - FLAT BED
DRLUBRICATION & MAINTENANCE 0 - 15
HOISTING (Continued)

A towed vehicle should be raised until lifted wheels
are a minimum 100 mm (4 in) from the ground. Be
sure there is adequate ground clearance at the oppo-
site end of the vehicle, especially when towing over
rough terrain or steep rises in the road. If necessary,
remove the wheels from the lifted end of the vehicle
and lower the vehicle closer to the ground, to
increase the ground clearance at the opposite end of
the vehicle. Install lug nuts on wheel attaching studs
to retain brake drums or rotors.
RAMP ANGLE
If a vehicle with flat-bed towing equipment is used,
the approach ramp angle should not exceed 15
degrees.
TOWING WHEN KEYS ARE NOT AVAILABLE
When the vehicle is locked and keys are not avail-
able, use a flat bed hauler. A Wheel-lift or Sling-type
device can be used on 4WD vehicles providedall the
wheels are lifted off the ground using tow dol-
lies.
FOUR-WHEEL-DRIVE VEHICLE TOWING
Chrysler Corporation recommends that a vehicle be
transported on a flat-bed device. A Wheel-lift or
Sling-type device can be used providedall the
wheels are lifted off the ground using tow dol-
lies.
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION (AUTO-
MATIC TRANSMISSION) OR A FORWARD DRIVE
GEAR (MANUAL TRANSMISSION).
CAUTION: Many vehicles are equipped with air
dams, spoilers, and/or ground effect panels. To
avoid component damage, a wheel-lift towing vehi-
cle or a flat-bed hauling vehicle is recommended.
0 - 16 LUBRICATION & MAINTENANCEDR
TOWING (Continued)

(7) Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
(8) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(9) Tighten pinion gear side adjuster firmly
against the differential case bearing cup.
(10) Rotate the pinion several times to seat the dif-
ferential bearings.
(11) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup.
(12) Tighten pinion gear side adjuster until it just
makes contact with the bearing cup.
(13) Tighten pinion gear side adjuster an addi-
tional:
²New Bearings:6 Adjuster Holes
²Original Bearings:4 Adjuster Holes
(14) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
(15) Tighten bearing cap bolts to 85 N´m (63 ft.
lbs.).
(16) Tighten adjuster lock bolts to 25 N´m (18 ft.
lbs.) (Fig. 39).(17) Measure ring gear backlash and check gear
tooth contact pattern. Refer to Adjustments for pro-
cedure.
(18) Install axle shafts and hub bearings.
(19) Install differential housing gasket and cover.
Tighten cover bolts to 40 N´m (30 ft. lbs.).
(20) Fill differential with lubricant, refer to Lubri-
cation & Maintenance for capacity and lubricant
type.
(21) Install fill plug and tighten to 32 N´m (24 ft.
lbs.).
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove the differential case from the housing.
(2) Install Plug 8888 into the end of the case.
(3) Remove differental case bearings with Bearing
Splitter 1130 and Bridge 938 (Fig. 40).
Fig. 39 ADJUSTER LOCK BOLT
1 - DIFFERENTIAL CASE
2 - ADJUSTER LOCK
3 - ADJUSTER LOCK BOLT
4 - BEARING CAP BOLT
Fig. 40 DIFFERENTIAL CASE BEARING
1 - BRIDGE
2 - SPLITTER
3 - BEARING
4 - PLUG
3 - 64 FRONT AXLE - 9 1/4 AADR
DIFFERENTIAL (Continued)

(8) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(9) Tighten pinion gear side adjuster firmly
against the differential case bearing cup.
(10) Rotate the pinion several times to seat the dif-
ferential bearings.
(11) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup.
(12) Tighten pinion gear side adjuster until it just
makes contact with the bearing cup.
(13) Tighten pinion gear side adjuster an addi-
tional:
²New Bearings6 Adjuster Holes
²Original Bearings4 Adjuster Holes
(14) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
(15) Tighten bearing cap bolts to 165 N´m (122 ft.
lbs.).
(16) Tighten adjuster lock bolts to 25 N´m (18 ft.
lbs.) (Fig. 37).
(17) Measure ring gear backlash and check gear
tooth contact pattern. Refer to Adjustments for pro-
cedure.
(18) Install axle shafts.
(19) Install differential housing gasket and cover.
Tighten cover bolts to 40 N´m (30 ft. lbs.).
(20) Fill axle with lubricant, refer to Lubrication &
Maintenance for capacity and lubricant type.
(21) Install fill plug and tighten to 32 N´m (24 ft.
lbs.).DIFFERENTIAL TRAC-RITE
DESCRIPTION
The Trac-RiteŸ differential is a helical gear differ-
ential. The differential has two side gears, six pinion
gears and six pinion brake shoes.
NOTE: The differential is seviced as an assembly
only if damaged, but can be disassembled for
cleaning. The assembly should be cleaned every
time a bearing is changed due to damage.
OPERATION
When one wheel begins to spin the pinion gears on
that side are forced toward the pinion brake shoes.
The pinion brake shoes then cause frictional drag on
the opposite pinion gears and the side gear. These
friction forces transfer the power to the opposite
wheel. Once the frictional forces are overcome, differ-
entiation will occur. The torque will be continually
biased by the frictional forces to the high traction
wheel.
DISASSEMBLY
(1) Remove differential ring gear bolts.
(2) Remove differential case cover locating screws
(Fig. 38).
(3) Remove differential case cover.
(4) Remove side gear and thrust washer (Fig. 39).
Fig. 37 ADJUSTER LOCK BOLT
1 - DIFFERENTIAL CASE
2 - ADJUSTER LOCK
3 - ADJUSTER LOCK BOLT
4 - BEARING CAP BOLT
Fig. 38 LOCATION SCREWS
1 - DIFFERENTIAL COVER
2 - LOCATION SCREWS
3 - 118 REAR AXLE - 10 1/2 AADR
DIFFERENTIAL (Continued)