2003 DODGE RAM steering wheel adjustment

DIAGNOSIS AND TESTING - MASTER
CYLINDER/POWER BOOSTER...........20
STANDARD PROCEDURE - MASTER
CYLINDER BLEEDING..................20
REMOVAL
REMOVAL - ALL EXCEPT HYDROBOOST . . . 21
REMOVAL - HYDROBOOST.............21
INSTALLATION
INSTALLATION - ALL EXCEPT
HYDROBOOST.......................22
INSTALLATION - HYDROBOOST..........22
PEDAL
DESCRIPTION.........................22
OPERATION...........................22
REMOVAL.............................23
INSTALLATION.........................23
ADJUSTABLE PEDAL MOTOR
DESCRIPTION.........................24
REMOVAL.............................24
INSTALLATION.........................24
POWER BRAKE BOOSTER
DESCRIPTION.........................25
OPERATION...........................25
REMOVAL.............................25
INSTALLATION.........................25
HYDRO-BOOST BRAKE BOOSTER
DIAGNOSIS AND TESTING - HYDRAULIC
BOOSTER...........................25
STANDARD PROCEDURE - BLEEDING......27
REMOVAL.............................27
INSTALLATION.........................27
ROTORS
REMOVAL
REMOVAL - REAR.....................28
REMOVAL - FRONT....................28
INSTALLATION
INSTALLATION - REAR.................28
INSTALLATION - FRONT................29SUPPORT PLATE
REMOVAL.............................29
INSTALLATION.........................29
PARKING BRAKE
DESCRIPTION.........................30
OPERATION...........................30
CABLES
REMOVAL
REMOVAL - FRONT PARKING BRAKE
CABLE..............................31
REMOVAL - REAR PARK BRAKE CABLE . . . 31
REMOVAL - RIGHT REAR CABLE.........31
REMOVAL - LEFT REAR CABLE..........32
INSTALLATION
INSTALLATION - FRONT PARKING BRAKE
CABLE..............................32
INSTALLATION - REAR PARK BRAKE
CABLE..............................32
INSTALLATION - RIGHT REAR CABLE.....32
INSTALLATION - LEFT REAR CABLE......33
SHOES
REMOVAL.............................33
CLEANING - REAR DRUM IN HAT BRAKE....33
INSPECTION - REAR DRUM IN HAT BRAKE . . 33
INSTALLATION.........................34
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE SHOES . . 34
ADJUSTMENT - WITH ADJUSTING TOOL . . . 36
PEDAL
REMOVAL.............................36
INSTALLATION.........................36
CABLE TENSIONER
ADJUSTMENTS
ADJUSTMENT........................37
RELEASE HANDLE
REMOVAL.............................38
INSTALLATION.........................38
BRAKES - BASE
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM
Base brake components consist of the brake shoes,
calipers, wheel cylinders, brake drums, rotors, brake
lines, master cylinder, booster, and parking brake
components.
Brake diagnosis involves determining if the prob-
lem is related to a mechanical, hydraulic, or vacuum
operated component.
The first diagnosis step is the preliminary check.
PRELIMINARY BRAKE CHECK
(1) Check condition of tires and wheels. Damaged
wheels and worn, damaged, or underinflated tires
can cause pull, shudder, vibration, and a condition
similar to grab.(2) If complaint was based on noise when braking,
check suspension components. Jounce front and rear
of vehicle and listen for noise that might be caused
by loose, worn or damaged suspension or steering
components.
(3) Inspect brake fluid level and condition. Note
that the brake reservoir fluid level will decrease in
proportion to normal lining wear.Also note that
brake fluid tends to darken over time. This is
normal and should not be mistaken for contam-
ination.
(a) If fluid level is abnormally low, look for evi-
dence of leaks at calipers, wheel cylinders, brake
lines, and master cylinder.
(b) If fluid appears contaminated, drain out a
sample to examine. System will have to be flushed
if fluid is separated into layers, or contains a sub-
stance other than brake fluid. The system seals
5 - 2 BRAKES - BASEDR

(6) Adjust brake shoes to drum with brake gauge
(Refer to 5 - BRAKES/PARKING BRAKE/SHOES -
ADJUSTMENTS).
(7) Install the rotor (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - INSTALLA-
TION).
(8) Install the caliper adapter (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(9) Install the caliper (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- INSTALLATION).
(10) Install wheel and tire assembly.
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION
Indications of fluid contamination are swollen or
deteriorated rubber parts.
Swollen rubber parts indicate the presence of
petroleum in the brake fluid.
To test for contamination, put a small amount of
drained brake fluid in clear glass jar. If fluid sepa-
rates into layers, there is mineral oil or other fluid
contamination of the brake fluid.
If brake fluid is contaminated, drain and thor-
oughly flush system. Replace master cylinder, propor-
tioning valve, caliper seals, wheel cylinder seals,
Antilock Brakes hydraulic unit and all hydraulic
fluid hoses.
STANDARD PROCEDURE - BRAKE FLUID
LEVEL
Always clean the master cylinder reservoir and
caps before checking fluid level. If not cleaned, dirt
could enter the fluid.
The fluid fill level is indicated on the side of the
master cylinder reservoir (Fig. 33).
The correct fluid level is to the MAX indicator on
the side of the reservoir. If necessary, add fluid to the
proper level.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications and SAE J1703 standards.
No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use
only Mopar brake fluid or an equivalent from a
tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container of brake fluid will absorb moisture
from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.
Fig. 32 CALIPER ADAPTER MOUNT - REAR
1 - CALIPER ADAPTER MOUNT
2 - AXLE TUBE
3 - MOUNTING STUDS
Fig. 33 FLUID LEVEL
1 - FLUID RESERVOIR
2 - MAX LEVEL MARK
5 - 18 BRAKES - BASEDR
DISC BRAKE CALIPER ADAPTER MOUNT (Continued)

(10) Install the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - INSTALLA-
TION).
(11) Reconnect the negative battery cable.
ADJUSTABLE PEDAL MOTOR
DESCRIPTION
The Adjustable Pedals System (APS) is designed to
enable the fore and aft repositioning of the brake and
accelerator pedals. This results in improved ergonom-
ics in relation to the steering wheel for taller and
shorter drivers. Being able to adjust the pedal posi-
tions also allows the driver to set steering wheel tilt
and seat position to the most comfortable position.
The position of the brake and accelerator pedals can
be adjusted without compromising safety or comfort
in actuating the pedals.
Change of pedal position is accomplished by means
of a motor driven screw. Operating the adjustable
pedal switch activates the pedal drive motor (Fig.
45). The pedal drive motor turns a screw that
changes the position of the brake and accelerator
pedals. The pedal can be moved rearward (closer to
the driver) or forward (away from driver). The brake
pedal is moved on its drive screw to a position where
the driver feels most comfortable.
The accelerator pedal is moved at the same time
and the same distance as the brake pedal.
Neither the pedal drive motor (Fig. 45) nor drive
mechanism are subject to the mechanical stress of
brake or accelerator application.
²SYSTEM FEATURES:
²Range of Adjustment: The pedals may be
adjusted up to 3 in. (75 mm)
²Pedal Adjustment Speed: 0.5 in./sec (12.5
mm/sec)
²Pedal Adjustment Inhibitors: Pedal adjust-
ment is inhibited when the vehicle is in reverse or
when cruise control is activated.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the kneeblocker (Refer to 23 - BODY/
INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - REMOVAL).
(3) Remove the brake light switch and discard
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/BRAKE LAMP SWITCH - REMOVAL).
(4) Disconnect the adjustable pedal cables from the
brake and accelerator pedals.
(5) Disconnect the electrical connector.
(6) Unclip the cable fasteners to the support.(7) Remove the one mounting bolt for the adjust-
able pedal motor (Fig. 46).
(8) Remove the adjustable pedal motor with the
cables.
NOTE: Adjustable pedal cables are not serviceable.
If they need service the adjustable pedal motor with
the cables must be installed.
INSTALLATION
NOTE: Adjustable pedal cables are not serviceable.
If they need service the adjustable pedal motor with
the cables must be installed.
(1) Install the adjustable pedal motor with the
cables.
Fig. 45 ADJUSTABLE PEDAL MOTOR
1 - ADJUSTABLE PEDAL MOTOR
2 - CABLES
3 - ELECTRICAL CONNECTOR
Fig. 46 ADJUSTABLE PEDAL MOTOR
1 - ADJUSTABLE PEDAL MOTOR
2 - MOUNTING BOLT
5 - 24 BRAKES - BASEDR
PEDAL (Continued)

NOTE: On a new vehicle or after parking brake lin-
ing replacement, it is recommended that the park-
ing brake system be conditioned prior to use. This
is done by making one stop from 25 mph on dry
pavement or concrete using light to moderate force
on the parking brake foot pedal.
(18) Road test the vehicle to ensure proper func-
tion of the vehicle's brake system.
ADJUSTMENT - WITH ADJUSTING TOOL
Adjustment can be made with a standard brake
gauge or with adjusting tool. Adjustment is per-
formed with the complete brake assembly installed
on the backing plate.
(1) Be sure parking brake lever is fully released.
(2) Raise vehicle so rear wheels can be rotated
freely.
(3) Remove plug from each access hole in brake
support plates.
(4) Loosen parking brake cable adjustment nut
until there is slack in front cable.
(5) Insert adjusting tool through support plate
access hole and engage tool in teeth of adjusting
screw star wheel (Fig. 70).
(6) Rotate adjuster screw star wheel (move tool
handle upward) until slight drag can be felt when
wheel is rotated.
(7) Push and hold adjuster lever away from star
wheel with thin screwdriver.
(8) Back off adjuster screw star wheel until brake
drag is eliminated.(9) Repeat adjustment at opposite wheel. Be sure
adjustment is equal at both wheels.
(10) Install support plate access hole plugs.
(11) Adjust parking brake cable and lower vehicle.
(12) Depress park brake pedal and make sure park
brakes hold the vehicle staionary.
(13) Release park brake pedal.
PEDAL
REMOVAL
(1) Release the parking brake.
(2) Raise the vehicle.
(3) Loosen the cable tensioner nut at the equalizer
to create slack in the front cable.
(4) Lower the vehicle.
(5) Remove the knee bolster, (Refer to 23 - BODY/
INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - REMOVAL).
(6) Disconnect the brake lamp wire from the
switch on the pedal assembly.
(7) Roll the carpet back, loosen the front cable
grommet from the floorpan and the cable retainer.
(8) Disengage the release rod (Fig. 71) from the
arm on the pedal assembly.
(9) Remove the bolts/nuts from the pedal assembly
and remove the assembly.
INSTALLATION
(1) Position the replacement pedal assembly on the
dash and cowl.
(2) Install the bolts/nuts and tighten to 28 N´m (21
ft. lbs.) (Fig. 72).
(3) Install the park brake release rod.
(4) Connect the front cable to the arm on the pedal
assembly.
Fig. 70 Brake Adjustment
1 - STAR WHEEL
2 - LEVER
3 - BRAKE SHOE WEB
4 - SCREWDRIVER
5 - ADJUSTING TOOL
6 - ADJUSTER SPRINGFig. 71 PARKING BRAKE PEDAL
1 - RELEASE ROD
2 - PEDAL ASSEMBLY
5 - 36 BRAKES - BASEDR
SHOES (Continued)

(5) Tighten the front cable grommet to the floor-
pan and the cable retainer, roll the carpet back.
(6) Connect the wires to the brake lamp switch.
(7) Install the knee bolster, (Refer to 23 - BODY/
INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - INSTALLATION).
(8) Raise the vehicle.
(9) Adjust the parking brake cable tensioner (Refer
to 5 - BRAKES/PARKING BRAKE/CABLE TEN-
SIONER - ADJUSTMENTS).
CABLE TENSIONER
ADJUSTMENTS
ADJUSTMENT
NOTE: Tensioner adjustment is only necessary
when the tensioner, or a cable has been replaced or
disconnected for service. When adjustment is nec-
essary, perform adjustment only as described in the
following procedure. This is necessary to avoid
faulty park brake operation.
(1) Raise the vehicle.
(2) Back off the cable tensioner adjusting nut to
create slack in the cables.
(3) Remove the rear wheel/tire assemblies. Then
remove the brake rotors (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - REMOVAL).
(4) Verify the brakes are in good condition and
operating properly.
(5) Verify the park brake cables operate freely and
are not binding, or seized.(6) Check the rear brake shoe adjustment with
standard brake gauge (Refer to 5 - BRAKES/PARK-
ING BRAKE/SHOES - ADJUSTMENTS).
(7) Install the rotors (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - INSTALLA-
TION) and verify that the rotors rotate freely
without drag.
(8) Install the wheel/tire assemblies, (Refer to 22 -
TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(9) Lower the vehicle enough for access to the park
brake foot pedal. Then fully apply the park brakes.
NOTE: Leave park brakes applied until adjustment
is complete.
(10) Raise the vehicle again.
(11) Mark the tensioner rod 6.35 mm (1/4 in.) from
edge of the tensioner (Fig. 73).
(12) Tighten the adjusting nut on the tensioner rod
until the mark is no longer visible.
CAUTION: Do not loosen, or tighten the tensioner
adjusting nut for any reason after completing
adjustment.
(13) Lower the vehicle until the rear wheels are
15-20 cm (6-8 in.) off the shop floor.
(14) Release the park brake foot pedal and verify
that rear wheels rotate freely without drag. Then
lower the vehicle.
Fig. 72 PARKING BRAKE ASSEMBLY
1 - PEDAL ASSEMBLY
2 - MOUNTING NUT
Fig. 73 Adjustment Mark
1 - TENSIONER CABLE BRACKET
2 - TENSIONER
3 - CABLE CONNECTOR
4 - 6.35mm
(1/4 IN.)
5 - ADJUSTER NUT
DRBRAKES - BASE 5 - 37
PEDAL (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)

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)

GEAR - LINK/COIL
TABLE OF CONTENTS
page page
GEAR - LINK/COIL
DESCRIPTION.........................19
OPERATION...........................19
REMOVAL.............................19
INSTALLATION.........................20
ADJUSTMENTS
ADJUSTMENT........................20
SPECIFICATIONS
POWER STEERING GEAR..............21
TORQUE CHART......................22
SPECIAL TOOLS
POWER STEERING GEAR..............22
PITMAN SHAFT SEAL
REMOVAL
REMOVAL - GAS ENGINE...............23REMOVAL - DIESEL...................24
INSTALLATION
INSTALLATION - GAS ENGINE...........24
INSTALLATION - DIESEL................25
STEERING GEAR INPUT SHAFT SEAL
REMOVAL.............................25
INSTALLATION.........................28
PITMAN SHAFT
REMOVAL
REMOVAL - GAS......................29
REMOVAL - DIESEL...................30
INSTALLATION
INSTALLATION - GAS..................30
INSTALLATION - DIESEL................30
GEAR - LINK/COIL
DESCRIPTION
The power steering gear is a recirculating ball type
gear (Fig. 1). The gear ratio's used are 12.5:1.
OPERATION
The gear acts as a rolling thread between the
worm shaft and rack piston. The worm shaft is sup-
ported by a thrust bearing at the lower end and a
bearing assembly at the upper end. When the worm
shaft is turned from input from the steering column
the rack piston moves. The rack piston teeth mesh
with the pitman shaft. Turning the worm shaft, turns
the pitman shaft, which turns the steering linkage.
REMOVAL
(1) Place the front wheels in a straight-ahead posi-
tion.
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.
(2) Lock the steering wheel.
(3) Siphon out as much power steering fluid as
possible.
Fig. 1 STEERING GEAR
1 - INPUT SHAFT
2 - OUTLET
3 - INLET
4 - VALVE ASSEMBLY HOUSING
5 - PITMAN SHAFT COVER BOLTS
6 - STEERING GEAR
7 - MESHLOAD ADJUSTER NUT
8 - PITMAN SHAFT
DRGEAR - LINK/COIL 19 - 19