ECU DODGE RAM 2003 Service Repair Manual

(2) Cycle the key from ACC to RUN and ensure
that the blocker does not stick or bind.
(3) Turn the key to the OFF position and ensure
that the shifter will not pull from the PARK position.
(4) Connect the over drive switch harness (if
equipped).
NOTE: Route and tie off harness to original loca-
tion.
(5) Connect the shift cable to the lever.
(6) Ensure the gear shift lever and transmission
are in the PARK position and snap the cable adjust
clip in place.
(7) Install a new brake light switch (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - INSTALLATION).
(8) Install the SKIM and halo.
(9) Install the upper and lower column shroud.
(10) Install the column back into place and
tighten.
(11) Install the kneeblocker. (Refer to 23 - BODY/
INSTRUMENT PANEL/KNEE BLOCKER - INSTAL-
LATION).
UPPER STEERING COUPLING
REMOVAL
(1) Disconnect the negative battery cable.
NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth-
ods of locking the steering wheel for service will
have to be used.(2) Lock the steering wheel with the tire in the
straight position.
(3) Remove and discard the lower pinch bolt.
(4) Lower the steering coupler shaft from the col-
umn.
(5) Remove the upper steering coupling shaft seal
by pushing in the four tags securing it to the panel
(Fig. 16).
(6) Remove and discard the lower coupler pinch
bolt from the lower steering coupling shaft (Fig. 17).
(7) Remove the upper steering coupling shaft from
the vehicle (Fig. 17).
Fig. 15 GEAR SHIFT LEVER SPRING
1 - BLOCKER TO INHIBIT LINK SLOT
2 - GEAR SHIFT LEVER
Fig. 16 RELEASE TANGS
1 - RELEASE TANGS (4)
2 - UPPER STEERING COUPLER SHAFT
Fig. 17 UPPER STEERING COUPLER SHAFT
1 - LOWER STEERING COUPLER
2 - RELEASE TANGS (4)
3 - UPPER STEERING COUPLER SHAFT
DRCOLUMN 19 - 13
GEAR SHIFT LEVER (Continued)

INSTALLATION
(1) Install the upper steering coupling shaft to the
vehicle (Fig. 17).
(2) Install the upper steering coupling shaft seal
by pushing it in securing the four tangs to the panel
(Fig. 16).
NOTE: Note: A new steering coupling shaft pinch
bolt for the upper and lower shafts must be used.
(3) Install the steering coupler shaft to the column
(Fig. 17).
(4) Install the upper pinch bolt use new bolt and
tighten to 57 N.m (42 ft.lbs).
(5) Install the shaft to the lower coupler (Fig. 17).
(6) Install the lower pinch bolt use new bolt and
tighten to 57 N.m (42 ft.lbs).
(7) Unlock the steering wheel.
(8) Reconnect the negative battery cable.
LOWER STEERING COUPLING
REMOVAL
REMOVAL - ALL LD & HD EXCEPT 4X4 HD
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle.
NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth-
ods of locking the steering wheel for service will
have to be used.
(3) Lock the steering wheel with the tire in the
straight position.
(4) Remove the left front tire and wheel assembly.
(5) Mark both coupler connections for proper
installation.
(6) Remove and discard the upper coupler pinch
bolt.
(7) Remove and discard the lower coupler pinch
bolt.
(8) Remove the lower steering shaft coupler (Fig.
18).
REMOVAL - 4X4 HD
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle.NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth-
ods of locking the steering wheel for service will
have to be used.
(3) Lock the steering wheel with the tire in the
straight position.
(4) Remove the left front tire and wheel assembly.
(5) Remove and discard the upper coupler pinch
bolt (Fig. 20).
(6) Remove and discard the lower coupler pinch
bolt (Fig. 19).
Fig. 18 LOWER STEERING COUPLER
Fig. 19 LOWER COUPLER PINCH BOLT
1 - INTERMEDIATE STEERING SHAFT
2 - LOWER COUPLING BOLT
3 - STEERING GEAR
19 - 14 COLUMNDR
UPPER STEERING COUPLING (Continued)

NOTE: The pitman shaft will not clear the housing if
it is not centered.
(6) Center the input shaft by rotating it from the
stop back 1 1/2 turns to achieve center position (Fig.
9).
(7) Remove the pitman shaft (Refer to 19 -
STEERING/GEAR/PITMAN SHAFT - REMOVAL).
(8) Remove the four bolts securing the valve hous-
ing.
(9) Remove the valve housing from the steering
gear (Fig. 10).(10) Remove the valve housing and wormshaft
assembly from the steering gear housing and place
the valve housing in a soft jawed vise (Fig. 11).
(11) Remove the retainer ring set screw from the
valve housing (Fig. 12).
Fig. 9 CENTERING STEERING GEAR
1 - STEERING GEAR
2 - 12 POINT SOCKET
3 - RATCHET
4 - INPUT SHAFT
Fig. 10 VALVE ASSEMBLY
1 - VALVE HOUSING
2 - WORMSHAFT BALLS
3 - STEERING GEAR HOUSING
Fig. 11 VALVE HOUSING AND WORMSHAFT
1 - VALVE HOUSING
2 - SET SCREW
3 - RETAINER RING
Fig. 12 SET SCREW FOR THE RETAINER RING
1 - SET SCREW
2 - 3/32 ALLEN HEAD SOCKET
3 - RETAINER RING
19 - 26 GEAR - LINK/COILDR
STEERING GEAR INPUT SHAFT SEAL (Continued)

(10) Remove the return line/lines from the pump
and plug the pump port/ports.
(11) Pour fresh fluid into the reservoir and check
the draining fluid for contamination. If the fluid is
still contaminated, then flush the system again.
(12) Install the return line/lines and perform
Steering Pump Initial Operation, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
REMOVAL
REMOVAL - GAS
(1) Drain and siphon the power steering fluid from
the reservoir.
(2) Remove the serpentine belt.
CAUTION: Do not remove the fitting on the pump
that the high pressure hose screws into. The fitting
may come loose unless it is backed up using
another wrench. If the fitting does come loose, it
must be retightened before continuing. (57 - 67Nm,
40 - 50 lbft) If this fitting comes out of the pump
body, the internal spring and valve parts will fall out
of the pump and they cannot be reinstalled prop-
erly. If this occurs the pump needs to be replaced
with a new pump.
(3) Disconnect the return hose. (Fig. 2)
(4) Disconnect the pressure hose. (Fig. 2)
(5) Access to remove the three bolts securing the
pump to the cylinder head can be gained thru the
pulley holes. (Fig. 2)
REMOVAL - DIESEL
(1) Drain and siphon the power steering fluid from
the reservoir.
(2) Remove the serpentine belt.
CAUTION: Do not remove the fitting on the pump
that the high pressure hose screws into. The fitting
may come loose unless it is backed up using
another wrench. If the fitting does come loose, it
must be retightened before continuing. (57 - 67Nm,
40 - 50 lbft) If this fitting comes out of the pump
body, the internal spring and valve parts will fall out
of the pump and they cannot be reinstalled prop-
erly. If this occurs the pump needs to be replaced
with a new pump.
(3) Disconnect the return hose.
(4) Disconnect the pressure hose.
(5) Access to remove the three bolts securing the
pump to the cylinder head can be gained thru the
pulley holes.
(6) Loosen the pump bracket to the block.
(7) Remove the 6 intake plenum bolts (Fig. 3).
(8) loosen the inner cooler tube clamp at the
intake plenum and remove the intake plenum.
(9) Loosen the inner cooler tube clamp at the radi-
ator support side and remove the tube from the vehi-
cle.
(10) Remove the power steering pump from the top
of the engine compartment where the intake plenum
was (Fig. 3).
Fig. 2 POWER STEERING PUMP
1 - POWER STEERING PULLEY
2 - POWER STEERING RESERVOIR
3 - RETURN HOSE
4 - HIGH PRESSURE HOSE
Fig. 3 POWER STEERING PUMP ACCESS
1 - INTAKE PLENUM MOUNTING
2 - POWER STEERING PUMP
19 - 40 PUMPDR
PUMP (Continued)

FLUID
DESCRIPTION
The recommended fluid for the power steering sys-
tem is MopartATF +4.
MopartATF+4, when new is red in color. The
ATF+4 is dyed red so it can be identified from other
fluids used in the vehicle such as engine oil or anti-
freeze. The red color is not permanent and is not an
indicator of fluid condition, As the vehicle is driven,
the ATF+4 will begin to look darker in color and may
eventually become brown.THIS IS NORMAL.
ATF+4 also has a unique odor that may change with
age. Consequently, odor and color cannot be used to
indicate the fluid condition or the need for a fluid
change.
STANDARD PROCEDURE - POWER STEERING
FLUID LEVEL CHECKING
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
CAUTION: MOPARTATF+4 is to be used in the
power steering system. No other power steering or
automatic transmission fluid is to be used in the
system. Damage may result to the power steering
pump and system if any other fluid is used, and do
not overfill.
The power steering fluid level can be viewed on the
dipstick attached to the filler cap. There are two
ranges listed on the dipstick, COLD and HOT. Before
opening power steering system, wipe the reservoir
filler cap free of dirt and debris. Remove the cap and
check the fluid level on its dipstick. When the fluid is
at normal ambient temperature, approximately 21ÉC
to 27ÉC (70ÉF to 80ÉF), the fluid level should read
between the minimum and maximum area of the cold
range. When the fluid is hot, fluid level is allowed to
read up to the highest end of the HOT range. Only
add fluid when the vehicle is cold.
Use only MopartATF+4Do not overfill the
power steering system.
FLUID COOLER
REMOVAL
(1) Drain and siphon the power steering fluid.
(2) Disconnect the return and supply hoses con-
nected to the power steering fluid cooler.(3) Remove the mounting bracket bolts securing
the fluid cooler to the brace. (Fig. 4)& (Fig. 5)
(4) Remove the fluid cooler from the vehicle.
INSTALLATION
(1) Install the fluid cooler to the vehicle.
(2) Install the mounting bracket bolts securing the
fluid cooler to the brace (Fig. 4)& (Fig. 5).
(3) Reclamp the return and supply hoses to the
power steering fluid cooler.
(4) Refill the power steering fluid (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
Fig. 4 V6 & V8 P/S FLUID COOLER
1 - POWER STEERING FLUID COOLER
2 - MOUNTING BOLTS
Fig. 5 V10 & DIESEL P/S FLUID COOLER
1 - RADIATOR
2 - POWER STEERING HOSES
3 - MOUNTING BOLTS
4 - P/S FLUID COOLER
19 - 42 PUMPDR

(13) Remove starter motor, structural dust cover,
dust shield and suspension crossmember (Fig. 3).
(14) Remove exhaust pipe from the exhaust mani-
folds.
(15) Support engine with adjustable jack stand
and wood block.
(16) Support and secure transmission to a trans-
mission jack with safety chains.
(17) Remove bolts from the rear transmission
mount.
(18) Remove the rear crossmember and transmis-
sion mount (Fig. 4).(19) Remove bolts attaching transmission to the
engine.
(20) Move transmission rearward until input shaft
is clear of clutch disc and pressure plate. Then lower
jack and remove transmission from under vehicle.
DISASSEMBLY
FRONT HOUSING
(1) Shift transmission into Neutral.
(2) If lubricant was not drained out of transmis-
sion during removal, remove drain plug and drain
lubricant.
(3) Inspect drain plug magnet for debris.
(4) Remove backup light switch located on passen-
ger side of rear housing (Fig. 5).
(5) Remove shift tower bolts and remove tower and
lever assembly (Fig. 6).
Fig. 3 DUST COVER
1 - DUST SHIELD
2 - STARTER MOTOR
3 - DUST COVER
4 - CROSSMEMBER
Fig. 4 CROSSMEMBER
1 - TRANSMISSION MOUNT
2 - CROSSMEMBER
Fig. 5 BACKUP LIGHT SWITCH
1 - BACKUP LIGHT SWITCH
Fig. 6 SHIFT TOWER
1 - SHIFT TOWER
2 - SHIFT SOCKET
3 - SEAL
21 - 4 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(6) Remove shift shaft lock bolt (Fig. 7) from the
top of front housing. The bolt secures the shift shaft
bushing and lever.
NOTE: This is a special bolt and can not be substi-
tuted with any other bolt.
(7) Remove input shaft bearing retainer bolts from
the front housing, then carefully pry on the retainer
to break sealer bead loose (Fig. 8).(8) Remove bearing retainer from input shaft (Fig.
9).
(9) Remove input shaft snap ring (Fig. 10).
Fig. 7 SHAFT LOCK BOLT
1 - SHIFT SHAFT LOCK BOLT
2 - SHAFT SOCKET
Fig. 8 BEARING RETAINER SEAL
1-PRYTOOL
2 - INPUT SHAFT BEARING RETAINER
Fig. 9 INPUT SHAFT BEARING RETAINER
1 - SHAFT BEARING
2 - BEARING RETAINER
3 - INPUT SHAFT
Fig. 10 INPUT SHAFT SNAP RING
1 - INPUT SHAFT SNAP RING
2 - OIL FEED
DRMANUAL TRANSMISSION - NV3500 21 - 5
MANUAL TRANSMISSION - NV3500 (Continued)

(4) Remove bearing retainer bolts and remove rear
bearing retainer and rear bearing (Fig. 33). Push or
tap bearing out of housing with a hammer handle if
needed.
NOTE: Housing must be replaced if race, bearing
bore or idler shaft notch are worn or damaged.
GEARTRAIN FROM FIXTURE
(1) Remove reverse idler gear assembly from
assembly fixture cup.
(2) Remove 1-2 and fifth-reverse forks from syn-
chro sleeves.
(3) Slide countershaft out of fixture tool.
(4) Remove output shaft bearing retainer from
rear surface of fifth gear (retainer will drop onto gear
after bolts are removed).
(5) Lift and remove output shaft and gears off
input shaft.
(6) Lift and remove input shaft, pilot bearing and
fourth gear synchro ring from the fixture.
OUTPUT SHAFT
NOTE: Synchronizer hubs and sleeves are different
and must not be mixed. Remove each synchronizer
unit as an assembly to avoid mixing parts. Mark
each synchro hub and sleeve with a scriber or paint
for correct assembly reference.(1) Remove snap ring that secures 3-4 synchro hub
on output shaft.
(2) Position Bearing Splitter 1130 between second
and third gears and press off 3-4 synchro assembly,
third gear synchro ring and third gear with a shop
press.
(3) Remove third gear needle bearing (Fig. 34).
(4) Remove retaining ring that secures two-piece
thrust washer on shaft with a small pry tool (Fig.
35).
Fig. 33 REAR ADAPTER HOUSING COMPONENTS
1 - BEARING RETAINER
2 - RETAINER BOLTS (3)
3 - IDLER SHAFT NOTCH
4 - COUNTERSHAFT REAR BEARING RACE
5 - REAR BEARING
Fig. 34 THIRD GEAR NEEDLE BEARING
1 - THIRD GEAR NEEDLE BEARING
Fig. 35 THRUST WASHER
1-PRYTOOL
2 - THRUST WASHER RETAINING RING
21 - 12 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(17) Remove reverse gear and needle bearing (Fig.
46).
REVERSE IDLER
(1) Remove idler gear snap rings (Fig. 47).
(2) Remove thrust washer, wave washer, thrust
plate and idler gear from shaft.
(3) Remove idler gear needle bearing from shaft.
CLEANING
Clean the gears, shafts, shift components and
transmission housings with a standard parts clean-
ing solvent. Do not use acid or corrosive base sol-
vents. Dry all parts except bearings with compressed
air.
Clean the shaft bearings with a mild solvent such
as Mopar degreasing solvent, Gunk or similar sol-
vents. Do not dry the bearings with compressed air.
Allow the bearings to either air dry or wipe them dry
with clean shop towels.
INSPECTION
SHIFT LEVER ASSEMBLY
The shift lever assembly is not serviceable. Replace
the lever and shift tower as an assembly if the tower,
lever, lever ball or internal components are worn or
damaged.
SHIFT SHAFT AND FORKS
Inspect the shift fork interlock arms and synchro
sleeve contact surfaces (Fig. 48). Replace any fork
exhibiting wear or damage in these areas. Do not
attempt to salvage shift forks.
Check condition of the shift shaft detent plunger
and spring. The plunger should be smooth and free of
nicks or scores. The plunger spring should be
straight and not collapsed, or distorted. Minor
scratches or nicks on the plunger can be smoothed
with 320/400 grit emery soaked in oil. Replace the
plunger and spring if in doubt about condition. Check
condition of detent plunger bushings. Replace if dam-
aged.
Inspect shift shaft, shift shaft bushing, bearing,
shaft lever and lever bushing that fits over the lever.
Replace shaft if bent, cracked or severely scored.
Minor burrs, nicks or scratches can be smoothed off
with 320/400 grit emery cloth followed by polishing
with crocus cloth. Replace the shift shaft bushing or
bearing if damaged.
Replace the shaft lever and bushing if either part
is deformed, or worn. Do not attempt to salvage these
parts as shift fork binding will occur. Replace the roll
pin that secures the lever to the shaft.
Fig. 47 Reverse Idler Components
1 - SNAP RING
2 - FLAT WASHER
3 - WAVE WASHER
4 - THRUST WASHER
5 - REVERSE IDLER GEAR6 - IDLER GEAR BEARING
7 - IDLER SHAFT
8 - THRUST WASHER
9 - SNAP RING
10 - THRUST WASHER LOCKBALLS
Fig. 46 REVERSE GEAR & NEEDLE BEARING
1 - REVERSE GEAR AND NEEDLE BEARING
DRMANUAL TRANSMISSION - NV3500 21 - 15
MANUAL TRANSMISSION - NV3500 (Continued)

Shift Socket
Inspect the shift socket for wear or damage.
Replace the socket if the roll pin or shift shaft bores
are damaged. Minor nicks in the shift lever ball seat
in the socket can be smoothed down with 400 grit
emery or wet/dry paper. Replace the socket if the ball
seat is worn or cracked. Do not reuse the original
shift socket roll pin. Install anewpin during assem-
bly. The socket roll pin is approximately 33 mm
(1-1/4 in.) long.
Output Shaft And Geartrain
Inspect all gears for worn, cracked, chipped or bro-
ken teeth. Also check condition of the bearing bore in
each gear. The bores should be smooth and free of
surface damage. Discoloration of the gear bores is a
normal occurrence and is not a reason for replace-
ment. Replace gears only when tooth damage has
occurred or if the bores are brinnelled or severely
scored.
Inspect the shaft splines and bearings surfaces.
Minor nicks on the bearing surfaces can be smoothed
with 320/420 grit emery and final polished with cro-
cus cloth. Replace the shaft if the splines are dam-
aged or bearing surfaces are deeply scored, worn or
brinnelled.
ASSEMBLY
NOTE: Sealers are used at all case joints. Use
Mopar Gasket Maker or equivalent for all case joints
and Mopar silicone sealer or equivalent for the
input shaft bearing retainer.
SYNCHRONIZER
(1) Slide sleeve onto the hub, leaving enough room
to install the spring in the hub and strut in the hub
groove.
(2) Install first spring in the hub, then install a
strut over the spring. Verify spring is seated in the
spring bore in the strut.
(3) Slide sleeve onto the hub far enough to hold
the first strut and spring in place.
(4) Place detent ball in the top of the strut, then
press the ball into place with a small screwdriver.
Work the sleeve over the ball to hold it in place.
(5) Repeat procedure for the remaining springs,
struts and balls. Use tape or rubber bands to tempo-
rarily secure each strut and ball as they are
installed.
(6) Verify the synchro three springs, struts and
detent balls are all in place (Fig. 49).
OUTPUT SHAFT
NOTE: Lubricate shaft, gears, bearings and
immerse each synchro ring with recommended
lubricant during assembly. Petroleum jelly can be
used to hold parts in place.
(1) Install reverse gear needle bearing up against
shoulder on output shaft (Fig. 50).
Fig. 49 SYNCHRONIZER COMPONENTS
1 - SLEEVE
2 - HUB SHOULDER
3 - SPRING (3)
4 - STRUT (3)
5 - DETENT BALL (3)
6 - HUB
Fig. 50 REVERSE GEAR BEARING
1 - REVERSE GEAR BEARING
2 - SHOULDER
DRMANUAL TRANSMISSION - NV3500 21 - 17
MANUAL TRANSMISSION - NV3500 (Continued)