2003 DODGE RAM Service Repair Manual

jacking points wheel size wiper size maintenance seats trailer

Page 49 of 2895

DODGE RAM 2003 Service Repair Manual LOWER CONTROL ARM
REMOVAL
REMOVAL - 4X4 (LD)
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the upper ball joint nut. Separate ball
joint from the steering knuck

LOWER CONTROL ARM
REMOVAL
REMOVAL - 4X4 (LD)
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the upper ball joint nut. Separate ball
joint from the steering knuckle with Remover 8677.
(4) Remove the front halfshaft, (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/HALF SHAFT -
REMOVAL).
(5) Remove the torsion bar, (Refer to 2 - SUSPEN-
SION/FRONT/TRACK BAR - REMOVAL).
(6) Remove the shock absorber lower bolt.
(7) Remove the stabilizer bar link (Refer to 2 -
SUSPENSION/FRONT/STABILIZER LINK -
REMOVAL).
(8) Remove the lower ball joint nut. Separate ball
joint from the steering knuckle with Remover 8677.
(9) Remove the control arm pivot bolts and suspen-
sion arm from frame rail brackets (Fig. 23).
REMOVAL - 4X2
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Support the lower control arm at the outboard
side of the lower control arm to support vehicle
weight.
(4) Remove the shock (Refer to 2 - SUSPENSION/
FRONT/SHOCK - REMOVAL).
(5) Install Spring Compressor DD-1278 up through
the lower suspension arm, coil spring and shock holein the frame. The bell-shaped adapter goes against
the lower suspension arm. Install the nut on top of
the tool at the shock hole.
(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.
NOTE: Do not allow the upper control arm and
steering knuckle to rebound downwards they must
be supported.
(10) 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.
(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).
(16) Remove the front and rear pivot bolts (Fig.
24).
(17) Remove the lower control arm.
Fig. 23 LOWER CONTROL ARM
1 - LOWER CONTROL ARM
2 - UPPER CONTROL ARM
3 - FRONT BOLT
4 - NUTS
5 - REAR BOLT
Fig. 24 LOWER CONTROL ARM - 4X2
1 - FRONT PIVOT BOLT
2 - REAR PIVOT BOLT
3 - LOWER CONTROL ARM
2 - 20 FRONT - INDEPENDENT FRONT SUSPENSIONDR

Page 50 of 2895

DODGE RAM 2003 Service Repair Manual 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

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)

Page 51 of 2895

DODGE RAM 2003 Service Repair Manual 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 contr

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)

Page 52 of 2895

DODGE RAM 2003 Service Repair Manual SHOCK
DIAGNOSIS AND TESTING - 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 ca

SHOCK
DIAGNOSIS AND TESTING - 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 shock absorber bushings do not require any
type of lubrication. Do not attempt to stop bushing
noise by lubricating them. Grease and mineral oil-
base lubricants will deteriorate the bushing.
REMOVAL
REMOVAL - 4X2
(1) Raise and support vehicle.
(2) Support the lower control arm outboard end.
(3) Remove the upper shock absorber nut, retainer
and grommet.
(4) Remove the lower nuts and remove the shock
absorber.
REMOVAL - 4X4
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Support the lower control arm outboard end.
(4) Remove the upper shock nut and with the insu-
lator and retainer (Fig. 27).
(5) Remove the lower shock bolt (Fig. 27).
(6) Remove the shock
INSTALLATION
INSTALLATION - 4X2
NOTE: Upper shock nut must be replaced or use
Mopar Lock 'N Seal or LoctiteT242 on existing nut.(1) Install the lower retainer and grommet on the
shock absorber stud. Insert the shock absorber
through the frame bracket hole.
(2) Install the lower nuts and tighten the nuts to
34 N´m (25 ft. lbs.).
(3) Install the upper grommet, retainer and new
nut or use Mopar Lock 'N Seal or Loctitet242 on
existing nut, on the shock absorber stud. Tighten nut
to 54 N´m (40 ft. lbs.).
(4) Remove the support from the lower control arm
outboard end.
(5) Lower the vehicle.
INSTALLATION - 4X4
(1) Install the upper part of the shock into the
frame bracket with the insulators and retainers (Fig.
27).
(2) Install the nut and Tighten to 54 N´m (40 ft.
lbs.).
(3) Install the lower part of the shock into the
lower control arm and Tighten the bolt to 135 N´m
(100 ft. lbs.) (Fig. 27).
(4) Remove the support from the lower control arm
outboard end.
(5) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(6) Remove the support and lower the vehicle.
Fig. 27 SHOCK 4X4
1 - INSULATOR & RETAINER
2 - NUT
3 - SHOCK ABSORBER
4 - BOLT
DRFRONT - INDEPENDENT FRONT SUSPENSION 2 - 23

Page 53 of 2895

DODGE RAM 2003 Service Repair Manual STABILIZER BAR
DESCRIPTION
The bar extends across the front underside of the
chassis and connects to the frame crossmember. The
ends of the bar mount to the lower suspension arm.
All mounting points o

STABILIZER BAR
DESCRIPTION
The bar extends across the front underside of the
chassis and connects to the frame crossmember. The
ends of the bar mount to the lower suspension arm.
All mounting points of the stabilizer bar are isolated
by bushings (Fig. 28).
OPERATION
The stabilizer bar is used to minimize vehicle front
sway during turns. The bar helps to maintain a flat
attitude to the road surface.
REMOVAL
NOTE: To service the stabilizer bar the vehicle
should be on a drive on hoist. The vehicle suspen-
sion must be at curb height for stabilizer bar instal-
lation.
(1) Remove the stabilizer bar link upper nuts and
remove the retainers and grommets (Fig. 29).
(2) Remove the stabilizer bar retainer, bolts and
retainers from the frame crossmember (Fig. 29) and
remove the bar.
(3) If necessary, remove the bushings from the sta-
bilizer bar.
INSTALLATION
NOTE: To service the stabilizer bar the vehicle must
be on a drive on hoist. The vehicle suspension
must be at curb height for stabilizer bar installation.
(1) If removed, install the bushings on the stabi-
lizer bar.(2) Position the stabilizer bar on the frame cross-
member brackets and install the bracket and bolts
finger-tight (Fig. 29).
NOTE: Check the alignment of the bar to ensure
there is no interference with the either frame rail or
chassis component. Spacing should be equal on
both sides.
(3) Install the stabilizer bar to the stabilizer link
and install the grommets and retainers.
(4) Install the nuts to the stabilizer link and
tighten to 38 N´m (27 ft. lbs.).
(5) Tighten the brackets to the frame to 61 N´m
(45 ft. lbs.).
STABILIZER LINK
REMOVAL
REMOVAL - 4X4
(1) Raise and support the vehicle.
(2) Remove the lower nut (Fig. 29).
(3) Remove the upper nut, retainers and grommets
(Fig. 29).
(4) Remove the stabilizer link from the vehicle
(Fig. 29).
REMOVAL - 4X2
(1) Raise and support the vehicle.
(2) Remove the lower nut (Fig. 29).
(3) Remove the upper nut, retainer and grommets
(Fig. 29).
(4) Remove the stabilizer link from the vehicle
(Fig. 29).
Fig. 28 STABILIZER BAR
Fig. 29 STABILIZER LINK
1 - STABILIZER LINK
2 - SWAY BAR BRACKET
2 - 24 FRONT - INDEPENDENT FRONT SUSPENSIONDR

Page 54 of 2895

DODGE RAM 2003 Service Repair Manual INSTALLATION
INSTALLATION - 4X4
(1) Install the stabilizer link to the vehicle.
(2) Install the lower nut and Tighten to 102 N´m
(75 ft. lbs.).
(3) Install the retainers, grommets and upper nut
and T

INSTALLATION
INSTALLATION - 4X4
(1) Install the stabilizer link to the vehicle.
(2) Install the lower nut and Tighten to 102 N´m
(75 ft. lbs.).
(3) Install the retainers, grommets and upper nut
and Tighten to 38 N´m (27 ft. lbs.).
(4) Remove the support and lower the vehicle.
INSTALLATION - 4X2
(1) Install the stabilizer link to the vehicle (Fig.
29).
(2) Install the lower nut and Tighten to 102 N´m
(75 ft. lbs.).
(3) Install the retainers, grommets and upper nut
and Tighten to 38 N´m (27 ft. lbs.).
(4) Remove the support and lower the vehicle.
TORSION BAR
DESCRIPTION
The front of the bar connects to the back side of
the lower suspension arm. The rear end of the bar is
mounted in a anchor that rests in the frame cross-
member.
OPERATION
The torsion bars are used to control ride height
and ride quality. The vehicle height is adjusted
through an anchor adjustment bolt that increases or
decreases the wind up of the torsion bar. Increasing
or decreasing the bar angle changes the wind up of
the suspension arms.
REMOVAL
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) Raise and support the vehicle with the front
suspension hanging.
(2) Remove the transfer case skid plate (Refer to
13 - FRAME & BUMPERS/FRAME/TRANSFER
CASE SKID PLATE - REMOVAL).
NOTE: Count and record the number of turns for
installation reference.
(3) Mark the adjustment bolt setting.
(4) Install Special Tool - 8686 to the anchor arm
and the cross member (Fig. 30).(5) Increase the tension on the anchor arm tool
until the load is removed from the adjustment bolt
and the adjuster nut (Fig. 30).
(6) Turn the adjustment bolt counterclockwise to
remove the bolt and the adjuster nut..
(7) Remove the Special Tool - 8686, allowing the
torsion bar to unload (Fig. 30).
(8) Remove torsion bar and anchor. Remove anchor
from torsion bar (Fig. 31).
(9) Remove all foreign material from torsion bar
mounting in anchor and suspension arm.
(10) Inspect adjustment bolt, bearing and swivel
for damage.
Fig. 30 LOADING/UNLOADING TORSION BAR
1 - SPECIAL TOOL ± 8686
2 - CROSSMEMBER
Fig. 31 TORSION BAR
1 - ANCHOR
2 - SWIVEL
3 - TORSION BAR
4 - LOWER CONTROL ARM
DRFRONT - INDEPENDENT FRONT SUSPENSION 2 - 25
STABILIZER LINK (Continued)

Page 55 of 2895

DODGE RAM 2003 Service Repair Manual 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 i

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)

Page 56 of 2895

DODGE RAM 2003 Service Repair Manual UPPER CONTROL ARM
REMOVAL
(1) Raise and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove the nut from upper ball joint.
(4) Separate upper ball joint from the steering
knuckle with Remo

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