2003 DODGE RAM Diesel

INSTALLATION
(1) Check condition of sensor o-ring.
(2) Clean sensor mounting area at intake manifold
(3) Position sensor into intake manifold.
(4) Install and tighten 2 screws.
(5) Connect electrical connector to sensor.
MAP SENSOR
DESCRIPTION
A combination, dual function Intake Manifold Air
Temperature Sensor/MAP Sensor is used. Refer to
Intake Air Temperature Sensor/MAP Sensor for infor-
mation.
THROTTLE CONTROL CABLE
REMOVAL
Early Diesel Engine
(1) Disconnect both negative battery cables at both
batteries.
(2) From inside vehicle, hold up accelerator pedal.
Remove plastic cable retainer and throttle cable core
wire from upper end of pedal arm (Fig. 33). The plas-
tic cable retainer snaps into pedal arm.
(3) From inside vehicle, remove cable clip (Fig. 33).
(4) Remove cable core wire at pedal arm.
(5) Remove cable housing from dash panel and
pull cable into engine compartment.
(6) Remove cable cover (Fig. 34). Cable cover is
attached with 2 Phillips screws, 2 plastic retention
clips and 2 push tabs (Fig. 34). Remove 2 Phillips
screws and carefully pry out 2 retention clips. After
clip removal, push rearward on front tab, and
upward on lower tab for cover removal.
(7) Using 2 screwdrivers, pry cable connector
socket from throttle lever ball (Fig. 35).Be very
careful not to bend throttle lever arm.
Fig. 31 INTAKE/MAP SENSOR
1 - TOP OF INTAKE MANIFOLD
2 - IAT/MAP SENSOR
3 - ELEC. CONNECTOR
4 - MOUNTING BOLTS (2)
Fig. 32 SENSOR O-RING
1 - IAT/MAP SENSOR
2 - O-RING
14 - 94 FUEL INJECTION - DIESELDR
INTAKE AIR TEMPERATURE SENSOR/MAP SENSOR (Continued)

Late Diesel Engine
The Throttle Control Cable on the late diesel
engine connects the accelerator pedal to the Acceler-
ator Pedal Position Sensor (APPS). A separate
mechanical cable is not routed to the throttle body.
CAUTION: Be careful not to damage or kink cable
core wire (within cable sheathing) while servicing
accelerator pedal, cables or APPS.
(1) Disconnect both negative battery cables at both
batteries.
(2) From inside vehicle, hold up accelerator pedal.
Remove plastic cable retainer and throttle cable core
wire from upper end of pedal arm (Fig. 36). The plas-
tic cable retainer snaps into pedal arm.
(3) Remove cable core wire at pedal arm.
(4) Remove APPS. Refer to (Diesel) Accelerator
Pedal Position Sensor (APPS) Removal / Installation.
(5) From inside vehicle, remove cable clip (Fig. 36).
(6) Remove cable housing from dash panel and
pull cable into engine compartment.
(7) Remove cable housing at APPS bracket by
pressing on release tab with a small screwdriver.To
prevent cable housing breakage, press on tab
only enough to release cable from APPS
bracket.
Fig. 33 ACCELERATOR PEDAL MOUNTING
1 - ACCELERATOR CABLE
2 - PLASTIC RETAINER (CLIP)
3 - THROTTLE PEDAL ARM
4 - PEDAL / BRACKET ASSEMBLY
5 - CABLE CLIP
Fig. 34 CABLE/LEVER/THROTTLE LINKAGE COVER
1 - CABLE/LEVER/LINKAGE COVER
2 - PUSH UP LOWER TAB
3 - SCREWS/CLIPS (2)
4 - TAB PUSH HERE
Fig. 35 SERVO CABLE AT THROTTLE LEVER
1 - PINCH (2) TABS
2 - CABLE MOUNTING BRACKET
3 - PINCH TABS (2)
4 - OFF
5 - THROTTLE CABLE
6 - THROTTLE LEVER
7 - THROTTLE LEVER PIN
8 - OFF
9 - CONNECTOR
10 - SPEED CONTROL CABLE
DRFUEL INJECTION - DIESEL 14 - 95
THROTTLE CONTROL CABLE (Continued)

INSTALLATION
Early Diesel Engine
(1) Install cable through mounting hole on cable
mounting bracket (Fig. 35). Cable snaps into bracket.
Be sure 2 pinch tabs are secure.
(2) Using large pliers, connect cable end socket to
throttle lever ball (snaps on).(3) Install remaining cable housing end into and
through dash panel opening (snaps into position).
The two plastic pinch tabs should lock cable to dash
panel.
(4) From inside vehicle, hold up accelerator pedal.
Install throttle cable core wire and plastic cable
retainer into and through upper end of pedal arm
(the plastic retainer is snapped into pedal arm).
When installing plastic retainer to accelerator pedal
arm, note index tab on pedal arm (Fig. 33). Align
index slot on plastic cable retainer to this index tab.
(5) Connect negative battery cables to both batter-
ies.
(6) Before starting engine, operate accelerator
pedal to check for any binding.
(7) Install cable/lever cover.
Late Diesel Engine
(1) Attach cable to Accelerator Pedal Position Sen-
sor (APPS). Refer to APPS (Diesel) Removal / Instal-
lation.
(2) Push cable housing into rubber grommet and
through opening in dash panel.
(3) From inside vehicle, install clip holding cable
to dashpanel (Fig. 36).
(4) From inside vehicle, slide throttle cable core
wire into opening in top of pedal arm.
(5) Push cable retainer (clip) into pedal arm open-
ing until it snaps in place.
(6) Before starting engine, operate accelerator
pedal to check for any binding.
(7) If necessary, use DRB IIItScan Tool to erase
any APPS Diagnostic Trouble Codes (DTC's) from
PCM.
Fig. 36 ACCELERATOR PEDAL MOUNTING
1 - ACCELERATOR CABLE
2 - PLASTIC RETAINER (CLIP)
3 - THROTTLE PEDAL ARM
4 - PEDAL / BRACKET ASSEMBLY
5 - CABLE CLIP
14 - 96 FUEL INJECTION - DIESELDR
THROTTLE CONTROL CABLE (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

(9) Remove washer from the housing.
NOTE: Tighten the slide hammer adapter 8990 into
the seal using wrenches, in order to make a tight fit
to pull the seal out. If this is not performed the seal
may tear on the removal making it difficult to
remove.
(10) Remove oil seal from the housing with a spe-
cial tool 8990 with slide hammer C-3752.
REMOVAL - DIESEL
(1) Seperate the pitman arm from the gear box
(Refer to 19 - STEERING/LINKAGE/PITMAN ARM -
REMOVAL).
(2) Remove the steering gear box (Refer to 19 -
STEERING/GEAR - REMOVAL).
(3) Install the steering gear in a soft jawed bench
vise.
(4) Clean exposed end of pitman shaft and housing
with a wire brush.
(5) Rotate the input shaft with a 12 point socket
from stop to stop and count the number of turns (Fig.
6).
(6) Center the input shaft by rotating it from the
stop 1/2 of the total amount of turns (Fig. 6).
(7) Remove the pitman shaft cover bolts.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(8) Remove the pitman shaft from the gear.
(9) Remove dust seal from the housing with a spe-
cial tool 8990 (Fig. 5).CAUTION: Use care not to score the housing bore
when prying out seals.
(10) Remove retaining ring with snap ring pliers.
(11) Remove washer from the housing.
NOTE: Tighten the slide hammer adapter 8990 into
the seal using wrenches, in order to make a tight fit
to pull the seal out. If this is not performed the seal
may tear on the removal making it difficult to
remove.
(12) Remove oil seal from the housing with a spe-
cial tool 8990 with slide hammer C-3752. (Fig. 5).
INSTALLATION
INSTALLATION - GAS ENGINE
NOTE: Generous amounts of the high temperature
grease from the seal kit should be applied to areas
between the pitman shaft bearing and oil seals and
also between the dust seals and snap ring.
(1) Coat the oil seal and washer withhigh temp
grease.
NOTE: Install the oil seal with the lip facing inward.
Flat side of the oil seal should be against the
washer.
(2) Install the oil seal with special tool 8989 driver
and C-4171 handle (Fig. 7).
(3) Install backup washer.
(4) Install the retainer ring with snap ring pliers.
Fig. 5 SLIDE HAMMER
1 - STEERING GEAR
2 - SLIDE HAMMER C-3752 USED WITH SPECIAL TOOL
ADAPTER
8990
Fig. 6 CENTERING STEERING GEAR
1 - STEERING GEAR
2 - 12 POINT SOCKET
3 - RATCHET
4 - INPUT SHAFT
19 - 24 GEAR - LINK/COILDR
PITMAN SHAFT SEAL (Continued)

(5) Coat the dust seal withhigh temp grease.
(6) Install the dust seal with a driver and handle
(Fig. 7).
(7) Install protective seal protector 8993 over the
shaft (Fig. 8).
(8) Install the pitman shaft into the steering gear
until it fully seats into the bearing.
(9) Install the new cover bolts and tighten to 68
N´m (50 ft. lbs.).
(10) Install the pitman arm (Refer to 19 - STEER-
ING/LINKAGE/PITMAN ARM - INSTALLATION).
INSTALLATION - DIESEL
NOTE: Generous amounts of the high temperature
grease from the seal kit should be applied to areas
between the pitman shaft bearing and oil seals and
also between the dust seals and snap ring.
(1) Coat the oil seal and washer withhigh temp
grease.
NOTE: Install the oil seal with the lip facing inward.
Flat side of the oil seal should be against the
washer.
(2) Install the oil seal with special tool 8989 driver
and C-4171 handle (Fig. 7).
(3) Install backup washer.
(4) Install the retainer ring with snap ring pliers.
(5) Coat the dust seal withhigh temp grease.
(6) Install the dust seal with special tool 8989
driver and C-4171 handle (Fig. 7).
(7) Install protective seal protector 8993 over the
shaft (Fig. 8).
(8) Install the pitman shaft into the steering gear
until it fully seats into the bearing.
(9) Install the new cover bolts and tighten to 68
N´m (50 ft. lbs.).
(10) Install the steering gear (Refer to 19 -
STEERING/GEAR - INSTALLATION).
(11) Install the pitman arm (Refer to 19 - STEER-
ING/LINKAGE/PITMAN ARM - INSTALLATION).
(12) Perform a wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
STEERING GEAR INPUT
SHAFT SEAL
REMOVAL
(1) Remove the steering gear from the vehicle
(Refer to 19 - STEERING/GEAR - REMOVAL).
CAUTION: Do not overtighten the vise on the gear
case. This may affect the adjustment
(2) Mount the steering gear upside down over a
drain pan in a soft jawed vise.
(3) Place a drain pan under the gear and rotate
the input shaft back and forth several times lock-to-
lock to discharge the fluid from the steering gear
(4) Drain all the remaining fluid from the gear.
(5) Rotate the input shaft from stop to stop and
count the number of turns using a 12 point socket
(Fig. 9).
Fig. 7 SEAL INSTALLATION
1 - SPECIAL TOOL
C-4171
2 - SPECIAL TOOL
8989
3 - STEERING GEAR
Fig. 8 PITMAN SHAFT SEAL PROTECTOR
1 - STEERING GEAR
2 - SPECIAL TOOL
8993
DRGEAR - LINK/COIL 19 - 25
PITMAN SHAFT SEAL (Continued)

REMOVAL - DIESEL
(1) Separate the pitman arm from the gear box
(Refer to 19 - STEERING/LINKAGE/PITMAN ARM -
REMOVAL).
(2) Remove the steering gear box (Refer to 19 -
STEERING/GEAR - REMOVAL).
(3) Install the steering gear in a soft jawed bench
vise.
(4) Clean exposed end of pitman shaft and housing
with a wire brush.
(5) Rotate the stub shaft with a 12 point socket
from stop to stop and count the number of turns (Fig.
23).
(6) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns (Fig. 23).
(7) Remove the pitman shaft cover bolts.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(8) Remove the pitman shaft from the gear (Fig.
24).
(9) Remove the cover if needed by loosing the
adjuster nut, Then removing the cover from the pit-
man shaft.
INSTALLATION
INSTALLATION - GAS
(1) Coat the seal withpower steering fluid.
(2) Install pitman shaft into the steering gear until
it fully seats into the bearing.
(3) Install the new cover bolts and tighten to 68
N´m (50 ft. lbs.).
(4) Perform over-center meshload adjustment,
(Refer to 19 - STEERING/GEAR - ADJUSTMENTS).
(5) Install the pitman arm (Refer to 19 - STEER-
ING/LINKAGE/PITMAN ARM - INSTALLATION).
(6) Perform a wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
INSTALLATION - DIESEL
(1) Coat the seal withpower steering fluid.
(2) Install the pitman shaft into the steering gear
until it fully seats into the bearing.
(3) Install the new cover bolts and tighten to 68
N´m (50 ft. lbs.).
(4) Perform over-center meshload adjustment
(Refer to 19 - STEERING/GEAR - ADJUSTMENTS).
(5) Install the steering gear (Refer to 19 - STEER-
ING/GEAR - INSTALLATION).
(6) Install the pitman arm (Refer to 19 - STEER-
ING/LINKAGE/PITMAN ARM - INSTALLATION).
(7) Perform a wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
Fig. 23 CENTERING STEERING GEAR
1 - STEERING GEAR
2 - 12 POINT SOCKET
3 - RATCHET
4 - INPUT SHAFT
Fig. 24 PITMAN SHAFT
1 - PITMAN SHAFT
2 - O-RING SEAL
3 - COVER
4 - ADJUSTING NUT
19 - 30 GEAR - LINK/COILDR
PITMAN SHAFT (Continued)

PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION.........................38
OPERATION...........................38
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 39
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER
STEERING PUMP - INITIAL OPERATION....39
STANDARD PROCEDURE - FLUSHING
POWER STEERING SYSTEM............39
REMOVAL
REMOVAL - GAS......................40
REMOVAL - DIESEL...................40
INSTALLATION
INSTALLATION - GAS..................41
INSTALLATION - DIESEL................41
SPECIFICATIONS
TORQUE CHART......................41
FLUID
DESCRIPTION.........................42
STANDARD PROCEDURE - POWER
STEERING FLUID LEVEL CHECKING......42
FLUID COOLER
REMOVAL.............................42
INSTALLATION.........................42
HOSES - I.F.S.
REMOVAL
REMOVAL - RETURN HOSE - GEAR TO
COOLER............................43
REMOVAL - PRESSURE HOSE...........43
REMOVAL - RETURN HOSE - RESERVOIR
TO COOLER.........................43INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO
COOLER............................43
INSTALLATION - PRESSURE HOSE.......43
INSTALLATION - RETURN HOSE -
RESERVOIR TO COOLER...............43
HOSES - LINK/COIL
REMOVAL
REMOVAL - RETURN HOSE - GEAR TO
COOLER............................43
REMOVAL - PRESSURE HOSE...........44
REMOVAL - RETURN HOSE - RESERVOIR
TO COOLER.........................44
INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO
COOLER............................44
INSTALLATION - PRESSURE HOSE.......44
INSTALLATION - RETURN HOSE -
RESERVOIR TO COOLER...............44
POWER STEERING PRESSURE SWITCH
DESCRIPTION.........................45
OPERATION...........................45
REMOVAL - 3.7L, 4.7L & 5.7L..............45
INSTALLATION - 3.7L, 4.7L & 5.7L..........45
PULLEY
REMOVAL.............................45
INSTALLATION.........................46
RESERVOIR
REMOVAL.............................46
INSTALLATION.........................46
PUMP
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.
The pump is connected to the steering gear via the
pressure hose and the return hose. The pump shaft
has a pressed-on pulley that is belt driven by the
crankshaft pulley.All vehicles are equipped with a power steering
fluid cooler.
NOTE: Power steering pumps are not interchange-
able with pumps installed on other vehicles.
OPERATION
Hydraulic pressure is provided for the power steer-
ing gear by the belt driven power steering pump (Fig.
1). The power steering pumps are constant flow rate
and displacement, vane-type pumps.
19 - 38 PUMPDR