dash DODGE RAM 2003 Service Workshop Manual

INSTALLATION
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED. REFER TO ELECTRICAL RESTRAINT SYS-
TEM FOR SERVICE PROCEDURES. FAILURE TO DO
SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIRBAG AND POSSIBLE PERSONAL INJURY.
CAUTION: All fasteners must be torqued to specifi-
cation to ensure proper operation of the steering
column.
(1) Position the steering column on the dash panel
support and loosely install the mounting nuts.
(2) Firmly slide the steering column upward
against the studs in dash panel and hand tighten the
nuts.
(3) Install the steering shaft coupler on the steer-
ing shaft and loosely install anewbolt.
(4) Center steering column in dash opening and
tighten mounting nuts to 28 N´m (250 in. lbs.).
NOTE: Torque the upper left nut first then the lower
right nut. Then torque the lower left nut then the
upper right nut.
NOTE: A new bolt must be used for reinstallation.
(5) Tighten the coupler bolt to 57 N´m (42 ft. lbs.).
(6) Install a new brake light switch (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL).(7) Install the shifter cable. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - 32RH/GEAR
SHIFT CABLE - INSTALLATION)
(8) Connect the wiring harness to the column.
(9) Install the SKIM module.
(10) Install the clockspring(Refer to 8 - ELECTRI-
CAL/RESTRAINTS/CLOCKSPRING - REMOVAL).
(11) Install the shrouds.
(12) Install the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - INSTALLA-
TION).
(13) Align the spline on the wheel hub to shaft.
(14) Then install the steering wheel and install a
newbolt. Tighten the bolt to 61 N´m (45 ft. lbs.).
(15) Install the airbag (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - INSTALLATION).
(16) Install the two steering wheel switches.
(17) Install the tilt lever handle.
(18) Install the negative battery terminal.
(19) Test the operation of the horn, Electronic
PRNDL Indicator, lights and any other functions that
are steering column operated.IGNITION SWITCH
DESCRIPTION
The ignition switch is located on the steering col-
umn. It is used as the main on/off switching device
for most electrical components. The mechanical key
cylinder is used to engage/disengage the electrical
ignition switch.
OPERATION
Vehicles equipped with an automatic trans-
mission and a steering column mounted shifter:
an interlock device is located within the shift cable.
This interlock device is used to lock the transmission
shifter in the PARK position when the key cylinder is
in any position and the brake pedal is not depressed.
DIAGNOSIS AND TESTING - IGNITION SWITCH
TEST AND REPAIR
If the key removal effort is excessive on a vehicle
with a automatic transmission first adjust the shift
linkage, (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 46RE/GEAR SHIFT CABLE -
ADJUSTMENTS).
If the ignition switch effort is excessive remove the
ignition key cylinder from the steering column. (Refer
to 19 - STEERING/COLUMN/LOCK CYLINDER
HOUSING - REMOVAL). Check the turning effort of
the key cylinder. If the ignition key cylinder effort is
excessive replace the key cylinder.
Fig. 7 STEERING COLUMN
1 - Steering Wheel
2 - Key Cylinder
3 - Gear Shift Lever
4 - Steering Column
5 - Tilt Lever Cable
DRCOLUMN 19 - 9
COLUMN (Continued)

(4) Lower the vehicle.
(5) Remove the dash panel insulation pad as nec-
essary to access the gearshift cable grommet (Fig.
114).
(6) Remove grommet from the dash panel.
(7) Remove any steering column trim necessary to
access the gearshift cable and BTSI mechanism.
(8) Disconnect the BTSI wiring connector.
(9) Disconnect cable at lower column bracket and
shift lever pin and pull the cable through the dash
panel opening into the vehicle (Fig. 115).
(10) Remove gearshift cable from vehicle.INSTALLATION
(1) Route the transmission end of the gearshift
cable through the opening in the dash panel (Fig.
116).
(2) Seat the cable grommet into the dash panel
opening.
(3) Snap the cable into the steering column
bracket so the retaining ears (Fig. 117) are engaged
and snap the cable eyelet onto the shift lever ball
stud.
Fig. 114 Gearshift Cable at the Dash Panel
1 - GEARSHIFT CABLE
2 - GROMMET
Fig. 115 Gearshift Cable at Steering Column
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
3 - GEARSHIFT CABLE LOCK TAB
4 - BTSI SOLENOID LOCK TAB
5 - BTSI CONNECTOR
Fig. 116 Gearshift Cable at the Dash Panel
1 - GEARSHIFT CABLE
2 - GROMMET
Fig. 117 Gearshift Cable at Steering Column
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
3 - GEARSHIFT CABLE LOCK TAB
4 - BTSI SOLENOID LOCK TAB
5 - BTSI CONNECTOR
21 - 210 AUTOMATIC TRANSMISSION - 46REDR
GEARSHIFT CABLE (Continued)

(4) Lower the vehicle.
(5) Remove the dash panel insulation pad as nec-
essary to access the gearshift cable grommet (Fig.
106).
(6) Remove grommet from the dash panel.
(7) Remove any steering column trim necessary to
access the gearshift cable and BTSI mechanism.
(8) Disconnect the BTSI wiring connector.
(9) Disconnect cable at lower column bracket and
shift lever pin and pull the cable through the dash
panel opening into the vehicle (Fig. 107).
(10) Remove gearshift cable from vehicle.INSTALLATION
(1) Route the transmission end of the gearshift
cable through the opening in the dash panel (Fig.
108).
(2) Seat the cable grommet into the dash panel
opening.
(3) Snap the cable into the steering column
bracket so the retaining ears (Fig. 109) are engaged
and snap the cable eyelet onto the shift lever ball
stud.
Fig. 106 Gearshift Cable at the Dash Panel
1 - GEARSHIFT CABLE
2 - GROMMET
Fig. 107 Gearshift Cable at Steering Column
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
3 - GEARSHIFT CABLE LOCK TAB
4 - BTSI SOLENOID LOCK TAB
5 - BTSI CONNECTOR
Fig. 108 Gearshift Cable at the Dash Panel
1 - GEARSHIFT CABLE
2 - GROMMET
Fig. 109 Gearshift Cable at Steering Column
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
3 - GEARSHIFT CABLE LOCK TAB
4 - BTSI SOLENOID LOCK TAB
5 - BTSI CONNECTOR
21 - 390 AUTOMATIC TRANSMISSION - 48REDR
GEARSHIFT CABLE (Continued)

(4) Lower the vehicle.
(5) Remove the dash panel insulation pad as nec-
essary to access the gearshift cable grommet (Fig.
70).
(6) Remove grommet from the dash panel.
(7) Remove any steering column trim necessary to
access the gearshift cable and BTSI mechanism.
(8) Disconnect the BTSI wiring connector.
(9) Disconnect cable at lower column bracket and
shift lever pin and pull the cable through the dash
panel opening into the vehicle (Fig. 71).
(10) Remove gearshift cable from vehicle.INSTALLATION
(1) Route the transmission end of the gearshift
cable through the opening in the dash panel (Fig.
72).
(2) Seat the cable grommet into the dash panel
opening.
(3) Snap the cable into the steering column
bracket so the retaining ears (Fig. 73) are engaged
and snap the cable eyelet onto the shift lever ball
stud.
Fig. 70 Gearshift Cable at the Dash Panel
1 - GEARSHIFT CABLE
2 - GROMMET
Fig. 71 Gearshift Cable at Steering Column
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
3 - GEARSHIFT CABLE LOCK TAB
4 - BTSI SOLENOID LOCK TAB
5 - BTSI CONNECTOR
Fig. 72 Gearshift Cable at the Dash Panel
1 - GEARSHIFT CABLE
2 - GROMMET
Fig. 73 Gearshift Cable at Steering Column
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
3 - GEARSHIFT CABLE LOCK TAB
4 - BTSI SOLENOID LOCK TAB
5 - BTSI CONNECTOR
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 545
GEARSHIFT CABLE (Continued)

TRANSFER CASE - NV243
TABLE OF CONTENTS
page page
TRANSFER CASE - NV243
DESCRIPTION........................658
OPERATION..........................659
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV243.......................659
REMOVAL............................660
DISASSEMBLY........................660
CLEANING...........................668
INSPECTION.........................668
ASSEMBLY...........................670
INSTALLATION........................679
SPECIFICATIONS
TRANSFER CASE - NV243.............680
SPECIAL TOOLS
TRANSFER CASE - NV241/NV243........680
EXTENSION HOUSING BUSHING AND SEAL
REMOVAL............................682
INSTALLATION........................682FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL............................682
FRONT OUTPUT SHAFT SEAL
REMOVAL............................683
INSTALLATION........................683
MODE SENSOR
DESCRIPTION........................684
OPERATION..........................684
SELECTOR SWITCH
DESCRIPTION........................685
OPERATION..........................685
SHIFT MOTOR
DESCRIPTION........................686
OPERATION..........................686
REMOVAL............................686
INSTALLATION........................686
TRANSFER CASE - NV243
DESCRIPTION
The NV243 is an electronically controlled part-time
transfer case with a low range gear reduction system.
The NV243 has three operating ranges plus a NEU-
TRAL position. The low range system provides a gear
reduction ratio for increased low speed torque capa-
bility.
The geartrain is mounted in two aluminum case
halves attached with bolts. The mainshaft front and
rear bearings are mounted in aluminum retainer
housings bolted to the case halves.
OPERATING RANGES
Transfer case operating ranges are:
²2WD (2-wheel drive)
²4HI (4-wheel drive)
²4LO (4-wheel drive low range)
²NEUTRAL
The 2WD range is for use on any road surface at
any time.The 4HI and 4LO ranges are for off road use only.
They are not for use on hard surface roads. The only
exception being when the road surface is wet or slip-
pery or covered by ice and snow.
The low range reduction gear system is operative
in 4LO range only. This range is for extra pulling
power in off road situations. Low range reduction
ratio is 2.72:1.
SHIFT MECHANISM
Operating ranges are selected with a dash
mounted shift selector switch. The shift selector
switch provides a input to the Transfer Case Control
Module (TCCM) to indicate the driver's desire to
change operating ranges. The TCCM uses this input,
along with input from the transfer case mounted
mode sensor and information from the vehicle's bus,
to determine if a shift is permitted. If the TCCM
decides the shift is permitted, the TCCM controls the
shift motor, mounted to the exterior of the transfer
case, to perform the shift.
21 - 658 TRANSFER CASE - NV243DR

TRANSFER CASE - NV273
TABLE OF CONTENTS
page page
TRANSFER CASE - NV273
DESCRIPTION........................687
OPERATION..........................688
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV273.......................688
REMOVAL............................689
DISASSEMBLY........................689
CLEANING...........................698
INSPECTION.........................699
ASSEMBLY...........................701
INSTALLATION........................713
SPECIFICATIONS
TRANSFER CASE - NV273.............713
SPECIAL TOOLS
TRANSFER CASE NV271/NV273.........714
EXTENSION HOUSING SEAL AND DUST BOOT
REMOVAL............................716
INSTALLATION........................716FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL............................716
FRONT OUTPUT SHAFT SEAL
REMOVAL............................717
INSTALLATION........................717
MODE SENSOR
DESCRIPTION........................718
OPERATION..........................718
SELECTOR SWITCH
DESCRIPTION........................719
OPERATION..........................719
SHIFT MOTOR
DESCRIPTION........................720
OPERATION..........................720
REMOVAL............................720
INSTALLATION........................720
TRANSFER CASE - NV273
DESCRIPTION
The NV273 is an electronically controlled part-time
transfer case with a low range gear reduction system.
The NV273 has three operating ranges plus a NEU-
TRAL position. The low range system provides a gear
reduction ratio for increased low speed torque capa-
bility.
The geartrain is mounted in two aluminum case
halves attached with bolts. The mainshaft front and
rear bearings are mounted in aluminum case halves.
OPERATING RANGES
Transfer case operating ranges are:
²2WD (2-wheel drive)
²4HI (4-wheel drive)
²4LO (4-wheel drive low range)
²NEUTRAL
The 2WD range is for use on any road surface at
any time.The 4HI and 4LO ranges are for off road use only.
They are not for use on hard surface roads. The only
exception being when the road surface is wet or slip-
pery or covered by ice and snow.
The low range reduction gear system is operative
in 4LO range only. This range is for extra pulling
power in off road situations. Low range reduction
ratio is 2.72:1.
SHIFT MECHANISM
Operating ranges are selected with a dash
mounted shift selector switch. The shift selector
switch provides a input to the Transfer Case Control
Module (TCCM) to indicate the driver's desire to
change operating ranges. The TCCM uses this input,
along with input from the transfer case mounted
mode sensor and information from the vehicle's bus,
to determine if a shift is permitted. If the TCCM
decides the shift is permitted, the TCCM controls the
shift motor, mounted to the exterior of the transfer
case, to perform the shift.
DRTRANSFER CASE - NV273 21 - 687

CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION
PC/ABS PC/ABS ALLOY GERMAX, BAY BLENDS,
PULSEDOORS, INSTRUMENT
PANELS
PPO POLYPHENYLENE OXIDE AZDEL, HOSTALEN,
MARLEX, PRFAX, NORYL,
GTX, PPOINTERIOR TRIM, DOOR
PANELS, SPLASH SHIELDS,
STEERING COLUMN SHROUD
PPO/PA POLYPHENYLENE/
POLYAMIDPPO/PA, GTX 910 FENDERS, QUARTER PANELS
PR/FV FIBERGLASS REINFORCED
PLASTICFIBERGLASS, FV, PR/FV BODY PANELS
PS POLYSTYRENE LUSTREX, STYRON, PS DOOR PANELS, DASH
PANELS
RTM RESIN TRANSFER
MOLDING COMPOUNDRTM BODY PANELS
SMC SHEET MOLDED
COMPOUNDSMC BODY PANELS
TMC TRANSFER MOLDING
COMPOUNDTMC GRILLES
UP UNSATURATED
POLYESTER
(THERMOSETTING)SMC, BMC, TMC, ZMC, IMC,
XSMC, UPGRILLE OPENING PANEL,
LIFTGATES, FLARESIDE
FENDERS, FENDER
EXTENSIONS
EEBC ETHER/ESTER BLOCKED
CO-POLYMEREEBC BUMPERS
EEBC/PBTP EEBC/POLYBUTYLENE
TEREPTHALATEEEBC, PBTP, BEXLOY BUMPER, ROCKER PANELS
EMPP ETHYLENE MODIFIED
POLYPROPYLENEEMPP BUMPER COVERS
EPDM ETHYLENE/
PROPROPYLENE DIENE
MONOMEREPDM, NORDEL, VISTALON BUMPERS
EPM ETHYLENE/
PROPROPYLENE CO-
POLYMEREPM FENDERS
MPU FOAM POLYURETHANE MPU SPOILERS
PE POLYETHYLENE ALATHON, DYLAN,
LUPOLEN, MARLEX-
PP POLYPROPYLENE
(BLENDS)NORYL, AZDEL, MARLOX,
DYLON, PRAVEXINNER FENDER, SPOILERS,
KICK PANELS
PP/EPDM PP/EPDM ALLOY PP/EPDM SPOILERS, GRILLES
PUR POLYURETHANE COLONELS, PUR, PU FASCIAS, BUMPERS
PUR/PC PUR/PC ALLOY TEXIN BUMPERS
PVC POLYVINYL CHLORIDE APEX, GEON, VINYLITE BODY MOLDINGS, WIRE
INSULATION, STEERING
WHEELS
RIM REACTION INJECTED
MOLDED POLYURETHANERIM, BAYFLEX FRONT FASCIAS, MODULAR
WINDOWS
RRIM REINFORCED REACTION
INJECTED MOLDEDPUR, RRIM FASCIAS, BODY PANELS,
BODY TRIMS
DRBODY 23 - 5
BODY (Continued)

(2) Snap the top edge of the bezel into place fully.
(3) Seat the two bottom clips fully.
(4) Install the two top screws.
(5) Install the center bezel (Refer to 23 - BODY/
INSTRUMENT PANEL/INSTRUMENT PANEL
CENTER BEZEL - INSTALLATION)
(6) Install the headlamp switch bezel. (Refer to 23
- BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL SWITCH BEZEL - INSTALLATION)
ASH RECEIVER
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.(1) Open ash receiver and place hand inside. (Fig.
2)
(2) Apply force with anabruptdownward motion
and roll rearward. (Fig. 3)
(3) Dislodge and roll ash receiver out of panel to
remove.
Fig. 1 CLUSTER BEZEL
1 - DASH PANEL
2 - SCREWS (2)
3 - CLUSTER BEZEL
4 - CLIP FASTENERS (2)
Fig. 2 ASH RECEIVER
1 - ASH RECEIVER
2 - CUP HOLDER
Fig. 3 ASH RECEIVER REMOVAL
1 - LOCKING TABS
2 - ASH RECEIVER
3 - CUP HOLDER
DRINSTRUMENT PANEL 23 - 51
CLUSTER BEZEL (Continued)

(2) Remove the top cover. (Refer to 23 - BODY/IN-
STRUMENT PANEL/INSTRUMENT PANEL TOP
COVER - REMOVAL)
(3) Disconnect the headliner harness electrical con-
nector at the a-pillar.
(4) Using a trim stick C-4755 or equivalent, from
the notch on the bottom, remove the left side cover.
(Fig. 20)
(5) Remove the steering column. (Refer to 19 -
STEERING/COLUMN - REMOVAL)
(6) Remove the two bolts at the column support
bracket. (Fig. 7)
(7) Remove the left cowl trim panel. (Refer to 23 -
BODY/INTERIOR/COWL TRIM - REMOVAL)
(8) Remove the instrument panel drivers side
bezel. (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL DRIVERS SIDE BEZEL -
REMOVAL)
(9) Remove the left side mounting bolts. (Fig. 8)
(10) Disconnect the wire harness electrical connec-
tors above the brake pedal. (Fig. 9)
(11) Loosen the screws and remove the hood
release handle from the bracket.
(12) Disconnect the park brake release handle
actuator rod.
(13) Remove the air bag control module trim cover,
if equipped. (Fig. 20)(14) Remove the floor console, if equipped. (Refer
to 23 - BODY/INTERIOR/FLOOR CONSOLE -
REMOVAL)
(15) Remove the center bracket bolts. (Fig. 10)
Fig. 7 COLUMN SUPPORT
1 - INSTRUMENT PANEL CLUSTER BEZEL
2 - STEERING COLUMN SUPPORT BRACKET
3 - BOLTS
Fig. 8 LEFT SIDE MOUNTING
1 - A-PILLAR
2 - DASH PANEL
3 - MOUNTING BOLTS (3)
Fig. 9 WIRE HARNESS CONNECTORS
1 - BULKHEAD CONNECTORS
2 - INSTRUMENT PANEL HARNESS CONNECTORS
23 - 54 INSTRUMENT PANELDR
INSTRUMENT PANEL ASSEMBLY (Continued)

(24) Remove the four top instrument panel screws.
(Fig. 15)
(25) Remove the two top instrument panel bolts
and remove the instrument panel.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERINGCOLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Position the instrument panel assembly in
vehicle.
(2) Route the park brake release rod through the
instrument panel. (Fig. 16)
(3) Install the instrument panel onto the left side
guide pin and the right side guide hook.
(4) Install the left side mounting bolts and tighten
to 12 N´m (9 ft. lbs.).
(5) Install the instrument panel drivers side bezel.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL DRIVERS SIDE BEZEL -
INSTALLATION)
(6) Install the left cowl trim panel. (Refer to 23 -
BODY/INTERIOR/COWL TRIM - INSTALLATION)
(7) Connect the headliner harness electrical con-
nector at the a-pillar.
(8) Install the left a-pillar trim. (Refer to 23 -
BODY/INTERIOR/A-PILLAR TRIM - INSTALLA-
TION)
(9) Position the left end cap and seat the attach-
ment clips fully.
(10) Install the right side mounting bolts on the
a-pillar and one right mounting bolt on the cowl side
panel and tighten to 12 N´m (9 ft. lbs.).
Fig. 14 PASSENGER SIDE MOUNTING
1 - DASH PANEL
2 - RIGHT SIDE MOUNTING HOOK
3 - A-PILLAR
4 - END CAP
5 - MOUNTING BOLTS (3)
Fig. 15 UPPER COWL PANEL BOLTS
1 - COWL PANEL
2 - FORWARD MOST SCREWS (4)
3 - BOLT INSERTS (6)
4 - REARWARD BOLTS (2)
5 - DASH PANEL
Fig. 16 BRAKE RELEASE ROD
1 - PARK BRAKE RELEASE HANDLE
2 - PARK BRAKE RELEASE ROD
3 - INSTRUMENT PANEL
23 - 56 INSTRUMENT PANELDR
INSTRUMENT PANEL ASSEMBLY (Continued)