wheel DODGE RAM 2003 Service Repair Manual

DESCRIPTION FIGURE
INNER BOX SIDE PANEL AND INNER TAILGATE PILLAR TO OUTER BOX SIDE PANEL 108
OUTER WHEELHOUSE PANEL TO INNER WHEELHOUSE PANEL 109
FRONT CROSSMEMBER, LONG CROSSMEMBER, AND WHEELHOUSE
CROSSMEMBER TO FLOOR PAN11 0
WHEELHOUSE CROSSMEMBER, LONG CROSSMEMBER AND REAR CROSS BOX
SILL TO BOX FLOOR PAN111
FRONT AND CENTER STAKE POCKET REINFORCEMENTS AND TIE DOWN
MOUNTING REINFORCEMENT TO INNER BOX SIDE PANEL11 2
OUTER FRONT AND CENTER STAKE POCKET REINFORCEMENT AND OUTER TIE
DOWN MOUNTING REINFORCEMENT TO INNER BOX SIDE PANEL11 3
OUTER WHEELHOUSE AND OUTER BRACE MOUNTING REINFORCEMENT TO
OUTER BOX SIDE PANEL11 4
TAILGATE BOX SIDE PIVOT REINFORCEMENT TO OUTER BOX SIDE PANEL 115
FRONT BOX SIDE PANEL TO FRONT CROSSMEMBER TO INNER BOX SIDE PANEL 116
FRONT BOX SIDE PANEL TO BOX FRONT PANEL TO INNER BOX SIDE PANEL/
FRONT STAKE POCKET REINFORCEMENT TO FRONT BOX SIDE PANEL TO BOX
FRONT PANEL11 7
BOX FRONT PANEL TO BOX FLOOR PANEL 118
BOX FLOOR PANEL TO INNER BOX SIDE PANEL 119
LONG CROSSMEMBERS TO CROSSMEMBER END SUPPORT BRACKETS TO INNER
BOX SIDE PANEL120
INNER WHEELHOUSE PANEL TO INNER BOX SIDE PANEL 121
TAILGATE PILLAR OUTER PANEL TO TAILGATE PILLAR INNER PANEL TO INNER
BOX SIDE PANEL122
REAR SILL CROSS BOX TO TAILGATE PILLAR OUTER PANEL AND INNER BOX SIDE
PANEL123
OUTER BOX SIDE PANEL TO BOX FRONT PANEL AND BOX FRONT SIDE PANEL 124
STAKE POCKET REINFORCEMENTS TO INNER BOX SIDE PANEL TO OUTER BOX
SIDE PANEL125
TAILGATE PIVOT REINFORCEMENT AND INNER TAILGATE PILLAR TO INNER BOX
SIDE PANEL TO OUTER BOX SIDE PANEL126
INNER WHEELHOUSE TO OUTER WHEELHOUSE/TAILGATE PIVOT
REINFORCEMENT TO OUTER TAILGATE PILLAR TO INNER TAILGATE PILLAR127
OUTER TAILGATE PILLAR TO OUTER BOX SIDE PANEL 128
INNER DOOR PANEL TO OUTER DOOR PANEL - FRONT DOOR (QUAD CAB) 129
INNER DOOR PANEL TO OUTER DOOR PANEL - FRONT DOOR (STANDARD CAB) 130
INNER DOOR PANEL TO OUTER DOOR PANEL - REAR DOOR (QUAD CAB) 131
DRBODY STRUCTURE 23 - 125
WELD LOCATIONS (Continued)

Fig. 95 OUTER BOX SIDE REINFORCEMENT BRACES - SHORT CARGO BOX ONLY
Fig. 96 OUTER WHEELHOUSE - SHORT CARGO BOX ONLY
DRBODY STRUCTURE 23 - 177
WELD LOCATIONS (Continued)

Fig. 108 INNER BOX SIDE PANEL - SHORT CARGO BOX ONLY
Fig. 109 OUTER WHEELHOUSE PANEL - SHORT CARGO BOX ONLY
DRBODY STRUCTURE 23 - 185
WELD LOCATIONS (Continued)

Fig. 111 WHEELHOUSE CROSSMEMBER - LONG CARGO BOX ONLY
DRBODY STRUCTURE 23 - 187
WELD LOCATIONS (Continued)

Fig. 114 OUTER WHEELHOUSE - LONG CARGO BOX ONLY
DRBODY STRUCTURE 23 - 189
WELD LOCATIONS (Continued)

Fig. 121 INNER WHEELHOUSE PANEL - LONG CARGO BOX ONLY
Fig. 122 TAILGATE PILLAR OUTER PANEL - LONG CARGO BOX ONLY
DRBODY STRUCTURE 23 - 193
WELD LOCATIONS (Continued)

Fig. 127 INNER WHEELHOUSE - LONG CARGO BOX ONLY
Fig. 128 OUTER TAILGATE PILLAR - LONG CARGO BOX ONLY
DRBODY STRUCTURE 23 - 197
WELD LOCATIONS (Continued)

CONTROLS
TABLE OF CONTENTS
page page
A/C COMPRESSOR CLUTCH
DESCRIPTION..........................9
OPERATION............................9
DIAGNOSIS AND TESTING - A/C
COMPRESSOR CLUTCH COIL...........10
STANDARD PROCEDURE - A/C
COMPRESSOR CLUTCH BREAK-IN.......10
REMOVAL.............................10
INSPECTION..........................12
INSTALLATION.........................12
A/C COMPRESSOR CLUTCH RELAY
DESCRIPTION.........................13
OPERATION...........................13
DIAGNOSIS AND TESTING - COMPRESSOR
CLUTCH RELAY......................13
REMOVAL.............................14
INSTALLATION.........................14
A/C HEATER CONTROL
DESCRIPTION.........................14
REMOVAL.............................14
INSTALLATION.........................15
A/C PRESSURE TRANSDUCER
DESCRIPTION - A/C PRESSURE
TRANSDUCER.......................15
OPERATION...........................15
DIAGNOSIS AND TESTING - A/C PRESSURE
TRANSDUCER.......................15
REMOVAL.............................16
INSTALLATION.........................16
BLEND DOOR ACTUATOR
DESCRIPTION.........................16
OPERATION...........................16REMOVAL.............................17
INSTALLATION.........................17
BLOWER MOTOR RESISTOR BLOCK
DESCRIPTION.........................17
OPERATION...........................17
DIAGNOSIS AND TESTING - BLOWER
MOTOR RESISTOR....................18
REMOVAL.............................18
INSTALLATION.........................18
BLOWER MOTOR SWITCH
DESCRIPTION.........................18
OPERATION...........................18
DIAGNOSIS AND TESTING - BLOWER
MOTOR SWITCH......................18
REMOVAL.............................19
INSTALLATION.........................19
DEFROST DOOR ACTUATOR
REMOVAL - FLOOR - DEFROST DOOR
ACTUATOR..........................19
INSTALLATION - FLOOR - DEFROST DOOR
ACTUATOR..........................20
MODE DOOR ACTUATOR
DESCRIPTION.........................20
OPERATION...........................21
REMOVAL.............................21
INSTALLATION.........................22
RECIRCULATION DOOR ACTUATOR
DESCRIPTION.........................22
OPERATION...........................22
REMOVAL.............................22
INSTALLATION.........................23
A/C COMPRESSOR CLUTCH
DESCRIPTION
The compressor clutch assembly consists of a sta-
tionary electromagnetic coil, a rotor bearing and
rotor assembly, and a clutch plate (Fig. 1). The elec-
tromagnetic coil unit and the rotor bearing and rotor
assembly are each retained on the nose of the com-
pressor front housing with snap rings. The clutch
plate is keyed to the compressor shaft and secured
with a nut. These components provide the means to
engage and disengage the compressor from the
engine serpentine accessory drive belt.
OPERATION
When the clutch coil is energized, it magnetically
draws the clutch into contact with the rotor and
drives the compressor shaft. When the coil is not
energized, the rotor freewheels on the clutch rotor
bearing, which is part of the rotor. The compressor
clutch and coil are the only serviced parts on the
compressor.
The compressor clutch engagement is controlled by
several components: the A/C Heater mode control
switch, the A/C high pressure transducer, the com-
pressor clutch relay, and the (JTEC). The JTEC may
delay compressor clutch engagement for up to thirty
DRCONTROLS 24 - 9

for relay terminal 86 with the ignition switch in the
On position. If OK, go to Step 5. If not OK, repair the
open circuit to the fuse in the junction block as
required.
(5) The coil ground terminal cavity (85) is switched
to ground through the Powertrain Control Module
(PCM). There should be continuity between this cav-
ity and the A/C compressor clutch relay control cir-
cuit cavity of the PCM wire harness connector C
(gray) at all times. If not OK, repair the open circuit
as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cover from the Power Distribution
Center (PDC).
(3) Refer to the label on the PDC for compressor
clutch relay identification and location.
(4) Unplug the compressor clutch relay from the
PDC.
INSTALLATION
(1) Install the compressor clutch relay by aligning
the relay terminals with the cavities in the PDC and
pushing the relay firmly into place.
(2) Install the PDC cover.
(3) Connect the battery negative cable.
(4) Test the relay operation.
A/C HEATER CONTROL
DESCRIPTION
The A/C heater system uses a seriers of electrical
controls. These controls provide the vehicle operator
with a number of setting options to help control the
climate and comfort within the vehicle. Refer to the
owner's manual in the vehicle glove box for more
information on the features, use, and suggested oper-
ation of these controls.
The A/C heater control - (Single Zone) or (Dual
Zone) panel is located to the right of the instrument
cluster on the instrument panel.
The control panel contains a rotary-type tempera-
ture control, a rotary-type mode control switch knob,
and a rotary-type blower motor speed switch knob.
The control also has a push button to activate the
Optional side view mirrors defroster elements and to
turn the A/C on.
The Dual Zone HVAC control panel contains a pair
of slider-type temperature controls, a rotary-type
mode control switch knob and a rotary-type blower
motor speed switch knob. The control also has but-
tons to turn the A/C ON, Set it on Max A/C and for
the Optional Heated Sideview Mirrors.The A/C heater control panel cannot be repaired. If
faulty or damaged, the entire unit must be replaced.
The illumination lamps are available for service
replacement.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the center bezel from the instrument
panel(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL CENTER BEZEL - REMOVAL).
(3) Remove the screws that secure the A/C Heater
control to the instrument panel (Fig. 11) or (Fig. 12).
(4) Pull the A/C Heater control assembly away
from the instrument panel far enough to access the
connections on the back of the control.
(5) Unplug the wire harness connectors from the
back of the A/C Heater control (Fig. 13).
Fig. 11 Single Zone HVAC Control
1 - Mounting Tab (4)
2 - A/C Button
3 - Sideview Mirror Defroster Button (if equiped)
4 - Mode Control
5 - Blend Air Control
6 - Blower Motor Speed Control
24 - 14 CONTROLSDR
A/C COMPRESSOR CLUTCH RELAY (Continued)

trol module learns the blend air door stop positions
during the calibration procedure and will store a
Diagnostic Trouble Code (DTC) for any problems it
detects in the blend door actuator circuits. The blend
door actuator can be diagnosed using a DRBIIItscan
tool. Refer to the appropriate diagnostic information.
REMOVAL
The single zone heating and air conditioning sys-
tem is equipped with a single blend door actuator.
The dual zone system has two blend door actuators,
one for the driver side blend air door and one for the
passenger side blend air door. The same service pro-
cedures can be used for each of these actuators.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel assembly(Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL).
(3) Disconnect the HVAC wire harness connector
for the blend door actuator from the actuator connec-
tor receptacle. (Fig. 14)
(4) Remove the screws that secure the blend door
actuator to the distribution housing.
(5) Remove the blend door actuator from the dis-
tribution housing.
INSTALLATION
(1) Position the blend door actuator into the heat-
er/air conditioner housing. If necessary, rotate the
actuator slightly to align the splines on the actuator
output shaft with those in the blend air door linkage.
(2) Install and tighten the three screws that secure
the blend door actuator to the distribution housing.
Tighten the screws to 2 N´m (17 in. lbs.).
(3) Reconnect the HVAC wire harness connector
for the blend door actuator to the actuator connector
receptacle.
(4) Install the instrument panel assembly(Refer to
23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION).(5) Reconnect the battery negative cable.
(6) Perform the heater-A/C control calibration pro-
cedure. (Refer to 24 - HEATING & AIR CONDITION-
ING/CONTROLS - FRONT/A/C-HEATER CONTROL
- STANDARD PROCEDURE - HEATER-A/C CON-
TROL CALIBRATION).BLOWER MOTOR RESISTOR
BLOCK
DESCRIPTION
The blower motor resistor is mounted to the rear
side of the HVAC housing on the passenger side of
the vehicle.
OPERATION
The resistor is a ceramic resistor that utilizes
resistor circuit tracers to reduce current flow to the
Fig. 14 HVAC Housing - Dual Zone Shown (Typical -
Single Zone)
1 - Mounting Nut
2 - Passenger Blend Door Actuator (dual zone)
3 - Mounting Nut
4 - Air Intake Spacer
5 - Recirculation Door Actuator
6 - Recirculation Door Assembly
7 - Driver Side Blend Door Actuator
8 - HVAC Housing
9 - Mounting Screw
10 - Defroster Door Actuator
11 - Panel Actuator
DRCONTROLS 24 - 17
BLEND DOOR ACTUATOR (Continued)