2003 DODGE RAM suspension

FRONT - INDEPENDENT
FRONT SUSPENSION
DESCRIPTION
DESCRIPTION
The front suspension is designed to allow each
wheel to adapt to different road surfaces indepen-
dently. The wheels are mounted to hub/bearings
units bolted to the steering knuckle. The double-row
hub bearings are sealed and lubricated for life. The
steering knuckles turn (pivot) on ball joints.
The front suspension is comprised of (Fig. 1) (Fig. 2):
²Shock absorbers
²Torsion bar - 4X4 (LD only)
²Coil Spring - 4X2
²Control arms
²Steering knuckles
²Stabilizer bar
²Stabilizer link
²Tie Rod Ends
²Hub/Bearing
²Rack & Pinion
²Ball Joints
NOTE: Components attached with a nut must be
torqued to specification.
NOTE: Suspension components with rubber/ure-
thane bushings should be tightened with the vehi-
cle 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 bushing wear may occur.
DESCRIPTION
The upper control arm bolts on frame brackets.
The frame brackets have slotted holes which allow
the arms to be adjusted for caster and camber.
The lower control arms bolt to the lower frame
brackets and pivots through bushings.
The control arms have lube for life ball studs. The
control arm travel (jounce) is limited through the use
of rubber/urethane bumpers. Rebound travel is lim-
ited by the shock absorber.
Fig. 1 FRONT SUSPENSION - 4X2
1 - STABILIZER BAR
2 - UPPER CONTROL ARM
3 - STEERING KNUCKLE
4 - ROTOR
5 - CALIPER ADAPTER
6 - OUTER TIE ROD END
7 - STABILIZER LINK
8 - LOWER CONTROL ARM
9 - RACK & PINION
10 - COIL SPRING
11 - SHOCK ABSORBER
Fig. 2 FRONT SUSPENSION - 4X4 (LD ONLY)
1 - STABILIZER BAR
2 - UPPER CONTROL ARM
3 - STEERING KNUCKLE
4 - ROTOR
5 - OUTER TIE ROD END
6 - SHOCK ABSORBER
7 - STABILIZER LINK
8 - LOWER CONTROL ARM
9 - INNER TIE ROD
10 - RACK & PINION
DRFRONT - INDEPENDENT FRONT SUSPENSION 2 - 9

SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Shock Absorber
Upper Nut
4X454 40 Ð
Shock Absorber
Lower Bolt
4X4135 100 Ð
Shock Absorber
Upper Nut
4X254 40 Ð
Shock Absorber
Lower Bolt
4X234 25 Ð
Lower Suspension Arm
Frame Nuts204 150 Ð
Lower Suspension Arm
Frame Nuts285 210 Ð
Lower Suspension Arm
Ball Joint Nut
1500 series only52
Then an additional 90É38
Then an additional 90ÉÐ
Lower Suspension Arm
Ball Joint Nut
(HD 4X2 only135 100 Ð
Upper Suspension Arm
Frame Nuts
(LD)132 97 Ð
Upper Suspension Arm
Frame Nuts
(HD 4X2 only)170 125 Ð
Upper Suspension Arm
Ball Joint Nut
1500 series only54
Then an additional 90É40
Then an additional 90ÉÐ
Stabilizer Bar
Frame Bolt61 45 Ð
Stabilizer Link
Lower Control Arm Nut102 75 Ð
Stabilizer Link
Stabilizer Bar Nut38 27 Ð
Hub/Bearing
Bolts
(LD)163 120 Ð
Hub/Bearing
Bolts
(HD 4X2)176 130 Ð
Tie Rod End
Nut61
Then an additional 90É45
Then an additional 90ÉÐ
2 - 10 FRONT - INDEPENDENT FRONT SUSPENSIONDR
FRONT - INDEPENDENT FRONT SUSPENSION (Continued)

SPECIAL TOOLS
FRONT SUSPENSION
PULLER - 8677
4WD BUSHING REMOVAL/INSTALL KIT - 8682
TORSION BAR LOADER/UNLOADER - 8686
TORSION BAR BUSHING REMOVAL/INSTALL - 8835
RECEIVER/ DRIVER BALLJOINT - 8698
BALL JOINT PRESS - C-4212F
2WD - LOWER CONTROL ARM BUSHING
REMOVAL/INSTALL - 8836
DRFRONT - INDEPENDENT FRONT SUSPENSION 2 - 11
FRONT - INDEPENDENT FRONT SUSPENSION (Continued)

BUSHINGS
REMOVAL
REMOVAL - LOWER CONTROL ARM
BUSHINGS - 4WD (LD)
(1) Remove the lower control arm (Refer to 2 -
SUSPENSION/FRONT/LOWER CONTROL ARM -
REMOVAL).
(2) Secure the control arm in a vise.
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
FRAME MOUNTED BUSHING
(1) Install the bushing tool 8682-3 (receiver) and
8682-4 (driver) with the threaded rod and the two
bearings as shown for the replacement of the frame
bushing (Fig. 3)
CONTROL ARM BUSHING
(1) Install bushing remover tools 8682-2 (adapter),
8682-3 (receiver) and 8682-4 (driver) with the
threaded rod and the two bearings as shown (Fig. 4)
REMOVAL - TORSION BAR CROSSMEMBER
BUSHING
(1) Remove the torsion bar cross member (Refer to
13 - FRAME & BUMPERS/FRAME/REAR CROSS-
MEMBER - REMOVAL).
(2) Secure the cross member in a vise.
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(3) Install special tools 8838 threaded rod, 8835-1,
8835-4 and 8835-3 as shown in the graphic below
(Fig. 5).
(4) Press out the bushing.
REMOVAL - LOWER CONTROL ARM
BUSHINGS - 2WD (LD)
NOTE: HD 4X2 bushings are not servicable.
(1) Remove the lower control arm (Refer to 2 -
SUSPENSION/FRONT/LOWER CONTROL ARM -
REMOVAL).
(2) Secure the control arm in a vise.
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
Fig. 3 FRAME BUSHING REMOVAL
1 - THREADED ROD
2 - BEARINGS
3 - 8682-3 (RECEIVER)
4 - FRAME
5 - 8682-4 (DRIVER)
6 - NUT
7 - BUSHING
Fig. 4 CONTROL ARM BUSHING REMOVAL
1 - 8682-4 (DRIVER)
2 - BUSHING
3 - LOWER CONTROL ARM
4 - 8682-2 (ADAPTER)
5 - 8682-3 (RECEIVER)
6 - BEARING
7 - THREADED ROD
2 - 12 FRONT - INDEPENDENT FRONT SUSPENSIONDR

LARGE BUSHING
(1) Install bushing remover tools 8836-2 (receiver),
8836-4 (spacer) and 8836-5 (driver) with the threaded
rod 8839 and the bearing as shown (Fig. 6) for
replacement of the large bushing.
SMALL BUSHING
(1) Install the bushing tool 8836-6 (driver), 8836-3
(spacer) and 8836-2 (receiver) with the threaded rod
8839 and the bearing as shown for the replacement
of the small bushing (Fig. 7)
INSTALLATION
INSTALLATION - LOWER CONTROL ARM
BUSHINGS - 4WD (LD)
NOTE: Be careful to properly orient the bushing
voids in the correct position to within   10É. The
correct position places the long narrow void out-
board of the bushing and the short wide void
inboard of the bushing (Fig. 8).
Fig. 5 TORSION BAR CROSS MEMBER BUSHING -
REMOVAL
1 - 8838
2 - 8835-1
3 - 8835-4
4 - 8835-3
Fig. 6 LARGE LOWER CONTROL ARM BUSHING -
REMOVAL
1 - 8836-4 (SPACER)
2 - 8836-5 (DRIVER)
3 - 8839 (THREADED ROD)
4 - 8836-2 (RECEIVER)
Fig. 7 SMALL LOWER CONTROL ARM BUSHING -
REMOVAL
1 - 8839 (THREADED ROD)
2 - 8836-6 (DRIVER)
3 - 8836-3 (SPACER)
4 - 8836-2 (RECEIVER)
Fig. 8 REAR LOWER CONTROL ARM BUSHING
1 - SHORT - WIDE VOID
2 - INWARD TOWARD VEHICLE
3 - LONG - THIN VOID
DRFRONT - INDEPENDENT FRONT SUSPENSION 2 - 13
BUSHINGS (Continued)

FRAME MOUNTED BUSHING
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(1) Install the new bushing into the frame using
special tools 8682-3 (receiver), 8682-1 (driver) with
the two bearings and the threaded rod (Fig. 9)mak-
ing sure to properly orient the bushing as shown
(Fig. 8).
CONTROL ARM BUSHING
(1) Install the new lower control arm bushings into
the lower control arm using tools 8682-1 (driver),
8682-5 (receiver) and the two bearings with the
threaded rod (Fig. 10) making sure to properly orient
the bushing in the control (Fig. 8).
(1) Remove the control arm from the vise.
(2) Install the lower control arm (Refer to 2 - SUS-
PENSION/FRONT/LOWER CONTROL ARM -
INSTALLATION).
(3) Reset the vehicle ride height (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
(4) Perform a wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
INSTALLATION - TORSION BAR CROSS
MEMBER BUSHING
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(1) Install the new bushing into the cross member
using special tools 8835-2, 8835-4 and 8835-3 with
the bearing and the threaded rod 8838 (Fig. 11) mak-
ing sure to properly orient the bushing.
(2) Remove the cross member from the vise.
(3) Install the torsion bar cross member (Refer to
13 - FRAME & BUMPERS/FRAME/REAR CROSS-
MEMBER - INSTALLATION).
(4) Reset the vehicle ride height (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
(5) Perform a wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
INSTALLATION - LOWER CONTROL ARM
BUSHINGS - 2WD (LD)
NOTE: HD 4X2 bushings are not servicable.
Fig. 9 FRAME BUSHING INSTALL
1 - THREADED ROD
2 - BEARINGS
3 - 8682-3 (RECEIVER)
4 - BUSHING
5 - 8682-1 (DRIVER)
Fig. 10 CONTROL ARM BUSHING INSTALL
1 - THREADED ROD
2 - BEARINGS
3 - 8682-1 (DRIVER)
4 - BUSHING
5 - CONTROL ARM
6 - 8682-5 (RECEIVER)
7 - NUT
2 - 14 FRONT - INDEPENDENT FRONT SUSPENSIONDR
BUSHINGS (Continued)

LARGE BUSHING
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(1) Install the new bushing into the lower control
arm using special tools 8836-2 (receiver), 8836-1
(driver), 8836-4 (spacer) with the bearing and the
threaded rod (8839) (Fig. 12).
SMALL BUSHING
(1) Install the small bushings into the lower con-
trol arm using tools 8836-7 (driver), 8836-2 (receiver),
8836±3 (spacer) and the bearing with the threaded
rod (8839) (Fig. 13).
(1) Remove the control arm from the vise.
(2) Install the lower control arm (Refer to 2 - SUS-
PENSION/FRONT/LOWER CONTROL ARM -
INSTALLATION).
(3) Reset the vehicle ride height (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
(4) Perform a wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
HUB / BEARING
REMOVAL
REMOVAL - 4X4
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the brake caliper and rotor (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).
(4) Remove the ABS wheel speed sensor if
equipped, (Refer to 5 - BRAKES/ELECTRICAL/
FRONT WHEEL SPEED SENSOR - REMOVAL).
(5) Remove the halfshaft nut.
Fig. 11 TORSION BAR CROSS MEMBER BUSHING -
INSTALLATION
1 - 8835-2
2 - 8835-4
3 - 8835-3
4 - 8838
Fig. 12 LARGE LOWER CONTROL ARM BUSHING -
INSTALL
1 - 8836-1 (DRIVER)
2 - 8839 (THREADED ROD)
3 - 8836-2 (RECEIVER)
4 - 8836-4 (SPACER)
Fig. 13 SMALL LOWER CONTROL ARM BUSHING -
INSTALL
1 - 8836-2 (RECEIVER)
2 - 8839 (THREADED ROD)
3 - 8836-3 (SPACER)
4 - 8836-7 (DRIVER)
DRFRONT - INDEPENDENT FRONT SUSPENSION 2 - 15
BUSHINGS (Continued)

NOTE: Do not strike the knuckle with a hammer to
remove the tie rod end or the ball joint. Damage to
the steering knuckle will occur.
(6) Remove the tie rod end nut and separate the
tie rod from the knuckle using special tool 8677.
(7) Remove the upper ball joint nut and separate
the upper ball joint from the knuckle using special
tool 8677.
(8) Pull down on the steering knuckle to separate
the halfshaft from the hub/bearing.
(9) Remove the three hub/bearing mounting bolts
from the steering knuckle (Fig. 14).
(10) Slide the hub/bearing out of the steering
knuckle (Fig. 14).
(11) Remove the brake dust shield.
REMOVAL - 4X2
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the brake caliper and rotor (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).
(4) Remove the ABS wheel speed sensor if
equipped, (Refer to 5 - BRAKES/ELECTRICAL/
FRONT WHEEL SPEED SENSOR - REMOVAL)
(Fig. 15)
(5) Remove the three hub/bearing mounting bolts
from the steering knuckle (Fig. 15).
(6) Slide the hub/bearing out of the steering
knuckle (Fig. 15).
(7) Remove the brake dust shield (Fig. 15).
INSTALLATION
INSTALLATION - 4X4
(1) Install the brake dust shield (Fig. 16).
(2) Install the hub/bearing into the steering
knuckle and tighten the bolts to 163 N´m (120 ft.
lbs.) (Fig. 16).
(3) Install the brake rotor and caliper (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
Fig. 14 HALFSHAFT / HUB/BEARING
1 - HUB/BEARING MOUNTING NUTS
2 - HALF SHAFT
Fig. 15 HUB/BEARING 4X2
1 - HUB/BEARING
2 - DUST SHIELD
3 - STEERING KNUCKLE
4 - WHEEL SPEED SENSOR WIRE
5 - HUB/BEARING MOUNTING NUT
Fig. 16 HUB/BEARING 4X4
1 - HUB/BEARING
2 - DUST SHIELD
3 - STEERING KNUCKLE
4- WHEEL SPEED SENSOR WIRE
5 - HUB/BEARING MOUNTING NUT
2 - 16 FRONT - INDEPENDENT FRONT SUSPENSIONDR
HUB / BEARING (Continued)