2003 DODGE RAM weight

INSTALLATION
INSTALLATION - 4X4 (LD)
(1) Position the lower control arm at the frame rail
brackets. Install the pivot bolts and nuts. Tighten the
nuts finger-tight.
CAUTION: The ball joint stud taper must be CLEAN
and DRY before installing the knuckle. Clean the
stud taper with mineral spirits to remove dirt and
grease.
(2) Insert the lower ball joint into the steering
knuckle. Install and tighten the retaining nut to 52
N´m (38 ft. lbs.)(on 1500 series only an additional 90É
turn is required).
(3) Install the torsion bar, (Refer to 2 - SUSPEN-
SION/FRONT/TRACK BAR - INSTALLATION).
(4) Install shock absorber lower bolt and tighten to
135 N´m (100 ft. lbs.).
(5) Install the front halfshaft, (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/HALF SHAFT -
INSTALLATION).
(6) Insert the upper ball joint into the steering
knuckle. Install and tighten the retaining nut to 54
N´m (40 ft. lbs.)(on 1500 series only an additional 90É
turn is required).
(7) Install the stabilizer bar link (Refer to 2 - SUS-
PENSION/FRONT/STABILIZER LINK - INSTALLA-
TION).
(8) Tighten the lower control arm front pivot nut
to 204 N´m (150 ft. lbs.). Tighten rear pivot bolt to
204 N´m (150 ft. lbs.).
(9) Install the wheel and tire assembly,(Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(10) Remove the support and lower the vehicle.
(11) Adjust the front suspension height and per-
form a wheel alignment (Refer to 2 - SUSPENSION/
WHEEL ALIGNMENT - STANDARD PROCEDURE).
INSTALLATION - 4X2
(1) Install the lower control arm into place on the
vehicle.
(2) Install the front and rear control arm pivot
bolts finger tight.
(3) Install the coil spring into the frame pocket(Re-
fer to 2 - SUSPENSION/FRONT/SPRING - INSTAL-
LATION).
(4) Install the Spring Compressor DD-1278 up
through the lower suspension arm, coil spring and
shock hole in the frame.
(5) Tighten the tool nut to compress the coil
spring.
(6) Remove the support from the upper control
arm and steering knuckle.(7) Position the lower ball joint into the steering
knuckle.
(8) Install the retaining nut on the lower ball joint
and tighten to 52 N´m (38 ft. lbs.)(on 1500 series only
an additional 90É turn is required) or 135 N´m (100
ft. lbs.)(HD 4X2 only).
(9) Support the lower control arm at the outboard
side of the lower control arm to support vehicle
weight.
(10) Remove the spring compressor tool.
(11) Install the shock absorber. (Refer to 2 - SUS-
PENSION/FRONT/SHOCK - INSTALLATION).
(12) Install the stabilizer link (Refer to 2 - SUS-
PENSION/FRONT/STABILIZER LINK - INSTALLA-
TION).
(13) Remove the lower control arm support.
(14) Install the wheel and tire assembly and lower
the vehicle. (Refer to 22 - TIRES/WHEELS/WHEELS
- STANDARD PROCEDURE).
(15) Lower the vehicle to the floor with vehicle
weight and Tighten the front and rear control arm
pivot bolts to 204 N´m (150 ft. lbs.)(LD) or 285 N´m
(210 ft. lbs.)(HD 4X2 only).
(16) Perform a wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
SPRING
REMOVAL
(1) Raise and support vehicle.
(2) Remove the front wheel and tire assembly.
(3)
Support the lower control arm at the outboard
side of the lower control arm to support vehicle weight.
(4) Remove the shock absorber (Refer to 2 - SUS-
PENSION/FRONT/SHOCK - REMOVAL).
(5) Install Spring Compressor DD-1278 up through
the lower suspension arm, coil spring and shock hole
in the frame. The bell-shaped adapter goes against
the lower suspension arm. Install the nut on top of
the tool at the shock hole (Fig. 25).
(6) Tighten the spring compressor nut against bell-
shaped adapter finger tight then loosen 1/2 turn.
NOTE: This will hold the spring in place until the
lower suspension arm is separated from the steer-
ing knuckle.
(7) Remove the stabilizer link (Refer to 2 - SUS-
PENSION/FRONT/STABILIZER LINK - REMOVAL).
(8) Remove the lower ball joint nut at the steering
knuckle.
(9) Install Ball Joint Remover tool 8677 on the
lower ball joint and separate the ball joint from the
knuckle.
(10)
DRFRONT - INDEPENDENT FRONT SUSPENSION 2 - 21
LOWER CONTROL ARM (Continued)

NOTE: Do not allow the upper control arm and
steering knuckle to rebound downwards they must
be supported.Support the upper control arm and
steering knuckle out of the way.
(11) Remove the lower control arm support.
(12) Tighten the spring compressor tool to allow
clearance for the lower ball joint to be removed out of
the knuckle.
NOTE: It may necessary to loosen the control arm
pivot bolt to allow downward swing.
(13) Loosen the tension on the spring compressor
tool slowly allowing the lower suspension arm to
pivot downward.
(14) Remove the spring compressor tool.
(15) Remove coil spring and isolator pad from the
vehicle (Fig. 26).
INSTALLATION
(1) Tape the isolator pad to the top of the coil
spring. Position the spring in the lower suspension
arm well. Be sure that the coil spring is seated in the
well.
(2) Install Spring Compressor DD-1278 up through
the lower suspension arm, coil spring and shock hole
in the frame.
(3) Tighten the tool nut to compress the coil
spring.(4) Remove the support from the upper control
arm and steering knuckle.
(5) Position the lower ball joint into the steering
knuckle.
(6) Install the retaining nut on the lower ball joint
and tighten to 52 N´m (38 ft. lbs.)(on 1500 series only
an additional 90É turn is required) or 135 N´m (100
ft. lbs.)(HD 4X2 only).
(7) Remove the spring compressor tool.
(8) Support the lower control arm at the outboard
side of the lower control arm to support vehicle
weight.
(9) Install the shock absorber. (Refer to 2 - SUS-
PENSION/FRONT/SHOCK - INSTALLATION).
(10) Install the stabilizer link (Refer to 2 - SUS-
PENSION/FRONT/STABILIZER LINK - INSTALLA-
TION).
(11) Remove the lower control arm support.
(12) Install the wheel and tire assembly and lower
the vehicle. (Refer to 22 - TIRES/WHEELS/WHEELS
- STANDARD PROCEDURE).
(13) Lower the vehicle to the floor with vehicle
weight and Tighten the front and rear control arm
pivot bolts if loosened to 204 N´m (150 ft. lbs.)(LD) or
285 N´m (210 ft. lbs.)(HD 4X2 only).
(14) Perform a wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
Fig. 25 SPRING COMPRESSOR TOOL
1 - SPECIAL TOOL DD-1278
2 - BELL-SHAPED ADAPTER
Fig. 26 COIL SPRING
1 - COIL SPRING
2 - STEERING KNUCKLE
3 - OUTER TIE ROD END
4 - LOWER CONTROL ARM
5 - SHOCK
2 - 22 FRONT - INDEPENDENT FRONT SUSPENSIONDR
SPRING (Continued)

INSTALLATION
CAUTION: The left and right side torsion bars are
NOT interchangeable. The bars are identified and
stamped R or L, for right or left. The bars do not
have a front or rear end and can be installed with
either end facing forward.
(1) Insert torsion bar ends into anchor and suspen-
sion arm.
(2) Position the anchor in the frame crossmember.
(3) Install Special Tool - 8686 to the anchor and
the crossmember (Fig. 30).
(4) Increase the tension on the anchor in order to
load the torsion bar.
(5) Install the adjustment bolt and the adjuster
nut.
(6) Turn adjustment bolt clockwise the recorded
amount of turns.
(7) Remove tool - 8686 from the torsion bar cross-
member (Fig. 30).
(8) Install the transfer case skid plate (Refer to 13
- FRAME & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - INSTALLATION).
(9) Lower vehicle and adjust the front suspension
height (Refer to 2 - SUSPENSION/WHEEL ALIGN-
MENT - STANDARD PROCEDURE).
(10) Perform a wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
UPPER BALL JOINT
DIAGNOSIS AND TESTING - UPPER BALL
JOINT
NOTE: If the ball joint is equipped with a lubrication
fitting, grease the joint then road test the vehicle
before performing test.
(1) Raise the front of the vehicle. Place safety floor
stands under both lower control arms as far outboard
as possible. Lower the vehicle to allow the stands to
support some or all of the vehicle weight.
(2) Remove the front tires.(3) Mount a dial indicator solidly to the frame and
then zero the dial indicator.
(4) Position dial indicator plunger on the topside of
the upper ball joint (Fig. 32).
NOTE: The dial indicator plunger must be perpen-
dicular to the machined surface of the ball joint
(Fig. 32).
NOTE: Use care not to pry or tear the ball joint
boot, when checking the free play.
(5) Position a pry bar between the steering
knuckle and the upper control arm. Pry upwards on
the upper control arm (Fig. 32).
(6) If the travel exceeds 0.5 mm (0.020 in.), replace
the upper control arm since the upper ball joint is
integral to the arm (Refer to 2 - SUSPENSION/
FRONT/UPPER CONTROL ARM - REMOVAL).
(7) If the upper ball joint is within specs reinstall
the front tires (Refer to 22 - TIRES/WHEELS/
WHEELS - STANDARD PROCEDURE).
Fig. 32 UPPER BALL JOINT PLAY
1 - DIAL INDICATOR
2 - UPPER CONTROL ARM
3-PRYBAR
4 - KNUCKLE
5 - BALL JOINT BOOT
2 - 26 FRONT - INDEPENDENT FRONT SUSPENSIONDR
TORSION BAR (Continued)

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Stabilizer Link
Stabilizer Bar Nut38 27 Ð
Hub/Bearing
Bolts202 149 Ð
Axle Nut 179 Beginning Torque, Then
Rotate 5 to 10 Times With a
Final Torque of 356132 Beginning Torque, Then
Rotate 5 to 10 Times With a
Final Torque of 263Ð
Tie Rod End
Nut75 55 Ð
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.
SPECIAL TOOLS
9 1/4 AA
Puller C-3894±A
Remover, Wheel Stud C-4150A
BALL JOINT PRESS - C-4212F
REMOVER / INSTALLER BALLJOINT - 8445
RECEIVER CUP - 6761
BALLJOINT RECIEVER/INSTALLER KIT- 8975
DRFRONT - LINK/COIL 2 - 29
FRONT - LINK/COIL (Continued)

REAR
TABLE OF CONTENTS
page page
REAR
DESCRIPTION.........................38
DIAGNOSIS AND TESTING - SPRING AND
SHOCK.............................38
SPECIFICATIONS
TORQUE CHART......................39
BUSHINGS
REMOVAL.............................39
INSTALLATION.........................39
JOUNCE BUMPER
REMOVAL.............................40
INSTALLATION.........................40
AUXILIARY SPRING BUMPERS (3500)
REMOVAL.............................40INSTALLATION.........................40
SHOCK
REMOVAL.............................40
INSTALLATION.........................40
SPRING
DESCRIPTION.........................41
OPERATION...........................41
REMOVAL.............................41
INSTALLATION.........................41
SPRING TIP INSERTS
REMOVAL.............................41
INSTALLATION.........................42
REAR
DESCRIPTION
The rear suspension is comprised of:
²Shock Absorbers
²Jounce Bumpers
²Stabilizer Bar (optional)
²Leaf Springs
²Auxiliary Leaf Spring (3500 series)
²Auxiliary Spring Bumpers (3500 series)
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.
2 - 38 REARDR

SPRING
DESCRIPTION
The rear suspension system uses a multi-leaf
springs and a solid drive axle. The forward end of the
springs are mounted to the body rail hangers
through rubber bushings. The rearward end of the
springs are attached to the body by the use of shack-
les. The spring and shackles use rubber bushings.
OPERATION
The springs control ride quality and maintain vehi-
cle ride height. The shackles allow the springs to
change their length as the vehicle moves over various
road conditions.
REMOVAL
(1) Raise and support the vehicle.
(2) Support the axle with a suitable holding fix-
ture.
(3) Remove the nuts, spring clamp bolts and the
plate that attach the spring to the axle (Fig. 4).
(4) Remove the nuts and bolts from the spring
front and rear shackle (Fig. 4).
(5) Remove the spring from the vehicle.
INSTALLATION
(1) Position spring on axle shaft tube so spring
center bolt is inserted into the locating hole in the
axle tube.
(2)
Align the front of the spring with the bolt hole in
the front bracket. Install the eye pivot bolt and nut.
(3) Align the rear of the spring into the shackle
and install the bolt and nut.
(4) Tighten the spring front and rear eye pivot bolt
snug do not torque.
(5) Install the spring clamp bolts, plate and the
retaining nuts.
(6) Remove the holding fixture for the rear axle.
(7) Remove the supports and lower the vehicle so
that the weight is being supported by the tires.
(8) Tighten the spring clamp retaining nuts to 149
N´m (110 ft. lbs.).
(9) Tighten the spring front and rear pivot bolt
nuts to 163 N´m (120 ft. lbs.).
SPRING TIP INSERTS
REMOVAL
(1) Raise and support the vehicle.
(2) Remove both rear tireand wheel assemblies
(3)
Position a large C-Clamp adjacent to the spring
clinch clip and clamp the leaves of the spring together
CAUTION: When working on the front leaf spring
clinch clamps finish the front before starting on the
rear to prevent personal injury.
(4) Use an appropriate pry bar to bend open the
spring clinch clip (Fig. 5). If necessary, remove the
existing spring clinch clip isolators.
Fig. 4 REAR SPRING
1 - LEAF SPRING
2 - PLATE
3 - NUTS
4 - FRONT NUT & BOLT
5 - SPRING CLAMP BOLTS
6 - SHACKLES
Fig. 5 C-CLAMP AND PRY BAR
1 - REAR LEAF SPRING CLINCH CLAMP
2-PRYBAR
3 - C-CLAMP
DRREAR 2 - 41

DRIVELINE VIBRATION
Drive Condition Possible Cause Correction
Propeller Shaft Noise 1) Undercoating or other foreign
material on shaft.1) Clean exterior of shaft and wash
with solvent.
2) Loose U-joint clamp screws. 2) Install new clamps and screws
and tighten to proper torque.
3) Loose or bent U-joint yoke or
excessive runout.3) Install new yoke.
4) Incorrect driveline angularity. 4) Measure and correct driveline
angles.
5) Rear spring center bolt not in
seat.5) Loosen spring u-bolts and seat
center bolt.
6) Worn U-joint bearings. 6) Install new U-joint.
7) Propeller shaft damaged or out
of balance.7) Installl new propeller shaft.
8) Broken rear spring. 8) Install new rear spring.
9) Excessive runout or unbalanced
condition.9) Re-index propeller shaft, test,
and evaluate.
10) Excessive drive pinion gear
shaft runout.10) Re-index propeller shaft and
evaluate.
11) Excessive axle yoke deflection. 11) Inspect and replace yoke if
necessary.
12) Excessive transfer case runout. 12) Inspect and repair as necessary.
Universal Joint Noise 1) Loose U-joint clamp screws. 1) Install new clamps and screws
and tighten to proper torque.
2) Lack of lubrication. 2) Replace as U-joints as
necessary.
PROPELLER SHAFT BALANCE
NOTE: Removing and re-indexing the propeller
shaft 180É relative to the yoke may eliminate some
vibrations.
If propeller shaft is suspected of being unbalanced,
it can be verified with the following procedure:
(1) Raise the vehicle.
(2) Clean all the foreign material from the propel-
ler shaft and the universal joints.
(3) Inspect the propeller shaft for missing balance
weights, broken welds, and bent areas.If the pro-
peller shaft is bent, it must be replaced.
(4) Inspect the universal joints to ensure that they
are not worn, are properly installed, and are cor-
rectly aligned with the shaft.
(5) Check the universal joint clamp screws torque.
(6) Remove the wheels and tires. Install the wheel
lug nuts to retain the brake drums or rotors.
(7) Mark and number the shaft six inches from the
yoke end at four positions 90É apart.(8) Run and accelerate the vehicle until vibration
occurs. Note the intensity and speed the vibration
occurred. Stop the engine.
(9) Install a screw clamp at position 1 (Fig. 1).
(10) Start the engine and re-check for vibration. If
there is little or no change in vibration, move the
clamp to one of the other three positions. Repeat the
vibration test.
(11) If there is no difference in vibration at the
other positions, the source of the vibration may not
be propeller shaft.
(12) If the vibration decreased, install a second
clamp (Fig. 2) and repeat the test.
(13) If the additional clamp causes an additional
vibration, separate the clamps (1/2 inch above and
below the mark). Repeat the vibration test (Fig. 3).
(14) Increase distance between the clamp screws
and repeat the test until the amount of vibration is
at the lowest level. Bend the slack end of the clamps
so the screws will not loosen.
3 - 2 PROPELLER SHAFTDR
PROPELLER SHAFT (Continued)

tial bearing noise is also constant and varies only
with vehicle speed.
Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by a worn
U-joint or by worn side-gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.
VIBRATION
Vibration at the rear of the vehicle is usually
caused by:
²Damaged drive shaft.
²Missing drive shaft balance weight(s).
²Worn or out of balance wheels.
²Loose wheel lug nuts.
²Worn U-joint(s).
²Loose/broken springs.
²Damaged axle shaft bearing(s).
²Loose pinion gear nut.
²Excessive pinion yoke run out.
²Bent axle shaft(s).Check for loose or damaged front end components
or engine/transmission mounts. These components
can contribute to what appears to be a rear end
vibration. Do not overlook engine accessories, brack-
ets and drive belts.
All driveline components should be examined
before starting any repair.
(Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
TESTING)
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged) can be caused by:
²High engine idle speed.
²Transmission shift operation.
²Loose engine/transmission/transfer case mounts.
²Worn U-joints.
²Loose spring mounts.
²Loose pinion gear nut and yoke.
²Excessive ring gear backlash.
²Excessive side gear to case clearance.
The source of a snap or a clunk noise can be deter-
mined with the assistance of a helper. Raise the vehi-
cle on a hoist with the wheels free to rotate. Instruct
the helper to shift the transmission into gear. Listen
for the noise, a mechanics stethoscope is helpful in
isolating the source of a noise.
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
3. End-play in pinion bearings. 3. Refer to pinion pre-load
information and correct as
necessary.
4. Excessive gear backlash
between the ring gear and pinion.4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.
5. Improper adjustment of pinion
gear bearings.5. Adjust the pinion bearings
pre-load.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.7. Inspect and replace as
necessary.
DRFRONT AXLE - C205F 3 - 19
FRONT AXLE - C205F (Continued)