app DODGE RAM 2003 Service Repair Manual

(9) Remove washer from the housing.
NOTE: Tighten the slide hammer adapter 8990 into
the seal using wrenches, in order to make a tight fit
to pull the seal out. If this is not performed the seal
may tear on the removal making it difficult to
remove.
(10) Remove oil seal from the housing with a spe-
cial tool 8990 with slide hammer C-3752.
REMOVAL - DIESEL
(1) Seperate the pitman arm from the gear box
(Refer to 19 - STEERING/LINKAGE/PITMAN ARM -
REMOVAL).
(2) Remove the steering gear box (Refer to 19 -
STEERING/GEAR - REMOVAL).
(3) Install the steering gear in a soft jawed bench
vise.
(4) Clean exposed end of pitman shaft and housing
with a wire brush.
(5) Rotate the input shaft with a 12 point socket
from stop to stop and count the number of turns (Fig.
6).
(6) Center the input shaft by rotating it from the
stop 1/2 of the total amount of turns (Fig. 6).
(7) Remove the pitman shaft cover bolts.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(8) Remove the pitman shaft from the gear.
(9) Remove dust seal from the housing with a spe-
cial tool 8990 (Fig. 5).CAUTION: Use care not to score the housing bore
when prying out seals.
(10) Remove retaining ring with snap ring pliers.
(11) Remove washer from the housing.
NOTE: Tighten the slide hammer adapter 8990 into
the seal using wrenches, in order to make a tight fit
to pull the seal out. If this is not performed the seal
may tear on the removal making it difficult to
remove.
(12) Remove oil seal from the housing with a spe-
cial tool 8990 with slide hammer C-3752. (Fig. 5).
INSTALLATION
INSTALLATION - GAS ENGINE
NOTE: Generous amounts of the high temperature
grease from the seal kit should be applied to areas
between the pitman shaft bearing and oil seals and
also between the dust seals and snap ring.
(1) Coat the oil seal and washer withhigh temp
grease.
NOTE: Install the oil seal with the lip facing inward.
Flat side of the oil seal should be against the
washer.
(2) Install the oil seal with special tool 8989 driver
and C-4171 handle (Fig. 7).
(3) Install backup washer.
(4) Install the retainer ring with snap ring pliers.
Fig. 5 SLIDE HAMMER
1 - STEERING GEAR
2 - SLIDE HAMMER C-3752 USED WITH SPECIAL TOOL
ADAPTER
8990
Fig. 6 CENTERING STEERING GEAR
1 - STEERING GEAR
2 - 12 POINT SOCKET
3 - RATCHET
4 - INPUT SHAFT
19 - 24 GEAR - LINK/COILDR
PITMAN SHAFT SEAL (Continued)

(5) Coat the dust seal withhigh temp grease.
(6) Install the dust seal with a driver and handle
(Fig. 7).
(7) Install protective seal protector 8993 over the
shaft (Fig. 8).
(8) Install the pitman shaft into the steering gear
until it fully seats into the bearing.
(9) Install the new cover bolts and tighten to 68
N´m (50 ft. lbs.).
(10) Install the pitman arm (Refer to 19 - STEER-
ING/LINKAGE/PITMAN ARM - INSTALLATION).
INSTALLATION - DIESEL
NOTE: Generous amounts of the high temperature
grease from the seal kit should be applied to areas
between the pitman shaft bearing and oil seals and
also between the dust seals and snap ring.
(1) Coat the oil seal and washer withhigh temp
grease.
NOTE: Install the oil seal with the lip facing inward.
Flat side of the oil seal should be against the
washer.
(2) Install the oil seal with special tool 8989 driver
and C-4171 handle (Fig. 7).
(3) Install backup washer.
(4) Install the retainer ring with snap ring pliers.
(5) Coat the dust seal withhigh temp grease.
(6) Install the dust seal with special tool 8989
driver and C-4171 handle (Fig. 7).
(7) Install protective seal protector 8993 over the
shaft (Fig. 8).
(8) Install the pitman shaft into the steering gear
until it fully seats into the bearing.
(9) Install the new cover bolts and tighten to 68
N´m (50 ft. lbs.).
(10) Install the steering gear (Refer to 19 -
STEERING/GEAR - INSTALLATION).
(11) Install the pitman arm (Refer to 19 - STEER-
ING/LINKAGE/PITMAN ARM - INSTALLATION).
(12) Perform a wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
STEERING GEAR INPUT
SHAFT SEAL
REMOVAL
(1) Remove the steering gear from the vehicle
(Refer to 19 - STEERING/GEAR - REMOVAL).
CAUTION: Do not overtighten the vise on the gear
case. This may affect the adjustment
(2) Mount the steering gear upside down over a
drain pan in a soft jawed vise.
(3) Place a drain pan under the gear and rotate
the input shaft back and forth several times lock-to-
lock to discharge the fluid from the steering gear
(4) Drain all the remaining fluid from the gear.
(5) Rotate the input shaft from stop to stop and
count the number of turns using a 12 point socket
(Fig. 9).
Fig. 7 SEAL INSTALLATION
1 - SPECIAL TOOL
C-4171
2 - SPECIAL TOOL
8989
3 - STEERING GEAR
Fig. 8 PITMAN SHAFT SEAL PROTECTOR
1 - STEERING GEAR
2 - SPECIAL TOOL
8993
DRGEAR - LINK/COIL 19 - 25
PITMAN SHAFT SEAL (Continued)

(16) Using special tool slide hammer C-3752 with
adapter 8990 remove the oil seal (Fig. 17).
INSTALLATION
(1) Inspect the piston teflon seals for damage.
Replace if needed.
NOTE: To replace the teflon seals, use a pick to
remove the teflon o-ring and the rubber o-ring
underneath. Install a new rubber o-ring in the piston
seal grove and a new teflon o-ring over the top of it.
(2) Install the valve into the valve housing.
(3) Thread the retainer ring into the valve housing
(Fig. 18). Tighten to 97 N´m (72 ft. lbs.)
NOTE: It is very important to make sure to compen-
sate for the added length of the torque wrench
when torquing to proper specifications.
(4) Install the retainer ring set screw. Tighten to
2.26 N´m (20 in. lbs.)
(5) Clean the steering gear housing.
CAUTION: Valve assembly must be centered to the
housing (Fig. 19).
(6) Install the valve assembly into the steering
gear (Fig. 19). Tighten the new bolts to 54 N´m (40 ft.
lbs.)
(7) Install the input shaft seal protector 8986 (Fig.
20).
(8) Coat the new seal inhigh temp greaseand
Install the new oil seal using special tool 8987 driver
and C-4171 handle (Fig. 21).NOTE: Drive the oil seal into the housing until the
outer edge does not quite clear the snap ring
groove.
(9) Insert the snap ring into the housing. Using
special tool 8987 driver and C-4171 handle push the
snap ring and oil seal together until the snap ring
seats in the groove.
NOTE: Generous amounts of the high temperature
grease from the seal kit should be applied to areas
between the pitman shaft bearing and oil seals and
also between the dust seals and snap ring.
Fig. 17 OIL SEAL REMOVAL
1 - SPECIAL TOOL
8990
WITH SLIDE HAMMER C-3752
2 - VALVE HOUSING
Fig. 18 RETAINER RING INSTALLATION
1 - VALVE HOUSING
2 - SPECIAL TOOL
3 - TORQUE WRENCH
Fig. 19 CENTERED GEAR TEETH
1 - GEAR INSTALLED WITH THE CENTER TOOTH CENTERED IN
HOLE
2 - VALVE HOUSING
19 - 28 GEAR - LINK/COILDR
STEERING GEAR INPUT SHAFT SEAL (Continued)

LINKAGE - LINK/COIL
TABLE OF CONTENTS
page page
LINKAGE - LINK/COIL
DESCRIPTION.........................33
STANDARD PROCEDURE - LUBRICATION....34
SPECIFICATIONS
TORQUE CHART......................34
SPECIAL TOOLS
STEERING LINKAGE...................35
DAMPER
REMOVAL.............................35
INSTALLATION.........................35
DRAG LINK
REMOVAL.............................35INSTALLATION.........................35
PITMAN ARM
REMOVAL.............................35
INSTALLATION.........................36
TIE ROD END
REMOVAL.............................36
INSTALLATION.........................37
TRACK BAR
REMOVAL.............................37
INSTALLATION.........................37
LINKAGE - LINK/COIL
DESCRIPTION
The steering linkage is comprised of a tie rod end,
tie rod, drag link, steering damper and pitman arm
(Fig. 1).
CAUTION: If any steering components are replaced
or serviced an alignment must be performed.
NOTE: To avoid damaging ball stud seals, use
Puller C-3894±A or an appropriate puller to remove
tie rod ends (Fig. 2).
Fig. 1 LINK/COIL FRONT SUSPENSION
1 - STABILIZER BAR
2 - PITMAN ARM
3 - STEERING GEAR
4 - STABILIZER LINK
5 - TIE ROD ENDS
6 - LOWER SUSPENSION ARMS
7 - DRAG LINK
8 - TRACK BAR
9 - DAMPER
10 - UPPER SUSPENSION ARM
DRLINKAGE - LINK/COIL 19 - 33

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

POWER STEERING PRESSURE
SWITCH
DESCRIPTION
A pressure sensing switch is used in the power
steering system. It is mounted on the high-pressure
steering hose (Fig. 9). This switch will be used with
both 3.7L, 4.7L and 5.7L engines. There is no pres-
sure switch used for the 5.9L pump.
OPERATION
The switch is used on the 3.7L V-6, 4.7L & 5.7L
V-8 engines.
The power steering pressure switch provides an
input to the Powertrain Control Module (PCM). This
input is provided during periods of high steering
pump load and low engine rpm; such as during park-
ing maneuvers. The PCM increases the idle speed
through the Idle Air Control (IAC) motor. This is
done to prevent the engine from stalling under the
increased load.
When steering pump pressure exceeds 3275 kPa  
690 kPa (475 psi   100 psi), the Normally Closed
(NC) switch will open and the PCM will increase the
engine idle speed. This will prevent the engine from
stalling.
When pump pressure drops to approximately 1379
kPa (200 psi), the switch circuit will re-close and
engine idle speed will return to its previous setting.
REMOVAL - 3.7L, 4.7L & 5.7L
The power steering pressure switch is installed in
the power steering high-pressure hose (Fig. 9).
(1) Disconnect electrical connector from power
steering pressure switch.
(2) Place a small container or shop towel beneath
switch to collect any excess fluid.
(3) Remove switch. Use back-up wrench on power
steering line to prevent line bending.
INSTALLATION - 3.7L, 4.7L & 5.7L
This switch is used only with the 3.7L V±6 and the
4.7L, 5.7L V-8 engines.
(1) Install power steering switch into power steer-
ing line.
(2) Tighten to 8±11 N´m (70±100 in. lbs.) torque.
(3) Connect electrical connector to switch.
(4) Check power steering fluid and add as neces-
sary.
(5) Start engine and again check power steering
fluid. Add fluid if necessary.
PULLEY
REMOVAL
CAUTION: Do not reuse the old power steering
pump pulley it is not intended for reuse. A new pul-
ley must be installed if removed.
(1) Remove the power steering pump assembly,
(Refer to 19 - STEERING/PUMP - REMOVAL).
(2) Remove the pulley from the pump with an
appropriate power steering pulley removal tool (Fig.
10).
Fig. 9 PRESSURE SWITCH
1 - POWER STEERING PULLEY
2 - POWER STEERING PUMP HOUSING
3 - POWER STEERING FLUID RESERVOIR
4 - RETURN HOSE
5 - HIGH PRESSURE HOSE WITH PRESSURE SWITCH
Fig. 10 PULLEY REMOVAL
1 - POWER STEERING PUMP
2 - PULLEY
3 - POWER STEERING PULLEY REMOVAL TOOL
DRPUMP 19 - 45

INSTALLATION
CAUTION: Do not reuse the old power steering
pump pulley it is not intended for reuse. A new pul-
ley must be installed if removed.
(1) Replace the pulley if it's bent, cracked, or loose.
(2) Install the pulley on the pump with an appro-
priate power steering pulley installation tool (Fig. 11)
making sure it is flush with the end of the shaft.
Ensure the tool and pulley remain aligned with the
pump shaft.
(3) Install the power steering pump assembly,
(Refer to 19 - STEERING/PUMP - INSTALLATION).
(4) Run engine until warm (5 min.) and note any
belt chirp. If chirp exists, move pulley outwardapproximately 0.5 mm (0.020 in.). If noise increases,
press on 1.0 mm (0.040 in.).Be careful that pulley
does not contact mounting bolts.
RESERVOIR
REMOVAL
(1) Drain and siphon the power steering fluid from
the reservoir.
(2) Remove the serpentine belt.
(3) Remove the power steering pump (Refer to 19 -
STEERING/PUMP - REMOVAL).
(4) Remove the reservoir mounting bolts.
(5) Remove the reservoir.
(6) Remove the rear bracket to the pump mounting
bolts.
INSTALLATION
(1) Install the reservoir bracket to the pump hous-
ing.Do not reuse the o-rings (install new
o-rings).Tighten bolts to 7 N´m (5 ft. lbs.).
NOTE: Ensure the reservoir is fully seated onto the
pump.
(2) Install the reservoir to the bracket/pump body.
(3) Install the reservoir mounting bolts. Tighten
bolts to 7 N´m (5 ft. lbs.).
(4) Install the power steering pump (Refer to 19 -
STEERING/PUMP - INSTALLATION).
(5) Install the serpentine drive belt, (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(6) Fill the power steering pump, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
Fig. 11 PULLEY INSTALLATION
1 - POWER STEERING PUMP
2 - PULLEY
3 - POWER STEERING PUMP PULLEY INSTALLATION TOOL
19 - 46 PUMPDR
PULLEY (Continued)

(10) Remove shift shaft detent plug from the side
of the transmission with Remover 8117A. Attach fin-
gers of the remover to the detent plug and push the
cup down till it contacts the trans. Then tighten the
nut till it pulls the plug from the case.
(11) Remove shift shaft detent plunger and spring
with a pencil magnet.
(12) Remove bolts that attach front housing to the
rear housing (Fig. 11). Three bolts at extreme rear of
housing are for the output shaft bearing retainer.
Leave one bolt in place until geartrain is ready to be
removed from case.(13) Separate the housings (Fig. 12) by tapping the
front housing off alignment dowels with a plastic
hammer.
(14) Remove input shaft bearing and countershaft
front bearing race (Fig. 13).
Fig. 11 HOUSING & BEARING RETAINER BOLT
1 - RETAINER BOLTS
2 - HOUSING BOLTS
3 - RETAINER BOLT
4 - HOUSING BOLT LOCATIONS
Fig. 12 FRONT HOUSING
1 - FRONT HOUSING
2 - REAR HOUSING
3 - DOWELS (2)
4 - PLASTIC MALLET
Fig. 13 Input Shaft Bearing and Countershaft Front
Bearing Race
1 - INPUT SHAFT BEARING
2 - FRONT HOUSING
3 - COUNTERSHAFT FRONT BEARING
21 - 6 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)

(15) Note position of input shaft, shift shaft, forks
and geartrain components in housing (Fig. 14).
SHIFT/FORK SHAFTS AND REVERSE IDLER
SEGMENT
(1) Place a shop towel over the shaft lever to con-
tain the lever detent ball and spring.
(2) Rotate lever and bushing upward out of the
shift forks and catch ball and spring (Fig. 15).
(3) Unseat shift socket roll pin with Remover 6858.
Position remover on shift shaft and center tool over
the roll pin. Verify tool legs are firmly seated on the
shift socket (Fig. 16).
(4) Tilt socket toward the side of the case to avoid
trapping the pin between the gear teeth.
(5) Tighten remover to press the roll pin down-
ward and out of the shift socket (Fig. 16).
NOTE: Roll pin must only clear the shift shaft. Do
not push the pin into the geartrain.
(6) Drive out shift bushing and lever roll pin with
a hammer and punch (Fig. 17).
NOTE: Use proper size punch to avoid bending the
shift shaft.
Fig. 15 DETENT SPRING AND BALL
1 - SHAFT LEVER
2 - SPRING AND BALL
3 - MAGNET
Fig. 16 SHIFT SOCKET
1 - REMOVER
2 - SHIFT SOCKET
Fig. 17 SHIFT SHAFT LEVER & BUSHING ROLL PIN
1 - PIN PUNCH
2 - BUSHING AND LEVER
3 - SHIFT SHAFT
Fig. 14 GEARTRAIN AND SHIFT COMPONENT
1 - SHIFT SHAFT
2 - BUSHING
3 - REAR HOUSING
4 - REVERSE IDLER AND SUPPORT
5 - OUTPUT SHAFT AND GEARS
6 - COUNTERSHAFT
7 - 1-2 FORK
8 - INPUT SHAFT
9 - 3-4 FORK
DRMANUAL TRANSMISSION - NV3500 21 - 7
MANUAL TRANSMISSION - NV3500 (Continued)

FRONT/REAR HOUSINGS AND BEARING
RETAINERS
Inspect the housings carefully. Look for cracks,
stripped threads, scored mating surfaces, damaged
bearing bores or worn dowel pin holes. Minor nicks
on mating surfaces can be dressed off with a fine file
or emery cloth. Damaged threads can be renewed by
either re-tapping or installing Helicoil inserts.
NOTE: The front housing contains the countershaft
front bearing race. The rear housing contains the
countershaft rear bearing race. These components
are NOT serviceable items. The front housing will
have to be replaced if the countershaft bearing race
is loose, worn or damaged. The rear housing will
have to be replaced if the countershaft rear bearing
race is loose, worn or damaged.
Inspect the input shaft bearing retainer. Be sure
the release bearing slide surface of the retainer is in
good condition. Minor nicks on the surface can be
smoothed off with 320/420 grit emery cloth and final
polished with oil coated crocus cloth. Replace the
retainer seal if necessary.
Inspect output shaft bearing retainer, the
U-shaped retainer must be flat and free of distortion.
Replace the retainer if the threads are damaged or if
the retainer is bent or cracked.
COUNTERSHAFT BEARINGS AND RACES
The countershaft bearings and races are machine
lapped during manufacture to form matched sets.
The bearings and races should not be interchanged.
NOTE: The bearing races are a permanent press fit
in the housings and are NOT serviceable. If a bear-
ing race becomes damaged, the front or rear hous-
ing must be replaced. A new countershaft bearing
will be supplied with each new housing for service
use.
REVERSE IDLER COMPONENTS
Inspect the idler gear, bearing, shaft, thrust
washer, wave washer and thrust plate. Replace the
bearing if any of the needle bearing rollers are worn,
chipped, cracked, flat-spotted or brinnelled. Also
replace the bearing if the plastic bearing cage is
damaged or distorted.
Replace thrust washer, wave washer or thrust
plate if cracked, chipped or worn. Replace idler gear
if the teeth are chipped, cracked or worn thin.
Replace shaft if worn, scored or the bolt threads are
damaged beyond repair. Replace support segment if
cracked or chipped and replace the idler attaching
bolts if the threads are damaged.
Fig. 48 Shift Forks And Shaft
1 - SHIFT SHAFT
2 - SHAFT LEVER
3 - SHAFT LEVER BUSHING4 - 3-4 SHIFT FORK
5 - 1-2 SHIFT FORK
6 - FIFTH-REVERSE SHIFT FORK
21 - 16 MANUAL TRANSMISSION - NV3500DR
MANUAL TRANSMISSION - NV3500 (Continued)