frame DODGE RAM 2003 Service Manual Online

CAUTION:
All welds should conform to DaimlerChrysler vehicle engineering process standard ªps 9472º.
WELD PROCESS SPECIFICATIONS
WELDING PROCESS FLUX CORED ARC GAS METAL ARC (MIG)* SHIELDED METAL ARC
(STICK)
Material Thickness3.7 mm to 4.2 mm 3.7 mm to 4.2 mm 3.7 mm to 4.2 mm
Electrode TypeLincoln Electrical Co.
Product #: NR-211 MP
(Do Not Substitute)AWS ER70S-3
(Do Not Substitute)** AWS E 7018
Electrodes Size Inches.045 Tubular .035 Solid 3/329
Electrode Stick Out3/89- 1/291/29- 5/89N/A
PolarityElectrode9-9
Work Piece9+9Electrode9+9
Work Piece9-9Electrode9+9
Work Piece9-9
Shielding GasSelf Shielded 75% Ar
25% CO2Self Shielded
Gas Flow RateN/A 25 - 35 CFM N/A
Wire Feed Speed
(inches per minute)110 - 130 Vertical Down
70 - 90 Flat & Overhead245 - 250 Vertical Down
210 - 225 Flat &
OverheadN/A
Approximate Amperage
Vertical110 - 130 175 85 (3/329Diameter)
Flat & Overhead70 - 90 155 90 (3/329Diameter)
Voltage15-18 19-20 N/A
Direction of Welding
VerticalVertical Down Hill (only) Vertical Down Hill (only) Vertical - Up Hill (only)
Flat & OverheadFlat - Push or Drag Flat - Push or Drag Flat - Drag
*First choice - Gas Metal Arc Welding Process:
Butt joints - apply two layers (passes) of weld metal.
First pass should only fill approximately
1¤2the thick-
ness. Vertical position welds - maintain electrode
wire at leading edge of weld puddle while traveling
down hill to produce maximum penetration into the
sleeve. These techniques work for FCAW as well.
**E7018new electrodes may be exposed to the
atmosphere for up to ten hours with no harmful
effect. Reconditioning schedules should come from
the manufacturer.
SPECIFICATIONS
SPECIFICATIONS - FRAME DIMENSIONS
NOTE: Frame dimensions are listed in metric scale.
All dimensions are from center to center of Princi-
pal Locating Point (PLP), or from center to center of
PLP and fastener location.
VEHICLE PREPARATION
Position the vehicle on a level work surface. Using
screw or bottle jacks, adjust the vehicle PLP heights
to the specified dimension above a level work surface.
Vertical dimensions can be taken from the work sur-
face to the locations indicated were applicable.
INDEX
DESCRIPTION FIGURE
Frame Dimensional Graphics, Side
And Top View24
140.5 In Wheelbase - Heavy Duty -
2 Wheel Drive25
140.5 In Wheelbase - Heavy Duty -
4 Wheel Drive26
160.5 In Wheelbase - Heavy Duty -
2 Wheel Drive27
160.5 In Wheelbase - Heavy Duty -
4 Wheel Drive28
DRFRAMES & BUMPERS 13 - 17
FRAME (Continued)

Fig. 24 FRAME DIMENSIONS
13 - 18 FRAMES & BUMPERSDR
FRAME (Continued)

Fig. 25 140.5 IN WHEELBASE - HEAVY DUTY - 2 WHEEL DRIVE
DRFRAMES & BUMPERS 13 - 19
FRAME (Continued)

Fig. 26 140.5 IN WHEELBASE - HEAVY DUTY - 4 WHEEL DRIVE
13 - 20 FRAMES & BUMPERSDR
FRAME (Continued)

Fig. 27 160.5 IN WHEELBASE - HEAVY DUTY - 2 WHEEL DRIVE
DRFRAMES & BUMPERS 13 - 21
FRAME (Continued)

Fig. 28 160.5 IN WHEELBASE - HEAVY DUTY - 4 WHEEL DRIVE
13 - 22 FRAMES & BUMPERSDR
FRAME (Continued)

SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Cab mount bolts 81 60 Ð
Cargo box bolts 108 80 Ð
Front crossmember bolts - 2WD 61 45 Ð
Front crossmember bolts - 4WD 102 75 Ð
Front skid plate bolts 34 25 Ð
Lower bumper support bracket bolt 54 40 Ð
Radiator crossmember bolts - lower 28 21 Ð
Radiator crossmember bolts - upper 28 21 Ð
Rear crossmember - 2WD 102 75 Ð
Rear crossmember - 4WD 102 75 Ð
Rear spring shackle bolts 163 120 Ð
Spare tire winch bolts 41 30 Ð
Trailer hitch reinforcement bracket bolt 170 125 Ð
Transfercase skid plate bolts 34 25 Ð
Transercase skid plate crossmember bolts 34 25 Ð
Transmission mount to crossmember nuts 61 45 Ð
FRONT CROSSMEMBER
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Remove the front skid plate, if equipped. (Refer
to 13 - FRAME & BUMPERS/FRAME/FRONT SKID
PLATE - REMOVAL)
(3) Remove the bolts and remove the crossmember.
(Fig. 29) or (Fig. 30)
INSTALLATION
(1) Install the crossmember.
(2) Install the bolts;
²On 2WD vehicles, tighten the bolts to 61 N´m
(45 ft. lbs.).
²On 4WD vehicles, tighten the bolts to 102 N´m
(75 ft. lbs.).
Fig. 29 FRONT CROSSMEMBER - 2WD
1 - CROSSMEMBER
2 - BOLTS (2 PER SIDE)
DRFRAMES & BUMPERS 13 - 23
FRAME (Continued)

(3) Install the front skid plate, if equipped. (Refer
to 13 - FRAME & BUMPERS/FRAME/FRONT SKID
PLATE - INSTALLATION)
FRONT SKID PLATE
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Remove the bolts. (Fig. 31)
(3) Slide skid plate back off of the crossmember
and remove.
INSTALLATION
(1) Snap the rear tabs over the front crossmember
and install the skid plate.
(2) Install the bolts and tighten to 34 N´m (25 ft.
lbs.).
TRANSMISSION
CROSSMEMBER
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Remove the transfercase skid plate, if
equipped. (Refer to 13 - FRAME & BUMPERS/
FRAME/TRANSFER CASE SKID PLATE -
REMOVAL)
(3) Support the transmission with a suitable lifting
device.
(4) Remove the transmission mount nuts. (Fig. 32)
or (Fig. 33)
(5) Remove the bolts and remove the crossmember.
Fig. 30 FRONT CROSSMEMBER - 4WD
1 - BOLTS (2 PER SIDE)
2 - CROSSMEMBER
Fig. 31 FRONT SKID PLATE
1 - FRONT CROSSMEMBER
2 - FRONT SKID PLATE
3 - BOLTS (2)
Fig. 32 REAR CROSSMEMBER - 2WD
1 - TRANSMISSION MOUNT
2 - REAR CROSSMEMBER
3 - TRANSMISSION MOUNT NUTS (2)
4 - CROSSMEMBER BOLTS (2 PER SIDE)
13 - 24 FRAMES & BUMPERSDR
FRONT CROSSMEMBER (Continued)

INSTALLATION
(1) Install the crossmember and install the bolts.
(2) Tighten the bolts to 102 N´m (75 ft. lbs.).
(3) Install the transmission mount nuts and
tighten to 61 N´m (45 ft. lbs.).
(4) Remove the transmission support.
(5) Install the transfercase skid plate. (Refer to 13
- FRAME & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - INSTALLATION)
TRAILER HITCH
REMOVAL
(1) Remove the rear bumper. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/REAR BUMPER -
REMOVAL)
(2) Remove the hitch bolts. (Fig. 34)
(3) Disconnect all wire harness support push pins.(4) Remove the rear two cargo box bolts and loosen
the remaining bolts. (Refer to 23 - BODY/EXTERI-
OR/CARGO BOX - REMOVAL)
(5) Using a suitable lifting device, lift and support
the rear of the cargo box and remove the hitch.
INSTALLATION
(1) Install the hitch onto the frame rails and make
sure the locators on the inside of the hitch brackets
are engaged with the holes in the top of the frame
rails properly.
(2) Lower the cargo box and install the rear bolts.
(Refer to 23 - BODY/EXTERIOR/CARGO BOX -
INSTALLATION)
(3) Install the hitch bolts and tighten to 170 N´m
(125 ft. lbs.).
(4) Connect all wire harness support push pins.
(5) Install the rear bumper. (Refer to 13 - FRAME
& BUMPERS/BUMPERS/REAR BUMPER - INSTAL-
LATION)
Fig. 33 REAR CROSSMEMBER - 4WD
1 - TRANSMISSION MOUNT
2 - TORSION BAR
3 - CROSSMEMBER BOLTS (3 PER SIDE)
4 - REAR CROSSMEMBER
5 - TRANSMISSION MOUNT NUTS (2)
Fig. 34 TRAILER HITCH
1 - HITCH
2 - HITCH BOLTS (4)
3 - BUMPER BRACKET BOLTS (4)
4 - BUMPER SUPPORT BRACKETS
DRFRAMES & BUMPERS 13 - 25
TRANSMISSION CROSSMEMBER (Continued)

TRANSFER CASE SKID PLATE
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Support the skid plate and remove the bolts.
(Fig. 35)
(3) Remove the skid plate.
(4) Support the skid plate crossmember and
remove the bolts.
(5) Remove the skid plate crossmember.
INSTALLATION
(1) Install the skid plate crossmember and install
the bolts.
(2) Tighten the bolts to 34 N´m (25 ft. lbs.).
(3) Install the skid plate and install the bolts.
(4) Tighten the bolts to 34 N´m (25 ft. lbs.).
FRONT TOW HOOK ASSEMBLY
REMOVAL
(1) Remove front bumper. (Refer to 13 - FRAME &
BUMPERS/BUMPERS/FRONT BUMPER -
REMOVAL)
(2) Remove the bolts and remove the tow hook
assembly. (Fig. 36)
INSTALLATION
(1) Install the tow hook assembly and bolts hand
tight.
(2) Install the front bumper. (Refer to 13 - FRAME
& BUMPERS/BUMPERS/FRONT BUMPER -
INSTALLATION)
(3) Tighten the tow hook bolts to 68 N´m (50 ft.
lbs.).
Fig. 35 TRANSFER CASE SKID PLATE
1 - CROSSMEMBER BOLTS (4)
2 - SKID PLATE CROSSMEMBER
3 - SKID PLATE
4 - SKID PLATE BOLTS (4)
Fig. 36 FRONT TOW HOOK ASSEMBLY
1 - BUMPER CENTER SUPPORT BRACKET
2 - BOLTS (6)
3 - TOW HOOK ASSEMBLY
13 - 26 FRAMES & BUMPERSDR