frame DODGE RAM 2003 Service Owner's Manual

(8) Align the bolt holes in the hub bearing flange
with the bolts installed in the knuckle. Then thread
the bolts into the bearing flange far enough to hold
the assembly in place.(9) Install the remaining bolts. Tighten the hub/
bearing bolts to 202 N´m (149 ft. lbs.
(10) Install the washer and axle nut and tighten a
beginning torque of 179 N´m (132 ft. lbs.).
(11) Rotate the axle 5 to 10 times to seat the hub
bearing.
(12) Tighten to a final torque of 356 N´m (263 ft.
lbs.).
(13) Align the axle nut to the next forward cotter
pin hole and install a new cotter pin in the axle nut.
(14) Install the brake caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION).
(15) Install the sensor wire to the steering knuckle
and frame and if equipped. Connect the wheel speed
sensor wire under the hood.
(16) Install the wheel and tire assemblies, (Refer
to 22 - TIRES/WHEELS/WHEELS - STANDARD
PROCEDURE).
(17) Remove the support and lower the vehicle.
(18) Apply the brakes several times to seat the
brake shoes and caliper piston. Do not move the vehi-
cle until a firm brake pedal is obtained.
LOWER BALL JOINT
REMOVAL
(1) Remove lower snap ring from the lower ball
joint (Fig. 11).
(2) Position special tool 8975±2 (RECEIVER) and
8975±4 (DRIVER) with tool C4212±F as shown to
remove lower ball stud (Fig. 12).
Fig. 9 Brake Shield
1 - BRAKE SHIELD
2 - HUB BEARING BOLTS
3 - STEERING KNUCKLE
Fig. 10 Brake Shield With Wheel Speed Sensor
1 - WHEEL SPEED SENSOR
2 - HUB BEARING
3 - SHIELD
Fig. 11 LOWER SNAP RING
2 - 32 FRONT - LINK/COILDR
HUB / BEARING (Continued)

KNUCKLE
REMOVAL
(1) Remove the hub bearing (Refer to 2 - SUSPEN-
SION/FRONT/HUB / BEARING - REMOVAL).
(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 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 (Refer to 2 - SUSPEN-
SION/FRONT/HUB / BEARING - INSTALLATION).
(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.
UPPER SUSPENSION ARM
REMOVAL
REMOVAL - LEFT
(1) Raise and support the vehicle.
(2) Remove the upper suspension arm nut and bolt
at the axle bracket (Fig. 16).
(3) Remove the nut and bolt at the frame rail and
remove the upper suspension arm.
REMOVAL - RIGHT
(1) Raise and support the vehicle.
(2) Disconnect the exhaust system at the mani-
folds.
(3) Disconnect the rubber exhaust mounts at the
muffler.
(4) Support the transmission.
(5) Remove the transmission cross member.
(6) Lower the exhaust system down in order to
gain access to the removal of the upper bolt.(7) Remove the nut and bolt at the frame rail and
remove the upper suspension arm.
(8) Remove the upper suspension arm nut and bolt
at the axle bracket.
(9) Remove the suspension arm from the vehicle.
INSTALLATION
INSTALLATION - LEFT
(1) Position the upper suspension arm at the axle
and frame rail.
(2) Install the bolts and finger tighten the nuts.
(3) Remove the supports and lower the vehicle.
(4) Tighten nut at the axle bracket to 163 N´m
(120 ft. lbs.). Tighten nut at frame bracket to 163
N´m (120 ft. lbs.).
INSTALLATION - RIGHT
(1) Position the upper suspension arm at the axle
and frame rail.
(2) Install the bolts, then finger tighten the nuts.
(3) Reconnect the rubber exhaust mounts at the
muffler.
(4) Reconnect the exhaust at the manifolds.
(5) Install the transmission crossmember.
(6) Remove the supports and lower the vehicle.
(7) Tighten nut at the axle bracket to 163 N´m
(120 ft. lbs.). Tighten nut at frame bracket to 163
N´m (120 ft. lbs.).
Fig. 16 Link/Coil Suspension
1 - STABILIZER BAR
2 - SHOCK ABSORBER
3 - COIL SPRING
4 - UPPER SUSPENSION ARM
5 - LOWER SUSPENSION ARM
6 - TRACK BAR
2 - 34 FRONT - LINK/COILDR

LOWER SUSPENSION 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. 17).
(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.
17).
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 217
N´m (160 ft. lbs.). Tighten rear nut at the frame
bracket to 217 N´m (160 ft. lbs.).
SHOCK
DIAGNOSIS AND TESTING - 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 shock absorber bushings do not require any
type of lubrication. Do not attempt to stop bushing
noise by lubricating them. Grease and mineral oil-
base lubricants will deteriorate the bushing.
REMOVAL
(1) Remove the nut, retainer and grommet from
the upper stud in the engine compartment.
(2) Remove three nuts from the upper shock
bracket (Fig. 18).
(3) Remove the lower bolt from the axle bracket
(Fig. 19). Remove the shock absorber from engine
compartment.
INSTALLATION
(1) Position the lower retainer and grommet on the
upper stud. Insert the shock absorber through the
spring from engine compartment.
(2) Install the lower bolt and tighten to 135 N´m
(100 ft. lbs.).
(3) Install the upper shock bracket and three nuts.
Tighten nuts to 75 N´m (55 ft. lbs.).
(4) Install upper grommet and retainer. Install
upper shock nut and tighten to 47 N´m (35 ft. lbs).
Fig. 17 Adjustment Cam
1 - ADJUSTMENT CAM
2 - AXLE BRACKET
3 - BRACKET REINFORCEMENT
4 - LOWER SUSPENSION ARM
DRFRONT - LINK/COIL 2 - 35

SPRING
REMOVAL
(1) Raise and support the vehicle. Position a
hydraulic jack under the axle to support it.
(2) Paint or scribe alignment marks on lower sus-
pension arm cam adjusters and axle bracket for
installation reference.
(3) Remove the upper suspension arm and loosen
lower suspension arm bolts.
(4) Mark and disconnect the front propeller shaft
from the axle 4x4 models.
(5) Disconnect the track bar from the frame rail
bracket.
(6) Disconnect the drag link from pitman arm.
(7) Disconnect the stabilizer bar link and shock
absorber from the axle.
(8) Lower the axle until the spring is free from the
upper mount. Remove the coil spring.
INSTALLATION
(1) Position the coil spring on the axle pad.
(2) Raise the axle into position until the spring
seats in the upper mount.
(3) Connect the stabilizer bar links and shock
absorbers to the axle bracket. Connect the track bar
to the frame rail bracket.
(4) Install the upper suspension arm.
(5) Install the front propeller shaft to the axle 4x4
model.
(6) Install drag link to pitman arm and tighten
nut to specifications. Install new cotter pin.
(7) Remove the supports and lower the vehicle.
(8) Tighten the following suspension components
to specifications:
²Link to stabilizer bar nut.
²Lower shock bolt.
²Track bar bolt at axle shaft tube bracket.
²Upper suspension arm nut at axle bracket.
²Upper suspension nut at frame bracket.
²Align lower suspension arm reference marks and
tighten cam nut.
²Lower suspension nut at frame bracket.Fig. 18 Shock Absorber and Bracket
1 - GROMMET
2 - RETAINER
3 - BRACKET
4 - RETAINER
5 - SHOCK
6 - GROMMET
Fig. 19 Shock Absorber Axle Mount
1 - SHOCK
2 - SPRING
3 - FLAG NUT
4 - SHOCK BOLT
2 - 36 FRONT - LINK/COILDR
SHOCK (Continued)

STABILIZER BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Hold the stabilizer link shafts with a wrench
and remove the link nuts at the stabilizer bar.
(3) Remove the retainers and grommets from the
stabilizer bar links.
(4) Remove the stabilizer bar link nuts from the
axle brackets.
(5) Remove the links from the axle brackets with
Puller C-3894-A (Fig. 20).
(6) Remove the stabilizer bar clamps from the
frame rails and remove the stabilizer bar.
INSTALLATION
(1) Position the stabilizer bar on the frame rail
and install the clamps and bolts. Ensure the bar is
centered with equal spacing on both sides.
(2) Tighten the clamp bolts to 61 N´m (45 ft. lbs.).
(3) Install links to the axle bracket and tighten
nut to 47 N´m (35 ft. lbs.).
(4) Install links, retainers, grommets and nuts to
the stabilizer bar. Hold the link shaft with a wrench
and tighten the nuts to 37 N´m (27 ft. lbs.).
(5) Remove the supports and lower the vehicle.
Fig. 20 Stabilizer Link
1 - PULLER
2 - LINK
DRFRONT - LINK/COIL 2 - 37

(6) Position upper and lower suspension arms in
the axle brackets. Install bolts, nuts and align the
suspension alignment cams to the reference marks.
Do not tighten at this time.
(7) Connect track bar to the axle bracket and
install the bolt. Do not tighten at this time.
(8) Install shock absorber and tighten bolts to 121
N´m (89 ft. lbs.).
(9) Install stabilizer bar link to the axle bracket.
Tighten the nut to 68 N´m (50 ft. lbs.).
(10) Install drag link and tie rod to the steering
knuckles and tighten the nuts to 108 N´m (80 ft.
lbs.).
(11) Install ABS wheel speed sensors.
(12) Install rotors and brake calipers.
(13) Connect the axle vent hose.
(14) Install front propeller shaft.
(15) Check and add differential lubricant, if neces-
sary.
(16) Install wheel and tire assemblies.
(17) Remove lower the vehicle.
(18) Tighten upper suspension arm nuts at axle to
149 N´m (110 ft. lbs.). Tighten upper suspension arm
nuts at frame to 149 N´m (110 ft. lbs.).
(19) Tighten lower suspension arm nuts at axle to
190 N´m (140 ft. lbs.). Tighten the lower suspension
arm nuts at frame to 190 N´m (140 ft. lbs.).
(20) Tighten track bar bolt at the axle bracket to
176 N´m (130 ft. lbs.).
(21) Check front wheel alignment.
ADJUSTMENTS
Ring and pinion gears are supplied as matched
sets only. Compensation for pinion depth variance is
achieved with a select shim. The shim is located
between the rear pinion bearing and the pinion gear
head.
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken with pinion bearing cups
and pinion bearings installed in the housing. Take
measurements with Pinion Gauge Set and Dial Indi-
cator C-3339 (Fig. 1).
(1) Assemble Pinion Height Block 6739, Pinion
Block 8878 and rear pinion bearing onto Screw 6741
(Fig. 1).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through pin-
ion bearing cups (Fig. 2).
(3) Install front pinion bearing and install the
Cone-nut 6740 hand tight. Then check tool rotating
torque with an inch pound torque wrench. The rotat-
ing torque should be 1.7-2.26 N´m (15-20 in. lbs.)
(4) Place Arbor Disc 8289 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 3).(5) Install differential bearing caps on arbor discs
and snug the bearing cap bolts. Then cross tighten
cap bolts to 85 N´m (63 ft. lbs.).
Fig. 1 PINION GEAR DEPTH GAUGE TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 2 PINION HEIGHT BLOCK
1. PINION HEIGHT BLOCK
2. PINION BLOCK
DRFRONT AXLE - 9 1/4 AA 3 - 49
FRONT AXLE - 9 1/4 AA (Continued)

ADJUSTABLE PEDAL SWITCH
REMOVAL
(1) Remove the lower drivers side bezel (Refer to
23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL DR SIDE BEZEL - REMOVAL).
(2) Disconnect the electrical connector from the
adjustable pedal switch.
(3) Remove the switch from the lower drivers side
bezel by squeezing the retaining clips together and
pushing the switch outwards (Fig. 2).
INSTALLATION
(1) Install the switch to the lower drivers side
bezel by pushing the switch inwards seating the
retaining clips to the lower drivers side bezel.(2) Reconnect the electrical connector to the
adjustable pedal switch.
(3) Install the lower drivers side bezel (Fig. 2)
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL DR SIDE BEZEL - INSTALLA-
TION).
HYDRAULIC/MECHANICAL
SPECIFICATIONS
SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Brake Booster
Mounting Nuts38 28 Ð
Master Cylinder
Mounting Nuts18 Ð 160
Caliper
Mounting Pins32 24 Ð
Caliper
Adapter Mounting Bolts176 130 Ð
Junction Block
Bolts To Frame10 7.5 Ð
Brake Pedal Assembly Bracket
Nuts28 21 Ð
CAP, MASTER CYLINDER PRESSURE BLEED 6921
GAUGE, BRAKE SAFE-SET C-3919
Fig. 2 LOWER DRIVERS SIDE BEZEL
1 - SCREWS (2)
2 - ADJUSTABLE PEDAL SWITCH
3 - PEDAL SWITCH ELECTRICAL CONNECTOR
4 - BEZEL
5 - 6 BRAKES - BASEDR
BRAKES - BASE (Continued)

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Support Plate
Mounting Bolts/Nuts64 47 Ð
Brake Line Fittings
Master Cylinder19 14 170
Brake Line Fittings
Junction Block19 14 170
Caliper
Brake Line Banjo Bolt27 20 245
Brake Hose
Front Bolts To Frame10 7.5 Ð
Brake Hose
Front Fitting19 14 250
Brake Hose
Rear Fitting19 14 250
Parking Brake Pedal Assembly 19 14 250
Hub/Bearing
Bolts163 120 Ð
BASE BRAKE
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Front Disc Brake Caliper
TypeDual Piston Sliding
Rear Disc Brake Caliper
TypeSingle Piston Sliding
Front Disc Brake Caliper 54 mm (2.00 in.)
Front Disc Brake Rotor 336ý28 mm (13.2ý1.1
in.)
Front/Rear Disc Brake
Rotor
Max. Runout0.127 mm (0.005 in.)
Front/Rear Disc Brake
Rotor
Max. Thickness Variation0.025 mm (0.001 in.)
Minimum Front Rotor
Thickness26.4 mm (1.039 in.)
Mininium Rear Rotor
Thickness28.39 mm (1.117 in)
Rear Disc Brake Caliper 1x54 mm (2.12 in)
Rear Disc Brake Rotor 350x22 mm (.86 in)
Brake Booster
Type
Gasoline EnginesVacuum Dual Diaphragm
BRAKE LINES
STANDARD PROCEDURE
STANDARD PROCEDURE - DOUBLE INVERTED
FLARING
A preformed metal brake tube is recommended and
preferred for all repairs. However, double-wall steel
tube can be used for emergency repair when factory
replacement parts are not readily available.
(1) Cut off damaged tube with Tubing Cutter.
(2) Ream cut edges of tubing to ensure proper
flare.
(3) Install replacement tube nut on the tube.
(4) Insert tube in flaring tool.
(5) Place gauge form over the end of the tube.
(6) Push tubing through flaring tool jaws until
tube contacts recessed notch in gauge that matches
tube diameter.
(7) Tighten the tool bar on the tube
(8) Insert plug on gauge in the tube. Then swing
compression disc over gauge and center tapered flar-
ing screw in recess of compression disc (Fig. 3).
(9) Tighten tool handle until plug gauge is
squarely seated on jaws of flaring tool. This will start
the inverted flare.
(10) Remove the plug gauge and complete the
inverted flare.
STANDARD PROCEDURE - ISO FLARING
A preformed metal brake tube is recommended and
preferred for all repairs. However, double-wall steel
DRBRAKES - BASE 5 - 7
HYDRAULIC/MECHANICAL (Continued)

tube can be used for emergency repair when factory
replacement parts are not readily available.
To make a ISO flare use an ISO flaring tool kit.
(1) Cut off damaged tube with Tubing Cutter.
(2) Remove any burrs from the inside of the tube.
(3) Install tube nut on the tube.
(4) Position the tube in the flaring tool flush with
the top of the tool bar (Fig. 4). Then tighten the tool
bar on the tube.
(5) Install the correct size adaptor on the flaring
tool yoke screw.
(6) Lubricate the adaptor.
(7) Align the adaptor and yoke screw over the tube
(Fig. 4).
(8) Turn the yoke screw in until the adaptor is
squarely seated on the tool bar.
REMOVAL
REMOVAL - REAR BRAKE HOSE
(1) Install prop rod on the brake pedal to keep
pressure on the brake system.
(2) Raise and support the vehicle.
(3) Remove the brake line from the hose at the
frame (Fig. 5).
(4) Remove the brake hose clip at the top of the
hose located at the frame (Fig. 5).
(5) Remove the vent tube (Fig. 6).
(6) Remove the two brake lines at the bottom of
the hose located at the axle (Fig. 6).
(7) Remove the mounting bolt for the brake hose
at the axle (Fig. 6).
(8) Remove the hose.
REMOVAL - REAR TUBE / HOSE ASSEMBLY
(1) Install prop rod on the brake pedal to keep
pressure on the brake system.
(2) Raise and support the vehicle.
(3) Remove the brake line located at the axle.
(4) Remove the mounting bolt for the brake hose
at the axle (Fig. 7).
Fig. 3 Inverted Flare Tools
Fig. 4 ISO Flaring
1 - ADAPTER
2 - LUBRICATE HERE
3 - PILOT
4 - FLUSH WITH BAR
5 - TUBING
6 - BAR ASSEMBLY
Fig. 5 BRAKE LINE CLIP
1 - BRAKE HOSE
2 - CLIP
3 - BRAKE LINE
5 - 8 BRAKES - BASEDR
BRAKE LINES (Continued)

(5) Remove the banjo bolt at the caliper (Fig. 7).
(6) Remove the hose.
REMOVAL - FRONT HOSE
(1) Install a prop rod on the brake pedal to keep
pressure on the brake system.
(2) Raise and support vehicle.
(3) Remove the tire and wheel assembly.
(4) Remove the brake hose from the brake line
located at the frame (Fig. 8).
(5) Remove the brake hose banjo bolt at the caliper
(Fig. 8).
(6) Remove the mounting bolt securing the brake
hose to the frame and remove the wheel speed sensor
wire from the brake hose (Fig. 8).
(7) Remove the hose.
INSTALLATION
INSTALLATION - REAR BRAKE HOSE
(1) Install the hose.
(2) Install the mounting bolt for the brake hose at
the axle (Fig. 6).
(3) Install the two brake lines at the bottom of the
hose located at the axle (Fig. 6).
(4) Install the vent tube (Fig. 6).
(5) Install the brake hose clip at the top of the
hose located at the frame (Fig. 5).
(6) Install the brake line to the hose at the frame
(Fig. 5).
(7) Lower the vehicle and remove the support.
(8) Remove the prop rod.
(9) Bleed the brake system (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
INSTALLATION - REAR TUBE / HOSE
ASSEMBLY
(1) Install the hose.
(2) Install the banjo bolt at the caliper (Fig. 7).
(3) Install the mounting bolt for the brake hose at
the axle (Fig. 7).
(4) Install the brake line located at the axle.
(5) Lower the vehicle and remove the support.
(6) Remove the prop rod.
(7) Bleed the brake system (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
INSTALLATION - FRONT BRAKE HOSE
(1) Install the hose.
(2) Install the mounting bolt for the brake hose at
the frame (Fig. 9).
Fig. 6 REAR HOSE
1 - BRAKE HOSE
2 - VENT HOSE
3 - BRAKE LINES
Fig. 7 BRAKE LINE WITH RUBBER HOSE
1 - BANJO BOLT
2 - MOUNTING BOLT
3 - REAR TUBE / HOSE ASSEMBLY
Fig. 8 BRAKE HOSE MOUNTED PASSENGER SIDE
1 - MOUNTING BOLT
2 - BRAKE HOSE
3 - BANJO BOLT
4 - WHEEL SPEED SENSOR WIRE
DRBRAKES - BASE 5 - 9
BRAKE LINES (Continued)