2002 DODGE RAM ABS

SPECIAL TOOLS
LINK/COIL SUSPENSION
HUB / BEARING
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the hub extension mounting nuts and
remove the extension from the rotor if equipped (Fig.
2).(4) Remove the brake caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).
(5) Remove the cotter pin and the hub nut from
the axle shaft (Fig. 3).
(6) Disconnect the ABS wheel speed sensor wire
from under the hood. Remove the sensor wire from
the frame and steering knuckle if equipped.
(7) Back off the hub/bearing mounting bolts 1/4
inch each (Fig. 4). Then tap the bolts with a hammer
to loosen the hub/bearing from the steering knuckle.
(8) Remove the hub/bearing mounting bolts and
remove the hub/bearing.
Puller C-3894±A
Remover, Wheel Stud C-4150A
Fig. 2 Hub Extension
1 - HUB EXTENSION
2 - HUB
Fig. 3 Hub Nut Cotter Pin
1 - HUB NUT
2 - COTTER PIN
Fig. 4 Hub/Bearing Mounting Bolts
1 - SOCKET AND EXTENSION
2 - ROTOR AND HUB
3 - STEERING KNUCKLE
2 - 16 FRONT - 4WDBR/BE
FRONT - 4WD (Continued)

(4) Apply a liberal quantity of anti-seize compound
to the splines of the front drive shaft.
(5) Insert the two rearmost, top and bottom rotor
hub bolts in the steering knuckle. Insert the bolts
through the back side of the knuckle so they extend
out the front face as shown.
(6) Position the hub spacer (Fig. 9) and brake
shield (Fig. 10) on bolts just installed in knuckle.
NOTE: If the vehicle is equipped with a wheel speed
sensor the brake shield must be positioned on the
hub bearing (Fig. 11).
(7) Align the rotor hub with the drive shaft and
start the shaft into the rotor hub splines.
NOTE: Position wheel speed sensor wire at the top
of the knuckle if equipped.
(8) Align the bolt holes in the hub bearing flange
with the bolts installed in the knuckle. Then thread
the bolts into the bearing flange far enough to hold
the assembly in place.
(9) Install the remaining bolts. Tighten the hub/
bearing bolts to 166 N´m (122 ft. labs.
(10) Install the washer and hub nut and tighten to
245 N´m (180 ft. lbs.).
(11) Install a new cotter pin in the hub nut.
Tighten the nut as needed to align the cotter pin hole
in the shaft with the opening in nut.
(12) Install the brake caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION).
(13) Install the sensor wire to the steering knuckle
and frame and if equipped. Connect the wheel speed
sensor wire under the hood.(14) Install the wheel and tire assemblies, (Refer
to 22 - TIRES/WHEELS/WHEELS - STANDARD
PROCEDURE).
(15) Remove the support and lower the vehicle.
(16) Apply the brakes several times to seat the
brake shoes and caliper piston. Do not move the vehi-
cle until a firm brake pedal is obtained.
Fig. 9 Hub Spacer
1 - ROTOR HUB BOLTS
2 - HUB SPACER (POSITION FLAT TO REAR)
3 - APPLY ANTI-SEIZE COMPOUND TO SPLINES
Fig. 10 Brake Shield
1 - BRAKE SHIELD
2 - HUB BEARING BOLTS
3 - STEERING KNUCKLE
Fig. 11 Brake Shield With Wheel Speed Sensor
1 - WHEEL SPEED SENSOR
2 - HUB BEARING
3 - SHIELD
2 - 18 FRONT - 4WDBR/BE
HUB / BEARING (Continued)

KNUCKLE
REMOVAL
(1) Remove hub bearing and axle shaft.
(2) Remove tie-rod or drag link end from the steer-
ing knuckle arm.
(3) Remove the ABS sensor wire and bracket from
knuckle. Refer to Brakes, for proper procedures.
(4) Remove the cotter pin from the upper ball stud
nut. Remove the upper and lower ball stud nuts.
(5) Strike the steering knuckle with a brass ham-
mer to loosen.
(6) Remove knuckle from axle tube yokes.
INSTALLATION
(1) Position the steering knuckle on the ball studs.
(2) Install and tighten lower ball stud nut to 47
N´m (35 ft. lbs.) torque. Do not install cotter pin at
this time.
(3) Install and tighten upper ball stud nut to 94
N´m (70 ft. lbs.) torque. Advance nut to next slot to
line up hole and install new cotter pin.
(4) Retorque lower ball stud nut to 190±217 N´m
(140±160 ft. lbs.) torque. Advance nut to next slot to
line up hole and install new cotter pin.
(5) Install the hub bearing and axle shaft.
(6) Install tie-rod or drag link end onto the steer-
ing knuckle arm.
(7) Install the ABS sensor wire and bracket to the
knuckle. Refer to Brakes, for proper procedure.
UPPER CONTROL ARM
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the upper suspension arm nut and bolt
at the axle bracket (Fig. 12).
(3) Remove the nut and bolt at the frame rail and
remove the upper suspension arm.
INSTALLATION
(1) Position the upper suspension arm at the axle
and frame rail.
(2) Install the bolts and finger tighten the nuts.
(3) Remove the supports and lower the vehicle.
(4) Tighten nut at the axle bracket to 163 N´m
(120 ft. lbs.). Tighten nut at frame bracket to 163
N´m (120 ft. lbs.).
UPPER BALL JOINT
REMOVAL - DANA 44 & 60
(1) Position tools as shown to remove upper ball
stud (Fig. 13).
Fig. 12 Upper and Lower Suspension Arm
1 - STABILIZER BAR
2 - SHOCK ABSORBER
3 - COIL SPRING
4 - UPPER SUSPENSION ARM
5 - LOWER SUSPENSION ARM
6 - TRACK BAR
Fig. 13 UPPER BALL JOINT REMOVAL
1 - SPECIAL TOOL C4212-F
2 - SPECIAL TOOL 6761
3 - KNUCKLE
4 - SPECIAL TOOL 8445-3
BR/BEFRONT - 4WD 2 - 19

INSTALLATION - DANA 60 AXLE
(1) Position tools as shown to install lower ball
stud (Fig. 21).
SHOCK
DIAGNOSIS AND TESTING - SHOCK
A knocking or rattling noise from a shock absorber
may be caused by movement between mounting
bushings and metal brackets or attaching compo-
nents. These noises can usually be stopped by tight-
ening the attaching nuts. If the noise persists,
inspect for damaged and worn bushings, and attach-
ing components. Repair as necessary if any of these
conditions exist.
A squeaking noise from the shock absorber may be
caused by the hydraulic valving and may be intermit-
tent. This condition is not repairable and the shock
absorber must be replaced.
The shock absorbers are not refillable or adjust-
able. If a malfunction occurs, the shock absorber
must be replaced. To test a shock absorber, hold it in
an upright position and force the piston in and out of
the cylinder four or five times. The action throughout
each stroke should be smooth and even.
The shock absorber bushings do not require any
type of lubrication. Do not attempt to stop bushing
noise by lubricating them. Grease and mineral oil-
base lubricants will deteriorate the bushing.
REMOVAL
(1) Remove the nut, retainer and grommet from
the upper stud in the engine compartment.
(2) Remove three nuts from the upper shock
bracket (Fig. 22).
(3) Remove the lower bolt from the axle bracket
(Fig. 23). Remove the shock absorber from engine
compartment.
INSTALLATION
(1) Position the lower retainer and grommet on the
upper stud. Insert the shock absorber through the
spring from engine compartment.
(2) Install the lower bolt and tighten to 135 N´m
(100 ft. lbs.).
(3) Install the upper shock bracket and three nuts.
Tighten nuts to 75 N´m (55 ft. lbs.).
(4) Install upper grommet and retainer. Install
upper shock nut and tighten to 47 N´m (35 ft. lbs).
Fig. 21 LOWER BALL JOINT INSTALL
1 - SPECIAL TOOL C4212-F
2 - KNUCKLE
3 - BALL JOINT
4 - SPECIAL TOOL 8445-2
Fig. 22 Shock Absorber and Bracket
1 - GROMMET
2 - RETAINER
3 - BRACKET
4 - RETAINER
5 - SHOCK
6 - GROMMET
2 - 22 FRONT - 4WDBR/BE
LOWER BALL JOINT (Continued)

SPRING
REMOVAL
(1) Raise and support the vehicle. Position a
hydraulic jack under the axle to support it.
(2) Paint or scribe alignment marks on lower sus-
pension arm cam adjusters and axle bracket for
installation reference.
(3) Remove the upper suspension arm and loosen
lower suspension arm bolts.
(4) Mark and disconnect the front propeller shaft
from the axle 4x4 models.
(5) Disconnect the track bar from the frame rail
bracket.
(6) Disconnect the drag link from pitman arm.
(7) Disconnect the stabilizer bar link and shock
absorber from the axle.
(8) Lower the axle until the spring is free from the
upper mount. Remove the coil spring.
INSTALLATION
(1) Position the coil spring on the axle pad.
(2) Raise the axle into position until the spring
seats in the upper mount.
(3) Connect the stabilizer bar links and shock
absorbers to the axle bracket. Connect the track bar
to the frame rail bracket.
(4) Install the upper suspension arm.
(5) Install the front propeller shaft to the axle 4x4
model.(6) Install drag link to pitman arm and tighten
nut to specifications. Install new cotter pin.
(7) Remove the supports and lower the vehicle.
(8) Tighten the following suspension components
to specifications:
²Link to stabilizer bar nut.
²Lower shock bolt.
²Track bar bolt at axle shaft tube bracket.
²Upper suspension arm nut at axle bracket.
²Upper suspension nut at frame bracket.
²Align lower suspension arm reference marks and
tighten cam nut.
²Lower suspension nut at frame bracket.
STABILIZER BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Hold the stabilizer link shafts with a wrench
and remove the link nuts at the stabilizer bar.
(3) Remove the retainers and grommets from the
stabilizer bar links.
(4) Remove the stabilizer bar link nuts from the
axle brackets.
(5) Remove the links from the axle brackets with
Puller C-3894-A (Fig. 24).
(6) Remove the stabilizer bar clamps from the
frame rails and remove the stabilizer bar.
INSTALLATION
(1) Position the stabilizer bar on the frame rail
and install the clamps and bolts. Ensure the bar is
centered with equal spacing on both sides.
(2) Tighten the clamp bolts to 54 N´m (40 ft. lbs.).
(3) Install links to the axle bracket and tighten
nut to 47 N´m (35 ft. lbs.).
Fig. 23 Shock Absorber Axle Mount
1 - SHOCK
2 - SPRING
3 - FLAG NUT
4 - SHOCK BOLT
Fig. 24 Stabilizer Link
1 - PULLER
2 - LINK
BR/BEFRONT - 4WD 2 - 23
SHOCK (Continued)

REAR
TABLE OF CONTENTS
page page
REAR
DESCRIPTION.........................25
DIAGNOSIS AND TESTING - SPRING AND
SHOCK.............................25
SPECIFICATIONS
TORQUE CHART......................26
SPECIAL TOOLS
SUSPENSION-REAR...................27
BUSHINGS
REMOVAL.............................27INSTALLATION.........................27
SHOCK
REMOVAL.............................27
INSTALLATION.........................27
SPRING
REMOVAL.............................27
INSTALLATION.........................28
STABILIZER BAR
REMOVAL.............................29
INSTALLATION.........................29
REAR
DESCRIPTION
The rear suspension is comprised of:
²Shock Absorbers
²Jounce Bumpers
²Stabilizer Bar (optional)
²Leaf Springs
²Drive Axle
CAUTION: A vehicle should always be loaded so
the vehicle weight center-line is located immedi-
ately forward of the rear axle. Correct vehicle load-
ing provides proper front tire-to-road contact. This
results in maximum vehicle handling stability and
safety. Incorrect vehicle weight distribution can
cause excessive tire tread wear, spring fatigue or
failure, and erratic steering.
CAUTION: Suspension components with rubber/ure-
thane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur.
DIAGNOSIS AND TESTING - SPRING AND
SHOCK
A knocking or rattling noise from a shock absorber
may be caused by movement between mounting
bushings and metal brackets or attaching compo-
nents. These noises can usually be stopped by tight-
ening the attaching nuts. If the noise persists,
inspect for damaged and worn bushings, and attach-
ing components. Repair as necessary if any of these
conditions exist.
A squeaking noise from the shock absorber may be
caused by the hydraulic valving and may be intermit-
tent. This condition is not repairable and the shock
absorber must be replaced.
The shock absorbers are not refillable or adjust-
able. If a malfunction occurs, the shock absorber
must be replaced. To test a shock absorber, hold it in
an upright position and force the piston in and out of
the cylinder four or five times. The action throughout
each stroke should be smooth and even.
The spring eye and shock absorber bushings do not
require any type of lubrication. Do not attempt to
stop spring bushing noise by lubricating them.
Grease and mineral oil-base lubricants will deterio-
rate the bushing rubber.
If the vehicle is used for severe, off-road operation,
the springs should be examined periodically. Check
for broken and shifted leafs, loose and missing clips,
and broken center bolts. Refer to Spring and Shock
Absorber Diagnosis chart for additional information.
BR/BEREAR 2 - 25

SPRING AND SHOCK ABSORBER
CONDITION POSSIBLE CAUSES CORRECTION
SPRING SAGS 1. Broken leaf. 1. Replace spring.
2. Spring fatigue. 2. Replace spring.
SPRING NOISE 1. Loose spring clamp bolts. 1. Tighten to specification.
2. Worn bushings. 2. Replace bushings.
3. Worn or missing spring tip inserts. 3. Replace spring tip inserts.
SHOCK NOISE 1. Loose mounting fastener. 1. Tighten to specification.
2. Worn bushings. 2. Replace shock.
3. Leaking shock. 3. Replace shock.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Shock Absorber
Lower Nut136 100 Ð
Shock Absorber
Upper Nut136 100 Ð
Spring Clamp Nuts
6,010-10,500 GVW149 110 Ð
Spring Clamp Nuts
11,000 GVW Cab-Chassis163 120 Ð
Spring Front and Rear
Eye and Shackle
Bolt/Nut 6,010-6,400 GVW163 120 Ð
Spring Front and Rear
Eye and Shackle
Bolt/Nut 8,800-11,000
GVW176 130 Ð
Stabilizer Bar
Retainer Nuts54 40 Ð
Stabilizer Bar
Link Ball Stud Nut68 50 Ð
Stabilizer Bar
Link Upper Nut68 50 Ð
Stabilizer Bar
Frame Bracket Nuts54 40 Ð
Jounce Bumper
Bolts61 45 Ð
2 - 26 REARBR/BE
REAR (Continued)

SPECIAL TOOLS
SUSPENSION-REAR
BUSHINGS
REMOVAL
(1) Remove the spring from the vehicle.
(2) Position the spring eye in a press.
(3) Press the bushing out with an appropriate size
driver.
INSTALLATION
(1) Press new bushing into the spring eye with an
appropriate size driver. The bushing should be cen-
tered in the spring eye.
(2) Install the spring on the vehicle.
SHOCK
REMOVAL
(1) Raise vehicle and support axle.
(2) Remove the bolt and flag nut from the frame
crossmember bracket (Fig. 1).
(3) Remove the bolt and nut from the axle bracket.
(4) Remove the rear shock absorber from the vehi-
cle.
INSTALLATION
(1) Position the shock absorber in the brackets.
(2) Install the bolts through the brackets and the
shock. Install the flag nut on the top bolt and nut on
lower bolt.
(3) Tighten the upper and lower bolt/nuts Tighten
to 136 N.m (100 ft. lbs.)
(4) Remove the support and lower the vehicle.
SPRING
REMOVAL
(1) Raise the vehicle and support the axle to
remove all weight from the springs.
(2) Remove the nuts and spring clamp bolts that
attach the spring to the axle (Fig. 2) and (Fig. 3)and
(Fig. 4).
(3) Remove the nuts and bolts from the spring
front and rear shackle eyes.Note: To remove front
eye bolt on left side spring fuel tank must be
removed, (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/FUEL TANK - REMOVAL).
(4) Remove the spring from the vehicle.
(5) Remove the shackle from the spring.
Puller C-3894-A
Fig. 1 Shock Absorber
1 - FLAG NUT
2 - AXLE
3 - SHOCK
BR/BEREAR 2 - 27
REAR (Continued)