2003 DODGE RAM torque

bolts when remounting a flywheel and secure the
bolts with Mopar Lock And Seal or equivalent.
Tighten flywheel bolts to specified torque only. Over-
tightening can distort the flywheel hub causing
runout.
REMOVAL
(1) Remove transmission.
(2) Remove pressure plate and clutch.
(3) Remove flywheel bolts and remove flywheel.
DISASSEMBLY
NOTE: If the teeth are worn or damaged, the fly-
wheel should be replaced as an assembly. This is
the recommended repair. In cases where a new fly-
wheel is not readily available, (V10/Diesel Engine
only) a replacement ring gear can be installed. The
following procedure must be observed to avoid
damaging the flywheel and replacement gear.
WARNING: WEAR PROTECTIVE GOGGLES OR
SAFETY GLASSES WHILE CUTTING RING GEAR.
(1) Mark position of the old gear for alignment ref-
erence on the flywheel. Use a scriber for this pur-
pose.
(2) Remove the old gear by cutting most of the way
through it (at one point) with an abrasive cut-off
wheel. Then complete removal with a cold chisel or
punch.
ASSEMBLY
NOTE: The ring gear is a shrink fit on the flywheel.
This means the gear must be expanded by heating
in order to install it. The method of heating and
expanding the gear is extremely important. Every
surface of the gear must be heated at the same
time to produce uniform expansion. An oven or
similar enclosed heating device must be used. Tem-
perature required for uniform expansion is approxi-
mately 375É F.
CAUTION: Do not use an oxy/acetylene torch to
remove the old gear, or to heat and expand a new
gear. The high temperature of the torch flame can
cause localized heating that will damage the fly-
wheel. In addition, using the torch to heat a replace-
ment gear will cause uneven heating and
expansion. The torch flame can also anneal the
gear teeth resulting in rapid wear and damage after
installation.WARNING: WEAR PROTECTIVE GOGGLES OR
SAFETY GLASSES AND HEAT RESISTENT GLOVES
WHEN HANDLING A HEATED RING GEAR.
(1) The heated gear must be installed evenly to
avoid misalignment or distortion.
(2) Position and install the heated ring gear on the
flywheel with a shop press and a suitable press
plates.
(3) Place flywheel on work bench and let it cool in
normal shop air. Allow the ring gear to cool down
completely before installation it on the engine.
CAUTION: Do not use water or compressed air to
cool the flywheel. The rapid cooling produced by
water or compressed air will distort or crack the
new gear.
INSTALLATION
(1) Install flywheel on the crank shaft.
(2) Install flywheel bolts and tighten to 95 N´m (70
ft. lbs.).
(3) Install clutch.
(4) Install transmission.
PILOT BEARING
REMOVAL
(1) Remove transmission.
(2) Remove clutch disc.
(3) Use a suitable blind hole puller to remove pilot
bearing.
INSTALLATION
(1) Clean bearing bore with solvent and wipe dry
with shop towel.
(2) Install new bearing with clutch alignment tool
(Fig. 19). Drive bearing into place with the letter side
of the bearing facing the transmission. Bearing
should be flush with edge of bearing bore.
CAUTION: Do not allow bearing to become cocked
and do not recess bearing.
6 - 12 CLUTCHDR
FLYWHEEL (Continued)

COOLING
TABLE OF CONTENTS
page page
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM FLOW
3.7L/4.7L ENGINE......................1
DESCRIPTION - COOLING SYSTEM FLOW -
5.9L ENGINE..........................1
DESCRIPTIONÐCOOLING SYSTEM FLOW -
5.9L DIESEL..........................2
DESCRIPTION - HOSE CLAMPS...........3
OPERATION
OPERATIONÐCOOLING SYSTEM.........3
OPERATIONÐHOSE CLAMPS............5
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐON-BOARD
DIAGNOSTICS (OBD)...................5
DIAGNOSIS AND TESTINGÐCOOLING
SYSTEM - TESTING FOR LEAKS..........5
DIAGNOSIS AND TESTING - COOLING
SYSTEM DIESEL ENGINE................7
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS............................10
STANDARD PROCEDURE
STANDARD PROCEDURE - COOLANT
LEVEL CHECK........................17STANDARD PROCEDURE - COOLING
SYSTEM CLEANING/REVERSE FLUSHING . . 17
STANDARD PROCEDUREÐDRAINING
COOLING SYSTEM 3.7L/4.7L/5.7L ENGINE . . 18
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM 3.7L/4.7L/5.7L ENGINE . . 18
STANDARD PROCEDUREÐDRAINING
COOLING SYSTEM 5.9L/8.0L ENGINE......18
STANDARD PROCEDUREÐREFILLING
COOLING SYSTEM 5.9L/8.0L ENGINE......18
STANDARD PROCEDUREÐDRAINING
COOLING SYSTEM 5.9L DIESEL ENGINE . . . 19
STANDARD PROCEDUREÐREFILLING
COOLING SYSTEM 5.9L DIESEL ENGINE . . . 19
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT.................19
SPECIFICATIONS
TORQUE............................20
SPECIFICATIONS -....................20
SPECIAL TOOLS
COOLING...........................20
ACCESSORY DRIVE......................22
ENGINE...............................35
TRANSMISSION.........................72
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM FLOW
3.7L/4.7L ENGINE
The cooling system regulates engine operating tem-
perature. It allows the engine to reach normal oper-
ating temperature as quickly as possible. It also
maintains normal operating temperature and pre-
vents overheating.
The cooling system provides a means of heating
the passenger compartment and cooling the auto-
matic transmission fluid (if equipped). The cooling
system is pressurized and uses a centrifugal water
pump to circulate coolant through the system and a
coolant deaeration and reserve system that utilizes a
pressurized degas bottle (hot bottle).
An optional factory installed maximum duty cool-
ing package is available on most models. This pack-
age will provide additional cooling capacity forvehicles used under extreme conditions such as
trailer towing in high ambient temperatures (Fig. 1).
DESCRIPTION - COOLING SYSTEM FLOW -
5.9L ENGINE
The cooling system regulates engine operating tem-
perature. It allows the engine to reach normal oper-
ating temperature as quickly as possible. It also
maintains normal operating temperature and pre-
vents overheating.
The cooling system also provides a means of heat-
ing the passenger compartment and cooling the auto-
matic transmission fluid (if equipped). The cooling
system uses a coolant recovery / reserve system that
utilizes an ambient overflow bottle.
An optional factory installed maximum duty cool-
ing package is available on most models. This pack-
age will provide additional cooling capacity for
vehicles used under extreme conditions such as
trailer towing in high ambient temperatures (Fig. 2).
DRCOOLING 7 - 1

WARNING: DO NOT REMOVE OR LOOSEN THE
RADIATOR CAP WITH THE COOLING SYSTEM HOT
AND UNDER PRESSURE. SERIOUS BURNS FROM
THE COOLANT OR HIGH PRESSURE STEAM CAN
OCCUR.
For 3.7L / 4.7L/5.9L engines, remove the radiator
cap from the coolant degas bottle to add coolant.
SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Automatic Belt Tensioner to
BlockÐBolts 41 30 Ð
Automatic Belt Tensioner
PulleyÐBolt 61 45 Ð
Block HeaterÐBolt 2 Ð 17
Generator/Compressor
Mounting BracketÐBolts
# 1 and 2 54 40 Ð
# 3 40 30 Ð
Fan Shroud to Radiator
MountingÐBolts6Ð55
Radiator to Support - Bolts 8.5 Ð 75
Fan Blade to Viscous Fan
DriveÐBolts24 18 Ð
Idler PulleyÐBolt 54 40 Ð
Thermostat HousingÐBolts
- All Except 5.9L13 Ð 112
Thermostat HousingÐBolts
- 5.9L23 16 Ð
Power Steering Oil Cooler
Ð Bolts6Ð55
Transmission Auxiliary Oil
CoolerÐBolts 6 Ð 55
Transmission Oil Cooler
Tube Nuts31.5 24 Ð
Coolant Bottle Ð Bolts 8.5 Ð 75
Transmission Oil Cooler to
Transmission - 5.9L/46RE -
Tube Nuts 31.5 24 Ð
Transmission Oil Cooler to
Transmission - 3.7L/4.7L/
45RFE - Tube Nuts20 18 Ð
Water PumpÐBolts 24 18 Ð
Water Pump Ð Bolts - 4.7L 58 43 Ð
SPECIFICATIONS -
SPECIFICATIONS
DESCRIPTION SPECIFICATION
3.7/4.7L Engine 15.4L (16.2 qts.)- to the
middle of the cold fill
range
5.7L Engine 15.4L (16.2 qts.)- to the
middle of the cold fill
range
5.9L Engine 15.5L (16.3 qts.)- to the
MIN mark after 3 warm
up, cool down cycles
8.0L Engine 24L (25.3 qts.)
5.9L Diesel Engine 28L (29.5 qts.)
SPECIAL TOOLS
COOLING
Pliers Constant Pressure Hose Clamp - 6094
3/8º Quick Connect Release Tool - 6935
SPANNER WRENCHÐ6958
7 - 20 COOLINGDR
COOLING (Continued)

NOTE: A used belt should be replaced if tensioner
indexing arrow has moved to the minimum tension
indicator. Tensioner travel stops at this point.
(1) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove tensioner assembly from mounting
bracket (Fig. 2).
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY EXCEPT FOR PULLEY ON TENSIONER.
(3) Remove pulley bolt. Remove pulley from ten-
sioner.
INSTALLATION
(1) Install pulley and pulley bolt to tensioner.
Tighten bolt to 61 N´m (45 ft. lbs.) torque.
(2) An indexing slot is located on back of tensioner.
Align this slot to the head of the bolt on the front
cover. Install the mounting bolt. Tighten bolt to 41
N´m (30 ft. lbs.).
(3) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(4) Check belt indexing marks (Fig. 1).
BELT TENSIONERS - 5.9L
DESCRIPTION
Correct drive belt tension is required to ensure
optimum performance of the belt driven engine acces-
sories. If specified tension is not maintained, belt
slippage may cause; engine overheating, lack of
power steering assist, loss of air conditioning capac-
ity, reduced generator output rate, and greatly
reduced belt life.
It is not necessary to adjust belt tension on the
3.9L or 5.9L engines. These engines are equipped
with an automatic belt tensioner (Fig. 3). The ten-
sioner maintains correct belt tension at all times.
Due to use of this belt tensioner, do not attempt to
use a belt tension gauge on 3.9L or 5.9L engines.
OPERATION
The automatic belt tensioner maintains belt ten-
sion by using internal spring pressure, a pivoting
arm and pulley to press against the drive belt.
REMOVAL
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY (EXCEPT FOR PULLEY).
(1) Remove accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Disconnect wiring and secondary cable from
ignition coil.
(3) Remove ignition coil from coil mounting
bracket (two bolts). Do not remove coil mounting
bracket from cylinder head.
(4) Remove tensioner assembly from mounting
bracket (one nut) (Fig. 4).
Fig. 2 AUTOMATIC BELT TENSIONER - 3.7L/4.7L
ENGINE
1 - TIMING CHAIN COVER
2 - BOLT TORQUE TO 41 N´m (30 FT LBS)
3 - AUTOMATIC BELT TENSIONER
Fig. 3 Automatic Belt Tensioner - 5.9L Engines
1 - AUTOMATIC TENSIONER
2 - COIL AND BRACKET
3 - SCREW AND WASHER
DRACCESSORY DRIVE 7 - 23
BELT TENSIONERS - 3.7L / 4.7L (Continued)

(5) Remove pulley bolt. Remove pulley from ten-
sioner.
INSTALLATION
(1) Install pulley and pulley bolt to tensioner.
Tighten bolt to 61 N´m (45 ft. lbs.) torque.
(2) Install tensioner assembly to mounting
bracket. An indexing tab is located on back of ten-
sioner. Align this tab to slot in mounting bracket.
Tighten nut to 67 N´m (50 ft. lbs.) torque.
(3) Connect all wiring to ignition coil.
CAUTION: To prevent damage to coil case, coil
mounting bolts must be torqued.
(4) Install coil to coil bracket. If nuts and bolts are
used to secure coil to coil bracket, tighten to 11 N´m
(100 in. lbs.) torque. If coil mounting bracket has
been tapped for coil mounting bolts, tighten bolts to 5
N´m (50 in. lbs.) torque.
(5) Install drive belt. (Refer to 7 - COOLING/AC-
CESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION).
(6) Check belt indexing marks (Fig. 4).
BELT TENSIONERS - 5.9L
DIESEL
DESCRIPTION
Drive belts on all engines are equipped with a
spring loaded automatic belt tensioner (Fig. 5). This
tensioner maintains constant belt tension at all times
and requires no maintenance or adjustment.
CAUTION: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
automatic belt tensioner.
OPERATION
WARNING: THE AUTOMATIC BELT TENSIONER
ASSEMBLY IS SPRING LOADED. DO NOT ATTEMPT
TO DISASSEMBLE THE TENSIONER ASSEMBLY.
The automatic belt tensioner maintains correct belt
tension using a coiled spring within the tensioner
housing. The spring applies pressure to the tensioner
arm pressing the arm into the belt, tensioning the
belt.
Fig. 4 Tensioner Indexing Marks And Mounting Nut
1 - TENSIONER ASSEMBLY
2 - TENSIONER MOUNTING NUT
3 - INDEXING ARROW
4 - INDEXING MARK
Fig. 5 Belt
1 - GENERATOR
2 - WATER PUMP
3 - IDLER
4 - POWER STEERING PUMP
5 - AUTOMATIC TENSIONER
6 - A/C COMPRESSOR
7 - 24 ACCESSORY DRIVEDR
BELT TENSIONERS - 5.9L (Continued)

REMOVAL
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY.
(1) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove tensioner mounting bolt (Fig. 6) and
remove tensioner.
INSTALLATION
(1) Install tensioner assembly to mounting
bracket. A dowel is located on back of tensioner. Align
this dowel to hole in tensioner mounting bracket.
Tighten bolt to 43 N´m (32 ft. lbs.) torque.
(2) Install drive belt (Refer to 7 - COOLING/AC-
CESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION).
DRIVE BELTS - 3.7L / 4.7L
DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT
VISUAL DIAGNOSIS
When diagnosing serpentine accessory drive belts,
small cracks that run across the ribbed surface of the
belt from rib to rib (Fig. 7), are considered normal.
These are not a reason to replace the belt. However,
cracks running along a rib (not across) arenotnor-
mal. Any belt with cracks running along a rib must
be replaced (Fig. 7). Also replace the belt if it has
excessive wear, frayed cords or severe glazing.
Refer to ACCESSORY DRIVE BELT DIAGNOSIS
CHART for further belt diagnosis.
NOISE DIAGNOSIS
Noises generated by the accessory drive belt are
most noticeable at idle. Before replacing a belt to
resolve a noise condition, inspect all of the accessory
drive pulleys for alignment, glazing, or excessive end
play.
Fig. 6 AUTOMATIC BELT TENSIONER DIESEL
ENGINE-TYPICAL
1 - GENERATOR
2 - WATER PUMP
3 - IDLER
4 - POWER STEERING PUMP
5 - AUTOMATIC TENSIONER
6 - A/C COMPRESSOR
Fig. 7 Belt Wear Patterns
1 - NORMAL CRACKS BELT OK
2 - NOT NORMAL CRACKS REPLACE BELT
DRACCESSORY DRIVE 7 - 25
BELT TENSIONERS - 5.9L DIESEL (Continued)

fluid in the viscous fan drive could drain into its
bearing assembly and contaminate lubricant.
CAUTION: Do not remove water pump pulley-to-wa-
ter pump bolts. This pulley is under spring tension.
(10) Remove four bolts securing fan blade assem-
bly to viscous fan drive (Fig. 4).CAUTION: Some engines equipped with serpentine
drive belts have reverse rotating fans and viscous
fan drives. They are marked with the word
REVERSE to designate their usage. Installation of
the wrong fan or viscous fan drive can result in
engine overheating.
CLEANING
Clean the fan blades using a mild soap and water.
Do not use an abrasive to clean the blades.
INSPECTION
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.
CAUTION: If fan blade assembly is replaced
because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.
(1) Remove fan blade assembly from viscous fan
drive unit (six bolts).
(2) Lay fan on a flat surface with leading edge fac-
ing down. With tip of blade touching flat surface,
replace fan if clearance between opposite blade and
surface is greater than 2.0 mm (.090 inch). Rocking
motion of opposite blades should not exceed 2.0 mm
(.090 inch). Test all blades in this manner.
(3) Inspect fan assembly for cracks, bends, or bro-
ken welds. Replace fan if any damage is found.
INSTALLATION
(1) Install fan blade assembly to the viscous fan
drive. Tighten the bolts (Fig. 4) to 24 N´m (18 ft. lbs.)
torque.
(2) Position the fan shroud and the fan blade/vis-
cous fan drive assembly to the vehicle as a complete
unit.
(3) Install the fan shroud.
(4) Install the fan blade/viscous fan drive assembly
to the water pump shaft (Fig. 4).
(5) Install the coolant reserve/overflow container
to the fan shroud.
(6) Connect the negative battery cable.
NOTE:
Viscous Fan Drive Fluid Pump Out Requirement:
After installing a new viscous fan drive, bring the
engine speed up to approximately 2000 rpm and
hold for approximately two minutes. This will
ensure proper fluid distribution within the drive.
Fig. 3 Using Special Tool 6958 Spanner Wrench
1 - SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER
PINS 8346
2-FAN
Fig. 4 Fan Blade/Viscous Fan Drive - Gas Engines -
Typical
1 - WATER PUMP BYPASS HOSE
2 - FAN BLADE ASSEMBLY
3 - VISCOUS FAN DRIVE
4 - WATER PUMP AND PULLEY
7 - 40 ENGINEDR
RADIATOR FAN (Continued)

RADIATOR FAN - 5.9L DIESEL
REMOVAL
CAUTION: If the electronically controlled viscous
fan drive is replaced because of mechanical dam-
age, the cooling fan blades should also be
inspected. Inspect for fatigue cracks, or loose rivets
that could have resulted from excessive vibration.
Replace fan blade assembly if any of these condi-
tions are found. Also inspect wiring harness and
connectors for damage.
(1) Disconnect the battery negative cables.
(2) Remove the fan shroud lower half. by unsnap-
ping the fastening tabs.
CAUTION: Do not remove the fan pulley bolts. This
pulley is under spring tension.
(3) Disconnect electrical connector.
(4) The electronically controlled viscous fan drive/
fan blade assembly is attached (threaded) to the fan
hub shaft (Fig. 5). Remove the fan blade/fan drive
assembly from fan pulley by turning the mounting
nut counterclockwise (as viewed from front). Threads
on the viscous fan drive areRIGHT-HAND.A
Snap-On 36 MM Fan Wrench (number SP346 from
Snap-On Cummins Diesel Tool Set number 2017DSP)
can be used. Place a bar or screwdriver between the
fan pulley bolts to prevent pulley from rotating.
(5) Remove the fan shroud and the fan blade/vis-
cous drive as an assembly from vehicle from under
the vehicle.
(6) Remove fan blade-to-viscous fan drive mount-
ing bolts.
(7) Inspect the fan for cracks, loose or bent fan
blades.
CAUTION: Some engines equipped with serpentine
drive belts have reverse rotating fans and viscous
fan drives. Installation of the wrong fan or viscous
fan drive can result in engine overheating.
CLEANING
Clean the fan blades using a mild soap and water.
Do not use an abrasive to clean the blades.
INSPECTION
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.CAUTION: If fan blade assembly is replaced
because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.
(1) Remove fan blade assembly from viscous fan
drive unit (six bolts).
(2) Lay fan on a flat surface with leading edge fac-
ing down. With tip of blade touching flat surface,
replace fan if clearance between opposite blade and
surface is greater than 2.0 mm (.090 inch). Rocking
motion of opposite blades should not exceed 2.0 mm
(.090 inch). Test all blades in this manner.
(3) Inspect fan assembly for cracks, bends, or bro-
ken welds. Replace fan if any damage is found.
INSTALLATION
(1) Install fan blade assembly to electrically con-
trolled viscous fan drive. Tighten mounting bolts to
23 N´m (17 ft. lbs.) torque.
(2) Position the fan blade/viscous fan drive to the
vehicle as an assembly.
(3) Install viscous fan drive assembly on fan hub
shaft (Fig. 5). Tighten mounting nut to 33 N´m (24 ft.
lbs.) torque.
(4) Connect electrical connector.
Fig. 5 Fan Blade/Viscous Fan Drive
1 - ELECTRICAL CONNECTOR
2 - VISCOUS FAN DRIVE
3 - FAN BLADE
4 - BOLT
5 - FAN DRIVE
DRENGINE 7 - 41