2003 DODGE RAM steering wheel

CONDITION POSSIBLE CAUSES CORRECTION
LUBRICATING OIL LOSS 1. External leaks. 1. Visually inspect for oil leaks. Repair as
required.
2. Crankcase being overfilled. 2. Verify that the correct dipstick is being
used.
3. Incorrect oil specification or
viscosity.3. (a) Make sure the correct oil is being
used (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
(b) Look for reduced viscosity from dilution
with fuel.
(c) Review/reduce oil change intervals.
4. Oil cooler leak 4. Check and replace the oil cooler.
5. High blow-by forcing oil out the
breather.5. Check the breather tube area for signs of
oil loss. Perform the required repairs.
6. Turbocharger leaking oil to the air
intake.6. Inspect the air ducts for evidence of oil
transfer. Repair as required.
COMPRESSION KNOCKS 1. Air in the fuel system. 1. Identify location of air leak and repair. Do
not bleed high pressure fuel system.
2. Poor quality fuel or water/gasoline
contaminated fuel.2. Verify by operating from a temporary
tank with good fuel. Clean and flush the
fuel tank. Replace fuel/water separator filter.
3. Engine overloaded. 3. Verify the engine load rating is not being
exceeded.
4. Improperly operating injectors. 5. Check and replace misfiring/inoperative
injectors.
EXCESSIVE VIBRATION 1. Loose or broken engine mounts. 1. Replace engine mounts.
2. Damaged fan or improperly
operating accessories.2. Check and replace the vibrating
components.
3. Improperly operating vibration
damper3. Inspect/replace vibration damper.
4. Improperly operating electronically
controlled viscous fan drive.4. Inspect/replace fan drive.
5. Worn or damaged generator
bearing.5. Check/replace generator.
6. Flywheel housing misaligned. 6. Check/correct flywheel alignment.
7. Loose or broken power
component.7. Inspect the crankshaft and rods for
damage that causes an unbalance
condition. Repair/replace as required.
8. Worn or unbalanced driveline
components.8. Check/repair driveline components.
EXCESSIVE ENGINE
NOISES1. Drive belt squeal, insufficient
tension or abnormally high loading.1. Check the automatic tensioner and
inspect the drive belt. Make sure water
pump, tensioner pulley, fan hub, generator
and power steering pump turn freely.
2. Intake air or exhaust leaks. 2. Refer to Excessive Exhaust Smoke
(Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING).
9 - 284 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

(2) Lower engine into the engine compartment and
install the engine the engine mount through bolts
and nuts.
(3) Tighten the mount through bolts and nuts to
88 N-m (65 ft-lbs) torque.
(4) Remove the engine lifting device (Tool 9009).
(5) Check cylinder head capscrew length and
install into cylinder head.
(6) Torque alternately to 70 N-m (52 ft-lbs). Torque
alternately to 105 N-m (77 ft-lbs). Rotate 90 degrees.
(7) Install rocker housing. Torque to 24 N-m (18 ft-
lbs). Refer to Section 9 Rocker Housing Installation
(8) Replace injector o-ring and sealing washer on
injectors #5 and #6. Install injectors and alternately
tighten hold-down capscrews to 10 N-m (89 in-lbs).
(9) Install fuel connector tube and fuel connector
tube nut. Torque to 50 N-m (37 ft-lb). 10.
(10) Install #5 and #6 high pressure fuel lines. Fol-
low correct torque sequence per section 14. Torque
fuel line fittings to 30 N-m (22 ft-lb). Torque brace
capscrew to 24 N-m (18 ft-lb).
(11) Install rear engine lift bracket. Torque to 77
N-m (57 ft-lb).
(12) Install push tubes, rocker arms, and pedestals
for cylinders #4, #5, and #6. Torque the mounting
bolts to 36 N-m (27 ft-lbs).
(13) Reset valve lash on cylinders #4, #5, and #6.
Torque adjusting nuts to 24 N-m (18 ft-lbs).
(14) Install cylinder head cover. Torque to 24 N-m
(18 ft-lbs).(Refer to 9 - ENGINE/CYLINDER HEAD -
INSTALLATION).
(15) Connect breather tube and lube oil drain tube
to breather housing. Install breather housing. Torque
capscrews to 24 N-m (18 ft-lbs)
(16) Connect fuel supply and return hoses.
(17) Connect ECM ground to hydroform screw.
Connect ECM power connector.
(18) Install the APPS cable(s) to the APPS. Install
the throttle linkage cover.
(19) Install the power steering pump.
(20) Install the damper and speed indicator ring.
Torque to 40 N-m (30 ft-lb) plus 60 degrees.
(21) Connect the engine block heater connection.
(22) Connect the A/C compressor and pressure sen-
sor connectors
(23) Install the charge air cooler and a/c condenser
(if equipped). Install and tighten the charge air
cooler mounting bolts to 2 N-m (17 in-lbs).
(24) Connect the charge air cooler piping. Torque
all clamps to 8 N-m (72 in-lbs).
(25) Connect the a/c refrigerant lines to the a/c
condenser (if equipped).
(26) Install the radiator upper support panel.
(27) Install radiator.
(28) Connect the transmission quick-connect oil
cooler lines.(29) Raise vehicle.
(30) Connect a/c compressor suction/discharge hose
(if equipped).
(31) Install the radiator lower hose and clamps.
(32) Install the battery negative cables to the
engine block on the driver and passenger side.
(33) Install the transmission adapter with a new
camshaft rectangular ring seal. Torque to 77 N-m (57
ft-lb).
(34) Install the flywheel/flexplate. Torque to 137
N-m (101 ft-lb).
(35) Install the starter motor. Torque to 43 N-m
(32 ft-lb). (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(36) Connect engine to vehicle harness connectors.
(37) Install transmission and transfer case (if
equipped).
(38) Connect the exhaust pipe to the turbocharger
elbow.
(39) Connect the transmission auxiliary oil cooler
lines (if equipped).
(40) Lower the vehicle.
(41)
Connect the heater core supply and return hoses.
(42) Install the cooling fan and upper fan shroud
at the same time. (Refer to 7 - COOLING/ENGINE/
RADIATOR FAN - INSTALLATION).
(43) Install the coolant recovery bottle.
(44) Install the windshield washer bottle.
(45) Install the upper radiator hose and clamps.
(46) Raise vehicle.
(47) Connect electronically controlled fan drive
wire harness. Install lower radiator fan shroud.
(48) Change oil filter and install new engine oil.
(49) Fill the cooling system with coolant. (Refer to
7 - COOLING - STANDARD PROCEDURE).
(50) Connect grid heater harness at grid heater
relays.
(51) Connect electrical connections to rear of alter-
nator.
(52) Start the engine and inspect for engine oil,
coolant, and fuel leaks.
INSTALLATIONÐCRANKCASE BREATHER
(1) Install a new o-ring onto the breather element.
(2) Lubricate o-ring and install into cylinder head
cover. Torque capscrews to 10 N´m (89 in. lbs.).
(3) Connect breather tube and lube oil drain tube.
(4) Install breather cover (Fig. 4). Torque to 24
N´m (18 ft. lbs.)
(5) Install oil fill cap.
9 - 292 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

STEERING
TABLE OF CONTENTS
page page
STEERING
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - POWER
STEERING SYSTEM....................2
DIAGNOSIS AND TESTING - POWER
STEERING FLOW AND PRESSURE........4
SPECIAL TOOLS
STEERING...........................5COLUMN...............................6
GEAR - INDEPENDENT FRONT SUSPENSION..16
GEAR - LINK/COIL.......................19
LINKAGE - INDEPENDENT FRONT
SUSPENSION...........................31
LINKAGE - LINK/COIL....................33
PUMP.................................38
STEERING
DESCRIPTION
CAUTION: MOPARTATF+4 is to be used in the
power steering system. No other power steering or
automatic transmission fluid is to be used in the
system. Damage may result to the power steering
pump and system if any other fluid is used, and do
not overfill.
Power steering systems consist of:
²Steering column
²Rack and pinion steering gear
²Belt driven hydraulic steering pump
²Pump pressure and return hoses
²Oil Cooler
OPERATION
The steering column shaft is attached to the gear
pinion. The rotation of the pinion moves the gear
rack from side-to-side. This lateral action of the rack
pushes and pulls the tie rods to change the direction
of the front wheels (Fig. 1).
Power assist is provided by an engine mounted
hydraulic pump which supplies hydraulic fluid pres-
sure to the steering gear.
Fig. 1 STEERING COMPONENTS
1 - POWER STEERING PUMP ASSEMBLY
2 - RESERVOIR
3 - HOSES
4 - TIE ROD ENDS
5 - MOUNTING BOLTS
6 - RACK & PINION
DRSTEERING 19 - 1

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - POWER STEERING
SYSTEM
There is some noise in all power steering systems. One of the most common is a hissing sound evident at a
standstill parking. Or when the steering wheel is at the end of it's travel. Hiss is a high frequency noise similar
to that of a water tap being closed slowly. The noise is present in all valves that have a high velocity fluid passing
through an orifice. There is no relationship between this noise and steering performance.
STEERING NOISE
CONDITION POSSIBLE CAUSES CORRECTION
OBJECTIONAL HISS OR
WHISTLE1. Steering intermediate shaft to dash panel
seal.1. Check and repair seal at dash
panel.
2. Noisy valve in power steering gear. 2. Replace steering gear.
RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification.
2. Loose or damaged suspension
components.2. Inspect and repair suspension.
3. Internal gear noise. 3. Replace steering gear.
4. Pressure hose in contact with other
components.4. Reposition hose.
5. Loose or damaged intermediate shaft or
column.5. Inspect and repair or replace.
CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.
WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level.
2. Pressure hose in contact with other
components.2. Reposition hose.
3. Internal pump noise. 3. Replace pump.
4. Air in fluid 4. Check for lekas, Evacuate air
from P/S system.
SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.
2. O-ring missing or damaged on hose
fitting.2. Replace o-ring.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and reservoir. 4. Repair as necessary.
5. Reservoir cap not installed correctly. 5. Install reservoir cap correctly.
SCRUBBING OR
KNOCKING1. Wrong tire size. 1. Verify tire size.
19 - 2 STEERINGDR
STEERING (Continued)

BINDING AND STICKING
CONDITION POSSIBLE CAUSE CORRECTION
DIFFICULT TO TURN WHEEL
STICKS OR BINDS1. Low fluid level. 1. Fill to proper level.
2. Tire pressure. 2. Adjust tire pressure.
3. Steering components (ball
joints/tie rod ends).3 Inspect and repair as necessary.
4. Loose belt. 4. Adjust or replace.
5. Low pump pressure. 5. Pressure test and replace if
necessary.
6. Column shaft coupler binding. 6. Replace coupler.
7. Steering gear worn. 7. Replace gear.
8. Pump seized / Stuck valve 8. Replace pump.
INSUFFICIENT ASST. OR POOR RETURN TO CENTER
CONDITION POSSIBLE CAUSE CORRECTION
HARD TURNING OR MOMENTARY
INCREASE IN TURNING EFFORT1. Tire pressure. 1. Adjust tire pressure.
2. Low fluid level. 2. Fill to proper level.
3. Loose belt. 3. Adjust or replace.
4. Low pump pressure. 4. Pressure test and repair as
necessary.
5. Internal gear leak. 5. Replace gear.
STEERING WHEEL DOES NOT
WANT TO RETURN TO CENTER
POSITION1. Tire pressure. 1. Adjust tire pressure.
2. Wheel alignment. 2. Align front end.
3. Lack of lubrication. 3. Inspect and lubricate suspension
compnents.
4. High friction in steering gear. 4. Replace gear.
LOOSE STEERING AND VEHICLE LEAD
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE PLAY IN STEERING
WHEEL1. Worn or loose suspension or
steering components.1. Inspect and repair as necessary.
2. Worn or loose wheel bearings. 2. Inspect and repair or adjust
bearings.
3. Steering gear mounting. 3. Tighten gear mounting bolts to
specification.
4. Gear out of adjustment. 4. Replace gear.
5. Worn or loose steering coupler. 5. Inspect and replace as
necessary.
VEHICLE PULLS OR LEADS TO
ONE SIDE.1. Tire Pressure. 1. Adjust tire pressure.
2. Radial tire lead. 2. Rotate tires.
3. Brakes dragging. 3. Repair as necessary.
4. Wheel alignment. 4. Align front end.
DRSTEERING 19 - 3
STEERING (Continued)

DIAGNOSIS AND TESTING - POWER STEERING
FLOW AND PRESSURE
The following procedure is used to test the opera-
tion of the power steering system on the vehicle. This
test will provide the gallons per minute (GPM) or
flow rate of the power steering pump along with the
maximum relief pressure. Perform test any time a
power steering system problem is present. This test
will determine if the power steering pump or power
steering gear is not functioning properly. The follow-
ing pressure and flow test is performed using Power
Steering Analyzer Tool kit 6815 and (Fig. 2) Adapter
Kit 6893.
FLOW AND PRESSURE TEST
(1) Check the power steering belt to ensure it is in
good condition and adjusted properly.
(2) Connect pressure gauge hose from the Power
Steering Analyzer to adapter 6826.
(3) Connect tube 6825A to Power Steering Ana-
lyzer test valve end.
(4) Disconnect the high pressure hose from the
power steering pump.
(5) Connect the tube 6825A to the pump fitting.
(6) Connect the power steering hose from the
steering gear to the adapter 6826.
(7) Open the test valve completely.
(8) Start engine and let idle long enough to circu-
late power steering fluid through flow/pressure test
gauge and to get air out of the fluid. Then shut off
engine.(9) Check fluid level, add fluid as necessary. Start
engine again and let idle.
(10) Gauge should read below 862 kPa (125 psi), if
above, inspect the hoses for restrictions and repair as
necessary. The initial pressure reading should be in
the range of 345-552 kPa (50-80 psi).
(11) Increase the engine speed to 1500 RPM and
read the flow meter. If the flow rate (GPM) is below
specification, (refer to pump specification chart for
GPM) the pump should be replaced.
CAUTION: The following test procedure involves
testing maximum pump pressure output and flow
control valve operation. Do not leave valve closed
for more than three seconds as the pump could be
damaged.
(12) Close valve fully three times and record high-
est pressure indicated each time.All three read-
ings must be above specifications and within
345 kPa (50 psi) of each other.
²Pressures above specifications but not within
345 kPa (50 psi) of each other, replace pump.
²Pressures within 345 kPa (50 psi) of each other
but below specifications, replace pump.
(13) Open the test valve and turn the steering
wheel to the extreme left and right positions three
times against the stops. Record the highest pressure
reading at each position. Compare readings to the
pump specifications chart. If pressures readings are
not within 50 psi of each other, the gear is leaking
internally and must be replaced.
CAUTION: Do not force the pump to operate against
the stops for more than 2 to 3 seconds at a time
because, pump damage will result.PUMP SPECIFICATION
ENGINERELIEF
PRESSURE  
65FLOW RATE
(GPM) AT 1500
RPM
1500 series11032 kPa
(1615   65 psi)3.1 - 3.5
2500 & 3500
series12400 kPa
(1800   50 psi)3.5 - 4.0
Fig. 2 Analyzer With Tube and Adapter
1 - TUBE
2 - ADAPTER FITTINGS
3 - ANALYZER
4 - GAUGE HOSE
19 - 4 STEERINGDR
STEERING (Continued)

COLUMN
TABLE OF CONTENTS
page page
COLUMN
DESCRIPTION..........................6
DIAGNOSIS AND TESTING - STEERING
COLUMN.............................7
REMOVAL.............................7
INSTALLATION..........................9
IGNITION SWITCH
DESCRIPTION..........................9
OPERATION............................9
DIAGNOSIS AND TESTING - IGNITION
SWITCH.............................9
REMOVAL.............................10
INSTALLATION.........................11
KEY-IN IGNITION SWITCH
DESCRIPTION.........................11
DIAGNOSIS AND TESTING - IGNITION
SWITCH AND KEY LOCK CYLINDER.......11
KEY CYLINDER
REMOVAL.............................12INSTALLATION.........................12
GEAR SHIFT LEVER
REMOVAL.............................12
INSTALLATION.........................12
UPPER STEERING COUPLING
REMOVAL.............................13
INSTALLATION.........................14
LOWER STEERING COUPLING
REMOVAL
REMOVAL - ALL LD & HD EXCEPT 4X4 HD . 14
REMOVAL - 4X4 HD...................14
INSTALLATION
INSTALLATION - ALL LD & HD EXCEPT 4X4
HD.................................15
INSTALLATION - 4X4 HD................15
STEERING WHEEL
REMOVAL.............................15
INSTALLATION.........................15
COLUMN
DESCRIPTION
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.
The tilt and standard column (Fig. 1) has been
designed to be serviced as an assembly; less wiring,
switches, shrouds, steering wheel, etc. Most steering
column components can be serviced without remov-
ing the steering column from the vehicle.
To service the steering wheel, switches or airbag,
refer to Restraints and follow all WARNINGS and
CAUTIONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG ANDPOSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
CAUTION: Do not hammer on steering column
shaft. This may cause damage to the shaft or bear-
ing.
CAUTION: Do not attempt to remove the pivot bolts
to disassemble the tilting mechanism. Do not
remove shaft lock plate or plate retainer. This will
damage the column.
CAUTION: Do not attempt to remove or modify the
park lock slider or link.
NOTE: When servicing the steering wheel after
removing the old bolt a new bolt must be used
when installing.
19 - 6 COLUMNDR

NOTE: When servicing the coupler a new bolt must
be used when installing.
DIAGNOSIS AND TESTING - STEERING
COLUMN
If the vehicle is involved in a front end collision/the
air bag has deployed the column must be inspected.
This inspection will determine if the Column has col-
lapsed. Inspect the column mounting capsules visu-
ally and manually push and pull them to check for
separation or fractures. If capsules are fractured or
have moved the column MUST be replaced.
REMOVAL
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 front wheelsstraight ahead.
(2) Disconnect the negative (ground) cable from
the battery.
(3) Remove the two switches from the steering
wheel.
(4) Remove the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - REMOVAL).
(5) Remove the steering wheel with special tool
CJ98±1 or an appropriate steering wheel puller.
CAUTION: Ensure the puller bolts are fully engaged
into the steering wheel and not into the clock-
spring, before attempting to remove the wheel. Fail-
ure to do so may damage the steering wheel/
clockspring.
(6) Remove the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - REMOVAL).
(7) Remove the tilt lever.
(8) Remove the column shrouds (Fig. 2).
(9) Remove the clock spring, (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/CLOCKSPRING - REMOV-
AL).
(10) Disconnect the wiring harness to the column.
(11) Remove the shift cable from the column shift
lever actuator (Refer to 21 - TRANSMISSION/
TRANSAXLE/AUTOMATIC - 32RH/GEAR SHIFT
CABLE - REMOVAL). (Fig. 3).
Fig. 1 STEERING COLUMN
1 - LOCK CYLINDER
2 - GEAR SHIFT LEVER
3 - MOUNTING HOLES
4 - STEERING COLUMN
5 - TILT LEVER
Fig. 2 UPPER & LOWER SHROUDS
1 - UPPER SHROUD
2 - LOWER SHROUD
DRCOLUMN 19 - 7
COLUMN (Continued)