2003 DODGE RAM washer fluid

MAINTENANCE SCHEDULES
DESCRIPTION
Maintenance Schedule Information not included in
this section, is located in the appropriate Owner's
Manual.
There are two maintenance schedules that show
therequiredservice for your vehicle.
First is ScheduleªBº. It is for vehicles that are
operated under the conditions that are listed below
and at the beginning of the schedule.
²Day or night temperatures are below 0É C (32É
F).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 16 km (10 miles).
²More than 50% of your driving is at sustained
high speeds during hot weather, above 32É C (90É F).
²Trailer towing.
²Taxi, police, or delivery service (commercial ser-
vice).
²Off-road or desert operation.
²If equipped for and operating with E-85
(ethanol) fuel.
NOTE: Most vehicles are operated under the condi-
tions listed for Schedule(B(.
Second is ScheduleªAº. It is for vehicles that are
not operated under any of the conditions listed under
Schedule9B9.
Use the schedule that best describes your driving
conditions. Where time and mileage are listed, follow
the interval that occurs first.
CAUTION: Failure to perform the required mainte-
nance items may result in damage to the vehicle.
At Each Stop for Fuel
²Check the engine oil level about 5 minutes after
a fully warmed engine is shut off. Checking the oil
level while the vehicle is on level ground will
improve the accuracy of the oil level reading. Add oil
only when the level is at or below the ADD or MIN
mark.
²Check the windshield washer solvent and add if
required.
Once a Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect the battery and clean and tighten the
terminals as required.
²Check the fluid levels of coolant reservoir, brake
master cylinder, power steering and transmission
and add as needed.
²Check all lights and all other electrical items for
correct operation.
At Each Oil Change
²Change the engine oil filter.
²Inspect the exhaust system.
²Inspect the brake hoses.
²Inspect the CV joints (if equipped) and front sus-
pension components.
²Check the automatic transmission fluid level.
²Check the manual transmission fluid level.
²Check the coolant level, hoses, and clamps.
²Rotate the tires at each oil change interval
shown on Schedule ªAº 10 000 km (6,000 miles) or
every other interval shown on Schedule ªBº 10 000
km (6,000 miles).
Schedule ªBº
Follow schedule ªBº if you usually operate your
vehicle under one or more of the following conditions.
²Day or night temperatures are below 0É C (32É
F).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 16 km (10 miles).
²More than 50% of your driving is at sustained
high speeds during hot weather, above 32É C (90É F).
²Trailer towing.
²Taxi, police, or delivery service (commercial ser-
vice).
²Off-road or desert operation.
²If equipped for and operating with E-85
(ethanol) fuel.
0 - 6 LUBRICATION & MAINTENANCEDR

(9) Inspect the axle shaft tube bore for roughness
and burrs. Remove as necessary.
INSTALLATION
(1) Wipe the axle shaft tube bore clean.
(2) Install axle shaft bearing with Installer 5063
and Handle C-4171 (Fig. 30).
(3) Install anewaxle shaft seal with Installer
8694 and Handle C-4171.
(4) Lubricate seal lip with gear lubricant.
(5) Insert axle shaft through seal, bearing and
engage it into side gear splines. Push firmly on the
axle shaft to engage the snap-ring.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip.(6) Install axle shaft O-ring.
(7) Check the differential fluid level and add fluid
if necessary.
(8) Install skid plate, if necessary.
(9) Install half shaft.
PINION SEAL
REMOVAL
(1) Remove skid plate, if equipped.
(2) Remove both half shafts.
(3) Mark the propeller shaft and pinion companion
flange (Fig. 31) for installation reference.
(4) Remove the front propeller shaft.
(5) Rotate the pinion gear three or four times and
verify pinion rotates smoothly.
(6) Record pinion rotating torque with an inch
pound torque wrench, for installation reference (Fig.
32).
(7) Position Holder 6719 against the companion
flange and install a four bolts and washers into the
threaded holes and tighten the bolts.
(8) Remove the pinion nut.
(9) Remove the companion flange with Remover
C-452 (Fig. 33).
(10) Remove pinion seal with a pry tool or a slide
hammer mounted screw.
Fig. 29 BEARING REMOVER CUP
1 - REMOVER CUP
2 - BEARING
3 - NUT
Fig. 30 BEARING INSTALLER
1 - INSTALLER
2 - HANDLE
Fig. 31 COMPANION FLANGE
1 - COMPANION FLANGE
2 - PROPELLER SHAFT
3 - FLANGE YOKE
4 - REFERENCE MARK
3 - 34 FRONT AXLE - C205FDR
AXLE BEARINGS (Continued)

(7) Install pinion into the housing and place front
pinion bearing onto the pinion shaft. Draw the pinion
shaft into the front bearing with Installer 8982 (Fig.
52).
(8) Installnewpinion seal (Fig. 53) with Installer
8882 and Handle C-4171.
(9) Apply a light coat of teflon sealant to the pin-
ion flange splines.
(10) Hold pinion and lightly tap the pinion flange
onto the pinion shaft, until a few threads are show-
ing.
(11) Install pinion flange washer andnewpinion
nut.
(12) Hold pinion flange with Flange Wrench 8979
and tighten pinion nut until end play is taken up.
(13) Rotate pinion several times to seat bearings.
(14) Measure pinion rotating torque with an inch
pound torque wrench (Fig. 54). Tighten pinion nut in
small increments until pinion rotating torque is:²New Pinion Bearings:1.7-2.8 N´m (15-25 in.
lbs.)
²Original Pinion Bearings:1.1-2.2 N´m (10-20
in. lbs.)
(15) Rotate pinion several times then verify pinion
rotating torque again.
(16) Position the ring gear on differential case and
start twonewring gear bolts.
(17) Install the rest of thenewring gear bolts and
tighten them alternately to seat the ring gear.
(18) Torque ring gear bolts to 140 N´m (103 ft.
lbs.).
(19) Install differential in housing.
(20) Measure final rotating torque with an inch
pound torque wrench. The final pinion rotating
torque plus differential case bearing preload is:
²New Bearings:3.4-5.6 N´m (30-50 in. lbs.)
²Original Bearings:2.8-5.1 N´m (25-45 in. lbs.)
(21) Install axle shafts.
(22) Verify ring gear backlash and gear contact
pattern.
(23) Install the propeller shaft with the reference
marks aligned.
(24) Install differential cover with gasket and
tighten to 40 N´m (30 ft. lbs.).
(25) Fill differential with fluid and tighten fill plug
to 32 N´m (24 ft. lbs.).
Fig. 52 PINION GEAR INSTALLER
1 - INSTALLER
2 - DIFFERENTIAL HOUSING
Fig. 53 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 54 PINION ROTATING TORQUE
1 - PINION FLANGE
2 - TORQUE WRENCH
3 - 68 FRONT AXLE - 9 1/4 AADR
PINION GEAR/RING GEAR (Continued)

(2) Raise and support the vehicle.
(3) Remove the tire and wheel assembly.
(4) Compress the disc brake caliper.
(5) Remove the banjo bolt and discard the copper
washer.
(6) Remove the caliper slide pin bolts.
(7) Remove the disc brake caliper (Fig. 19) or (Fig.
20).
DISASSEMBLY
(1) Drain the brake fluid from caliper.
(2) C-clamp a block of wood over one piston (Fig.
21).
(3) Take another piece of wood and pad it with
one-inch thickness of shop towels. Place this piece in
the outboard shoe side of the caliper in front of the
other piston. This will cushion and protect caliper
piston during removal (Fig. 22).
(4) To remove the caliper piston directshort
bursts of low pressure airwith a blow gun
through the caliper brake hose port. Use only enough
air pressure to ease the piston out.
Fig. 18 DISC BRAKE CALIPER - REAR
1 - CALIPER ADAPTER
2 - CALIPER ADAPTER MOUNTING BOLTS
3 - CALIPER SLIDE BOLTS
4 - BRAKE HOSE
5 - CABLE
6 - CALIPER
7 - ROTOR
8 - ANTI-RATTLE CLIPS
Fig. 19 DISC BRAKE CALIPER - FRONT
1 - STEERING KNUCKLE
2 - DISC BRAKE CALIPER
3 - CALIPER MOUNTING ADAPTER
4 - DISC BRAKE ROTOR
Fig. 20 8 LUG ROTOR & CALIPER ASSEMBLY
1 - ROTOR
2 - CALIPER ADAPTER
3 - ANTI-RATTLE CLIPS
4 - BRAKE HOSE WITH BANJO BOLT
5 - DISC BRAKE CALIPER
6 - OUTBOARD BRAKE PAD
Fig. 21 C-Clamp One Piston
1 - BLOCK OF WOOD
2 - C-CLAMP
3 - CALIPER
DRBRAKES - BASE 5 - 13
DISC BRAKE CALIPERS (Continued)

CAUTION: Use of alternative grease may cause
damage to the boots seals.
(9) Install the boot seals into the caliper seal bores
and center the seals in the bores.
(10) Install mounting bolt bushings into the boot
seals and insure seal lip is engaged into the bushing
grooves at either end of the bushing.
(11) Install caliper bleed screw.
INSTALLATION
INSTALLATION - REAR
(1) Install caliper to the caliper adapter.
(2) Coat the caliper mounting slide pin bolts with
silicone grease. Then install and tighten the bolts to
15 N´m (11 ft. lbs.).
(3) Install the brake hose banjo bolt if removed.
(4) Install the brake hose to the caliper withnew
seal washersand tighten fitting bolt to 31 N´m (23
ft. lbs.).
CAUTION: Verify brake hose is not twisted or
kinked before tightening fitting bolt.
(5) Remove the prop rod from the vehicle.
(6) Bleed the base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE) OR (Refer to
5 - BRAKES - STANDARD PROCEDURE).
(7) Install the wheel and tire assemblies (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(8) Remove the supports and lower the vehicle.
(9) Verify a firm pedal before moving the vehicle.
INSTALLATION - FRONT
NOTE: Install a new copper washers on the banjo
bolt when installing
(1) Install the disc brake caliper (Fig. 19) or (Fig.
20).
CAUTION: Verify brake hose is not twisted or
kinked before tightening fitting bolt.
(2) Install the banjo bolt with new copper washers
to the caliper. Tighten to 27 N´m (20 ft. lbs.)
(3) Install the caliper slide pin bolts. tighten to 32
N´m (24 ft. lbs.)
(4) Remove the prop rod.
(5) Bleed the base brake system, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - STAN-
DARD PROCEDURE).
(6) Install the tire and wheel assembly, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(7) Lower the vehicle.
DISC BRAKE CALIPER
ADAPTER
REMOVAL
REMOVAL - REAR
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Drain a small amount of fluid from master cyl-
inder brake reservoir with acleansuction gun.
(4) Bottom the caliper pistons into the caliper by
prying the caliper over.
(5) Remove the caliper mounting bolts (Fig. 30).
(6) Remove the disc brake caliper from the mount.
CAUTION: Never allow the disc brake caliper to
hang from the brake hose. Damage to the brake
hose will result. Provide a suitable support to hang
the caliper securely.
(7) Remove the inboard and outboard brake pads
(Fig. 30).
(8) Remove the anti-rattle clips (Fig. 30).
(9) Remove the caliper adapter mounting bolts
(Fig. 30).
REMOVAL - FRONT
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
Fig. 29 Seating Dust Boot
1 - HANDLE
2 - CALIPER
3 - DUST BOOT INSTALLER
5 - 16 BRAKES - BASEDR
DISC BRAKE CALIPERS (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Brakes Self Apply 1. Dump valve faulty. 1. Replace booster.
2. Contamination in hydraulic
system.2. Flush hydraulic system and replace
booster.
3. Restriction in booster return hose. 3. Replace hose.
Booster Chatter, Pedal
Vibration1. Slipping pump belt. 1. Replace power steering belt.
2. Low pump fluid level. 2. Fill pump and check for leaks.
Grabbing Brakes 1. Low pump flow. 1. Test and repair/replace pump.
2. Faulty spool valve action. 2. Replace booster.
STANDARD PROCEDURE - BLEEDING
The hydraulic booster is generally self-bleeding,
this procedure will normally bleed the air from the
booster. Normal driving and operation of the unit will
remove any remaining trapped air.
(1) Fill power steering pump reservoir.
(2) Disconnect fuel shutdown relay and crank the
engine for several seconds, Refer to Fuel System for
relay location and WARNING.
(3) Check fluid level and add if necessary.
(4) Connect fuel shutdown relay and start the
engine.
(5) Turn the steering wheel slowly from lock to
lock twice.
(6) Stop the engine and discharge the accumulator
by depressing the brake pedal 5 times.
(7) Start the engine and turn the steering wheel
slowly from lock to lock twice.
(8) Turn off the engine and check fluid level and
add if necessary.
NOTE: If fluid foaming occurs, wait for foam to dis-
sipate and repeat steps 7 and 8.
REMOVAL
NOTE: If the booster is being replaced because the
power steering fluid is contaminated, flush the
power steering system before replacing the booster.
(1) With engine off depress the brake pedal 5
times to discharge the accumulator.
(2) Remove brake lines from master cylinder.
(3) Remove mounting nuts from the master cylin-
der.
(4) Remove the bracket from the hydraulic booster
lines and master cylinder mounting studs.
(5) Remove the master cylinder.
(6) Remove the return hose and the two pressure
lines from the hydraulic booster (Fig. 49).(7) Remove the booster push rod clip, washer and
rod remove from the brake pedal.
(8) Remove the mounting nuts from the hydraulic
booster and remove the booster.INSTALLATION
(1) Install the hydraulic booster and tighten the
mounting nuts to 28 N´m (21 ft. lbs.).
(2) Install the booster push rod, washer and clip
onto the brake pedal.
(3) Install the master cylinder on the mounting
studs. and tighten the mounting nuts to 23 N´m (17
ft. lbs.).
(4) Install the brake lines to the master cylinder
and tighten to 19-200 N´m (170-200 in. lbs.).
(5) Install the hydraulic booster line bracket onto
the master cylinder mounting studs.
(6) Install the master cylinder mounting nuts and
tighten to 23 N´m (17 ft. lbs.).
Fig. 49 HYDRO-BOOST UNIT
1 - INLET HOSE
2 - HYDRO-BOOST UNIT
3 - MASTER CYLINDER UNIT
4 - RETURN HOSE
5 - OUTLET HOSE
DRBRAKES - BASE 5 - 27
HYDRO-BOOST BRAKE BOOSTER (Continued)

(6) Install the clutch housing dust shield to the
clutch housing.
(7) Install transmission and transfer case, if
equipped.
CLUTCH RELEASE BEARING
REMOVAL
(1) Remove transmission and transfer case, if
equipped.
(2) Remove spring clip.
(3) Disconnect release bearing from release fork
and remove bearing (Fig. 17).
INSTALLATION
(1) Inspect bearing slide surface on transmission
front bearing retainer. Replace retainer if slide sur-
face is scored, worn, or cracked.
(2) Inspect release lever and pivot stud. Be sure
stud is secure and in good condition. Be sure fork is
not distorted or worn. Replace fork spring clips if
bent or damaged.
(3) Lubricate input shaft splines, bearing retainer
slide surface, lever pivot ball stud, and release lever
pivot surface with Moparthigh temperature bearing
grease.
(4) Install release fork and release bearing (Fig.
18). Be sure fork and bearing are properly secured by
spring clips. Also be sure that the release fork is
installed properly. The rear side of the release lever
has one end with a raised area. This raised area goes
toward the slave cylinder side of the transmission.
(5) Install clutch housing, if removed.(6) Install transmission and transfer case.
(7) Check clutch master cylinder fluid level.
FLYWHEEL
DIAGNOSIS AND TESTING
Check flywheel runout whenever misalignment is
suspected. Flywheel runout should not exceed 0.08
mm (0.003 in.). Measure runout at the outer edge of
the flywheel face with a dial indicator. Mount the
indicator on a stud installed in place of one of the fly-
wheel bolts.
Common causes of runout are:
²heat warpage
²improper machining
²incorrect bolt tightening
²improper seating on crankshaft flange shoulder
²foreign material on crankshaft flange
Flywheel machining is not recommended. The fly-
wheel clutch surface is machined to a unique contour
and machining will negate this feature. Minor fly-
wheel scoring can be cleaned up by hand with 180
grit emery or with surface grinding equipment.
Remove only enough material to reduce scoring
(approximately 0.001 - 0.003 in.). Heavy stock
removal isnot recommended.Replace the flywheel
if scoring is severe and deeper than 0.076 mm (0.003
in.). Excessive stock removal can result in flywheel
cracking or warpage after installation; it can also
weaken the flywheel and interfere with proper clutch
release.
Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may
cock the flywheel causing excessive runout. Use new
Fig. 17 CLUTCH RELEASE COMPONENTS
1 - CONED WASHER
2 - CLUTCH HOUSING
3 - RELEASE FORK
4 - RELEASE BEARING AND SLEEVE
5 - PIVOT 23 N´m (200 IN. LBS.)
6 - SPRING CLIP
Fig. 18 Clutch Release Fork And
1 - PIVOT BALL
2 - FORK
3 - SLAVE CYLINDER OPENING
4 - BEARING
DRCLUTCH 6 - 11
CLUTCH HOUSING (Continued)

(12) Install coolant reserve/overflow container or
degas container to fan shroud and tighten the bolts
to 8.5 N´m (75 in. lbs.).
(13) Connect upper radiator hose and install
clamp.
(14) Install battery negative cable.
(15) Fill cooling system with coolant (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(16) Operate the engine until it reaches normal
operating temperature. Check cooling system fluid
levels.
RADIATOR - 5.9L DIESEL
DESCRIPTION
The radiator is a aluminum cross-flow design with
horizontal tubes through the radiator core and verti-
cal plastic side tanks (Fig. 35).
This radiator does not contain an internal trans-
mission oil cooler
OPERATION
The radiator supplies sufficient heat transfer using
the cooling fins interlaced between the horizontal
tubes in the radiator core to cool the engine.
DIAGNOSIS AND TESTINGÐRADIATOR
COOLANT FLOW
Use the following procedure to determine if coolant
is flowing through the cooling system.
(1) Idle engine until operating temperature is
reached. If the upper radiator hose is warm to the
touch, the thermostat is opening and coolant is flow-
ing to the radiator.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. USING A RAG TO
COVER THE RADIATOR PRESSURE CAP, OPEN
RADIATOR CAP SLOWLY TO THE FIRST STOP. THIS
WILL ALLOW ANY BUILT-UP PRESSURE TO VENT
TO THE RESERVE/OVERFLOW TANK. AFTER PRES-
SURE BUILD-UP HAS BEEN RELEASED, REMOVE
CAP FROM FILLER NECK.
(2) Drain a small amount of coolant from the radi-
ator until the ends of the radiator tubes are visible
through the filler neck. Idle the engine at normal
operating temperature. If coolant is flowing past the
exposed tubes, the coolant is circulating.
REMOVAL
(1) Disconnect both battery negative cables.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20)
MAY BE USED FOR LARGER CLAMPS. ALWAYS
WEAR SAFETY GLASSES WHEN SERVICING CON-
STANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with a matching number or letter.
(3) Remove air box and turbocharger inlet tube.
(4) Remove coolant tank hose, washer bottle hose
and the positive battery cable from the fastening
clips located on top of the radiator.
(5) Remove hose clamps and hoses from radiator.
Fig. 35 Radiator Ð Typical
1 - SCREW
2 - SCREW
3 - LOWER MOUNT
4 - RADIATOR
5 - DRAINCOCK
6 -LOWER MOUNT
DRENGINE 7 - 59
RADIATOR (Continued)