2003 DODGE RAM Service Repair Manual

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Page 33 of 2895

DODGE RAM 2003 Service Repair Manual To adjust the vehicle height turn the torsion bar
adjustment bolt CLOCKWISE to raise the vehicle
and COUNTER CLOCKWISE to lower the vehicle.
CAUTION: ALWAYS raise the vehicle to the correct
suspension

To adjust the vehicle height turn the torsion bar
adjustment bolt CLOCKWISE to raise the vehicle
and COUNTER CLOCKWISE to lower the vehicle.
CAUTION: ALWAYS raise the vehicle to the correct
suspension height, NEVER lower the vehicle to
obtain the correct suspension height. If the vehicle
suspension height is too high, lower the vehicle
below the height specification. Then raise the vehi-
cle to the correct suspension height specification.
This will insure the vehicle maintains the proper
suspension height.
NOTE: If a height adjustment has been made, per-
form height measurement again on both sides of
the vehicle.
STANDARD PROCEDURE - CAMBER AND
CASTER ADJUSTMENT
NOTE: 4X4 (LD) SUSPENSION HEIGHT MEASURE-
MENT MUST BE PERFORMED BEFORE AN ALIGN-
MENT.
NOTE: When the upper control arm pivot bolts are
loosened the upper control arm will normally go
inwards toward the frame automatically with the
weight of the vehicle.
Camber and caster angle adjustments involve
changing the position of the upper control arm incon-
junction with the slotted holes in the frame brackets,
Install special tool 8876 between the top of the upper
control arm bracket and the upper control arm (on
1500 series 4X2 & 4X4). Install special tool 8876
between the bottom of the upper control arm bracket
pressing the tool against the frame and the upper
control arm (on 2500/3500 series 4X2) in order to
move the upper control arm outwards for proper
adjustment with the vehicle at normal ride height
(Fig. 3).
STANDARD PROCEDURE - TOE ADJUSTMENT
4X4 SUSPENSION HEIGHT MESUREMENT
MUST BE PERFORMED BEFORE AN ALIGN-
MENT.
The wheel toe position adjustment is the final
adjustment.
(1) Start the engine and turn wheels both ways
before straightening the wheels. Secure the steering
wheel with the front wheels in the straight-ahead
position.
(2) Loosen the tie rod jam nuts.NOTE: Each front wheel should be adjusted for
one-half of the total toe position specification. This
will ensure the steering wheel will be centered
when the wheels are positioned straight-ahead.
(3) Adjust the wheel toe position by turning the
inner tie rod as necessary (Fig. 4).
(4) Tighten the tie rod jam nut to 75 N´m (55 ft.
lbs.).
(5) Verify the specifications
(6) Turn off engine.
STANDARD PROCEDURE - CAMBER, CASTER
AND TOE ADJUSTMENT
NOTE: 4X4 (LD) SUSPENSION HEIGHT MEASURE-
MENT MUST BE PERFORMED BEFORE AN ALIGN-
MENT.
Camber and caster angle adjustments involve
changing the position of the upper control arm with
the slots in the frame brackets using special tool
8876 to move the upper control arm outwards for
proper adjustment. (Fig. 3)
NOTE: When the upper control arm pivot bolts are
loosened the upper control arm will normally go
inwards toward the frame automatically with the
weight of the vehicle.
CASTER
Moving the front or rear position of the upper con-
trol arm in or out, will change the caster angle and
camber angle significantly. To maintain the camber
Fig. 3 CASTER & CAMBER ADJUSTMENT
1 - FRONT PIVOT BOLT
2 - REAR PIVOT BOLT
3 - SLOTTED HOLES FOR ADJUSTMENT OF CASTER &
CAMBER
4 - UPPER CONTROL ARM
2 - 4 WHEEL ALIGNMENTDR
WHEEL ALIGNMENT (Continued)

Page 34 of 2895

DODGE RAM 2003 Service Repair Manual angle while adjusting caster, move one pivot bolt of
the upper control arm in or out. Then move the other
pivot bolt of the upper control arm in the opposite
direction. Install special tool 8876 betwe

angle while adjusting caster, move one pivot bolt of
the upper control arm in or out. Then move the other
pivot bolt of the upper control arm in the opposite
direction. Install special tool 8876 between the top of
the upper control arm bracket and the upper control
arm (on 1500 series 4X2 & 4X4). Install special tool
8876 between the bottom of the upper control arm
bracket pressing the tool against the frame and the
upper control arm (on 2500/3500 series 4X2) in order
to move the upper control arm outwards for proper
adjustment with the vehicle at normal ride height
(Fig. 3).
To increase positive caster angle, move the rear
position of the upper control arm inward (toward the
engine). Move the front of the upper control arm out-
ward (away from the engine) slightly until the origi-
nal camber angle is obtained using special tool 8876
to move the upper control arm for proper adjustment.
(Fig. 3)
CAMBER
Move both pivot bolts of the upper control arm
together in or out. This will change the camber angle
significantly and little effect on the caster angle
using special tool 8876 to move the upper control
arm for proper adjustment. (Fig. 3)
After adjustment is made tighten the upper control
arm nuts to proper torque specification.
TOE ADJUSTMENT
The wheel toe position adjustment is the final
adjustment.
(1) Start the engine and turn wheels both ways
before straightening the wheels. Secure the steering
wheel with the front wheels in the straight-ahead
position.
(2) Loosen the tie rod jam nuts.
NOTE: Each front wheel should be adjusted for
one-half of the total toe position specification. This
will ensure the steering wheel will be centered
when the wheels are positioned straight-ahead.
(3) Adjust the wheel toe position by turning the
inner tie rod as necessary (Fig. 4).
(4) Tighten the tie rod jam nut to 75 N´m (55 ft.
lbs.).
(5) Verify the specifications
(6) Turn off engine.
STANDARD PROCEDURE - ALIGNMENT
LINK/COIL SUSPENSION
Before each alignment reading the vehicle should
be jounced (rear first, then front). Grasp each
bumper at the center and jounce the vehicle up and
down several times. Always release the bumper inthe down position.Set the front end alignment to
specifications while the vehicle is in its NOR-
MALLY LOADED CONDITION.
CAMBER:The wheel camber angle is preset and
is not adjustable.
CASTER:Check the caster of the front axle for
correct angle. Be sure the axle is not bent or twisted.
Road test the vehicle and make left and right turn.
Observe the steering wheel return-to-center position.
Low caster will cause poor steering wheel returnabil-
ity.
Caster can be adjusted by rotating the cams on the
lower suspension arm (Fig. 5).
TOE POSITION:The wheel toe position adjust-
ment should be the final adjustment.
Fig. 4 TIE ROD END
1 - JAM NUT
2 - TIE ROD - INNER
3 - TIE ROD END - OUTER
Fig. 5 ALIGNMENT ADJUSTMENT CAM
1 - BRACKET REINFORCEMENT
2 - ADJUSTING BOLT
3 - ADJUSTMENT CAM
DRWHEEL ALIGNMENT 2 - 5
WHEEL ALIGNMENT (Continued)

Page 35 of 2895

DODGE RAM 2003 Service Repair Manual (1) Start the engine and turn wheels both ways
before straightening the wheels. Center and Secure
the steering wheel and turn off engine.
(2) Loosen the adjustment sleeve clamp bolts.
(3) Adjust the r

(1) Start the engine and turn wheels both ways
before straightening the wheels. Center and Secure
the steering wheel and turn off engine.
(2) Loosen the adjustment sleeve clamp bolts.
(3) Adjust the right wheel toe position with the
drag link. Turn the sleeve until the right wheel is at
the correct TOE-IN position. Position clamp bolts to
their original position and tighten to specifications.
Make sure the toe setting does not change dur-
ing clamp tightening.
(4) Adjust left wheel toe position with tie rod at
left knuckle. Turn the sleeve until the left wheel is at
the correct TOE-IN position. Position clamp bolts to
their original position and tighten to specifications.
Make sure the toe setting does not change dur-
ing clamp tightening.
(5) Verify the right toe setting and a straight steer-
ing wheel.
(6) Road test the vehicle.
SPECIFICATIONS
ALIGNMENT
NOTE: All alignment specifications are in degrees.
SPECIFICATIONS
DESCRIP-
TIONSPECIFICATION
VEHICLE
1500WHEEL
BASECASTER
(3.0É
Max,
+.75É
Target)CAMBER
( .50É)TOTAL
TOE-IN
( .10É)
4X2 120.5
in4.0É .0É .10É
4X2 140.5
in4.2É .0É .10É
4X2 160.5
in4.4É .0É .10É
VEHICLE
1500WHEEL
BASECASTER
(3.0É
Max,
+.75É
Target)CAMBER
( .50É)TOTAL
TOE-IN
( .10É)
4X4 120.5
in4.2É .0É .10É
4X4 140.5
in4.4É .0É .10É
4X4 160.5
in4.6É .0É .10É
DESCRIP-
TIONSPECIFICATION
MAX RT/LT
DIF-
FERENCE
4X2
1500Ð .40É .50É 0.06É
MAX RT/LT
DIF-
FERENCE
4X4
1500Ð .40É .60É 0.06É
VEHICLE
4X2
2500 &
3500WHEEL
BASECASTER
(3.25É
Max,
+.75É
Target)CAMBER
( .50É)TOTAL
TOE-IN
(0.20É
.10É)
4X2
2500&3500140 4.0É 0.0É .10É
.05É
4X2
2500&3500160 4.3É 0.0É .10É
.05É
MAX RT/LT
DIF-
FERENCE
4X2
2500&3500Ð 0.4É 0.6É 0.1É
VEHICLE
4X4
2500&3500WHEEL
BASECASTER
(4.0É
Min,
+.75É
Target)CAMBER
(.25É
.5É)TOTAL
TOE-IN
(0.20É
.10É)
4X4
2500&3500140 4.5É .25É .10É
.05É
4X4
2500&3500160 4.7É .25É .10É
.05É
MAX RT/LT
DIF-
FERENCE
4X4
2500&3500Ð .5É .5É 0.1É
DESCRIP-
TIONREAR SPECIFICATION
CAMBER
(-.10É 0.35É)TOTAL TOE-IN
(0.30É 0.35É)
THRUST ANGLE 0É 0.4É
4X2
4X4
1500
THRUST ANGLE -0.2É 0.2É
4X2
4X4
2500&3500
2 - 6 WHEEL ALIGNMENTDR
WHEEL ALIGNMENT (Continued)

Page 36 of 2895

DODGE RAM 2003 Service Repair Manual SPECIAL TOOLS
WHEEL ALIGNMENT
8876 - CAMBER/CASTER ADJUSTMENT TOOL
DRWHEEL ALIGNMENT 2 - 7
WHEEL ALIGNMENT (Continued)

Page 37 of 2895

DODGE RAM 2003 Service Repair Manual FRONT - INDEPENDENT FRONT SUSPENSION
TABLE OF CONTENTS
page page
FRONT - INDEPENDENT FRONT SUSPENSION
DESCRIPTION
DESCRIPTION........................9
DESCRIPTION........................9
SPECIFICATIO

FRONT - INDEPENDENT FRONT SUSPENSION
TABLE OF CONTENTS
page page
FRONT - INDEPENDENT FRONT SUSPENSION
DESCRIPTION
DESCRIPTION........................9
DESCRIPTION........................9
SPECIFICATIONS
TORQUE CHART......................10
SPECIAL TOOLS
FRONT SUSPENSION..................11
BUSHINGS
REMOVAL
REMOVAL - LOWER CONTROL ARM
BUSHINGS - 4WD (LD).................12
REMOVAL - TORSION BAR
CROSSMEMBER BUSHING..............12
REMOVAL - LOWER CONTROL ARM
BUSHINGS - 2WD (LD).................12
INSTALLATION
INSTALLATION - LOWER CONTROL ARM
BUSHINGS - 4WD (LD).................13
INSTALLATION - TORSION BAR CROSS
MEMBER BUSHING....................14
INSTALLATION - LOWER CONTROL ARM
BUSHINGS - 2WD (LD).................14
HUB / BEARING
REMOVAL
REMOVAL - 4X4......................15
REMOVAL - 4X2......................16
INSTALLATION
INSTALLATION - 4X4...................16
INSTALLATION - 4X2...................17
KNUCKLE
DESCRIPTION.........................17
OPERATION...........................17
REMOVAL.............................17
INSTALLATION.........................18
LOWER BALL JOINT
DIAGNOSIS AND TESTING - LOWER BALL
JOINT..............................18
REMOVAL.............................18
INSTALLATION.........................19LOWER CONTROL ARM
REMOVAL
REMOVAL - 4X4 (LD)...................20
REMOVAL - 4X2......................20
INSTALLATION
INSTALLATION - 4X4 (LD)...............21
INSTALLATION - 4X2...................21
SPRING
REMOVAL.............................21
INSTALLATION.........................22
SHOCK
DIAGNOSIS AND TESTING - SHOCK........23
REMOVAL
REMOVAL - 4X2......................23
REMOVAL - 4X4......................23
INSTALLATION
INSTALLATION - 4X2...................23
INSTALLATION - 4X4...................23
STABILIZER BAR
DESCRIPTION.........................24
OPERATION...........................24
REMOVAL.............................24
INSTALLATION.........................24
STABILIZER LINK
REMOVAL
REMOVAL - 4X4......................24
REMOVAL - 4X2......................24
INSTALLATION
INSTALLATION - 4X4...................25
INSTALLATION - 4X2...................25
TORSION BAR
DESCRIPTION.........................25
OPERATION...........................25
REMOVAL.............................25
INSTALLATION.........................26
UPPER BALL JOINT
DIAGNOSIS AND TESTING - UPPER BALL
JOINT..............................26
UPPER CONTROL ARM
REMOVAL.............................27
INSTALLATION.........................27
2 - 8 FRONT - INDEPENDENT FRONT SUSPENSIONDR

Page 38 of 2895

DODGE RAM 2003 Service Repair Manual 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/bea

Page 39 of 2895

DODGE RAM 2003 Service Repair Manual 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
S

Page 40 of 2895

DODGE RAM 2003 Service Repair Manual 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

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