2003 DODGE RAM frame

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
3Differential & Driveline
5Brakes
6Clutch
7Cooling
8AAudio
8BChime/Buzzer
8EElectronic Control Modules
8FEngine Systems
8GHeated Systems
8HHorn
8IIgnition Control
8JInstrument Cluster
8LLamps
8MMessage Systems
8NPower Systems
8ORestraints
8PSpeed Control
8QVehicle Theft Security
8RWipers/Washers
8WWiring
9Engine
11Exhaust System
13Frame & Bumpers
14Fuel System
19Steering
21Transmission and Transfer Case
22Tires/Wheels
23Body
24Heating & Air Conditioning
25Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)

VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
VIN CODING/LOCATIONS
The Vehicle Identification Number (VIN) plate is
located on the lower windshield fence near the left
a-pillar (Fig. 2). The VIN contains 17 characters that
provide data concerning the vehicle. Refer to the VIN
decoding chart to determine the identification of a
vehicle.
The VIN is also imprinted on the:
²Body Code Plate.
²Equipment Identification Plate.
²Vehicle Safety Certification Label.
²Frame rail.
To protect the consumer from theft and possible
fraud the manufacturer is required to include a
Check Digit at the ninth position of the VIN. The
check digit is used by the manufacturer and govern-
ment agencies to verify the authenticity of the vehi-cle and official documentation. The formula to use
the check digit is not released to the general public.
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = Manufactured By DaimlerChrysler Corporation
3 = Manufactured By DaimlerChrysler De Mexico
2 Make D = Dodge
3 Vehicle Type 2 = Incomplete with Side Airbag
3 = Truck with Side Airbag
6 = Incomplete Less Side Airbag
7 = Truck Less Side Airbag
4 Gross Vehicle Weight Rating G = 5,001-6000 lbs.
H = 6,001-7,000 lbs.
J = 7,001-8,000 lbs.
K = 8,001-9,000 lbs.
L = 9,001-10,000 lbs.
M = 10,001-14,000 lbs.
W = Buses/Incomplete Vehicles with Hydraulic Brakes
5 Vehicle Line A = Ram Pickup 4X2
U = Ram Pickup 4X4
6 Series 1 = 1500
2 = 2500
3 = 3500 Less Dual Rear Wheels
4 = 3500 With Dual Rear Wheels
7 Body Style 6 = Conventional Cab
8 = Quad Cab Full Rear Doors
Fig. 2 VIN LOCATION
1 - DASH PANEL
2 - VIN CODE PLATE
2 INTRODUCTIONDR

HOISTING
STANDARD PROCEDURE - HOISTING
Refer to the Owner's Manual for emergency vehicle
lifting procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT (Fig. 5) OR SECURE VEHICLE TO HOIST-
ING DEVICE WHEN THESE CONDITIONS EXIST.
FLOOR JACK
When properly positioned, a floor jack can be used
to lift a vehicle (Fig. 6). Support the vehicle in the
raised position with jack stands at the front and rear
ends of the frame rails (Fig. 5).
CAUTION: Do not lift vehicle with a floor jack posi-
tioned under:
²An axle tube.
²A body side sill.
²A steering linkage component.²A drive shaft.
²The engine or transmission oil pan.
²The fuel tank.
²A front suspension arm.
NOTE: Use the correct frame rail lifting locations
only (Fig. 7) and (Fig. 8).
HOIST
A vehicle can be lifted with:
²A single-post, frame-contact hoist.
²A twin-post, chassis hoist.
²A ramp-type, drive-on hoist.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly
(Fig. 6). The forward lifting pads should be posi-
tioned against the forward flange of the transmis-
sion crossmember brackets at the bottom of the
frame rail (Fig. 7). The real lifting pads should be
wedged between the forward flange of the leaf
spring bracket and the frame rail (Fig. 8). Safety
stands should be placed under the frame rails at
the front and rear ends (Fig. 5).
Fig. 5 Safety Stands
1 - SAFETY STANDS
Fig. 6 Vehicle Lifting Locations
0 - 14 LUBRICATION & MAINTENANCEDR

TOWING
STANDARD PROCEDURE - TOWING
A vehicle equipped with SAE approved sling-type
towing equipment can be used to tow all vehicles.
When towing a 4WD vehicle using a wheel-lift towing
device, use tow dollies under the opposite end of the
vehicle. A vehicle with flat-bed device can also be
used to transport a disabled vehicle (Fig. 9).
A wooden crossbeam may be required for proper
connection when using the sling-type, front-end tow-
ing method.
SAFETY PRECAUTIONS
CAUTION: The following safety precautions must be
observed when towing a vehicle:
²Secure loose and protruding parts.
²Always use a safety chain system that is inde-
pendent of the lifting and towing equipment.
²Do not allow towing equipment to contact the
disabled vehicle's fuel tank.
²Do not allow anyone under the disabled vehicle
while it is lifted by the towing device.
²Do not allow passengers to ride in a vehicle
being towed.
²Always observe state and local laws regarding
towing regulations.
²Do not tow a vehicle in a manner that could
jeopardize the safety of the operator, pedestrians or
other motorists.
²Do not attach tow chains, T-hooks, J-hooks, or a
tow sling to a bumper, steering linkage, drive shafts
or a non-reinforced frame hole.
²Do not tow a heavily loaded vehicle. Damage to
the cab, cargo box or frame may result. Use a flatbed
device to transport a loaded vehicle.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums or rotors.
Fig. 7 FRONT LIFT PAD LOCATION
1 - BODY MOUNT BRACKET
2 - FRONT LIFT PAD
3 - TRANSMISSION CROSSMEMBER BRACKET
4 - FRAME RAIL
Fig. 8 REAR LIFT PAD LOCATION
1 - FRAME RAIL
2 - REAR LIFT PAD
3 - LEAF SPRING MOUNTING BRACKET
4 - BOX MOUNTING BRACKET
Fig. 9 Tow Vehicles With Approved Equipment
1 - SLING TYPE2 - WHEEL LIFT3 - FLAT BED
DRLUBRICATION & MAINTENANCE 0 - 15
HOISTING (Continued)

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)

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)

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)