lock DODGE RAM 2003 Service Repair Manual

KEY CYLINDER
REMOVAL
The ignition key must be in the key cylinder for
cylinder removal.
(1) Disconnect negative cable from battery.
(2) Remove upper and lower covers (shrouds) from
steering column.
(3) Place shifter in PARK position.
(4) A retaining pin (Fig. 12) is located at side of
key cylinder assembly.
(a) Rotate key to RUN position.
(b) Press in on retaining pin while pulling key
cylinder from ignition switch (Fig. 13).
INSTALLATION
The ignition key must be in the key cylinder for
cylinder installation.
(1) Install the key cylinder into the housing using
care to align the end of the key cylinder with the
ignition switch.
(2) Push the key cylinder in until it clicks.
(3) Replace the upper and lower shrouds.
(4) Reconnect the battery.
GEAR SHIFT LEVER
REMOVAL
(1) Remove the kneeblocker. (Refer to 23 - BODY/
INSTRUMENT PANEL/KNEE BLOCKER - REMOV-
AL).
(2) Remove the upper and lower column shroud.
(3) Remove and discard the brake light switch.
(4) Loosen the column bolts and lower the column
enough to allow clearance for the gear shift lever
removal.
(5) Disconnect the overdrive switch harness (if
equipped).
(6) Disconnect the shift cable from the shift lever.
(7) Remove the SKIM.
(8) Remove the gear shift lever mounting screws
and remove the lever. (Fig. 14)
(9) Remove the blocker pin from the inhibit link
slot (Fig. 14).
INSTALLATION
(1) Install the lever assembly using care to install
the pin in the blocker to slider slot (Fig. 15) and
install the mounting screws and tighten to 12 N´m
(105 in. lbs.).
Fig. 12 KEY CYLINDER
1 - KEY
2 - KEY CYLINDER
3 - RETAINING PIN HOLE
Fig. 13 KEY CYLINDER
1 - KEY CYLINDER
2 - PUNCH
Fig. 14 GEAR SHIFT LEVER
1 - PARK INHIBIT BLOCKER SPRING
2 - GEAR SHIFT LEVER
19 - 12 COLUMNDR

(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)

(7) Remove the lower steering shaft coupler (Fig.
20).
INSTALLATION
INSTALLATION - ALL LD & HD EXCEPT 4X4
HD
(1) Install the coupler to the steering rack & pin-
ion using the marks made in the removal process.
(2) Install the coupler to the intermediate shaft
using the marks made in the removal process.
NOTE: New pinch bolts must be used for reinstalla-
tion.
(3) Install the lower pinch bolt and tighten to 57
N´m (42 ft. lbs.).
(4) Install the upper pinch bolt and tighten to 57
N´m (42 ft. lbs.).
(5) Install the left front tire and wheel assembly
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
(6) Lower the vehicle.
(7) Reconnect the negative battery cable.
(8) Unlock the steering wheel.
INSTALLATION - 4X4 HD
(1) Install the coupler to the steering gear.
(2) Install the coupler to the intermediate shaft.
NOTE: New pinch bolts must be used for reinstalla-
tion.
(3) Install the lower pinch bolt and tighten to 28
N´m (250 in. lbs.).
(4) Install the upper pinch bolt and tighten to 57
N´m (42 ft. lbs.).(5) Install the left front tire and wheel assembly
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
(6) Lower the vehicle.
(7) Reconnect the negative battery cable.
(8) Unlock the steering wheel.
STEERING WHEEL
REMOVAL
(1) Disable and remove the driver's side air-
bag.(Refer to 8 - ELECTRICAL/RESTRAINTS/
DRIVER AIRBAG - REMOVAL).
(2) Partially remove the steering wheel bolt and
leave the bolt in the column.
(3) Install puller CJ98-1 or equivalent using the
top of the bolt to push on. (Fig. 21)
(4) Remove and discard the steering wheel bolt.
(5) Remove the steering wheel.
INSTALLATION
NOTE: Do not reuse the old steering wheel bolt (a
new bolt must be used)
(1) Install steering wheel to the column
NOTE: Be certain that the steering wheel mounting
bolt is tightened to the proper torque specification
to ensure proper clockspring operation.
(2) Install the new steering wheel bolt. Tighten the
bolt to 61 N´m (45 ft. lbs.).
(3) Install the driver's side air bag. (Refer to 8 -
ELECTRICAL/RESTRAINTS/DRIVER AIRBAG -
INSTALLATION).
Fig. 20 INTERMEDIATE STEERING SHAFT
1 - UPPER COUPLING BOOT AND BOLT
2 - INTERMEDIATE STEERING SHAFT
3 - LOWER COUPLING BOLT
4 - STEERING GEAR
Fig. 21 STEERING WHEEL PULLER
1 - STEERING WHEEL
2 - SPECIAL TOOL CJ98-1
DRCOLUMN 19 - 15
LOWER STEERING COUPLING (Continued)

GEAR - INDEPENDENT FRONT SUSPENSION
TABLE OF CONTENTS
page page
GEAR - INDEPENDENT FRONT SUSPENSION
DESCRIPTION.........................16
REMOVAL.............................16
INSTALLATION.........................17
SPECIFICATIONS
TORQUE CHART......................18BUSHING
REMOVAL.............................18
INSTALLATION.........................18
GEAR - INDEPENDENT FRONT
SUSPENSION
DESCRIPTION
A rack and pinion steering gears (Fig. 1) is made
up of two main components, the pinon shaft and the
rack. The gear cannot be adjusted or internally ser-
viced. If a malfunction or a fluid leak occurs, the gear
must be replaced as an assembly.
REMOVAL
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.
(1) Lock the steering wheel.(2) Drain and siphon the power steering fluid from
the reservoir.
(3) Raise the vehicle.
(4) Remove and discard the steering coupler pinch
bolt.
(5) Remove the power steering hoses from the rack
& pinion.
(6) Remove the tire and wheel assembly.
(7) Remove the tie rod end nuts and separate tie
rod ends from the knuckles with Special tool 8677
(Refer to 19 - STEERING/LINKAGE/TIE ROD END -
REMOVAL).
(8) Remove the skid plate (Refer to 13 - FRAME &
BUMPERS/FRAME/FRONT SKID PLATE - REMOV-
AL).
(9) Remove the rack & pinion mounting bolts. (Fig.
2) & (Fig. 3)
(10) Remove the rack & pinion from the vehicle.
Fig. 1 STEERING GEAR
1 - OUTER TIE ROD ENDS
2 - MOUNTING BUSHINGS
3 - BELLOWS
Fig. 2 STEERING GEAR MOUNTING BOLTS
1 - STEERING GEAR MOUNTING BOLTS 4X4
19 - 16 GEAR - INDEPENDENT FRONT SUSPENSIONDR

GEAR - LINK/COIL
TABLE OF CONTENTS
page page
GEAR - LINK/COIL
DESCRIPTION.........................19
OPERATION...........................19
REMOVAL.............................19
INSTALLATION.........................20
ADJUSTMENTS
ADJUSTMENT........................20
SPECIFICATIONS
POWER STEERING GEAR..............21
TORQUE CHART......................22
SPECIAL TOOLS
POWER STEERING GEAR..............22
PITMAN SHAFT SEAL
REMOVAL
REMOVAL - GAS ENGINE...............23REMOVAL - DIESEL...................24
INSTALLATION
INSTALLATION - GAS ENGINE...........24
INSTALLATION - DIESEL................25
STEERING GEAR INPUT SHAFT SEAL
REMOVAL.............................25
INSTALLATION.........................28
PITMAN SHAFT
REMOVAL
REMOVAL - GAS......................29
REMOVAL - DIESEL...................30
INSTALLATION
INSTALLATION - GAS..................30
INSTALLATION - DIESEL................30
GEAR - LINK/COIL
DESCRIPTION
The power steering gear is a recirculating ball type
gear (Fig. 1). The gear ratio's used are 12.5:1.
OPERATION
The gear acts as a rolling thread between the
worm shaft and rack piston. The worm shaft is sup-
ported by a thrust bearing at the lower end and a
bearing assembly at the upper end. When the worm
shaft is turned from input from the steering column
the rack piston moves. The rack piston teeth mesh
with the pitman shaft. Turning the worm shaft, turns
the pitman shaft, which turns the steering linkage.
REMOVAL
(1) Place the front wheels in a straight-ahead posi-
tion.
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.
(3) Siphon out as much power steering fluid as
possible.
Fig. 1 STEERING GEAR
1 - INPUT SHAFT
2 - OUTLET
3 - INLET
4 - VALVE ASSEMBLY HOUSING
5 - PITMAN SHAFT COVER BOLTS
6 - STEERING GEAR
7 - MESHLOAD ADJUSTER NUT
8 - PITMAN SHAFT
DRGEAR - LINK/COIL 19 - 19

(1) Remove the steering gear from the vehicle
(Refer to 19 - STEERING/GEAR - REMOVAL).
(2) Mount the gear carefully into a soft-jawed vise.
CAUTION: Do not overtighten the vise on the gear
case. This may affect the adjustment
(3) Hold the steering gear upside down over a
drain pan and rotate the input shaft back and forth
several times lock-to-lock to discharge the fluid from
the steering gear
(4) Rotate the input shaft to the left stop and then
back-off approximately 45 degrees. Using an inch-
pound torque wrench on the input shaft, record the
peak torque required to slowly and evenly rotate the
input shaft clockwise
1¤2turn (180 degrees) starting
from the 45 degree position. This peak torque read-
ing is the preload torque. The preload torque must be
within2-10in-lbs.
(5) Rotate the input shaft to its center of travel
(approximately 1.5 turns from either stop). Place the
torque wrench on the input shaft with the handle in
the vertical position. Rotate the torque wrench slowly
and evenly
1¤4turn (90 degrees) each side of center
and record the peak torque measure on or near cen-
ter. This total on-center torque reading must be5-9
in-lbs higher than the previously measured preload
torque without exceeding a total of 17 in-lbs. The
value of the total on-center minus the preload torque
is defined as the meshload torque(6) If required, adjust the on-center torque by loos-
ening the adjuster screw lock nut and turning the
adjuster screw until the total on-center and meshload
torque readings fall within the specified values. Turn
the adjuster screw clockwise to increase and counter-
clockwise to decrease the torque reading. While hold-
ing the adjuster screw in place, tighten the lock nut
to 31 N´m (23 ft. lbs.).
(7) Re-check the preload and on-center torque
readings.
(8) Install pitman arm on the steering gear (Refer
to 19 - STEERING/LINKAGE/PITMAN ARM -
INSTALLATION).
(9) Reinstall steering gear to the vehicle (Refer to
19 - STEERING/GEAR - INSTALLATION).
SPECIFICATIONS
POWER STEERING GEAR
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Steering Gear
TypeRecirculating Ball
Gear Code & Ratio 12.5:1
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Preload
Torque0.23-1.13 Ð 2-10
Meshload Torque 0.56-1.02 Ð 5-9
+ Preload (17 Max)
DRGEAR - LINK/COIL 19 - 21
GEAR - LINK/COIL (Continued)

TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Steering Gear Mounting
Frame Bolts196 145 Ð
Power Steering Line
Pressure32 23 Ð
Power Steering Line
Return71 52 Ð
Power Steering Line
Pressure Line To Pump37 27 Ð
Steering Gear
Adjustment Screw Locknut31 23 Ð
Steering Gear
Pitman Shaft Nut305 225 Ð
Steering Gear
Pitman Shaft Cover Bolts68 50 Ð
Steering Gear
Valve Housing to Gear
Bolts54 40 Ð
Steering Gear
Retainer Ring Screw2.26 Ð 20
Steering Gear
Retainer Ring97 72 Ð
SPECIAL TOOLS
POWER STEERING GEAR
HANDLE C-4171INPUT SHAFT SEAL INSTALLER - 8987
19 - 22 GEAR - LINK/COILDR
GEAR - LINK/COIL (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)

INSTALLATION
(1) Align reference marks and install pitman arm.
(2) Install the lock washer and retaining nut on
the pitman shaft and tighten nut to 251 N´m (185 ft.
lbs.).
(3) Install the drag link to the pitman arm (Fig. 6).
Install the nut and tighten to 108 N´m (80 ft. lbs.).
(4) Remove the supports and lower the vehicle to
the surface. Center steering wheel and adjust toe,
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE).
(5) After adjustment tighten tie rod adjustment
sleeve clamp bolts to 61 N´m (45 ft. lbs.).NOTE: Position the clamp on the sleeve so retain-
ing bolt is located on the bottom side of the sleeve.
TIE ROD END
REMOVAL
(1) Remove tie rod nuts (Fig. 7).
(2) Remove tie rod from drag link and left knuckle
with Puller C-4150A.
Fig. 4 PITMAN ARM REMOVAL
1 - PITMAN ARM
2 - C-4150A PULLER
Fig. 5 PITMAN ARM REMOVAL/INSTALLATION
1 - STEERING GEAR
2 - PITMAN ARM
3 - NUT
4 - WASHER
Fig. 6 PITMAN ARM INSTALLED
1 - DRAGLINK
2 - STEERING GEAR
3 - SWAYBAR
4 - NUT/WASHER
5 - PITMAN ARM
Fig. 7 TIE ROD ENDS
1 - NUT
2 - TIE ROD ENDS
19 - 36 LINKAGE - LINK/COILDR
PITMAN ARM (Continued)