Accessories and Equipment Body-Interior & Exterior - Ram Pickup

2014 RAM 3500 HD Laramie
2014 ACCESSORIES AND EQUIPMENT Body-Interior & Exterior - Ram Pickup
2014 ACCESSORIES AND EQUIPMENT
Body-Interior & Exterior - Ram Pickup
WARNING
WARNINGS
WARNING: Use an Occupational Safety and Health Administration (OSHA) approved

breathing filter, when spraying paint or solvents in a confined area.
Failure to follow these instructions may result in possible serious or fatal
injury.
avoid prolonged skin contact with petroleum or alcohol based

cleaning solvents.
do not stand under a hoisted vehicle that is not properly supported
on safety stands. Failure to follow these instructions may result in
possible serious or fatal injury.
CAUTION: When holes are drilled or punched in an inner body panel, verify the depth
of space to the outer body panel, electrical wiring or other components.
Damage to the vehicle can result.
do not weld exterior panels unless combustible material on the

interior of vehicle is removed from the repair area. Fire or hazardous
conditions, can result.
always have a fire extinguisher ready for use when welding.
disconnect the negative (-) cable clamp from the battery when
servicing electrical components that are live when the ignition is off.
Damage to electrical system can result.
do not use abrasive chemicals or compounds on painted surfaces.
Damage to finish can result.
do not use harsh alkaline based cleaning solvents on painted or
upholstered surfaces. Damage to finish or color can result.
do not hammer or pound on plastic trim panel when servicing interior
trim. Plastic panels can break.
RESTRAINT WARNINGS
WARNING: To avoid potential physical injury, or damage to sensitive electronic

circuits and systems, always disconnect and isolate the battery negative
(ground) cable and the positive cable, then ground the positive cable to
discharge the ORC capacitor before performing any welding operations
on the vehicle. Failure to take the proper precautions could result in
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accidental airbag deployment, possible damage to the Supplemental

Restraint System (SRS) circuits and components, and possible damage to
other electronic circuits and components. Whenever a welding process is
being performed within 30 cm (12 in) of an electronic module/harness,
then that module/harness should be relocated out of the way, or
disconnected. Always protect against component or vehicle damage from
weld spatter by using weld blankets and screens. Failure to follow these
instructions may result in serious or fatal injury.
WARNING: To avoid serious or fatal injury on vehicles equipped with the

Supplemental Restraint System (SRS), never attempt to repair the
electrically conductive circuits or wiring components related to the SRS
for which there is no MOPAR wiring repair kit. It is important to use ONLY
the recommended splicing kit and procedure. For applicable and available
MOPAR wiring repair kits, please visit the MOPAR Connector Web Site at
the following address on the Internet:
(http://dto.vftis.com/mopar/disclaimer.asp). Inappropriate repairs can
compromise the conductivity and current carrying capacity of those
critical electrical circuits, which may cause SRS components not to
deploy when required, or to deploy when not required. Only minor cuts or
abrasions of wire and terminal insulation where the conductive material
has not been damaged, or connector insulators where the integrity of the
latching and locking mechanisms have not been compromised may be
repaired using appropriate methods.
WARNING: To avoid serious or fatal injury during and following any seat belt or child
restraint anchor service, carefully inspect all seat belts, buckles,
mounting hardware, retractors, tether straps, and anchors for proper
installation, operation, or damage. Replace any belt that is cut, frayed, or
torn. Straighten any belt that is twisted. Tighten any loose fasteners.
Replace any belt that has a damaged or ineffective buckle or retractor.
Replace any belt that has a bent or damaged latch plate or anchor plate.
Replace any child restraint anchor or the unit to which the anchor is
integral that has been bent or damaged. Never attempt to repair a seat
belt or child restraint component. Always replace damaged or ineffective
seat belt and child restraint components with the correct, new and
unused replacement parts listed in the Chrysler Mopar® Parts Catalog.
injury.
WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable
the Supplemental Restraint System (SRS). Refer to RESTRAINTS -
SERVICE INFORMATION - 2500 HD & 3500 HD before attempting any
steering wheel, steering column, airbag, Occupant Classification System
(OCS), seat belt tensioner, impact sensor or instrument panel component
diagnosis or service. Disconnect and isolate the battery negative (ground)
Thursday, November 16, 2017 18:35:28 Page 2

cable, then wait two minutes for the system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to
disable the SRS. Failure to follow these instructions may result in
accidental airbag deployment.
WARNING: To avoid potential physical injury or damage to sensitive electronic

discharge the Occupant Restraint Controller (ORC) capacitor before
performing any welding operations on the vehicle. Failure to take the
proper precautions could result in accidental airbag deployment, possible
damage to the Supplemental Restraint System (SRS) circuits and
components, and possible damage to other electronic circuits and
components. Whenever a welding process is being performed within 12
inches (30 centimeters) of an electronic module or wiring harness, then
that module or harness should be relocated out of the way, or
weld spatter by using weld blankets and screens.
WARNING: To avoid serious or fatal injury, do not attempt to dismantle an airbag unit
or tamper with its inflator. Do not puncture, incinerate or bring into
contact with electricity. Do not store at temperatures exceeding 93° C
(200° F). An airbag inflator unit may contain sodium azide and potassium
nitrate. These materials are poisonous and extremely flammable. Contact
with acid, water, or heavy metals may produce harmful and irritating
gases (sodium hydroxide is formed in the presence of moisture) or
combustible compounds. An airbag inflator unit may also contain a gas
canister pressurized to over 17.24 kPa (2500 psi). Failure to follow these
instructions may result in possible serious or fatal injury.
WARNING: To avoid serious or fatal injury when handling a seat belt tensioner
retractor. Exercise proper care to keep fingers out from under the
retractor cover and away from the seat belt webbing where it exits from
the retractor cover. Failure to follow these instructions may result in
WARNING: To avoid serious or fatal injury, replace all Supplemental Restraint System
(SRS) components only with parts specified in the Chrysler Mopar® Parts
Catalog. Substitute parts may appear interchangeable, but internal
differences may result in inferior occupant protection.
WARNING: To avoid serious or fatal injury, the fasteners, screws, and bolts originally
used for the Supplemental Restraint System (SRS) components must
never be replaced with any substitutes. These fasteners have special
coatings and are specifically designed for the SRS. Anytime a new

fastener is needed, replace it with the correct fasteners provided in the

service package or specified in the Chrysler Mopar® Parts Catalog.
WARNING: To avoid serious or fatal injury when a steering column has an airbag unit
attached, never place the column on the floor or any other surface with
the steering wheel or airbag unit face down. Failure to follow these
USE OF HEAT DURING REPAIR
WARNING: Chrysler Group LLC engineering's position on the use of heat during
collision repair is as follows:
Any body panel or frame component damaged which is to be

repaired and reused, must be repaired using the "cold straightening"
method. No heat may be used during the straightening process.
During rough straightening prior to panel replacement, damaged
panels or frame components may be heated to assist in body/frame
realignment. The application of heat must be constrained to the
parts which will be replaced and not allowed to affect any other
components.
This "no heat" recommendation is due to the extensive use of high

strength and advanced high strength steels in Chrysler Group LLC
products. High-strength materials can be substantially and negatively
affected from heat input which will not be obviously known to the repairer
or consumer.
Ignoring these recommendations may lead to serious compromises in the

ability to protect occupants in a future collision event, reduce the
engineered qualities and attributes, or decrease the durability and
reliability of the vehicle.
This statement supersedes any previously released information by the

Chrysler Group LLC.
Failure to follow these instructions may result in serious or fatal injury.
DIAGNOSIS AND TESTING

GENERAL WATER LEAKS
Water leaks can be caused by poor sealing, improper body component alignment, body seam porosity, missing
plugs, or blocked drain holes. Centrifugal and gravitational force can cause water to drip from a location away
from the actual leak point, making leak detection difficult. All body sealing points should be water tight in

normal wet-driving conditions. Water flowing downward from the front of the vehicle should not enter the
passenger or luggage compartment. Moving sealing surfaces will not always seal water tight under all
conditions. At times, side glass or door seals will allow water to enter the passenger compartment during high
pressure washing or hard driving rain (severe) conditions. Overcompensating on door or glass adjustments to
stop a water leak that occurs under severe conditions can cause premature seal wear and excessive closing or
latching effort. After completing a repair, water test vehicle to verify leak has stopped before returning vehicle
to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Verify that floor and body plugs are in place, body drains are clear, and body components are properly aligned
and sealed. If component alignment or sealing is necessary, refer to the appropriate service information in this
article for proper procedures.
WATER LEAK TESTS
WARNING: Do not use electric shop lights or tools in water test area. Personal injury
can result.
When the conditions causing a water leak have been determined, simulate the conditions as closely as possible.
If a leak occurs with the vehicle parked in a steady light rain, flood the leak area with an open-ended
garden hose.
If a leak occurs while driving at highway speeds in a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water. Direct the spray in a direction comparable to actual conditions.
If a leak occurs when the vehicle is parked on an incline, hoist the end or side of the vehicle to simulate
this condition. This method can be used when the leak occurs when the vehicle accelerates, stops or turns.
If the leak occurs on acceleration, hoist the front of the vehicle. If the leak occurs when braking, hoist the
back of the vehicle. If the leak occurs on left turns, hoist the left side of the vehicle. If the leak occurs on
right turns, hoist the right side of the vehicle. For hoisting recommendations. Refer to HOISTING,
STANDARD PROCEDURE .
WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water test and watch for water tracks or droplets forming on the
inside of the vehicle. If necessary, remove interior trim covers or panels to gain visual access to the leak area. If
the hose cannot be positioned without being held, have someone help do the water test.
Some water leaks must be tested for a considerable length of time to become apparent. When a leak appears,
find the highest point of the water track or drop. The highest point usually will show the point of entry. After
leak point has been found, repair the leak and water test to verify that the leak has stopped.
Locating the entry point of water that is leaking into a cavity between panels can be difficult. The trapped water
may splash or run from the cavity, often at a distance from the entry point. Most water leaks of this type become
apparent after accelerating, stopping, turning, or when on an incline.

MIRROR INSPECTION METHOD
When a leak point area is visually obstructed, use a suitable mirror to gain visual access. A mirror can also be
used to deflect light to a limited-access area to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can be detected without water testing. Position the vehicle in a
brightly lit area. From inside the darkened luggage compartment inspect around seals and body seams. If
necessary, have a helper direct a drop light over the suspected leak areas around the luggage compartment. If
light is visible through a normally sealed location, water could enter through the opening.
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compartment cannot be detected by water testing, pressurize the
passenger compartment and soap test exterior of the vehicle. To pressurize the passenger compartment, close all
doors and windows, start engine, and set heater control to high blower in HEAT position. If engine can not be
started, connect a charger to the battery to ensure adequate voltage to the blower. With interior pressurized,
apply dish detergent solution to suspected leak area on the exterior of the vehicle. Apply detergent solution with
spray device or soft bristle brush. If soap bubbles occur at a body seam, joint, seal or gasket, the leak entry point
could be at that location.
WATER LEAKS
NOTE: GENERAL NOTES
This service information applies to all Ram models, 2009 MY and beyond.
Each leak area can have multiple root causes, as noted in the diagnosis
chart. It is important to water test each repair before starting the next.
If a leak cannot be reproduced, it is due to the period of time the vehicle is
under wet conditions. Some leaks may take hours before leaking.
If a leak cannot be reproduced, apply all the repairs as noted in the
diagnosis chart.
It is important to understand where the leak ENDS up when diagnosing the
vehicle. Where the leak ends up, does not always explain where the leak
originates. Refer to the DIAGNOSIS CHART when determining which
repairs to perform.
This repair procedure does NOT cover every possible water leak on the
RAM. The issues identified in this document are the severe leaks that may
occur in the field.
Generally, a car wash is the preferred method to diagnose a vehicle.
The content identifies the known areas of water leaks, the critical
characteristics of each area and how to repair them.
DIAGNOSIS CHART

Water Leak Conditions

Water entering the vehicle
Water entering the vehicle at the Water is on the rear carpet
through the grab handle or
back glass area (C-pillars) between the rear seats
overhead console
Refer to - REPAIR Refer to - REPAIR PROCEDURE Refer to - REPAIR
PROCEDURE FOR FOR CHMSL (3RD BRAKE PROCEDURE FOR CAB-
WINDSHIELD URETHANE LIGHT) BACK EXHAUSTER
Refer to - REPAIR Refer to - REPAIR PROCEDURE
PROCEDURE FOR FOR BACK-GLASS/POWER
ROOF/BODY SEAMS SLIDER
Refer to - REPAIR
Refer to - REPAIR PROCEDURE
PROCEDURE FOR
FOR ROOF/BODY SEAMS
SUNROOF DRAIN SYSTEM
Refer to - REPAIR Refer to - REPAIR PROCEDURE
PROCEDURE FOR FOR APERTURE/CAB-BACK
SUNROOF GLASS SYSTEM SEAMS
Refer to - REPAIR PROCEDURE
FOR SUNROOF DRAIN
SYSTEM
WATER ENTERING THE VEHICLE THROUGH THE GRAB HANDLE OR OVERHEAD CONSOLE
REPAIR PROCEDURE FOR WINDSHIELD URETHANE
Required Parts:
Mopar Glass Sealer

Paintable Clear Seam Sealer
Potential Parts Required:
Molding, Windshield, Right (Only replace if damage occurs during removal)

Molding, Windshield, Left (Only replace if damage occurs during removal)
TWO METHODS OF TESTING:
METHOD 1:
With a person inside the vehicle, run water around windshield starting at the lower left or right side A-Pillar
slowly moving up the A-pillar and watch for water to drip inside the vehicle from A-Pillar and/or Grab Handle.
Next, move across the top of the windshield. If water is seen dripping from any area, stop running water and
proceed with the applicable repair procedure below:
METHOD 2:
Gain access to both body exhausters and tape off to block air escaping. Turn the ignition to the run position and

turn the HVAC blower on High. Make sure all windows are up and close all the doors. Depending on the size of
cabin area will affect the time it could take to pressurize the cabin. Next, spray soapy water or foaming window
cleaner around the windshield molding. As cabin begins to pressurize inspect for air bubbles to form around
windshield molding. If any air bubbles are noticed proceed with the applicable repair procedure below:
WINDSHIELD URETHANE SKIP REPAIR
Fig. 1: Identifying A-Pillar Windshield Molding

Courtesy of CHRYSLER GROUP, LLC
1. If the leak is determined to be adjacent to the windshield, then the A-Pillar windshield molding (1) should
be removed. The windshield molding can be removed pulling it away from the cab at its four attach
points (2), Refer to WEATHERSTRIP, WINDSHIELD, A-PILLAR, REMOVAL.
Fig. 2: Exposed Body Seam


NOTE: Sealer skips or pinholes can be seen along the exposed body seams (1)
NOTE: A special area of concern is where the windshield and body seams meet at
the upper a-pillar (1), which is shown in the illustration.
2. Once the windshield molding is removed, inspect for sealer skips. Apply Mopar Glass Sealer to any skip
in the urethane around windshield.
3. For sealer skips in the A-Pillar body seam apply a Clear Hi-Flow Paintable Seam Sealer.
4. Prior to re-assembly, re-test the area to ensure it is properly sealed.
5. Carefully reinstall windshield molding. Refer to WEATHERSTRIP, WINDSHIELD, A-PILLAR,
INSTALLATION.
REPAIR PROCEDURE FOR ROOF/BODY SEAMS
Required Parts:
Potential Parts Required:
Molding - Roof Ditch Right

Molding - Roof Ditch Left
1. Gain access to the A-Pillar body seam and roof ditch seam by removing the windshield A-Pillar molding
and roof ditch molding. Refer to WEATHERSTRIP, WINDSHIELD, A-PILLAR, REMOVAL.

Fig. 3: Roof Ditch Molding

NOTE: Dashed line indicates starting and ending points (path) for clear sealer
2. Using the diagram above apply Paintable Clear Seam Sealer along the whole length of the roof ditch (1),
beginning at the A-pillar (3) and ending at the Roof to Aperture/Rap Joint (2). Be certain to cover any and
all pin holes.
3. Prior to re-assembly, re-test the area to be certain it is properly sealed.
4. Reinstall windshield A-Pillar molding and Roof Ditch molding. Refer to WEATHERSTRIP,
WINDSHIELD, A-PILLAR, INSTALLATION.
REPAIR PROCEDURE FOR SUNROOF DRAIN SYSTEM
1. Inspect for water dripping from Overhead Console, also inspect for water marks/stains and/or dampness
on Headliner.

Fig. 4: Sunroof Drain Tubes

2. Lower the headliner. Inspect all four sunroof drain tubes (2) and make certain all connections are secure
to each barb (3). Refer to HEADLINER, REMOVAL.
3. Verify that all four drain tubes are securely fastened, prior to re-assembly. Re-test the area by opening
sunroof and using a small cup of water, slowly pour water into sunroof trough (1) to make certain water
flows and the drains are properly sealed.
4. Install Headliner. Refer to HEADLINER, INSTALLATION.
Fig. 5: Sunroof Drain Tube Grommets

5. Inspect both rear sunroof drain tube grommets (1) behind rear seat to make sure they are fully seated into
the inner rear cab (2).

REPAIR PROCEDURE FOR SUNROOF GLASS SYSTEM
Fig. 6: Checking Sunroof Glass Flushness

1. Using the specifications listed, Visually inspect sunroof glass (1) flushness to roof panel (2). Refer to
GLASS, SUNROOF, ADJUSTMENTS.
2. If adjustments need to be made to the sunroof glass (1) height and gap tolerances, Refer to GLASS,
SUNROOF, ADJUSTMENTS.
WATER ENTERING THE VEHICLE AT THE BACK GLASS AREA (C-PILLARS)
REPAIR PROCEDURE FOR CHMSL (3RD BRAKE LIGHT)
Parts Required:
Mopar Glass Sealer

Fig. 7: Identifying Center High Mounted Stop Lamp Assembly

1. Remove the CHMSL (Center High Mounted Stop Lamp) assembly. Refer to LAMP, CENTER HIGH
MOUNTED STOP, REMOVAL .
Fig. 8: Identifying Bead Of Heavy Bodied Sealer

2. Apply 1/8 inch bead of Heavy Bodied Sealer (3) around the lamp (1) on the foam gasket material (2),
leaving no gaps.
3. Install the CHMSL assembly. Refer to LAMP, CENTER HIGH MOUNTED STOP,
INSTALLATION .
4. Remove any excess sealer that squeezes out onto the painted surface or exterior lamp assembly.
REPAIR PROCEDURE FOR BACK-GLASS/POWER SLIDER

Parts Required:
Mopar Glass Sealer
Fig. 9: Check Back Glass Drains

1. For the back-glass drains (1) being plugged or restricted the back-glass will have to be removed and
replaced.
2. If the water leak is found around the parameter of the back-glass due to urethane skips it is recommended
to apply Mopar Glass Sealer.
3. Water test area inspecting for water entering vehicle. If water still enters vehicle, back-glass will have to
be replaced.
REPAIR PROCEDURE FOR APERTURE/CAB-BACK SEAMS
Parts Required:

Fig. 10: Rat Hole Locations

1. Inspect both areas indicated.

2. If a skip crack or pinhole is found use Paintable Clear Seam Sealer. Apply sealer as indicated in
illustrations below.
NOTE: It is important to fill the entire seam located within the brackets to be
certain of full coverage and proper sealing of the rat hole.
Fig. 11: Roof/Aperture Rap Joint

3. Apply clear sealer on entire seam indicated within the bracket.

Fig. 12: Cab Back/Body Seam

4. Apply clear sealer on entire seam indicated within the bracket.
WATER IS ON THE REAR CARPET BETWEEN THE REAR SEATS
REPAIR PROCEDURE FOR CAB-BACK EXHAUSTER
1. Review examples below of what to look for and make certain they are properly installed and seated
against the body of the vehicle. Example1: Seal folded - Example 2: Exhauster not fully seated
2. If any of the conditions are found remove exhauster from vehicle inspect for tearing or ripping of the seal.
If seal has no tears or rips then reinstall on to vehicle making sure it clicks in on all four corners and that
the seal is not rolled.
3. If seal is damaged or torn then replace body exhauster.

Fig. 13: Cab-Back Exhauster

WIND NOISE
Wind noise is the result of most air leaks. Air leaks can be caused by poor sealing, improper body component
alignment, body seam porosity, or missing plugs in the engine compartment or door hinge pillar areas. All body
sealing points should be airtight in normal driving conditions. Moving sealing surfaces will not always seal
airtight under all conditions. At times, side glass or door seals will allow wind noise to be noticed in the
passenger compartment during high cross winds. Over compensating on door or glass adjustments to stop wind
noise that occurs under severe conditions can cause premature seal wear and excessive closing or latching
effort. After a repair procedure has been performed, test vehicle to verify noise has stopped before returning
vehicle to use.
VISUAL INSPECTION BEFORE TESTS
Verify that floor and body plugs are in place and body components are aligned and sealed. If component
alignment or sealing is necessary, refer to the appropriate service information in this article for proper
procedures.
ROAD TESTING WIND NOISE
1. Drive the vehicle to verify the general location of the wind noise.
2. Apply 50 mm (2 in.) masking tape in 150 mm (6 in.) lengths along weatherstrips, weld seams or
moldings. After each length is applied, drive the vehicle. If noise goes away after a piece of tape is
applied, remove tape, locate, and repair defect.

POSSIBLE CAUSE OF WIND NOISE
Moldings standing away from body surface can catch wind and whistle.
Gaps in sealed areas behind overhanging body flanges can cause wind-rushing sounds.
Misaligned movable components.
Missing or improperly installed plugs in pillars.
Weld burn through holes.
Improperly installed roof rack cross bars.
Side door mirror leaks.
STANDARD PROCEDURE
BODY LUBRICATION
LUBRICATION REQUIREMENTS
Locks and all body pivot points, including such items as seat tracks, door hinge pivot points and rollers, liftgate,
tailgate, sliding doors and hood hinges, should be lubricated periodically with a lithium based grease such as
Mopar ® Spray White Lube to ensure quiet, easy operation and to protect against rust and wear. Prior to the
application of any lubricant, wipe the parts clean, to remove dust and grit. After lubricating, excess oil and
grease should be removed. Particular attention should also be given to hood latching components to make sure
they function properly. When performing other underhood services, clean and lubricate the hood latch release
mechanism and safety catch.
The external lock cylinders should be lubricated twice a year, preferably in the fall and spring. Apply a small
amount of a high quality lubricant such as Mopar ® Lock Cylinder Lubricant directly into the lock cylinder.
LUBRICANT APPLICATION
DOOR LOCK CYLINDERS
1. Apply a small amount of lubricant directly into the lock cylinder.

2. Apply a small amount of lubricant to the key.
3. Insert key into lock cylinder and cycle the mechanism from the locked to the unlocked position.
NOTE: Do not add more lubricant.
4. Cycle the lock cylinder mechanism several times to allow the lubricant to flow throughout the cylinder.
5. Wipe all lubricant from exterior of lock cylinder and key.
ALL OTHER BODY MECHANISMS
1. Clean component as described above.

2. Apply specified lubricant to all pivoting and sliding contact areas of component.

LUBRICANT USAGE
Engine Oil
door hinges - hinge pin and pivot contact areas

hood hinges - pivot points
liftgate hinges
Mopar ® Spray White Lube or Equivalent
door check straps

liftgate latches
liftgate prop pivots
ash receiver
fuel filler door remote control latch mechanism
parking brake mechanism
sliding seat tracks
liftgate latch
Mopar ® Multipurpose Grease or Equivalent
all other hood mechanisms
Mopar ® Lock Cylinder Lubricant or Equivalent
door lock cylinders

liftgate lock cylinder
HEAT STAKING
1. Remove trim panel.

2. Bend or move the trim panel components at the heat staked joints. Observe the heat staked locations
and/or component seams for looseness.
3. Heat stake the components.
a. If the heat staked or component seam location is loose, hold the two components tightly together
and using a soldering gun with a flat tip, melt the material securing the components together. Do
not over heat the affected area, damage to the exterior of the trim panel may occur.
b. If the heat staked material is broken or missing, use a hot glue gun to apply new material to the area
to be repaired. The panels that are being heat staked must be held together while the applying the
glue. Once the new material is in place, it may be necessary to use a soldering gun to melt the
newly applied material. Do not over heat the affected area, damage to the exterior of the trim panel
may occur.
4. Allow the repaired area to cool and verify the repair.

5. Install trim panel.
BUZZ, SQUEAK AND RATTLE
Buzz, squeak and rattles (BSR) may be caused by any one or more of the following and may be corrected as
indicated:
Loose fasteners should be tightened to specifications.

Damaged or missing clips should be replaced.
Damaged trim panels should be replaced.
Incorrectly installed trim panels should be reinstalled properly.
Many BSR complaints such as loose trim, can be serviced using the Mopar® Parts BSR Noise Reduction Kit.
This kit contains various tapes including foam, flock and anti-squeak used to eliminate noises caused by metal,
plastic and vinyl components. Long life lubricants and greases can also be used on a variety of components.
Refer to the table below for material contents and usage.
BUZZ, SQUEAK AND RATTLE KIT

ITEM FEATURES APPLICATIONS SERVICE TEMP
Itch And Squeak An abrasion resistant Between metal and metal, metal -40° to 107° C
Tape material thin enough to and plastic, metal and vinyl, vinyl (-40° to 225° F)
conform to most irregular and plastic. Interior.
surfaces. Stops most itches Examples: Trim panels and
and squeaks. bezels.
Black Nylon Flock Nylon Flock with an Between metal and metal, metal -40° to 82° C
aggressive acrylic adhesive. and plastic, vinyl and plastic. (-40° to 180° F)
Provides for cushioning and Examples: Pull cups, bezels,
compression fit, also isolates clips, ducts, top cover to glass,
components. Water-resistant. cowl panel.
High Density Tear resistant, highly Between metal and metal, metal -40° to 82° C
Urethane Foam resilient and durable. and plastic. Water-resistant. (-40° to 180° F)
Examples: I/P, heavy metal
rattles, isolating brackets.
Open Cell Foam Soft foam conforms to Wire harness and connector wrap. -40° to 82° C
Tape irregular surfaces. Examples: Seals, gasket, wiring, (-40° to 180° F)
heat ducts.
Closed Cell Low Soft, conformable. Water- Wherever bulk is needed. -40° to 82° C
Density Foam Tape resistant. Prevents closing flutters and (-40° to 180° F)
rattles when applied to door water
shield.
Examples: Door, I/P.
NYE® Grease 880 Long life. Suspensions. -40° to 200° C
Examples: Strut bushings, sway (-40° to 390° F)
bars.
Krytox® Oil Long life. Will not dry out When access is not possible, oil -34° to 205° C

or harm plastics or rubber. will migrate to condition. Vinyl, (-30° to 400° F)

rubber, plastic, metal.
Examples: Convertible top
bushings, pull cups trim panel
inserts.
Krytox® Grease Long life. Will not dry out Vinyl, rubber, plastic, metal, -34° to 205° C
or harm plastics or rubber. glass. (-30° to 400° F)
Examples: Weather-strips,
backlite and windshield
moldings.
NET, FORM AND PIERCE REPAIR
CAUTION: Failure to follow these recommendations could result in damage or failure

to the part and the related parts.
Net, form and pierce is a manufacturing process which takes place during the original build of the vehicle. The
original part will have a beveled platform that will decrease toward the fastener location mounting hole.
Replacement parts in these areas may not include bevel (form) and / or fastener hole (pierce) and will need to be
adapted for proper fit and finish.
The primary locations which may utilize net, form and pierce are:
Fender Reinforcement (at front end module mount)

Fender Tower Mounts
Hood Hinge (lower half)
Rear Body Header (liftgate hinge mounts)
Strut Tower (at upper control arm mount)
NOTE: Shock tower is net, pierce only.
NOTE: The thickness of shims is not to exceed the original thickness of the factory
bevel. If more shims are needed damage is still present and must be repaired
properly.
If the replacement part did not come with a fastener hole, one of equal size and location will have to be drilled.
Body shims should be used in the fender reinforcement to front end module. The hood hinge area, fender tower
mounts, and rear body header will utilize washers as spacers where a specific spacer does not exist. The shims
and spacers should be sealed between each other and to the stationary surface. Care should be taken when
smoothing sealer around washers to ensure undetectable repair. Refinish the repair area per the paint
manufacturers recommendations for corrosion resistance and appearance purposes.
PLASTIC BODY PANEL REPAIR

There are many different types of plastics used in today's automotive environment. We group plastics in three
different categories: Rigid, Semi-Rigid, and Flexible. Any of these plastics may require the use of an adhesion
promoter for repair. These types of plastic are used extensively on Chrysler LLC vehicles. Always follow repair
material manufacturer's plastic identification and repair procedures.
RIGID PLASTICS
Examples of rigid plastic use: Fascias, Hoods, Doors, and other Body Panels, which include SMC, ABS, and
Polycarbonates.
SEMI-RIGID PLASTICS
Examples of semi-rigid plastic use: Interior Panels, Under Hood Panels, and other Body Trim Panels.
FLEXIBLE PLASTICS
Examples of flexible plastic use: Fascias, Body Moldings, and upper and lower Fascia Covers.
REPAIR PROCEDURE
The repair procedure for all three categories of plastics is basically the same. The one difference is the material
used for the repair. The materials must be specific for each substrate, rigid repair material for rigid plastic
repair, semi-rigid repair material for semi-rigid plastic repair and flexible repair material for flexible plastic
repair.
ADHESION PROMOTER/SURFACE MODIFIER
Adhesion Promoters/Surface Modifiers are required for certain plastics. All three categories may have plastics
that require the use of adhesion promoter/surface modifiers. Always follow repair material manufacturer's
plastic identification and repair procedures.
SAFETY PRECAUTION AND WARNINGS
WARNING: Eye protection should be used when servicing components.

Personal injury can result.
Use an OSHA approved breathing mask when mixing epoxy,
grinding, and spraying paint or solvents in a confined area. Personal
injury can result.
Avoid prolonged skin contact with resin, petroleum, or alcohol
based solvents. Personal injury can result.
Do not venture under a hoisted vehicle that is not properly
supported on safety stands. Personal injury can result.
WARNING: Failure to follow these instructions may result in serious or fatal injury.

NOTE: When holes must be drilled or cut in body panels, verify locations of
internal body components and electrical wiring. Damage to vehicle can
result.
Do not use abrasive chemicals or compounds on undamaged painted
surfaces around repair areas. Damage to finish can result.
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES
CODE FAMILY NAME COMMON TRADE TYPICAL

NAME APPLICATION
ASA ACRYLONITRILE STYRENE LURAN S CONSOLES, GRILLES
ACRYLITE
ABS ACRYLONITRILE BUTADIENE TERLURAN "A" PILLARS,
STYRENE CONSOLES, GRILLES
ABS/PC ABS/PC ALLOY PULSE, PROLOY, DOORS,
BAYBLEND INSTRUMENT
PANELS
ABS/PVC ABS/PV ALLOY PROLOY, PULSE, DOOR PANELS,
LUSTRAN, GRILLES, TRIM
CYCLOVIN
BMC BULK MOLDING COMPOUND BMC FENDER
EXTENSIONS
EMA EHTYLENE METHYL SURLYN, EMA, BUMPER GUARDS,
ACRYLATE/IONOMER IONOMER PADS
METTON METTON METTON GRILLES, KICK
PANELS, RUNNING
BOARDS
MPPO MODIFIED POLYPHENYLENE MPPO SPOILER ASSEMBLY
OXIDE
PA POLYAMID ZYTEL, VYDYNE, FENDERS, QUARTER
PA, MINLON PANELS
PET THERMOPLASTIC POLYESTER RYNITE TRIM
PBT/PPO PBT/PPO ALLOY GERMAX CLADDINGS
PBTP POLYBUTYLENE PBT, PBTP, POCAN,WHEEL COVERS,
THEREPTHALATE VALOX FENDERS, GRILLES
PBTP/EEBC POLYBUTYLENE BEXLOY, "M", FASCIAS, ROCKER
THEREPTHALATE/EEBC ALLOY PBTP/EEBC PANEL, MOLDINGS
PC POLYCARBONATE LEXAN, MERLON, TAIL LIGHT LENSES,
CALIBRE, IP TRIM, VALANCE
MAKROLON PC PANELS
PC/ABS PC/ABS ALLOY GERMAX, BAY DOORS,
BLENDS, PULSE INSTRUMENT
PANELS
PPO POLYPHENYLENE OXIDE AZDEL, HOSTALEN, INTERIOR TRIM,

MARLEX, PRFAX, DOOR PANELS,

NORYL, GTX, PPO SPLASH SHIELDS,
STEERING COLUMN
SHROUD
PPO/PA POLYPHENYLENE/POLYAMID PPO/PA, GTX 910 FENDERS, QUARTER
PANELS
PR/FV FIBERGLASS REINFORCED FIBERGLASS, FV, BODY PANELS
PLASTIC PR/FV
PS POLYSTYRENE LUSTREX, STYRON, DOOR PANELS,
PS DASH PANELS
RTM RESIN TRANSFER MOLDING RTM BODY PANELS
COMPOUND
SMC SHEET MOLDED COMPOUND SMC BODY PANELS
TMC TRANSFER MOLDING COMPOUND TMC GRILLES
UP UNSATURATED POLYESTER SMC, BMC, TMC, GRILLE OPENING
(THERMOSETTING) ZMC, IMC, XSMC, PANEL, LIFTGATES,
UP FLARESIDE
FENDERS, FENDER
EXTENSIONS
EEBC ETHER/ESTER BLOCKED CO- EEBC BUMPERS
POLYMER
EEBC/PBTP EEBC/POLYBUTYLENE EEBC, PBTP, BUMPER, ROCKER
TEREPTHALATE BEXLOY PANELS
EMPP ETHYLENE MODIFIED EMPP BUMPER COVERS
POLYPROPYLENE
EPDM ETHYLENE/PROPROPYLENE EPDM, NORDEL, BUMPERS
DIENE MONOMER VISTALON
EPM ETHYLENE/PROPROPYLENE CO- EPM FENDERS
POLYMER
MPU FOAM POLYURETHANE MPU SPOILERS
PE POLYETHYLENE ALATHON, DYLAN,
"?
LUPOLEN, MARLEX
PP POLYPROPYLENE (BLENDS) NORYL, AZDEL, INNER FENDER,
MARLOX, DYLON, SPOILERS, KICK
PRAVEX PANELS
PP/EPDM PP/EPDM ALLOY PP/EPDM SPOILERS, GRILLES
PUR POLYURETHANE COLONELS, PUR, PU FASCIAS, BUMPERS
PUR/PC PUR/PC ALLOY TEXIN BUMPERS
PVC POLYVINYL CHLORIDE APEX, GEON, BODY MOLDINGS,
VINYLITE WIRE INSULATION,
STEERING WHEELS
RIM REACTION INJECTED MOLDED RIM, BAYFLEX FRONT FASCIAS,
POLYURETHANE MODULAR
WINDOWS

RRIM REINFORCED REACTION PUR, RRIM FASCIAS, BODY

INJECTED MOLDED PANELS, BODY
TRIMS
TPE THERMO POLYETHYLENE TPE, HYTREL, FASCIAS, BUMPERS,
BEXLOY-V CLADDINGS
TPO THERMOPOLYOLEFIN POLYTROPE, BUMPERS, END
RENFLEX, CAPS, TELCAR,
SANTOPRENE, RUBBER, STRIPS,
VISAFLEX, ETA, SIGHT, INTERIOR B
APEX, TPO, POST
SHIELDS,
CLADDINGS
TPP THERMO-POLYPROPYLENE TPP BUMPERS
TPU THERMOPOLYURETHANE, TPU, HYTREL, BUMPERS, BODY
POLYESTER TEXIN, ESTANE SIDE, MOLDINGS,
FENDERS, FASCIAS
PANEL SECTIONING
Fig. 14: Identifying Panel Sectioning

1 - EXISTING PANEL
2 - NEW PANEL
3 - PANEL ADHESIVE
4 - BONDING STRIP
If it is required to section a large panel for a plastic repair, it will be necessary to reinforce the panel. To bond
two plastic panels together, a reinforcement must overlap both panels. The panels must be "V'd" at a 20 degree
angle. The area to be reinforced should be washed, then sanded. Be sure to wipe off any excess soap and water
when finished. Lightly sand or abrade the plastic with an abrasive pad or sandpaper. Blow off any dust with
compressed air or wipe with a clean dry rag.

When bonding plastic panels, follow repair material manufacturers recommendations. Be sure that enough
adhesive has been applied to allow squeeze out and to fill the full bond line. Once the pieces have been brought
together, do not move them until the adhesive is cured. The assembly can be held together with clamps, rivets,
etc. A faster cure can be obtained by heating with a heat lamp or heat gun. After the parts have been bonded and
have had time to cure, rough sand the seam and apply the final adhesive filler to the area being repaired. Smooth
the filler with a spreader, wooden tongue depressor, or squeegee. For fine texturing, a small amount of water
can be applied to the filler surface while smoothing. The cured filler can be sanded as necessary and, as a final
step, cleanup can be done with soapy water. Wipe the surface clean with a dry cloth allowing time for the panel
to dry before moving on with the repair.
PANEL REINFORCEMENT
Fig. 15: Identifying Panel Reinforcement

1 - SOFTENED EDGES
2 - PANEL ADHESIVE
3 - BONDING STRIP
Structural repair procedures for rigid panels with large cracks and holes will require a reinforcement backing.
Reinforcements can be made with several applications of glass cloth saturated with structural adhesive. Semi-
rigid or flexible repair materials should be used for semi-rigid or flexible backing reinforcement and open
meshed fiberglass dry wall tape can be used to form a reinforcement. The dry wall tape allows the resin to
penetrate through and make a good bond between the panel and the adhesive. Structurally, the more dry wall
tape used, the stronger the repair.
Fig. 16: Identifying Panel Reinforcement


1 - PANEL ADHESIVE
2 - REINFORCEMENT
Another kind of repair that can be done to repair large cracks and holes is to use a scrap piece of similar plastic
and bond with structural adhesive. The reinforcement should cover the entire break and should have a generous
amount of overlap on either side of the cracked or broken area.
Fig. 17: Beveling Area Around Crack At 20 Degree Angle

When repairing plastic, the damaged area is first "V'd" out, or beveled. Large bonding areas are desirable when
repairing plastic because small repairs are less likely to hold permanently. Beveling the area around a crack at a
20° angle will increase the bonding surface for a repair. It is recommended that sharp edges be avoided because
the joint may show through after the panel is refinished.
Fig. 18: Identifying Bonding Surface Repair Area

Panel repair for both flexible and rigid panels are basically the same. The primary difference between
flexible panel repair and rigid panel repair is in the adhesive materials used.
The technician should first decide what needs to be done when working on any type of body panel. One
should determine if it is possible to return the damage part to its original strength and appearance without
exceeding the value of the replacement part.
When plastic repairs are required, it is recommended that the part be left on the vehicle when ever
possible. That will save time, and the panel will remain stationary during the repair. Misalignment can

cause stress in the repair areas and can result in future failure.
VISUAL INSPECTION
Fig. 19: Puncture

1 - PUNCTURE
Composite materials can mask the severity of an accident. Adhesive bond lines, interior structure of the doors,
and steel structures need to be inspected carefully to get a true damage assessment. Close inspection may
require partial removal of interior trim or inner panels.
Identify the type of repair: Puncture (1) or Crack - Damage that has penetrated completely through the panel.
Damage is confined to one general area; a panel section is not required. However, a backer panel, open
fiberglass tape, or matted material must be bonded from behind.
PANEL SURFACE PREPARATION
If a body panel has been punctured, cracked, or crushed, the damaged area must be removed from the panel to
achieve a successful repair. All spider web cracks leading away from a damaged area must be stopped or
removed. To stop a running crack in a panel, drill a 6 mm (0.250 in.) hole at the end of the crack farthest away
from the damage. If spider web cracks can not be stopped, the panel would require replacement. The surfaces
around the damaged area should be stripped of paint and freed from wax and oil. Sand surfaces around repair
area with 80 -120 grit sandpaper, or equivalent, to assure adhesion of repair materials.
PATCHING PANELS

Fig. 20: Identifying Damaged Panel Cutout And Patch

1 - CUTOUT
2 - DAMAGED BODY PANEL
3 - 4 MM (0.160 IN.) HOLES
4 - PATCH CUT TO SIZE
A panel that has extensive puncture type damage can be repaired by cutting out the damaged material. Use a
suitable reciprocating saw or cut off wheel to remove the section of the panel that is damaged. The piece cut out
can be used as a template to shape the new patch. It is not necessary to have access to the back of the panel to
install a patch. Bevel edges of cutout at 20° to expose a larger bonding area on the outer side. This will allow for
an increased reinforcement areas.
PANEL PATCH FABRICATIONS
Fig. 21: Identifying Fabricated Panel

1 - STRUCTURAL ADHESIVE

2 - FIBERGLASS CLOTH OR FIBERGLASS MESH TAPE

3 - WIDTH OF V-GROOVE
4 - WAXED PAPER
A patch can be fabricated from any rigid fiberglass panel that has comparable contour with the repair area. Lift
gates and fenders can be used to supply patch material. If existing material is not available or compatible, a
patch can be constructed with adhesive and reinforcement mesh (dry wall tape). Perform the following
operation if required:
1. Cover waxed paper or plastic with adhesive backed nylon mesh (dry wall tape) larger than the patch
required.
2. Tape waxed paper or plastic sheet with mesh to a surface that has a compatible contour to the repair area.
3. Apply a liberal coat of adhesive over the reinforcement mesh. If necessary apply a second or third coat of
adhesive and mesh after first coat has cured. The thickness of the patch should be the same as the repair
area.
4. After patch has cured, peel waxed paper or plastic from the back of the patch.
5. If desired, a thin film coat of adhesive can be applied to the back of the patch to cover mesh for added
strength.
PANEL PATCH INSTALLATION
Fig. 22: Securing Support Squares To Body Panel

1 - SUPPORT SQUARES
2 - SCREWS
3 - DAMAGED BODY PANEL
1. Make a paper or cardboard pattern the size and shape of the cutout hole in the panel.
2. Trim 3 mm (0.125 in.) from edges of pattern so patch will have a gap between connecting surfaces.

3. Using the pattern as a guide, cut the patch to size.

4. Cut scrap pieces of patch material into 50 mm (2 in.) squares to use as patch supports to sustain the patch
in the cutout.
5. Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) in from edge of cutout hole.
6. Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) away from edge of patch across from holes drilled around
cutout.
7. Drill 3 mm (0.125 in.) holes in the support squares 13 mm (0.5 in.) from the edge in the center of one
side.
8. Scuff the backside of the body panel around the cutout hole with a scuff pad or sandpaper.
9. Mix enough adhesive to cover one side of all support squares.
10. Apply adhesive to cover one side of all support squares.
11. Using number 8 sheet metal screws, secure support squares to back side of body panel with adhesive
sandwiched between the panel and squares.
Fig. 23: Identifying Cutout And Support Squares

1 - CUTOUT
2 - SUPPORT SQUARES
12. Position patch in cutout (1) against support squares (2) and adjust patch until the gap is equal along all
sides.
13. Drill 3 mm (0.125 in.) holes in the support squares through the pre-drilled holes in the patch.

Fig. 24: Applying Adhesive

1 - APPLICATOR
2 - SUPPORT SQUARES
3 - ADHESIVE
14. Apply a coat of adhesive (3) to the exposed ends of the support squares (2).
Fig. 25: Identifying Patch & Gap

1 - PATCH
2 - GAP
15. Install screws to hold the patch (1) to support squares. Tighten screws until patch surface is flush with
panel surface.
16. Allow adhesive to cure, and remove all screws.

Fig. 26: Identifying Patch, Gap & Disc Grinder

1 - PATCH
2 - GAP
3 - DISC GRINDER
17. Using a 125 mm (5 in.) 24 grit disc grinder (3), grind a 50 mm (2 in.) to 75 mm (3 in.) wide and 75% -
80% deep (original material thickness) path across the gaps (2) around the patch (1). With compressed
air, blow dust from around patch.
Fig. 27: Covering Gaps With Mesh

1 - GROUND DOWN AREA

2 - PATCH
3 - MESH

18. Apply adhesive backed nylon mesh (dry wall tape) over gaps around patch.
19. Mix enough adhesive to cover the entire patch area.
Fig. 28: Applying Adhesive Over Mesh Around Patch

1 - ADHESIVE
2 - MESH
3 - PATCH
4 - SPREADER
20. Apply adhesive over the mesh around patch, and smooth epoxy with a wide spreader to reduce finish
grinding. Use two to three layers of mesh and adhesive to create a stronger repair.
PATCHED PANEL SURFACING
After patch panel is installed, the patch area can be finished using the same methods as finishing other types of
body panels. If mesh material is exposed in the patched area, grind surface down, and apply a coat of high
quality rigid plastic body filler. Prime, block sand, and paint as required.
SPECIFICATIONS
SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION N.m Ft Lbs In Lbs
A-pillar bolts 5 - 44
Body isolator nuts 68 50 -
B-pillar grab handle bolts 5 - 44
Cab mounting bolts 108 80 -
Cargo box mounting bolts 108 80 -

Cargo tie down bolts 34 25 -

Door striker bolts 28 21 -
Floor console floor bracket
screws 7 5 62.0
Front door carrier plate bolts 5.5 - 49
Front door exterior handle bolts 7 5 62.0
Front door hinge to pillar bolts 24 18 -
Front door latch screws 7 5 62.0
Front door lower belt channel
shut face screw 8 6 71
Front door striker bolts 28 21 -
Front door to hinge nuts 22 16 -
Front seat back bolts 40 29.5 -
Front seat belt buckle bolts 50 37 -
Front seat lumbar motor bolts 10 7 89
Front seat mounting bolts 47 35 -
Hood hinge to fender rail bolts 19 14 -
Hood hinge to hood nuts 18 13 -
Hood latch bolts 11 8 97
Hood striker bolts 17 12.5 -
Instrument panel center
mounting bolts 12 9 -
Instrument panel fence line
bolts 12 9 -
Instrument panel side mounting
bolts 12 9 -
Lower seat belt anchor bolts
rear 40 29.5 -
Ram box mounting bolts 7 5 62.0
Rear door exterior handle bolts 7 5 62.0
Rear door hinge to pillar bolts 24 18 -
Rear door striker bolts 26 19 -
Rear door to hinge bolts 22 16 -
Rear outer seat belt anchor bolts 40 29.5 -
Rear seat armrest fasteners 28 21 -
Rear seat back pivot bolts 28 21 -
Rear seat belt buckle bolts 47 35 -
Rear seat belt turning loop bolts 40 29.5 -
Rear seat cushion frame bolts 55 41 -
Rear seat storage lid bolts 28 21 -
Rear view mirror set screw 1 - 9

Seat belt turning loop bolts 40 29.5 -

Side step bolts 17 12.5 -
Sunroof assembly screws 9 - 80
Sunroof glass screws 3.5 - 31
Tailgate handle nuts 6 - 53
Tailgate latch bolts 23 17.0 -
Tailgate striker 34 25 -
Visor support screws 6 - 53
CAUTION: ** Whenever a body isolator bolts requires servicing or tightening, it is

necessary to remove the bolt and install new thread locker compound to
the threads.
SPECIAL TOOLS
SPECIAL TOOLS
C-4755 - Trim Stick

(Originally Shipped In Kit Number(s)
9299, 9299CC, 9299CC, 9300A-CAN.)
DECKLID/HATCH/LIFTGATE/TAILGATE
CABLE, TAILGATE
REMOVAL
REMOVAL

Fig. 29: Tailgate Check Cable-Cargo Box

1. Open the tailgate and locate the tailgate check cable (3) on the left and right of the cargo box below the
tailgate striker (1) as necessary.
2. Pry the cable lock tab(s) (4) outward using a screwdriver or flat bladed tool (2) and remove the tailgate
check cable(s) from the cargo box.
Fig. 30: Tailgate Check Cable & Bolt

3. Remove the bolt (4) that secures the tailgate check cable (3) to the left and right side of the tailgate.
4. Remove the tailgate check cable(s) from the tailgate.
INSTALLATION

INSTALLATION

1. Position the tailgate check cable (3) onto the left and right side of the tailgate as necessary.
2. Install the bolt (4) that secures the small end of the tailgate check cable(s) to the tailgate and tighten the
bolt(s) to 23 N.m (17 ft. lbs.).

3. Position the tailgate check cable (3) to the left and right side of the cargo box below the tailgate striker (1)
as necessary.
4. Install the large end of the tailgate check cable(s) onto the cargo box. Make sure that the cable lock tab(s)
(4) fully engage.

COVER, TAILGATE
REMOVAL
REMOVAL
Fig. 33: Tailgate Liner

1. Open the tailgate (3).

2. Remove the screws (1) and remove the tailgate liner (2), if equipped.
Fig. 34: Tailgate Cover

3. Remove the bolts (1) that secure the tailgate cover (2) to the inside of the tailgate and remove the cover.
INSTALLATION
INSTALLATION
Fig. 35: Tailgate Cover

1. For vehicles without a tailgate liner, install the cover (2) onto the tailgate (1) and install the bolts (3).
2. Tighten the bolts using the sequence shown in the illustration.

Fig. 36: Tailgate Liner

3. On vehicles with a tailgate liner, position the tailgate cover onto the inside of the tailgate (3).
4. Install the liner (2) onto the tailgate.
5. Install the screws (1) that secure the tailgate cover to the tailgate.
6. Tighten the screws using the sequence shown in the illustration.
CYLINDER, LOCK
REMOVAL
REMOVAL

Fig. 37: Lock Cylinder & Handle

1. Remove the latch release handle (3). Refer to HANDLE, LATCH RELEASE, REMOVAL.
2. Remove the screws (1) and remove the lock cylinder (2).
INSTALLATION
INSTALLATION
Fig. 38: Lock Cylinder & Handle

1. Install the lock cylinder (2) and install the screws (1).
2. Install the latch release handle (3). Refer to HANDLE, LATCH RELEASE, INSTALLATION.
LOCK CYLINDER CODING INSTRUCTIONS
1. If present, remove the protective label off of the new lock cylinder.
2. Insert the key that is intended for everyday use, fully into the cylinder.
3. Slowly rotate the key clockwise, while maintaining full key insertion, to 180 degrees or slightly more (6
or 7 o'clock position).
NOTE: The lock will code at 180 degrees.
4. Then rotate the key counter-clockwise to 90 degrees or 3 o'clock.

5. You will hear the lock activate, then rotate the key to vertical key-out position and remove the key.
HANDLE, LATCH RELEASE

REMOVAL
REMOVAL
Fig. 39: Tailgate Control Rod

1. Open the tailgate and remove the tailgate liner (if equipped) and cover. Refer to COVER, TAILGATE,
REMOVAL .
2. Using a grease pencil or equivalent, mark the location of the actuator rods (2) at the control.
3. Disconnect the actuator rods from the control.
Fig. 40: Backup Camera Electrical Connector


4. Disconnect the backup camera electrical connector (1), if equipped.
Fig. 41: Tailgate Release Handle & Actuator Rods

5. Remove the two nuts (3) that secure the release handle (1) and the control (2) to the tailgate.
6. Remove the control (2) and the release handle (1) from the tailgate.
INSTALLATION
INSTALLATION
Fig. 42: Tailgate Release Handle & Actuator Rods

1. Position the release handle (1) and the control (2) onto the tailgate.
2. Install the two nuts (3) that secure the release handle and control to the tailgate. Tighten the nuts to 6 N.m
(53 in. lbs.).
Fig. 43: Backup Camera Electrical Connector

3. Connect the backup camera electrical connector (1), if equipped.
Fig. 44: Tailgate Control Rod


4. Locate the actuator rods (2) to the control using the reference marks made during the removal procedure
and connect the rods to the control.
5. Install the tailgate cover and liner, if equipped. Refer to COVER, TAILGATE, INSTALLATION.
LATCH
REMOVAL
REMOVAL
Fig. 45: Actuator Rod

1. Remove the tailgate cover. Refer to COVER, TAILGATE, REMOVAL.

2. Using a grease pencil or equivalent, mark the actuator rod (3) at the control (2) for the latch (1) being
serviced.
3. Disconnect the actuator rod from the control.


4. Remove the two bolts (1 and 4) that secure the latch (2) to the tailgate and position the tailgate check
cable (6) out of the way.
5. Remove the latch from the tailgate.
INSTALLATION
INSTALLATION


1. Loose assemble the latch (2) to the tailgate.

2. Install the cable and anchor bolt (4) to the latch.
3. Install the bolt (1) securing the latch (2).
4. Tighten the fasteners to 23 N.m (17 ft. lbs.).
Fig. 48: Actuator Rod

5. Install the actuator rod (3) and secure the clip (1) fully.
6. Install the tailgate cover. Refer to COVER, TAILGATE, INSTALLATION.
SPOILER
REMOVAL
REMOVAL

Fig. 49: Spoiler

1. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, release the retaining clips and remove
the spoiler (1) from the tailgate (2).
INSTALLATION
INSTALLATION
Fig. 50: Spoiler


1. Position the spoiler (1) to the holes in the top of the tailgate (2).
2. Insert the locating pin into the center of the tailgate top and line up the retaining clips into the holes.
3. Working from the center out tap the retaining clips into the holes fully.
STRIKER, LATCH
REMOVAL
REMOVAL
Fig. 51: Tailgate Latch Striker

1. Open the tailgate and using a grease pencil or equivalent, mark the location of the tailgate striker (1)
being serviced.
2. Remove the striker from the cargo box (2).
INSTALLATION
INSTALLATION

Fig. 52: Identifying Tailgate Latch Striker

1. Position the striker (1) onto the cargo box (2) using the reference mark made during the removal
procedure.
2. Tighten the striker to 34 N.m (25 ft. lbs.).
TAILGATE
REMOVAL
REMOVAL


1. Open the tailgate and locate the tailgate check cable (3) on the left and right of the cargo box below the
tailgate striker (1) as necessary.
2. Pry the cable lock tab(s) (4) outward using a screwdriver or flat bladed tool (2) and remove the tailgate
check cable(s) from the cargo box.
Fig. 54: Tailgate

3. If equipped, disconnect the electrical connectors.

4. Partially close the tailgate so that the notch in the right side tailgate pivot pocket (2) aligns with the flats
on the right side tailgate pivot pin.
5. Lift the tailgate upward far enough to disengage the tailgate pivot pocket from the right side tailgate pivot
pin.
6. Carefully slide the tailgate to the right far enough to disengage it from the left side tailgate pivot pin and
remove the tailgate.

Fig. 55: Tailgate Pivot Pocket & Bushing

7. If required, remove the bushing (2) from each tailgate pivot pocket (3).
INSTALLATION
INSTALLATION
Fig. 56: Tailgate Pivot Pocket & Bushing

1. If removed, install the bushing (2) into each tailgate pivot pocket (3).

Fig. 57: Tailgate

2. Position the tailgate (1) onto the left side tailgate pivot pin (3).
3. Partially close the tailgate so that the notch in the right side tailgate pivot pocket (2) aligns with the flats
on the right side tailgate pivot pin.
4. Lower the tailgate onto the right side tailgate pivot pin.

5. If equipped, connect the electrical connectors.

6. Connect the tailgate check cables (3) to the cable bolts (2) located below each tailgate striker (1). Refer to
CABLE, TAILGATE, INSTALLATION.

DOOR - FRONT
CYLINDER, DOOR LOCK
REMOVAL
REMOVAL
Fig. 59: Lock Cylinder

1. Remove the exterior door handle. Refer to HANDLE, EXTERIOR, REMOVAL.

2. Separate the lock cylinder (1) from the handle.
INSTALLATION
INSTALLATION


1. Position the door lock cylinder (1) into the exterior door handle.
2. Install the exterior handle. Refer to HANDLE, EXTERIOR, INSTALLATION.
DOOR
ADJUSTMENTS
ADJUSTMENTS
NOTE: For quad cab vehicles, it is recommended that you adjust the rear door before
adjusting the front door. Refer to DOOR, REAR, ADJUSTMENTS.
Door adjustment measurements should be taken from stationary or

welded body panels like the roof, rocker or quarter panels.
During adjustment procedures, it is recommended that all the hinge
fasteners be loosened except for the upper most fasteners. Adjustments
can be made using the upper bolts to hold the door with final torque of the
fasteners occurring after correct door positioning is achieved.
A suitable body sealant should be used when removing or moving the
hinges.
FORE/AFT

Fig. 61: Hinge Pillar

NOTE: Fore/aft (lateral) door adjustment is done by loosening the hinge to the hinge
pillar fasteners one hinge at a time and moving the door to the correct position.
1. Support the door with a suitable lifting device.

2. Loosen the upper and lower hinge to hinge pillar fasteners (2). Refer to HINGE, DOOR, REMOVAL.
3. Adjust the door to the correct position. Refer to GAP AND FLUSH, SPECIFICATIONS.
4. Tighten the hinge to hinge pillar bolts (2) to 24 N.m (18 ft. lbs.).
UP/DOWN

Fig. 62: Removing/Installing Front Door Latch Striker

NOTE: Up/down door adjustment is done by loosening either the hinge to the hinge
pillar fasteners or the hinge to door fasteners and moving the door to the
correct position.
NOTE: When the up/down adjustments are done correctly, the top of the door is
positioned over flush to the roof. Refer to GAP AND FLUSH, SPECIFICATIONS.

2. Remove the latch striker (1). Refer to STRIKER, DOOR LATCH, REMOVAL.

Fig. 63: Door Hinges

3. If necessary, loosen the hinge to door fasteners (1) and (3). Refer to DOOR, REMOVAL.

4. If necessary, loosen the hinge to hinge pillar fasteners (2). Refer to HINGE, DOOR, REMOVAL.


6. Tighten the door to hinge fasteners to 22 N.m (16 ft. lbs.)



8. Install the latch striker(1). Refer to STRIKER, DOOR LATCH, INSTALLATION.
IN/OUT

NOTE: In/out door adjustment is done by loosening the hinge to door fasteners one
hinge at a time and moving the door to the correct position.

NOTE: When adjustment of the door requires the loosening of the door to hinge
fasteners, it will be necessary to separate the epoxy bonded washers with a
chisel or other suitable tool.


3. Loosen the hinge to door fasteners. Refer to DOOR, REMOVAL.

5. Tighten the door to hinge fasteners to 22 N.m (16 ft. lbs.).


6. Install the latch striker (1). Refer to STRIKER, DOOR LATCH, INSTALLATION.
REMOVAL
REMOVAL
1. Disconnect and isolate the negative battery cable.

2. Disconnect the door electrical connector.
Fig. 71: Door Harness Connector

NOTE: The following illustration shows a typical door harness connector.
3. Peel the A Pillar grommet (1) off of the connector/retainer and move it up the wire harness.

4. Grasp the wire harness (2) by the convolute section of the grommet and gently pull the wire harness down
towards the floor to expose the connector lock tabs.
CAUTION: Do not force the locking tab past the connector body, as damage to
the connector may occur.
5. While still pulling down on the harness, use a small slotted screw driver (3) to gently push one of the top
lock tabs until the lock feature is flush with the connector/retainer body.
6. Repeat the step 3 for the remaining top lock tab.
7. The connector should now be able to rock out of the sheet metal hole without causing any damage to the
connector or sheet metal.

8. Using a grease pencil or equivalent, mark the location of the door hinges on the door.
9. Support the door with a suitable lifting device and remove the nuts (1 and 3) that secure the door to the
hinges.
10. Carefully remove the door from the hinges.
INSTALLATION
INSTALLATION


1. Carefully position the door studs (2) onto the hinges and support the door with a suitable lifting device.
2. Loosely install the nuts (1 and 3) secure the door to the hinges.
3. Align the door to the hinges using the reference marks made during the removal procedure
4. Tighten the nuts to 22 N.m (16 ft. lbs.) using the following sequence;
1. Tighten the upper nut of the top hinge.
2. Tighten the lower nut of the bottom hinge.
3. Tighten the upper nut of the bottom hinge.
4. Tighten the lower nut of the top hinge.
5. Connect the door wire harness to the body wire harness.
6. Install the grommet over the connector and seat the connector into the A-pillar fully.
7. Reconnect the negative battery cable.
8. If necessary, adjust the door. Refer to DOOR, ADJUSTMENTS.
FLAG, MIRROR
REMOVAL
REMOVAL

Fig. 74: Mirror Flag

1. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, remove the mirror flag (1).
INSTALLATION
INSTALLATION
Fig. 75: Mirror Flag

1. Position the mirror flag (1) onto the door and seat the clips fully.

GLASS, DOOR
REMOVAL
REMOVAL
Fig. 76: Inner Belt Molding

1. Remove the trim panel. Refer to PANEL, DOOR TRIM, REMOVAL.

2. Remove the door speaker. Refer to SPEAKER, REMOVAL .
3. Remove the inner belt molding (3).

Fig. 77: Window Switch

4. Install the window switch if required and lower the glass (1) down in the door to position the glass
attachment clips (2) for access through the speaker opening and the service access plug.
5. Separate the glass clips (2) from the regulator lift plates (3 and 4).
Fig. 78: Door Glass

6. Rotate the top of the glass (1) forward in the door to release the glass from the run channels.
7. Remove the door glass (1) from the door (3) and separate the clips (2) if necessary.

INSTALLATION
INSTALLATION
Fig. 79: Door Glass

1. Install the mounting clips (2) onto the glass, if necessary.

2. Insert the narrow end of the glass (1) into the door through the opening between the inner and outer
panels (3). Then engage the front edge of the glass into the front portion of the glass run weatherstrip
before rotating the back edge of the glass rearward into the B-pillar portion of the weatherstrip.

3. Pull the glass upward evenly far enough so it can be verified that the glass is seated into both glass run
channels.
4. Push the glass down to seat the clips (2) into regulator lift plates (3 and 4) fully.
5. Pull up on the glass and make sure that it is secure.

6. Install the inner belt molding (3) onto the door and seat fully.
7. Install the door speaker. Refer to SPEAKER, INSTALLATION .
8. Install the trim panel. Refer to PANEL, DOOR TRIM, INSTALLATION.
HANDLE, INTERIOR
REMOVAL
REMOVAL
HANDLE COVER

Fig. 82: Interior Door Handle Trim & Interior Door Panel
1. Remove the door trim panel. Refer to PANEL, DOOR TRIM, REMOVAL.
Fig. 83: Lifting Handle Cover

2. Locate the snap feature (1) on the lower cover surface.

3. Using a medium sized flat bladed tool (2), or equivalent, lift up on the cover (1).

Fig. 84: Removing Handle Cover

4. Remove the cover (1) and verify that the handle (2) functions correctly.
HANDLE ASSEMBLY

Fig. 86: Interior Handle

2. Remove the handle mounting screw (1).

3. Disconnect the control cable or rod (3) from the handle (2).
Fig. 87: Identifying Disposable Clip Tool

4. Locate the disposable clip tool.
Fig. 88: Rubber Bumper

5. Remove the rubber bumper (3) which supports the forward edge of the handle from the module plate.
6. Open the handle to the full open position and place the included clip tool (1) as shown in the illustration.
NOTE: The tip of the clip (1) should engage the lower pivot stanchion snap tab (2).

Fig. 89: Positioning Tip Of Clip Over Stanchion Snap Tab

NOTE: Snap tab (2) will depress when the handle is brought to the closed
position.
7. Position the tip of the clip (1) over the stanchion snap tab (2).

Fig. 90: Rotating Handle

8. With the clip tool properly located, rotate the handle until the tip rests on the carrier plate surface and
release the handle pivot shaft.
9. Apply a nominal force at the tip of the handle (1) and rotate the handle out of the pivot supports.
10. Remove the handle from the door.
INSTALLATION
INSTALLATION
HANDLE COVER

Fig. 91: Rotating Handle Cover Down Onto Handle

1. Make sure there is no tape pieces left on the interior handle (2) and clean if necessary.
2. Remove the film from the double sided tape on the new handle cover (1).
3. Align the tip of the cover to the tip of the handle and rotate the handle cover (1) down onto the handle (2).
4. Seat the handle cover (1) onto the snap feature fully.

5. Install the door trim panel. Refer to PANEL, DOOR TRIM, INSTALLATION.
HANDLE ASSEMBLY
Fig. 93: Placing Handle Into Position

1. Place the handle into position at the door and make sure the return spring is positioned in the grove (1).

Fig. 94: Rotating Handle

2. Engage upper pivot first, rotate into snapped position when handle (1) is at rest position.

3. Connect the control rod (3) to the handle.

4. Install the handle mounting screw (1).
5. Verify handle operation.

6. Install the door trim panel.
Refer to PANEL, DOOR TRIM, INSTALLATION.
HANDLE, EXTERIOR
REMOVAL
REMOVAL
Fig. 96: Carrier Plate Assembly

1. Disconnect and isolate the battery negative cable.

2. Remove the carrier plate (1). Refer to PLATE, CARRIER, REMOVAL.

Fig. 97: Exterior Handle Bolts

3. Remove the bolts (1) and remove the exterior handle (2) from the door.
Fig. 98: Exterior Handle Linkages

4. Release the clips (1) and disconnect the linkages (2 and 3) from the handle.
INSTALLATION
INSTALLATION

Fig. 99: Exterior Handle Linkages

1. Install the linkages (2 and 3) onto the door handle and secure the clips (1).

2. Position the linkages (3) into the door and install the handle (2).
3. Install the bolts (1) and tighten to 7 N.m (62 in. lbs.).


4. Install the carrier plate. Refer to PLATE, CARRIER, INSTALLATION.

5. Connect the battery negative cable.
HINGE, DOOR
STANDARD PROCEDURE
STANDARD PROCEDURE - HINGE LUBRICATION

Fig. 102: Door Hinge

CAUTION: Door hinge pivot points (1) including the roller (3) and detent lever (2),
should be lubricated periodically using Mopar ® Spray White Lube with
Lithium or equivalent.
1. Spray parts as necessary using Mopar ® Spray White Lube with Lithium or equivalent.
2. Remove any excess grease.
REMOVAL
REMOVAL


NOTE: A suitable body sealant should be used when removing or moving the hinges.
1. Remove the door. Refer to DOOR, REMOVAL.

2. Using a grease pencil or equivalent, mark the hinge location and remove the bolts (2) for the hinge being
serviced.

INSTALLATION
INSTALLATION

1. Install the hinges (3) and bolts (2).

2. Tighten the hinge bolts to 24 N.m (18 ft. lbs.).


3. Install the door. Refer to DOOR, INSTALLATION.
LATCH, DOOR
REMOVAL
REMOVAL


2. Disconnect the door wire harness connector from the door latch (4).
3. Separate the latch assembly from the latch presenter bracket and remove.
INSTALLATION
INSTALLATION


1. Seat the latch (4) onto the presenter bracket fully.

2. Connect the door wire harness electrical connector to the latch.
3. Install the carrier plate (1). Refer to PLATE, CARRIER, INSTALLATION.
MOLDING, DOOR BELT, INNER
REMOVAL
REMOVAL


2. Separate the belt molding (3) from the door mounting flange from the back to the front.
INSTALLATION
INSTALLATION


1. Position the belt molding (3) and seat onto the door mounting flange fully.
MOLDING, DOOR BELT, OUTER
REMOVAL
REMOVAL


1. Remove the screw from the rear of the outer belt molding (2).
2. Starting from the rear of the door, carefully lift the belt molding upward and disengage the inner portion
of the molding from the tabs on the door.
3. Pull the molding rearward to disengage the molding from the outside mirror.
4. Remove the belt molding from the door.
INSTALLATION
INSTALLATION


1. Place the belt molding (2) into position and insert the front portion under the outside mirror housing.
2. Working from the front of the door, press down on the molding and engage the clips to the door.
3. Install the screw at the rear of the belt molding.
PANEL, DOOR TRIM
REMOVAL
REMOVAL

Fig. 113: Door Switch/Bezel

NOTE: Rear door switch shown in the illustration, front doors are similar.
1. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, release the door switch/bezel (1) from
the door trim and disconnect the electrical connectors (2), if equipped.
Fig. 114: Window Crank Removal Tool

2. If equipped, remove the manual window crank (1) using a window crank removal tool (2).

3. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, remove the mirror flag (4).
4. Remove the screw (2) and remove the interior handle bezel (3).
5. Release the plastic push pins (1).
6. Raise the trim panel (6) upward far enough to disengage the hooks on the back of the panel from the inner
door and the door lock knob from the top of the panel.
INSTALLATION
INSTALLATION

1. Position the lower end of the trim panel (6) to the carrier plate on the inner door aligning the hooks on the
back of the panel to the slotted holes in the carrier. Then, using a rotating arc motion, feed the lock knob
through the hole at the upper rear corner of the trim panel, and align and push down the trim panel to seat
the hooks into the holes in the carrier plate.
NOTE: Make sure the upper flange of trim is fully seated into inner belt molding.
2. Install the plastic push pins (1) around the perimeter of the panel and seat fully.
3. Install the interior handle bezel (3) and install the screw (2).
4. Position the mirror flag (4) onto the door and seat the clips fully.
5. If equipped, verify that the window handle clip is installed correctly and seat the handle onto the window
regulator shaft fully.

NOTE: Rear door switch shown in the illustration, front doors are similar.
6. If equipped, connect the window switch electrical connectors (2) and seat the window switch/bezel into
the door trim fully.
PLATE, CARRIER
REMOVAL
REMOVAL

1. Remove the trim panel (6). Refer to PANEL, DOOR TRIM, REMOVAL.

3. If required, reinstall the regulator handle or window switch to enable lowering of the glass (1) for access
to the glass attachment clips (2) through the speaker opening and the service access plug.
4. Separate the glass clips (2) from the regulator lift plates (3 and 4).

5. Raise the glass (1) into the full up position and secure in place using tape or equivalent.


Fig. 121: Exterior Handle

12. Remove the service access plug (2) and disconnect the exterior handle linkages (1).
Fig. 122: Door Wire Harness Connector

13. Remove the screws (2) and separate the wire harness (1) from the door.

Fig. 123: Lower Belt Channel

14. On standard cab models only, remove the lower belt channel (2) shut face screw (1).
Fig. 124: Door Latch Mounting Screws

15. Remove the door latch (2) mounting screws (3).


NOTE: Standard cab model shown in the illustration, all others similar.
16. Remove the bolts (5) (quantity of 13 on standard cab, 12 on all other models) and remove the carrier plate
assembly (1) from the door.
INSTALLATION
INSTALLATION


NOTE: On standard cab models perform the following steps.
1. Insert the carrier plate assembly (1) into door, latch (4) side first, and tip the regulator rails into place
through the door opening.
2. Lift the carrier plate and seat the two locating pins into the locating holes.
3. Install the 13 bolts (5) and, moving clockwise starting at position (2), tighten the bolts in a clockwise
direction to 5.5 N.m (49 in. lbs.).

NOTE: On crew/club cab models perform the following steps.
4. Insert the carrier plate assembly (1) into door, latch (4) side first, and tip the regulator rails into place
through the door opening.
5. Lift the carrier plate and seat the two locating pins into the locating holes.
6. Install the 12 bolts (5) and, moving clockwise starting at position (2), tighten the bolts in a clockwise
direction to 5.5 N.m (49 in. lbs.).


7. Install the latch screws (3) and tighten to 7 N.m (62. in. lbs.)
Fig. 129: Lower Belt Channel

8. On standard cab models only, install the lower belt channel (2) shut face screw (1) and tighten to 8 N.m
(71 in. lbs.).


9. Install the wire harness (1) and install the screws (2).

10. Connect the linkages (1) to the latch and secure the clips.


11. Pull the glass up evenly so front of glass can be verified it is seated into both glass run channels.
12. Push the glass down to seat the clips (2) into regulator lift plates (3 and 4) fully.


16. Connect the electrical connector and secure the grommet (1) back over the connector/retainer and seat the
connector into the pillar fully.
REGULATOR, WINDOW, MANUAL
DESCRIPTION
DESCRIPTION

Fig. 135: Identifying Window Regulators & Carrier Plate (Manual)

The window regulators (1) are serviced as an assembly with the carrier plate (2) and include the following parts:
glass bumpers
lock grommets
release rod grommet
handle bumper
service plug
Refer to PLATE, CARRIER, REMOVAL.
REGULATOR, WINDOW, POWER
DESCRIPTION
DESCRIPTION

Fig. 136: Identifying Window Regulators & Carrier Plate (Power)

glass bumpers
lock grommets
release rod grommet
handle bumper
service plug
STRIKER, DOOR LATCH
ADJUSTMENTS
ADJUSTMENTS


1. Using a grease pencil or equivalent, mark the location of the door latch striker (1) on the B-pillar (2) to
aid in adjustment.
2. Loosen the two bolts (3) that secure the door latch striker to the B-pillar.
3. To adjust the rear gap and flush measurement, change the position of the door latch striker and then
tighten the two bolts to 30 N.m (22 ft. lbs.). Refer to GAP AND FLUSH, SPECIFICATIONS.
4. Verify correct door and latch position.
REMOVAL
REMOVAL


1. Using a grease pencil or equivalent, mark the location of the door latch striker (1) on the B-pillar (2).
2. Remove the two bolts (3) that secure the door latch striker to the B-pillar and remove the striker.
INSTALLATION
INSTALLATION


1. Position the door latch striker (1) onto the B-pillar (2) and loosely install the two bolts (3).
2. Align the door latch striker to the B-pillar using the reference marks made during the removal procedure
and tighten the bolts to 28 N.m (21 ft. lbs.).
3. If necessary, adjust the door latch striker. Refer to STRIKER, DOOR LATCH, ADJUSTMENTS.
DOORS - REAR
DOOR, REAR
ADJUSTMENTS
ADJUSTMENTS
NOTE: For quad cab vehicles, it is recommended that you adjust the rear door before
adjusting the front door.
Door adjustment measurements should be taken from stationary or

welded body panels like the roof, rocker or quarter panels.
During adjustment procedures, it is recommended that all the hinge
fasteners be loosened except for the upper most fasteners. Adjustments
can be made using the upper fasteners to hold the door with final torque
of the fasteners occurring after correct door positioning is achieved.
A suitable body sealant should be used when removing or moving the
hinges.
FORE/AFT

NOTE: Fore/aft (lateral) door adjustment is done by loosening the hinge to the hinge
pillar fasteners one hinge at a time and moving the door to the correct position.

2. Loosen the upper and lower (2) hinge to hinge pillar fasteners. Refer to HINGE, DOOR, REMOVAL.
4. Tighten the remaining hinge to hinge pillar bolts (2) to 24 N.m (18 ft. lbs.).
UP/DOWN
Fig. 141: Removing/Installing Rear Door Striker

NOTE: Up/down door adjustment is done by loosening either the hinge to the hinge
pillar fasteners or the hinge to door fasteners and moving the door to the
correct position.
NOTE: When the up/down adjustments are done correctly, the top of the door is
positioned over flush to the roof. Refer to GAP AND FLUSH, SPECIFICATIONS.


Fig. 142: Rear Door

3. If necessary, loosen the hinge to door fasteners (3). Refer to HINGE, DOOR, REMOVAL.

4. If necessary, loosen the hinge to hinge pillar fasteners (2). Refer to DOOR, REAR, REMOVAL.

Fig. 144: Rear Door

6. Tighten the door to hinges fasteners to 22 N.m (16 ft. lbs.)



8. Install the latch striker. Refer to STRIKER, DOOR LATCH, INSTALLATION.
IN/OUT

NOTE: In/out door adjustment is done by loosening the hinge to door fasteners one
hinge at a time and moving the door to the correct position.

NOTE: When adjustment of the door requires the loosening of the door to hinge
fasteners, it will be necessary to separate the epoxy bonded washers with a
chisel or other suitable tool.

2. Remove the latch striker. Refer to STRIKER, DOOR LATCH, REMOVAL.
Fig. 148: Rear Door

3. Loosen the hinge to door fasteners (3). Refer to DOOR, REAR, REMOVAL.
4. Adjust the front of the door to the correct position. Refer to GAP AND FLUSH, SPECIFICATIONS.
5. Tighten the door to hinges fasteners to 22 N.m (16 ft. lbs.).


6. Install the latch striker (1). Refer to STRIKER, DOOR LATCH, INSTALLATION.
REMOVAL
GROMMET - A PILLAR


REMOVAL

2. Disconnect the door electrical connector. Refer to GROMMET - A PILLAR
Fig. 151: Rear Door

3. Using a grease pencil or equivalent, mark the location of the door hinges on the door (1).
4. Support the door with a suitable lifting device and remove the nuts (3) that secure the door to the hinges.
5. Carefully remove the door from the hinges.
INSTALLATION
INSTALLATION

Fig. 152: Rear Door

1. Carefully position the door studs (2) onto the hinges and support the door with a suitable lifting device.
2. Loosely install the nuts (3) and secure the door to the hinges.
3. Align the door to the hinges using the reference marks made during the removal procedure
4. Tighten the nuts to 22 N.m (16 ft. lbs.) using the following sequence;
1. Tighten the upper nut of the top hinge.
2. Tighten the lower nut of the bottom hinge.
3. Tighten the upper nut of the bottom hinge.
4. Tighten the lower nut of the top hinge.
5. Connect the door wire harness to the body wire harness.
6. Install the grommet over the connector and seat the connector into the A-pillar fully.
8. If necessary, adjust the door. Refer to DOOR, REAR, ADJUSTMENTS.
GLASS, DOOR
REMOVAL
REMOVAL

Fig. 153: Carrier Plate

Fig. 154: Door Glass

2. Lower the glass (1) and remove from the lower door opening.

Fig. 155: Glass Clips

3. If necessary, remove the glass clips (3 - 4) from the glass.
INSTALLATION
INSTALLATION
Fig. 156: Glass Clips

1. Install the mounting clips (3 - 4) onto the glass, if necessary.

Fig. 157: Door Glass

2. Install the glass (1) into the door through the lower door opening and secure in the full up position using
tape or equivalent.

HANDLE, INTERIOR

REMOVAL
REMOVAL

NOTE: Front door shown in the illustration, rear door similar.
1. Remove the door trim panel.

2. Remove the handle mounting screw (1).
3. Disconnect the control rod (3) from the handle (2).
4. Remove the handle from the door.
INSTALLATION
INSTALLATION


1. Place the handle (2) into position at the door.

2. Connect the control rod (3) to the handle.
3. Install the handle mounting screw (1).
4. Install the door trim panel.
HANDLE, EXTERIOR
REMOVAL
REMOVAL



2. Remove the bolts (1) and remove the exterior handle (2) from the door.

Fig. 163: Door Handle Linkage

3. Release the clips (1) and disconnect the linkage (2) from the handle.
INSTALLATION
INSTALLATION
Fig. 164: Door Handle Linkage

1. Install the linkage (2) onto the door handle and secure the clips (1).


NOTE: Front door shown in the illustration, rear doors are similar.
2. Position the linkages (3) into the door and install the handle (2).
3. Install the bolts (1) and tighten to 7 N.m (62 in. lbs.)


HINGE, DOOR
STANDARD PROCEDURE
STANDARD PROCEDURE - HINGE LUBRICATION
Fig. 167: Door Hinge

CAUTION: Door hinge pivot points (1) including the roller (3) and detent lever (2),
should be lubricated periodically using Mopar ® Spray White Lube with
Lithium or equivalent.
1. Spray parts as necessary using Mopar ® Spray White Lube W/Lithium or equivalent.
2. Remove any excess grease.
REMOVAL
REMOVAL

Fig. 168: Rear Door

NOTE: It is not necessary to remove the door to replace the hinges if they are replaced
one at a time.
1. Open the front door

2. Using a grease pencil or equivalent, mark the position of the hinge on the door and B-pillar.
3. Remove the nuts (3) attaching the hinge to the door (1).


4. Remove the bolts (2) attaching the hinge (1) to the B-pillar and remove the hinge.
INSTALLATION
INSTALLATION


1. Install the hinge (1) and install the B-pillar bolts (2).
2. Tighten the bolts to 24 N.m (18 ft. lbs.).
Fig. 171: Rear Door

3. Position rear door assy studs (2), through appropriate holes in hinge assy.
NOTE: The shoulders of the studs (2) must be fully engaged into hinges, prior to
securing.
4. Install the nuts and tighten to 22 N.m (16 ft. lbs.).

5. Adjust the door if needed. Refer to DOOR, REAR, ADJUSTMENTS.
LATCH, DOOR
REMOVAL
REMOVAL



2. Disconnect the door wire harness connector from the door latch (4).
3. Separate the latch assembly from the latch presenter bracket and remove.
INSTALLATION
INSTALLATION


1. Seat the latch onto the presenter bracket fully.

2. Connect the electrical connector.
MOLDING, DOOR BELT, INNER
REMOVAL
REMOVAL

2. Separate the belt molding (3) the door mounting flange from the back to the front.
INSTALLATION
INSTALLATION


1. Position the belt molding (3) and seat onto the door mounting flange fully.
MOLDING, DOOR BELT, OUTER
REMOVAL
REMOVAL


NOTE: Front door shown in the illustration, rear door similar
1. Remove the screw from the rear of the outer belt molding (2).
2. Starting from the rear of the door, carefully lift the belt molding upward and disengage the inner portion
of the molding from the tabs on the door.
3. Pull the molding rearward to disengage the molding from the outside mirror.
4. Remove the belt molding from the door.
INSTALLATION
INSTALLATION


1. Place the belt molding (2) into position and insert the front portion under the outside mirror housing.
2. Working from the front of the door, press down on the molding and engage the clips to the door.
3. Install the screw at the rear of the belt molding.
PANEL, REAR DOOR TRIM
REMOVAL
REMOVAL


1. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, release the door switch/bezel (1) from
the door trim and disconnect the electrical connectors (2).
Fig. 179: Upper Trim Bezel

2. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, release the upper trim bezel (1).

Fig. 180: Window Crank Removal Tool

3. If equipped, remove the manual window crank (1) using a window crank removal tool (2).
Fig. 181: Door Trim Panel

4. Remove the screw (3) and remove the interior handle bezel (5).
5. Release the plastic screw/rivets (4).
6. Raise the trim panel (2) up and off the hooks and door lock knob (1).
INSTALLATION
INSTALLATION


1. Load the trim panel (2) bottom first on an angle then rotate toward inner aligning window crank shaft,
feed lock knob (1) through the trim panel (2), then align and push down hooks into holes in door module,
(this will be an arc motion).
NOTE: Make sure the upper flange of trim is fully seated into inner belt molding.
2. Install the plastic screw/rivets (4) and seat fully.

3. Install the interior handle bezel (5) and install the screw (3).
4. If equipped, verify that the window handle clip is installed correctly and seat the handle onto the window
regulator shaft fully.

Fig. 183: Upper Trim Bezel

5. Position the trim bezel (1) onto the door and seat the clips fully.

6. If equipped, connect the window switch electrical connectors (2) and seat the window switch/bezel into
the door trim fully.
PLATE, CARRIER

REMOVAL
REMOVAL
CLUB CAB

Fig. 186: Power Window Motor

2. If equipped, using a punch or similar tool, carefully remove the glass disconnect hole plugs (1).
3. Install the window switch if required and lower the glass down in the door to position the glass
attachment clip for access through the service access plug (1).
4. Release the two glass retainer tabs and separate the glass clip from the regulator lift plate.
5. Raise the glass into the full up position and secure in place using tape or equivalent.
CREW CAB




3. Install the window switch if required and lower the glass down in the door to position the glass
attachment clips for access through the speaker opening (4) and the service access plug.
4. Release the two glass retainer tabs and separate the glass clip from the regulator lift plate.
5. Raise the glass into the full up position and secure in place using tape or equivalent.
GROMMET - A PILLAR



7. Remove the service access plug (2) and disconnect the exterior handle linkages (1).


8. Remove the screws (2) and separate the wire harness (1) from the door.

9. Remove the door latch (2) mounting screws (3).


10. Remove the 11 bolts (2) on the club cab or the 12 bolts on the crew cab model and remove the carrier
plate assembly (3) from the door.
INSTALLATION
INSTALLATION


1. Insert the carrier plate assembly (3) into door, latch side first, and tip the regulator rails into place through
the door opening.
2. Lift the carrier plate and seat the two locating pins into the retaining holes.
3. Install the bolts (2) and starting at position (1) tighten the bolts in a clockwise direction to 5.5 N.m (49 in.
lbs.)

4. Install the latch screws (3) and tighten to 7 N.m (62. in. lbs.)

5. Install the wire harness (1) and install the screws (2).

6. Connect the linkages (1) to the latch and secure the clips.

7. Connect the electrical connector and secure the grommet (1) back over the connector/retainer and seat the
connector into the pillar fully.
CLUB CAB


2. Push the glass down to seat the clips into regulator liftplates fully.
4. Seal the glass disconnect holes (1) with a suitable foam tape or equivalent.


5. Install the door trim panel. Refer to PANEL, REAR DOOR TRIM, INSTALLATION.
CREW CAB

2. Push the glass down to seat the clips into regulator liftplates fully.
4. Seal the glass disconnect holes (3) with a suitable foam tape or equivalent.



6. Install the door trim panel. Refer to PANEL, REAR DOOR TRIM, INSTALLATION.
REGULATOR, WINDOW, MANUAL
DESCRIPTION
DESCRIPTION
Fig. 203: Identifying Window Regulators & Carrier Plate (Manual)

glass bumpers
lock grommets
release rod grommet
handle bumper

service plug
REGULATOR, WINDOW, POWER
DESCRIPTION
DESCRIPTION
Fig. 204: Identifying Window Regulators & Carrier Plate (Power)

glass bumpers
lock grommets
release rod grommet

handle bumper
service plug
STRIKER, DOOR LATCH
ADJUSTMENTS
ADJUSTMENTS

1. Using a grease pencil or equivalent, mark the location of the door latch striker (1) on the C-pillar (2) to
aid in adjustment.
2. Loosen the two bolts (3) that secure the door latch striker to the C-pillar.
3. To adjust the rear gap and flush measurement, change the position of the door latch striker and then
tighten the two bolts to 28 N.m (21 ft. lbs.). Refer to GAP AND FLUSH, SPECIFICATIONS.
4. Verify correct door and latch position.
REMOVAL
REMOVAL


1. Using a grease pencil or equivalent, mark the location of the door latch striker (1) on the C-pillar (2).
2. Remove the two bolts (3) that secure the door latch striker to the C-pillar and remove the striker.
INSTALLATION
INSTALLATION


1. Position the door latch striker (1) onto the C-pillar (2) and loosely install the two bolts (3).
2. Align the door latch striker to the C-pillar using the reference marks made during the removal procedure
and tighten the bolts to 28 N.m (21 ft. lbs.).
3. If necessary, adjust the door latch striker. Refer to STRIKER, DOOR LATCH, ADJUSTMENTS.
EXTERIOR
BOX, PICKUP
REMOVAL
PICKUP BOX
Fig. 208: Removing/Installing Fuel Filler

NOTE: Long cargo box shown in illustration. Short cargo box similar.
1. Disconnect the fuel filler neck from the fuel tank. Refer to TANK, FUEL, REMOVAL , TANK, FUEL,
REMOVAL or TANK, FUEL, REMOVAL .
2. Remove the fuel filler from the cargo box and position it out of the way.
3. If necessary, remove the fuel filler door from the cargo box. Refer to DOOR, FUEL FILL, REMOVAL.

Fig. 209: Pickup Box

4. Disconnect the tail lamp wire harness from the underbody wire harness.
5. If necessary, remove the tail lamp units and wire harness from the cargo box. Refer to LAMP, TAIL
STOP TURN, REMOVAL .
6. If necessary, remove the tailgate. Refer to TAILGATE, REMOVAL.
7. If necessary, remove the rear bumper. Refer to BUMPER, REAR, REMOVAL .
8. Remove the bolts (3) that secure the cargo box (1) to the frame (2) (six short box, eight long box) and
remove the cargo box.
RAM BOX LOCK CYLINDER

Fig. 210: Lock Cylinder Cover

1. Open the Ram Box lid (1).

2. Remove the two screws (2) that secure the cover (3) to the lid latch.

3. Remove the nut (1) that secures the lock cylinder (3) to the lid latch (2).
4. Push the lock cylinder out through the latch and remove it from the outside of the lid.
RAM BOX STORAGE

Fig. 212: Removing/Installing Ram Box

1. Open the Ram Box lid (3).

2. Remove the four hinge bolts (2).
3. Remove the four bolts from the bottom (6).
4. Remove the two outboard bolts (5).
5. Remove the three inboard bolts (4).
6. Disconnect the electrical connector (1) and remove the Ram Box.
NOTE: If necessary to remove the Ram Box Applique, it is fastened with double
sided body tape.
RAMBOX LID GAP ADJUSTMENT
NOTE: Follow this procedure if the latch closing efforts are high or if the gap between
the Ram box lid and box side outer are inconsistent.
NOTE: On vehicles with a 5.7L engine, the striker is riveted to the Ram box. The rivets
must be removed to allow for proper adjustment. After adjustment has been
made, new rivets must be installed.

Fig. 213: Locating Scribe Marks

1. Scribe the current location of the striker base (1), on the inside of the ram box for reference.
2. Loosen the two lower nuts (2) and push them outboard to loosen them from plastic bin.
NOTE: If the striker is riveted to the Ram box, remove the rivets that are in place
of the two nuts (2).

Fig. 214: Upper Bolts

3. Loosen the two upper bolts (1) slightly in order to make the striker movable.
4. Adjust the striker (2) as needed and tighten the fasteners and recheck the fit of the lid to the box outer.
Perform this procedure until a 5 ± 2 mm gap is established. Note that in some cases the striker will have
to be adjusted beyond what the fasteners will allow.
NOTE: If the striker was riveted to Ram box, install new rivets after adjustment is
completed.

Fig. 215: Identifying Bumper

5. After adjusting the striker to achieve a nominal 5 mm gap at the latch, the front and rear bumpers (1) can
be adjusted to obtain the proper at the front and rear of the lid. The bumpers are adjusted up/down with a
3 mm hex wrench.
BED LINER

Fig. 216: Bed Liner

1. Open the tailgate.

2. Remove the plastic screw type rivets (3).
3. Lift up the center of the bottom of the linger and release the sides (2) from the box rails.
4. Remove the liner (1).
INSTALLATION
PICKUP BOX

Fig. 217: Pickup Box

NOTE: Long cargo box shown in illustration. Short cargo box similar.
1. Position the cargo box (1) onto the frame (2) and loosely install the bolts (3) (six short box, eight long
box).
2. Align the cargo box to the cab and tighten the bolts to 108 N.m (80 ft. lbs.).
3. If removed, install tail lamp units and wire harness onto the cargo box. Refer to LAMP, TAIL STOP
TURN, INSTALLATION .
4. Connect the tail lamp wire harness to the underbody wire harness.
5. If removed, install the tailgate. Refer to TAILGATE, INSTALLATION.
6. If removed, install the rear bumper. Refer to BUMPER, REAR, INSTALLATION .

Fig. 218: Removing/Installing Fuel Filler

7. If removed, install the fuel filler door. Refer to DOOR, FUEL FILL, INSTALLATION.
8. Position the fuel filler (2) to the cargo box (3).
9. Connect the fuel filler neck at the fuel tank. Refer to TANK, FUEL, INSTALLATION , TANK, FUEL,
INSTALLATION or TANK, FUEL, INSTALLATION .
RAM BOX LOCK CYLINDER

1. Position the lock cylinder (3) to the outside of the Ram Box lid and push it through the lid latch (2).

2. Install and tighten the nut (1) that secures the lock cylinder to the lid latch. Tighten the nut to 8.6 N.m (6
ft. lbs.).
Fig. 220: Lock Cylinder Cover

3. Position the cover (3) over the latch on the underside of the lid (1).
4. Install and tighten the two screws (2) that secure the cover to the lid latch.
5. Close the Ram Box lid.
LOCK CYLINDER CODING INSTRUCTIONS
1. If present, remove the protective label from over the key slot on the face of the new lock cylinder.
2. Fully insert the key into the lock cylinder.
3. Slowly rotate the key clockwise 270 degrees.
4. Rotate the key counterclockwise back to the vertical position.
5. Remove the key from the lock cylinder.
RAM BOX STORAGE

Fig. 221: Removing/Installing Ram Box

1. Install the ram box.

2. Install the three inboard bolts (4).
3. Install the two outboard bolts (5).
4. Install the four bolts from the bottom (6).
5. Install the four hinge bolts (2).
6. Connect the electrical connector (1).

Fig. 222: Box Storage Mounting Bolts

7. Tighten the bolts to 7 N.m (5 ft. lbs.) using the sequence shown in the illustration.
RAMBOX LID GAP ADJUSTMENT
NOTE: Follow this procedure if the latch closing efforts are high or if the gap between
the Ram box lid and box side outer are inconsistent.
NOTE: On vehicles with a 5.7L engine, the striker is riveted to the Ram box. The rivets
must be removed to allow for proper adjustment. After adjustment has been
made, new rivets must be installed.

Fig. 223: Placing Scribe Marks

1. Scribe the current location of the striker base (1), on the inside of the ram box for reference.
2. Loosen the two lower nuts (2) and push them outboard to loosen them from plastic bin.
NOTE: If the striker is riveted to the Ram box, remove the rivets that are in place
of the two nuts (2).

Fig. 224: Upper Bolts

3. Loosen the two upper bolts (1) slightly in order to make the striker movable.
4. Adjust the striker (2) as needed and tighten the fasteners and recheck the fit of the lid to the box outer.
Perform this procedure until a 5 ± 2 mm gap is established. Note that in some cases the striker will have
to be adjusted beyond what the fasteners will allow.
NOTE: If the striker was riveted to Ram box, install new rivets after adjustment is
completed.

Fig. 225: Identifying Bumper

5. After adjusting the striker to achieve a nominal 5 mm gap at the latch, the front and rear bumpers (1) can
be adjusted to obtain the proper at the front and rear of the lid. The bumpers are adjusted up/down with a
3 mm hex wrench.
BED LINER

Fig. 226: Bed Liner

1. Place the liner (1) into the cargo box with the liner extension on top of the box front panel. Bend the liner
along the middle of the floor and position the sides of the bed liner (2) under the box side rails.
2. Adjust as necessary to square the bed liner to the cargo box.
3. Drive the scrivets (3) through the holes in the liner and into the holes in the d-pillar using a rubber mallet
or equivalent.
COVER, COWL PANEL
REMOVAL
REMOVAL

Fig. 227: Front Cowl Cover

1. Remove the wiper arms. Refer to ARM, WIPER, REMOVAL .

2. Remove the push pins (2) that secure the front of the cowl cover (1) to the dash panel.
3. Pull the cowl cover forward to disengage the hooks from the windshield.
4. If necessary, remove the washer hose from the cowl cover.
INSTALLATION
INSTALLATION
Fig. 228: Front Cowl Cover

1. Position the panel assembly cowl cover (1) over the pivot shafts.
2. Push down on the cowl cover while moving it forward to make sure the six hooks are forward of the
windshield edge.
3. Center cowl cover over the wiper pivot shafts, push down on the cowl cover then push rearward with both

hands and slide hooks under the edge of the windshield.

4. Secure the front edge to the cowl by installing the push pins (2).
5. Fit soft rubber ends to fender by pulling up molded in feature to engage to fender flange.
6. Install the wiper arms. Refer to ARM, WIPER, INSTALLATION .
DOOR, FUEL FILL
REMOVAL
REMOVAL
Fig. 229: Removing/Installing Fuel Fill Door

1. Open the fuel filler door (1).

2. Remove the two bolts (2) that secure the fuel filler door to the cargo box and remove the door.
INSTALLATION
INSTALLATION

Fig. 230: Removing/Installing Fuel Fill Door

1. Position and align the fuel filler door (1) to the cargo box.
2. Install the two bolts (2) that secure the fuel filler door to the cargo box. Tighten the bolts to 9 N.m (80 in.
lbs.).
FENDER, FRONT
REMOVAL
REMOVAL
Fig. 231: Radio Antenna Connector


1. Remove the radio antenna if necessary. Refer to MAST, ANTENNA, REMOVAL .
Fig. 232: Rear Upper Screw

2. Remove the headlamp unit. Refer to UNIT, FRONT LAMP, REMOVAL .

3. Open the door and remove the rear upper screw (1).

Fig. 233: Support Screws

4. Remove the front fascia. Refer to FASCIA, FRONT, REMOVAL .

5. Remove the front wheel opening molding. Refer to MOLDING, FRONT WHEEL OPENING,
REMOVAL .
6. Remove the wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE,
REMOVAL .
7. Remove the support screws (4).

Fig. 234: Fender Bolts

8. Remove the battery tray (depending on fender being serviced). Refer to TRAY, BATTERY,
REMOVAL .
9. Remove the bolts (1) and on the right side (3) and remove the fender (4).
INSTALLATION
INSTALLATION

Fig. 235: Fender Bolts

1. Position the fender (4) onto the hydroform fender supports (2).
2. Loosely install the bolts (1) and (3) for the right side.
Fig. 236: Support Screws

3. Loosely install the support bolts (4).

4. Check and adjust the fender gap and flush. Refer to GAP AND FLUSH, SPECIFICATIONS.
5. Tighten all the bolts to 9 N.m (80 in. lbs.).
Fig. 237: Rear Upper Screw

6. Install the bolt (1) and tighten to 9 N.m (80 in. lbs.).
7. Install the battery tray, if required. Refer to TRAY, BATTERY, INSTALLATION .
8. Install the wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE,
INSTALLATION .
9. Install the front wheel opening molding. Refer to MOLDING, FRONT WHEEL OPENING,
INSTALLATION .
10. Install the front fascia. Refer to FASCIA, FRONT, INSTALLATION .
11. Install the headlamp unit. Refer to UNIT, FRONT LAMP, INSTALLATION .

Fig. 238: Radio Antenna Connector

12. Install the antenna, if necessary. Refer to MAST, ANTENNA, INSTALLATION .
GRILLE
REMOVAL
REMOVAL
Fig. 239: Upper Radiator Seal


1. Remove the four push pins (1).

2. Remove the two plastic rivets (2) and remove the upper radiator seal.
Fig. 240: Upper Grille Support Bolts

3. Remove the four upper grille support bolts (1).
Fig. 241: Grille Lower Spring Clips & Hooks


4. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, separate the two lower spring clips (2).
5. Release the two lower hooks (1) and remove the grille.
INSTALLATION
INSTALLATION
Fig. 242: Grille Lower Spring Clips & Hooks

1. Position the grille onto the front of the vehicle and locate using the tab (4).
2. Working from behind the grille, make sure the lower tabs (3) are positioned through the slots in the
fascia.
3. Seat the lower spring clips (2) fully.

Fig. 243: Upper Grille Support Bolts

4. Install the four upper bolts (1).
Fig. 244: Upper Radiator Seal

5. Position the upper radiator seal back into place over the radiator.
6. Install the four push pin fasteners (1) and seat fully.
7. Install the two plastic rivets (2) and seat fully.

GRILLE, ACTIVE SHUTTER
DESCRIPTION
DESCRIPTION
Fig. 245: Identifying Active Grille Shutter (AGS) System Components

This vehicle features an Active Grille Shutter (AGS) system. The AGS is located behind the front lower portion
of the grill and in front of the radiator.
The AGS system consist of an electric motor, shutter vanes, linkage, and seals that are located behind the front
grille. The AGS components include:
1. Right Side Seal

2. Actuator Bracket
3. Actuator Bolts
4. Link
5. Drive Arm
6. Vanes
7. Actuator
8. Left Side Seal
9. Frame

10. Lower Attachment Bolts

11. Lower Seal
12. Center Seal
13. Upper Attachment Bolts
Aerodynamics plays an important role in regards to fuel efficiency. Aerodynamic drag increases as vehicle
speed increases. With the vehicle traveling at highway speeds, engine power requirements increase in order to
overcome wind drag across the front of the vehicle. Reducing the wind drag coefficient across the front of the
vehicle is directly proportional to an improvement in fuel efficiency.
OPERATION
OPERATION
The AGS system is controlled by the powertrain control module (PCM) over a dedicated network LIN bus.
When the ambient air and engine coolant temperatures are below a specified threshold, airflow across the
radiator is not required. When airflow across the radiator is not required and vehicle speeds reach a calibrated
threshold, the PCM will command the shutter vanes to close.
Closing the grill shutter vanes creates an improved drag coefficient across the front of the vehicle. If additional
cooling is required due to increasing engine coolant temperatures, the PCM commands the grill shutter vanes to
open. In cold climates, the active grill shutter system may be used to improve engine coolant warm-up times
further increasing fuel economy.
To aid with diagnosis, the grill shutter vanes can be commanded to the open or closed positions with a scan tool.
The active grill shutters perform an initialization each time the vehicle is started. The initialization can be used
as a quick way to validate the operation of the AGS. To perform the AGS validation, start the engine and
observe the grill shutters, the shutters will cycle to the fully open position and then to the fully closed positions
to initialize and learn the hard stops on the grill shutter frame for that key cycle.
If the AGS smart module detects the grill shutters are jammed, it will attempt to free them by cycling the
shutters from the open to close positions 3 times. If this condition is detected when the ambient air temperature
is greater than 4.4° C (40° F) the MIL will illuminate and a diagnostic trouble code (DTC) will set. If the
ambient air temperature is below 4.4° C (40° F) and a jammed condition is detected, the smart module will
assume the shutters are frozen and will not illuminate the MIL or set a DTC.
The active grill shutter assembly contains an integral smart module, the module receives a command position
signal from the PCM to properly position the shutter vanes. The AGS module reports the position to the PCM
on the LIN bus. The AGS module four-pin connector also contains a battery voltage, ignition voltage, and a
ground circuit.
REMOVAL
REMOVAL
NOTE: When replacing the Active Grille Shutter (AGS) assembly or AGS actuator with a

service part it will be necessary to perform a counter reset with a scan tool.
Follow the scan tool prompts as located under PCM/Misc. Functions/Active Grill
Shutter Replace.
Fig. 246: Positioning Hood Switch

1. Remove the grille.
Refer to GRILLE, REMOVAL.
2. Separate the hood switch (1) and position aside.

Fig. 247: Upper And Lower Bolts

3. Remove the upper (1) and lower bolts (2) and tip the top of the AGS assembly down towards the front of
the vehicle.
Fig. 248: Lower Hooks, Wire Harness And Electrical Connector


4. Disconnect the electrical connector (3) and position aside the wire harness (2).
5. Lift the AGS assembly off the lower hooks (1) and remove the assembly.
DISASSEMBLY
DISASSEMBLY
Fig. 249: Identifying Flat Bladed Tool, Active Grill Shutter Frame & Vane
NOTE: When replacing the active grill shutter assembly or active grill shutter actuator
with a service part it will be necessary to perform a counter reset with a scan
tool. Follow the scan tool prompts as located under PCM/Misc. Functions/Active
Grill Shutter Replace.
1. Place an appropriate sized flat bladed tool (1), or equivalent between the active grill shutter frame (2) and
the vane (3) outer end.
2. Gently pry until the vane (3) tab is released from the frame (2).

Fig. 250: Identifying Frame, Linkage & Vane

3. Upper and lower vanes will need to be unclipped from the linkage (2), center vanes sit in the slot guides.
4. Move vane outward (3) to release it from the frame (1).
Fig. 251: Lower Vanes And Linkage

5. Remove the six lower vanes (2) from the active grill shutter housing.
6. Rotate the linkage (1) upward.

Fig. 252: Fasteners And Active Grill Shutter Actuator

7. Remove the two fasteners (1).

8. Remove the active grill shutter actuator (2) from the active grill shutter frame.
ASSEMBLY
ASSEMBLY
Fig. 253: Fasteners And Active Grill Shutter Actuator


1. Place the active grill shutter actuator (2) into the active grill shutter frame.
2. Install the two actuator fasteners (1) and tighten securely.
Fig. 254: Linkage, Actuator Arm And Frame

3. Rotate the linkage (1) onto the frame (3).

4. Align the actuator arm (2) to the center notch on the linkage (1).
Fig. 255: Identifying Frame, Linkage & Vane


5. The vane (3) has two inner tabs, guide one into the appropriate hole in center of the frame (1).
6. Guide the second inner tab into the appropriate slot on the linkage (2). The linkage (2) will clip onto the
vane tab on the upper and lower shutters, center shutters will sit in the center piece slots.
Fig. 256: Identifying Flat Bladed Tool, Active Grill Shutter Frame & Vane
7. Place an appropriate sized flat bladed tool (1) or equivalent, between the active grill shutter frame (2) and
the vane (3) outer end.
8. Gently pry until the vane (3) tab can be inserted into the appropriate hole in the frame (2).
9. Repeat until all vanes have been placed.
10. When replacing the active grill shutter assembly or active grill shutter actuator with a service part it will
be necessary to perform a counter reset with a scan tool. Follow the scan tool prompts as located under
PCM/Misc. Functions/Active Grill Shutter Replace.
INSTALLATION
INSTALLATION

Fig. 257: Lower Hooks, Wire Harness And Electrical Connector

1. Position the AGS assembly back onto the vehicle and secure on the lower hooks (1).
2. Position the wire harness (2) back onto the AGS assembly and connect the electrical connector (3).
Fig. 258: Upper And Lower Bolts

3. Position the AGS assembly back up onto the radiator support fully.
4. Install the upper bolts (1) and tighten to
5. Install the lower bolts (2) and tighten to
Fig. 259: Positioning Hood Switch

6. Position the hood switch (1) back and seat fully.

7. Install the grille.
Refer to GRILLE, INSTALLATION.
8. When replacing the active grill shutter assembly or active grill shutter actuator with a service part it will
be necessary to perform a counter reset with a scan tool. Follow the scan tool prompts as located under
PCM/Misc. Functions/Active Grill Shutter Replace.
ISOLATOR, BODY
REMOVAL
REMOVAL

Fig. 260: Mounting Bolts & Body Isolators

NOTE: Quad and club cab model shown in the illustration. Body isolators for regular
cab models are similar.
1. Loosen all cab to frame mounting bolts (2) (six regular cab, eight quad and club cab).
Fig. 261: Body Isolators


2. Using a suitable lifting device, lift the body to gain access to the isolators (1).
3. Remove the nuts (2) and remove the isolators as necessary.
INSTALLATION
INSTALLATION
Fig. 262: Body Isolators

CAUTION: Whenever a body isolator bolt requires servicing or tightening, it is

necessary to remove the bolt and install new thread locker compound to
the threads.
NOTE: Quad cab model shown in the illustration. Body isolators for regular and club
cab models are similar.
1. Position the isolators (1) under the cab as necessary.

2. Install the nuts (2).
3. Lower the cab onto the isolators (1) and install the mounting nuts (2).
4. Tighten the nuts to 68 N.m (50 ft. lbs.).

Fig. 263: Mounting Bolts & Body Isolators

5. Lower the cab onto the isolators and install the mounting bolts (2) and mass damper (1) as necessary (six
Regular cab, eight Quad Cab).
6. Tighten the mounting bolts to 108 N.m (80 ft. lbs.).
MIRROR, OUTSIDE REARVIEW
REMOVAL
REMOVAL

Fig. 264: Door Module & Outside Rearview Mirror Harness Connector
1. Remove the door trim panel as necessary to gain access to the mirror. Refer to PANEL, DOOR TRIM,
REMOVAL.
2. If equipped, disconnect the wire harness connector (2) from the door module (3) and separate the support
clip.

Fig. 265: Outside Rearview Mirror & Harness Connector

3. Remove the three nuts (2) that secure the mirror to the door and carefully remove the mirror.
INSTALLATION
INSTALLATION
Fig. 266: Outside Rearview Mirror & Harness Connector

1. If equipped, position the wire harness (3) through the door.

2. Position the mirror (1) onto the door.
3. Install the three nuts (2) that secure the mirror to the door. Tighten the nuts to 7 N.m (60 in. lbs.).

Fig. 267: Door Module & Outside Rearview Mirror Harness Connector
4. If equipped, connect the wire harness connector (2) to the door module (3).
MIRROR, OUTSIDE REARVIEW, GLASS
REMOVAL
REMOVAL
STANDARD MIRROR GLASS

Fig. 268: Mirror Glass Assembly

1. Move the mirror into the full down position.

2. Firmly and carefully grasp the mirror at the top (1) and pull out to separate the upper mounting clips.
Fig. 269: Hinge Type Clips

3. Separate the lower hinge type clips (1) and remove the mirror glass assembly.
4. Disconnect the electrical connectors (2), if equipped.
FOLDING MIRROR GLASS

Fig. 270: Mirror Glass & Trim Stick

1. Using a trim stick (2) or equivalent, carefully pry up the mirror glass from the bottom to release the glass
(1) from the actuator.
Fig. 271: Mirror Glass, Actuator & Electrical Connector

2. Remove the glass (2) from the actuator (3) and disconnect the electrical connectors (1).
INSTALLATION
INSTALLATION
STANDARD MIRROR GLASS

Fig. 272: Hinge Type Clips

1. Connect the electrical connectors (2), if equipped.

2. Position the mirror glass assembly into the housing and seat the lower hinge type clips (1) fully.
Fig. 273: Mirror Glass Assembly

3. Push the top of the glass (1) back into the housing and seat the mounting clips fully.
FOLDING MIRROR GLASS

Fig. 274: Mirror Glass, Actuator & Electrical Connector

1. Connect the electrical connectors (1) and position the glass (2) onto the actuator (3).
Fig. 275: Glass Tabs & Actuator Tabs

2. Position the glass tabs (1) over the actuator tabs (2).

Fig. 276: Mirror Glass

3. Using a trim stick or equivalent, gently pry down on the glass (1) and seat the glass onto the actuator
fully.
4. Verify glass operation.
MOLDING, FRONT WHEEL OPENING
REMOVAL
REMOVAL
1500 LIGHT DUTY
Fig. 277: Identifying Front Fender Flare & Center Push-Pin

1. Remove the seven fender flare retainers (1).
NOTE: Make sure the push-pin is completely removed.
2. Cut off the alignment push-pin (3) located in the middle of the fender flare.
CAUTION: Use of a trim stick maybe necessary to remove the fender flare. Use
care not to scratch the paint.
3. Remove the fender flare (2) by starting at the bottom rear of the fender flare.
NOTE: Make sure all adhesive tape is removed.
4. Remove the adhesive tape from the fender using 3M General Purpose Adhesive Cleaner or equivalent.
2500/3500 HEAVY DUTY

1. Remove the six fender flare retainers (3).

3. Remove the fender flare by starting at the bottom rear of the fender flare.
FLARE MOLDING
Fig. 279: Fender Flare Retainers

1. Remove the seven fender flare retainers (2).

Fig. 280: Flare Molding

2. Cut off the alignment push-pins (1) located in the middle of the fender flare.
3. Remove the fender flare by starting at the bottom rear of the fender flare.
FLARE EXTENSION MOLDING
Fig. 281: Flare Extension Molding Rivets

1. Remove the rivets (3).

2. Remove the flare extension (2) from the front bumper assembly (1).
INSTALLATION
INSTALLATION
1500 LIGHT DUTY


NOTE: Be sure the surface is clean and dry before installing the fender flare.
1. Wipe the fender surface with alcohol or equivalent and let dry for three minutes.
2. Align new front fender flare (2) by installing the center push-pin (3) first.
NOTE: It is important for a correct fit to hold the flare tight against the fender as
the screws are tightened.
3. Loosely install the seven fender flare retainers (1).

Fig. 283: Retainer Tightening Sequence

4. Tighten the seven retainers (1) to 2.8 N.m (25 In. lbs.) using the sequence shown in the illustration.
5. If any gaps are found, loosen the nearest retainers, apply pressure to the gap area and retighten the
retainers. Repeat until all gaps are gone.
NOTE: Do not remove protective film until fender flare is secured and fits with no
gaps.
6. Remove the protective film from the back of the fender flare and apply inward pressure the whole length
of the fender flare.
2500/3500 HEAVY DUTY

NOTE: Be sure the surface is clean and dry before installing the fender flare.
1. Wipe the fender surface with alcohol or equivalent and let dry for three minutes.
2. Align new front fender flare (2) by installing the center push-pin (1) first.
3. Loosely install the six fender flare retainers (3).

Fig. 285: Identifying Retainers

4. Tighten the six retainers (1) to 2.8 N.m (25 In. lbs.) using the sequence shown in the illustration.
NOTE: Do not remove adhesive tape protective film until fender flare is secured
and fits with no gaps.
FLARE MOLDING

Fig. 286: Installing Flare Molding

NOTE: It is important for a correct fit to hold the flare tight against the fender as the
screws are tightened.
1. Position the flare (4) onto the vehicle and insert the alignment push pins (1) first to hold the flare in place.
NOTE: Lift and push to the inside of the vehicle the rear portion of the wheel
fender in order to reduce the gap between the flare and the sheet metal.
2. While lifting and holding the flare (4) to the rear lower portion of the fender (2) seat the remaining push
pins (3) fully.
Fig. 287: Identifying Flare Molding Push Pins

3. Tighten the sever retainers (2) in sequence starting from the front screw, then the remaining screws in the
direction from front to rear.
Tighten retainers to 2.8 N.m (25 In. lbs.).
FLARE EXTENSION MOLDING

Fig. 288: Flare Extension Molding Rivets

1. Install the flare extension (2) onto the front bumper assembly (1) and install the rivets (3).
MOLDING, REAR WHEEL OPENING
REMOVAL
REMOVAL

1. Remove the eight fender flare retainers (3).

3. Pull the fender flare off, starting at the bottom rear of the fender flare.
INSTALLATION
INSTALLATION
Fig. 290: Rear Fender Flare & Center Push-Pin

NOTE: Be sure the surface is clean and dry before installing the rear fender flare.
1. Wipe the fender surface with alcohol and let dry for three minutes.
2. Align new rear fender flare (1) by installing the center push-pin (2) first.

Fig. 291: Aligning Fender Flare Groove

NOTE: Incorrect fender flare to fender flange installation will cause gaps between
the fender and fender flare.
3. Align the fender flare so that the groove at the bottom of the fender flare (1) completely wraps around the
fender flange (2).


4. Loosely install the eight fender flare retainers (3).
Fig. 293: Rear Retainer Tightening Sequence

5. Tighten the retainers to 2.8 N.m (25 In. Lbs.) on fender flare (1) using the sequence shown in the
illustration.
6. If any gaps are found, loosen nearest retainer, apply pressure to the gap area and retighten the retainer.
Repeat until all gaps are gone.
NOTE: Do not remove protective film until fender flare is secured and fits with no
gaps.
NAMEPLATE
REMOVAL
REMOVAL

Fig. 294: Name Plates

1 - "HEMI 5.7 LITER"

2 - "RAM HEAD MEDALLION"
3 - "4X4"
4 - "FLEX FUEL E85 ETHANOL"
5 - "SLT", "LONE STAR", "BIG HORN", "LARAMIE"
6 - "TRX4 OFF-ROAD"
7- "RAM"
NOTE: Standard Cab model shown in the illustration. Exterior name plates and decals
for all other cab models are similar. Exterior name plate and decal usage vary
by model.
1. As a guide for installation, apply a length of masking tape on the body, parallel to the top edge and, to one
end of the name plate or decal being removed.
CAUTION: Do not exceed 52° C (120° F) when heating name plates, decals or
body panels. Failure to follow this caution may result in damage to
the name plates, decals and/or the vehicle paint finish.
2. If the temperature is below 21° C (70° F), warm the name plate or decal with a heat lamp or heat gun.
NOTE: The exterior name plates are attached to the body with adhesive tape.
3. Using a trim stick (special tool #C-4755, Trim Stick) or equivalent, carefully remove the name plate or

decal from the body panel, as necessary.
INSTALLATION
INSTALLATION
Fig. 295: Name Plates

1 - "RAM"
2 - "TRX4 OFF-ROAD"
3 - "SLT", "LONE STAR", "BIG HORN", "LARAMIE"
4 - "FLEX FUEL E85 ETHANOL"
5 - "4X4"
6 - "RAM HEAD MEDALLION"
NOTE: Standard Cab model shown in the illustration. Exterior name plates and decals
for all other cab models are similar. Exterior name plate and decal usage vary
by model.
1. Thoroughly clean all residue from the name plate or decal attachment areas of the body.
2. Wipe the attachment areas with a clean, lint-free cloth, moistened with a 50% solution of water and
alcohol and then wipe dry the areas immediately with a dry, lint-free cloth.
CAUTION: Do not exceed 52° C (120° F) when heating name plates, decals or
body panels. Failure to follow this caution may result in damage to
the name plates, decals and/or the vehicle paint finish.

NOTE: If ambient temperatures are below 21° C (70° F), warm the name plate or
decal and body panel with a heat lamp or gun to assure proper adhesion.
3. Remove the protective covering from the back of name plate or decal and position the name plate or decal
onto the body using the previously installed guide tape.
NOTE: To ensure proper name plate or decal adhesion, apply consistent and
uniform pressure of approximately 40 p.s.i. over the entire surface of each
name plate or decal.
4. Install the name plate or decal onto the body.
PANEL, CLOSURE, RADIATOR
REMOVAL
REMOVAL
1. Disconnect and isolate battery negative cable.

2. Remove the grille. Refer to GRILLE, REMOVAL.
3. Remove the washer bottle, if necessary. Refer to RESERVOIR, WINDSHIELD WASHER,
REMOVAL .
4. Remove the coolant bottle, if necessary. Refer to BOTTLE, COOLANT RECOVERY, REMOVAL .
5. Remove the hood latch. Refer to LATCH, HOOD, REMOVAL.
6. Remove the front bumper. Refer to BUMPER, FRONT, REMOVAL .
7. Remove the A/C condenser, if equipped. Refer to CONDENSER, A/C, REMOVAL .
8. Remove the charge air cooler, if equipped. Refer to COOLER AND HOSES, CHARGE AIR,
REMOVAL, 6.7L .
9. Remove the headlamps. Refer to UNIT, FRONT LAMP, REMOVAL .
10. Remove the air cleaner. Refer to AIR CLEANER, REMOVAL, 5.7L ,AIR CLEANER, REMOVAL,
5.7L , AIR CLEANER, REMOVAL, 6.4L or AIR CLEANER, REMOVAL, 6.7L .

Fig. 296: Identifying Foam & Push Pin Fasteners

11. Separate the push pin fasteners (2) and remove the foam (1).
12. Remove the upper radiator bolts and position back supported in the vehicle.
13. Disconnect the TIPM.
14. Remove the trim pieces below the headlights, if equipped.
15. Open the access covers in the wheelhouse splash shields and remove the bolts supporting the fender on
each side.
16. Remove the bolts and disconnect any ground cables as necessary.
Fig. 297: Installing Closure Panel & Front End Sheet Metal Mounting

17. Remove the upper (2) and lower (4) bolts supporting the closure panel (1) to the front end sheet metal
mounting (3).
18. Carefully remove the closure making sure the paint on the front edge of the fenders is protected from
damage.
INSTALLATION
INSTALLATION
Fig. 298: Closure Panel & Front End Sheet Metal Mounting
1. Carefully position the closure assembly (1) up onto the front end sheet metal mounting (3) and avoid
damaging the front edges of the fenders.
2. Install the lower bolts (4) and tighten to 20 N.m (15 ft. lbs.)
3. Install the upper bolts (2) and tighten to 20 N.m (15 ft. lbs.)
4. Install the ground cables and install the bolts if necessary.
5. Install the fender support bolt from inside the wheelhouse splash shield.
6. Install the trim pieces below the headlights, if equipped.
7. Connect the TIPM electrical connectors and position the TIPM back into place.
8. Position the radiator back and insert the lower radiator mounts.
9. Install the upper radiator bolts.

Fig. 299: Installing Foam & Push Pin Fasteners

10. Install the foam (1) and seat the push pin fasteners (2) fully.
11. Install the air cleaner assembly. Refer to AIR CLEANER, INSTALLATION, 5.7L ,AIR CLEANER,
INSTALLATION, 5.7L ,AIR CLEANER, INSTALLATION, 6.4L or AIR CLEANER,
INSTALLATION, 6.7L .
12. Install the headlamps. Refer to UNIT, FRONT LAMP, INSTALLATION .
13. Install the charge air cooler, if equipped. Refer to COOLER AND HOSES, CHARGE AIR,
INSTALLATION, 6.7L .
14. Install the A/C condenser, if equipped. Refer to CONDENSER, A/C, INSTALLATION .
15. Install the front bumper. Refer to BUMPER, FRONT, INSTALLATION .
16. Install the hood latch. Refer to LATCH, HOOD, INSTALLATION.
17. Install the coolant bottle, if necessary. Refer to BOTTLE, COOLANT RECOVERY,
INSTALLATION .
18. Install the washer bottle, if necessary. Refer to RESERVOIR, WINDSHIELD WASHER,
INSTALLATION .
19. Install the grille. Refer to GRILLE, INSTALLATION.
SHIELD, SPLASH, FRONT WHEELHOUSE
REMOVAL
REMOVAL

Fig. 300: Inner Shield Push Pins

1. Release the ABS harness push pin from the inner shield.
2. Remove the push pins (2, 3, 4).
Fig. 301: Inner Shield Screws

3. Remove the inner screws (3 and 4).

4. Remove the screws securing the shield to the fascia and the outer fender flange (2).
5. Release the outboard edge of the shield (1) from the fender flange and remove the shield (1).

INSTALLATION
INSTALLATION
Fig. 302: Inner Shield Screws

1. Position the shield (1) inside the wheelhouse opening and tuck the outboard edge of the shield behind the
flange on the fender outer panel.
2. Align and secure the outboard edge of the splash shield to the outer fender. Drive the screws (2) through
the fender flange and into the shield.
3. Install the screw (3) and install the screw (4).

Fig. 303: Inner Shield Push Pins

4. Install the push pin (2) and seat fully.

7. Secure the ABS harness push pin to the inner shield and seat fully.
SHIELD, SPLASH, REAR WHEELHOUSE
REMOVAL
REMOVAL
Fig. 304: Rear Wheelhouse Splash Shield Screws

1. Remove the inner screw (1).

2. Remove the three screws (3) and remove the splash shield (2).
INSTALLATION
INSTALLATION

Fig. 305: Rear Wheelhouse Splash Shield Screws

1. Position the rear splash shield (2) onto the cargo box.
2. Install the three screws (3).
3. Install the inner screw (1).
STEP, SIDE
REMOVAL
REMOVAL
Fig. 306: Removing/Installing Side Step


1. Remove the bolts (3) and remove the step (2) from the body side aperture (1).
INSTALLATION
INSTALLATION
Fig. 307: Removing/Installing Side Step

1. Install the side step (2) onto the body side aperture (1) and install the bolts (3).
TIE DOWN, PICKUP BOX
REMOVAL
REMOVAL

Fig. 308: Removing/Installing Tie Down Cleat

1. Remove the two bolts (1) that secure each cargo box tie down (2) to the cargo bed and remove the cleats
as necessary.
INSTALLATION
INSTALLATION

Fig. 309: Removing/Installing Tie Down Cleat

1. Position the cargo box tie downs (2) to the cargo box as necessary.
2. Install the two bolts (1) that secure each cargo box tie down to the cargo box. Tighten the bolts to 34 N.m
(25 ft. lbs.).
HOOD
CABLE, HOOD RELEASE
REMOVAL
REMOVAL

Fig. 310: Hood Release Cable

1. Release the cable end (1) from the latch mechanism (5) and release the collar (2) from the latch.
2. Release the support clip (4).
Fig. 311: Hood Release Cable Retainers

3. Remove the three hood release cable retainers (2) from the upper radiator crossmember and the left fender
rail.

Fig. 312: Releasing Hood Release Clip

4. From inside the vehicle using a small flat bladed tool (3), release the clip (2) attaching the hood release
handle (1) to the instrument panel.

Fig. 313: Removing/Installing Handle

5. Separate the handle (1) by pulling down and release the handle assembly tabs from the instrument panel.

Fig. 314: Hood Release Handle

6. Remove the grommet from the cowl panel and remove the hood release cable and handle assembly.
INSTALLATION
INSTALLATION

Fig. 315: Removing/Installing Handle

1. Position the handle (1) and align the clips to the instrument panel feature location.
2. Press handle to seat the clips to the instrument panel.

Fig. 316: Hood Release Cable Retainers

3. Route the latch end of hood latch release cable tube through the dash panel and into the engine
compartment. Feed the entire length of the cable through the dash panel.
4. Press the grommet (1) into the hole in the dash panel by hand until fully seated.
5. Route the cable along the fender rail and to the outboard and front of the vertical support post and seat the
mounting clips (2) fully.

6. Route cable (3) through the front end module and on to the latch (5).

7. Align and insert end of cable (1) to the mechanism on the latch (5).
8. Press the collar (2) into the hole and snap into place.
9. Seat the mounting clips (4) fully.
HINGE, HOOD
REMOVAL
REMOVAL
Fig. 318: Hood Hinge

NOTE: It is not necessary to remove the hood to replace the hood hinges. Hood hinges
can be replaced one at a time.
1. Using a grease pencil or equivalent, mark the position of the hood hinge (1) on the hood for the hinge
being serviced.
2. Support the hood and disconnect the gas prop from the hood. Refer to PROP, GAS, REMOVAL.
3. Remove the two nuts (2) that secure the hood to the hood hinge.
4. Remove the wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE,
REMOVAL or SHIELD, SPLASH, REAR WHEELHOUSE, REMOVAL.
5. Remove the bolts (4) that secure the hood hinge (1) to the fender rail (3).
6. Slide the hood hinge forward and remove the hinge.
INSTALLATION
INSTALLATION


NOTE: It is not necessary to remove the hood to replace the hood hinges. Hood hinges
can be replaced one at a time.
1. Position the hood hinge (2) onto the fender rail (1) and slide it rearward to its installed location.
2. Install the bolts (4) that secure the hood hinge to the fender rail and tighten to 19 N.m (14 ft. lbs.).
3. Loosely install the two nuts (2) that secure the hood to the hood hinge.
4. Align the hood to the hood hinge using the reference marks made during the Removal procedure and
tighten the nuts to 18 N.m (13 ft. lbs.).
5. Install the support cylinder. Refer to PROP, GAS, INSTALLATION.
6. If required, adjust the hood to the correct position. Refer to GAP AND FLUSH, SPECIFICATIONS.
7. Install the wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE,
INSTALLATION or SHIELD, SPLASH, REAR WHEELHOUSE, INSTALLATION.
8. Install the cowl grille. Refer to COVER, COWL PANEL, INSTALLATION.
HOOD
REMOVAL
REMOVAL

Fig. 320: Hood Gas Prop


2. Using a grease pencil or equivalent, mark the position of the hood hinges (2) on the hood.
3. Support the hood and disconnect the gas prop (2) from the hood. Refer to PROP, GAS, REMOVAL.

4. Remove the two nuts (2) that secure the hood to each hood hinge (1) and remove the hood.
INSTALLATION

INSTALLATION

NOTE: The Vehicle Emission Control Information (VECI) label(s) must be in place for
the life of the vehicle. When replacing the component in which the VECI label is
adhered, a new VECI label must also be adhered to the new component.
1. Position the hood onto the hood hinges (1) and loosely install the two nuts (2) that secure the hood to each
hood hinge.
2. Align the hood to the hood hinges using the reference marks made during the Removal procedure and
tighten the nuts to 18 N.m (13 ft. lbs.).
3. Install the support cylinders to the hood. Refer to PROP, GAS, INSTALLATION.
LATCH, HOOD
REMOVAL
REMOVAL

Fig. 323: Hood Latch

1. Remove the grille. Refer to GRILLE, REMOVAL.

2. Using a grease pencil or equivalent, mark the position of the hood latch (1) on the upper radiator
crossmember.
3. Remove the two bolts (3) that secure the hood latch to the upper radiator crossmember.

4. Disconnect the hood latch cable (1) from the hood latch and remove the latch.
INSTALLATION

INSTALLATION

1. Connect the hood latch cable (1) to the hood latch (5).
Fig. 326: Hood Latch

2. Position the hood latch to the upper radiator crossmember and loosely install the two bolts (2) that secure
the latch to the crossmember.
3. Align the hood latch to the upper radiator crossmember using the reference marks made during the
Removal procedure and tighten the bolts to 11 N.m (8 ft. lbs.).

PROP, GAS
REMOVAL
REMOVAL
Fig. 327: Support Cylinder-Ball Socket-Typical

NOTE: The hood support cylinders can be replaced one at a time.
1. Open and support the hood.
CAUTION: Do not pull on the hood support cylinders at the middle of the
support cylinder during removal. Failure to follow this caution can
result in damage to the hood support cylinders.
2. Using a small flat bladed tool, or equivalent (3), release the retaining clip (2) at each end of the support
cylinder while carefully pulling the ball socket (1) away from the ball stud (4).

Fig. 328: Support Cylinder Retaining Clip

1 - RETAINING CLIP
2 - BALL SOCKET
3 - BALL STUD
NOTE: Lift the clips (1) only enough to release the ball studs (3).


3. Disconnect the hood support cylinder (2) from the hood and the fender rail (1).
INSTALLATION
INSTALLATION

CAUTION: Do not push on the hood support cylinders at the middle of the support
cylinder during installation. Failure to follow this caution can result in
damage to the hood support cylinders.
NOTE: Install the hood support cylinders with the cylinder end connected to the hood
as shown in the illustration.
NOTE: If required, only release each retaining clip enough to install the ball socket
onto the ball stud.
1. Install the hood support cylinder (2) over the upper and lower ball studs and fully engage the retaining
clips.
STRIKER, HOOD
REMOVAL
REMOVAL

Fig. 331: Hood Striker

1. Remove the two bolts (2) that fasten the striker to the hood and remove the striker (1).
INSTALLATION
INSTALLATION
Fig. 332: Hood Striker

CAUTION: Make sure the striker assembly is seated into the pocket on the hood

inner. If not seated correctly, the striker will damage the paint when
secured.
1. Install the striker and install the bolts.

2. Tighten the bolts to 17 N.m (12.5 ft. lbs.)
INSTRUMENT PANEL
WARNING
WARNING

Supplemental Restraint System (SRS), never attempt to repair the
WARNING: To avoid serious or fatal injury during and following any seat belt or child
restraint anchor service, carefully inspect all seat belts, buckles,
injury.
WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain
airbags, disable the Supplemental Restraint System (SRS) before

attempting any Occupant Restraint Controller (ORC) diagnosis or service.

The ORC may contain a rollover sensor, which enables the system to
deploy the side SRS components in the event of a vehicle rollover event.
If an ORC containing a rollover sensor is accidentally rolled during
service while still connected to battery power, the side SRS components
will deploy. Disconnect and isolate the battery negative (ground) cable,
then wait two minutes for the system capacitor to discharge before
disable the SRS. Failure to take the proper precautions could result in
the Supplemental Restraint System (SRS) before attempting any steering
wheel, steering column, airbag, seat belt tensioner, impact sensor or
instrument panel component diagnosis or service. Disconnect and isolate
the battery negative (ground) cable, then wait two minutes for the system
capacitor to discharge before performing further diagnosis or service.
This is the only sure way to disable the SRS. Failure to take the proper
precautions could result in accidental airbag deployment.

or tamper with its inflator. Do not puncture, incinerate or bring into
contact with electricity. Do not store at temperatures exceeding 93° C

BEZEL, INSTRUMENT CLUSTER
REMOVAL
REMOVAL
WARNING: On vehicles equipped with airbags, disable the airbag system before
attempting any steering wheel, steering column, seat belt tensioner, or
the battery negative (ground) cable, then wait two minutes for the airbag
system capacitor to discharge before performing further diagnosis or
service. This is the only sure way to disable the airbag system. Failure to
take the proper precautions could result in accidental airbag deployment
and personal or fatal injury.

Fig. 333: Instrument Cluster Bezel, Instrument Panel & Fasteners


2. Remove the fasteners (2) that secure the top of the instrument cluster bezel (3) to the instrument panel (1).
Fig. 334: Instrument Panel Cluster Bezel

3. Using a trim stick (special tool #C-4755, Trim Stick) or equivalent, disengage the retainer clips that

secure the instrument cluster bezel (2) to the instrument panel (1) and remove the bezel.
INSTALLATION
INSTALLATION
Fig. 335: Instrument Cluster Bezel

1. Install the instrument cluster bezel onto the instrument panel and fully engage the retainer clips to the
instrument panel.

Fig. 336: Instrument Cluster Bezel

2. Install the fasteners (2) that secure the instrument cluster bezel (3) to the instrument panel (1).
3. Connect the negative battery cable.
BEZEL, INSTRUMENT PANEL, CENTER
REMOVAL
REMOVAL

Fig. 337: Center Bezel Tray Liners

2. Remove the upper and lower center bezel tray liners (1).


Fig. 339: Power Outlet Trim Bezel

3. Using a trim stick (special tool #C-4755, Trim Stick) or equivalent, disengage the retain clips that secure
the power outlet trim bezel (1) to the center bezel (2).
Fig. 340: Center Bezel Fasteners (1 Of 3)

NOTE: For vehicles not equipped with a center console, there are only 3 bezel

fasteners.



Fig. 343: Shifter Bezel Trim Ring

4. Remove the five center bezel fasteners (1).

secure the trim ring to the floor console.
Fig. 344: Console Bezel

secure the shifter bezel to the floor console

Fig. 345: Instrument Panel Center Bezel Retaining Clips

secure the instrument panel center bezel (1) to the instrument panel.
8. Disconnect the wire harness connectors (4) and remove the center bezel from the vehicle.
INSTALLATION
INSTALLATION

Fig. 346: Instrument Panel Center Bezel Retaining Clips

1. Position the instrument panel center bezel (1) near the instrument panel and connect the wire harness
connectors (4).
2. Install the instrument panel center bezel (1) onto the instrument panel and fully engage the retainer clips.
Fig. 347: Console Bezel

3. Install the shifter bezel to the floor console and fully engage the retainer clips.

4. Install the shifter bezel trim ring and fully engage the retainer clips.

NOTE: For vehicles not equipped with a center console, there are only 3 bezel
fasteners.



Fig. 352: Power Outlet Trim Bezel

5. Install the five instrument panel fasteners.

6. Install the power outlet trim bezel (1), to the center bezel (2), fully engaging the retainer clips.

7. Install the upper and lower center bezel tray liners (1).


BIN, INSTRUMENT PANEL
REMOVAL
REMOVAL
Fig. 355: Storage Bin Fastener

1. Remove glove box from instrument panel. Refer to GLOVE BOX, INSTRUMENT PANEL,
REMOVAL.
2. Through the glove box opening remove storage bin fastener (2) located at the back of the storage bin (1).

Fig. 356: Storage Bin

3. Open storage bin door (1).

4. Disengage the retainer clips that secure the storage bin (2) to the instrument panel (3).
5. Partial remove the storage bin and disconnect the storage bin light electrical connector.
6. Remove storage bin (2) from vehicle.
INSTALLATION
INSTALLATION


1. Partial install the storage bin and connect the storage bin light electrical connector.
2. Engage the storage bin retainer clips and fully seat the storage bin (2) to the instrument panel (3).
3. Close storage bin door (1).
Fig. 358: Storage Bin Fastener


4. Through the glove box opening install the storage bin fastener (2) at rear of storage bin (1).
5. Install the glove box to the instrument panel. Refer to GLOVE BOX, INSTRUMENT PANEL,
INSTALLATION.
COVER, INSTRUMENT PANEL
REMOVAL
REMOVAL

2. Remove the steering column opening cover Refer to COVER, STEERING COLUMN OPENING,
REMOVAL.
3. Remove the steering column as necessary. Refer to COLUMN, REMOVAL .
Fig. 359: Floor Console


4. Remove the floor console, if equipped. Refer to CONSOLE, FLOOR, REMOVAL and CONSOLE,
FLOOR, LID, REMOVAL.
5. Using a trim stick (special tool #C-4755, Trim Stick) or equivalent remove the Lower Center Bezel.
Fig. 360: Removing/Installing A-Pillar Trim/Grab Handle

NOTE: Right side shown in the illustration, left side similar.
6. Remove the left and right A-pillar trim. Refer to PANEL, A-PILLAR TRIM, WITH GRAB HANDLE,
REMOVAL.

Fig. 361: Fence Line Bolt Access Covers

7. Remove fence line bolt access covers.

8. Remove fence line bolts.
9. Remove the instrument panel center bezel. Refer to BEZEL, INSTRUMENT PANEL, CENTER,
REMOVAL.
10. Remove the Radio. Refer to RADIO, REMOVAL .
11. Remove right and left power outlets and bezels.


12. Remove the instrument panel cluster bezel. Refer to BEZEL, INSTRUMENT CLUSTER,
REMOVAL.
Fig. 363: Instrument Cluster Gauges And Indicators

13. Remove the instrument cluster. Refer to INSTRUMENT CLUSTER, REMOVAL .

14. Remove the parking brake Lever bezel. Refer to HANDLE, PARKING BRAKE RELEASE,
REMOVAL .

Fig. 364: Headlamp Switch & Left Distribution Register

15. Remove the headlamp switch / left distribution register. Refer to SWITCH, HEADLAMP,
REMOVAL .
16. Remove the left and right instrument panel speakers. Refer to SPEAKER, REMOVAL .
Fig. 365: Locating Sun Sensor

17. Remove the center Instrument panel speaker and sun sensor. Refer to SPEAKER, REMOVAL .

Fig. 366: Right Distribution Register

18. Remove the right distribution register. Refer to OUTLET, AIR, REMOVAL .
Fig. 367: Glove Box

19. Remove the glove box (2) from the instrument panel. Refer to GLOVE BOX, INSTRUMENT PANEL,
REMOVAL.


20. Remove the instrument panel storage bin. (2) Refer to BIN, INSTRUMENT PANEL, REMOVAL.
Fig. 369: Passenger Air Bag

21. Remove the passenger air bag support bolts.

22. Remove the 26 instrument panel cover fasteners.
23. Partial remove the instrument panel cover to access and disconnect the PAB harness.
24. Remove the instrument panel cover from the vehicle.

INSTALLATION
INSTALLATION
1. Partial install the instrument panel cover into the vehicle access and connect the passenger side airbag
harness.
2. Install the 23 instrument panel cover fasteners.
Fig. 370: Passenger Air Bag

3. Install the passenger air bag. Refer to AIR BAG, PASSENGER, INSTALLATION .


4. Install the instrument panel storage bin. Refer to BIN, INSTRUMENT PANEL, INSTALLATION.
Fig. 372: Glove Box

5. Install the glove box from the instrument panel. Refer to GLOVE BOX, INSTRUMENT PANEL,
INSTALLATION.

Fig. 373: Right Distribution Register

6. Install the right distribution register. Refer to OUTLET, AIR, INSTALLATION .
Fig. 374: Locating Sun Sensor

7. Install the center instrument panel speaker and sun sensor. Refer to SPEAKER, INSTALLATION .
8. Install the left and right instrument panel speakers. Refer to SPEAKER, INSTALLATION .

Fig. 375: Headlamp Switch & Left Distribution Register

9. Install the headlamp switch / left distribution register. Refer to SWITCH, HEADLAMP,
INSTALLATION .
10. Install the parking brake lever bezel.
Fig. 376: Instrument Cluster Gauges And Indicators

11. Install the instrument cluster. Refer to INSTRUMENT CLUSTER, INSTALLATION .


12. Install the instrument panel cluster bezel. Refer to BEZEL, INSTRUMENT CLUSTER,
INSTALLATION.
13. Install right and left power outlets and bezels.
14. Install the radio. Refer to RADIO, INSTALLATION .
15. Install the instrument panel center bezel. Refer to BEZEL, INSTRUMENT PANEL, CENTER,
INSTALLATION.


16. Install fence line bolt access covers.

17. Install fence line bolts.
18. Install the defroster grille


19. Install the left and right A-pillar trim. Refer to PANEL, A-PILLAR TRIM, WITH GRAB HANDLE,
INSTALLATION.
20. Install the Lower Center Bezel.

21. Install the floor console, if equipped. Refer to CONSOLE, FLOOR, INSTALLATION and
CONSOLE, FLOOR, LID, INSTALLATION.
22. Install the WIC Module and install the WIC Module fasteners.
23. Connect the WIC Module electrical connectors.
24. Install the steering column as necessary. Refer to COLUMN, INSTALLATION .
25. Install the steering column opening cover Refer to COVER, STEERING COLUMN OPENING,
INSTALLATION.
COVER, STEERING COLUMN OPENING
REMOVAL
REMOVAL

Fig. 381: Steering Column Opening Cover & Fasteners

1. Using a trim stick (special tool #C-4755, Trim Stick) or equivalent, disengage the retainer clip that
secures the hood release to the steering column opening cover, and remove the hood release handle from
the cover.
2. Remove the two fasteners (2) that secure the bottom of the steering column opening cover (1) to the
instrument panel.

Fig. 382: Data Link Connector

3. Remove the Data Link Connector (3) from the steering column opening cover (2) by pressing in the tabs
(1) and pushing the connector through the opening on the back side of the cover.
Fig. 383: Steering Column Opening Cover

4. Using a trim stick (special tool #C-4755, Trim Stick) or equivalent, release the retainer clips that secure
the steering column opening cover (1) to the instrument panel and remove the cover.
INSTALLATION
INSTALLATION

Fig. 384: Steering Column Opening Cover

1. Position the steering column opening cover (2) to the instrument panel and fully engage the retainer clips
to the instrument panel.
Fig. 385: Data Link Connector


2. Install the Data Link Connector (3) to the steering column opening cover (2) by pushing the connector
through the opening on the back side of the cover and fully engaging the lock tabs (1) of the connector.
Fig. 386: Steering Column Opening Cover & Fasteners

3. Install the two fasteners (2) that secure the steering column opening cover (1) to the instrument panel.
4. Position the hood release hand onto the column opening cover and fully engage the retainer clip that
secures the hood release handle to the steering column opening cover.
CUPHOLDER, INSTRUMENT PANEL
REMOVAL
REMOVAL

Fig. 387: Lower Closeout Trim

1. Remove the center bezel. Refer to BEZEL, INSTRUMENT PANEL, CENTER, REMOVAL.
2. Remove the lower closeout trim (1).
Fig. 388: Side Trim & Screws

3. Remove the screws (1) and separate the side trim (2).

Fig. 389: Cup Holder

4. Remove the cup holder (1).
INSTALLATION
INSTALLATION
Fig. 390: Removing Cup Holder

1. Position the cup holder (1) onto the alignment tabs and seat fully.

Fig. 391: Side Trim & Screws

2. Install the lower side trim panels (2) and install the screws (1).
Fig. 392: Lower Closeout Trim

3. Position the lower closeout trim (1) back and seat the clips fully.
4. Install the center bezel. Refer to BEZEL, INSTRUMENT PANEL, CENTER, INSTALLATION.
GLOVE BOX, INSTRUMENT PANEL
REMOVAL

REMOVAL
Fig. 393: Installing Damper Spring

1. Open the glove box.

2. Release the damper string (1).
Fig. 394: Glove Box

Fig. 395: Glove Box Hinges

3. Release the two glove box stops (1) and lower the glove box (2) downward past the stops.
4. Disengage the glove box hinges (1) from the instrument panel and remove the glove box (2).
INSTALLATION
INSTALLATION

Fig. 396: Glove Box Hinges

1. Engage the hinges (1) of the glove box (2) to the instrument panel.
Fig. 397: Glove Box

2. Press downward on the back edge of the glove box (2) and raise the glove box past the two stops (1).

Fig. 398: Installing Damper Spring

3. Connect the damper string (1).

4. Close the glove box.
PANEL, INSTRUMENT
REMOVAL
REMOVAL

2. Remove the front seat assembly. Refer to SEAT, FRONT, REMOVAL or SEAT, FRONT CENTER,
REMOVAL, .

Fig. 399: Identifying Cowl/Sill Trim Panel

3. Remove the left cowl trim panel. Refer to PANEL, COWL TRIM, REMOVAL.

Fig. 400: Instrument Panel Wire Harness Connector

4. Remove the steering column opening cover. Refer to COVER, STEERING COLUMN OPENING,
REMOVAL.
5. Disconnect the instrument panel wire harness connector (2) located above the brake pedal from the
bulkhead wire harness connector (1).
6. Remove the steering column as necessary. Refer to COLUMN, REMOVAL .
Fig. 401: Trim Panel

7. Using a (special tool #C-4755, Trim Stick) or equivalent, remove the trim panel (1) from the instrument
panel.
Fig. 402: Trim Stick


Fig. 403: Bolts And Park Release Lever

8. Remove the bolts (1) and position the manual park release lever (2) aside.
9. Remove the hood release handle and position aside. Refer to CABLE, HOOD RELEASE, REMOVAL

Fig. 404: Park Release Handle And Link

10. Disconnect the park brake release handle (1) link (2).


Fig. 406: Instrument Panel Side Cover

11. Remove the left A-pillar trim. Refer to PANEL, A-PILLAR TRIM, WITH GRAB HANDLE,
REMOVAL.

12. Using a trim stick (special tool #C-4755, Trim Stick) or equivalent, from the notch on the bottom, remove
the left instrument panel side cover.
Fig. 407: Headliner Wire Harness Connector And Push Pin

13. Disconnect the headliner wire harness connector (2), release the push pin (1) located at the A-pillar, and
position the harness aside.

Fig. 408: Left Side Of Instrument Panel To Dash Panel Bolts

14. Remove the three bolts (1) that secure the left side of the instrument panel to the dash panel.


15. Remove the floor console, if equipped. Refer to CONSOLE, FLOOR, REMOVAL and CONSOLE,
16. Remove the Brake Sled to I/P Bolts
Fig. 410: Instrument Panel To Center Of Floor Panel Bolt

17. Remove the two bolts (1) that secure the instrument panel to the center of the floor panel.


18. Remove the right A-pillar trim. Refer to PANEL, A-PILLAR TRIM, WITH GRAB HANDLE,
REMOVAL.


NOTE: Left side shown in the illustration, right side similar
19. Using a trim stick (special tool #C-4755, Trim Stick) or equivalent, from the notch on the bottom, remove
the right instrument panel side cover (1) from the instrument panel.

NOTE: Left side shown in the illustration, right side typical.
20. Disconnect the headliner wire harness connector (2), release the push pin (1) located at the A-pillar, and
position the harness aside.
21. Remove the glove box from the instrument panel. Refer to GLOVE BOX, INSTRUMENT PANEL,
REMOVAL.


22. Remove the right cowl trim cover. Refer to PANEL, COWL TRIM, REMOVAL.
Fig. 415: Removing/Installing Right Wire Harness Connections


23. Disconnect the five instrument panel wire harness connectors from the two body wire harness connectors
(1) located on the right side of the cowl panel (2).
Fig. 416: Removing/Installing Antenna Connection

24. Disconnect the antenna coaxial cable connectors (1) from the radio coaxial cable connector (2) located on
the right side of the cowl panel.

Fig. 417: Right Side Instrument Panel Bracket Bolts

25. Remove the three bolts (1) that secure the right side instrument panel bracket to the dash panel.


26. Remove fence line bolt access covers.

27. Remove fence line bolts.
28. Pull carpet back as necessary to remove the ground eyelet fastener at ORC/YAWL Modules.
29. Disconnect the ORC Module electrical connector and remove the wiring from under the carpet.
30. With the help of an assistant, lift the instrument panel up and off of the cowl panel and remove the
instrument panel from the vehicle.
INSTALLATION
INSTALLATION
1. With the help of an assistant, position the instrument panel (5) into the vehicle and install the right side
guide pin and the left side guide hook to the sides of the cowl panel.
2. Connect the ORC Module electrical connector and position the wiring under the carpet.
3. Install the ground eyelet fastener at ORC/YAWL Modules and position the carpet back as necessary.


4. Install the fence line bolts on top of I/P.

6. Install the fence line bolt access covers.

Fig. 420: Right Side Instrument Panel Bracket Bolts

7. Install the three bolts (1) that secure the right side instrument panel bracket to the cowl panel.

Fig. 421: Removing/Installing Antenna Connection

9. Connect the coaxial cable connectors (2) to the antenna coaxial cable connectors (1) located on the right
side of the cowl panel.
Fig. 422: Removing/Installing Right Wire Harness Connections

10. Connect the five instrument panel wire harness connectors to the two body wire harness connectors (1)
located on the right side of the cowl panel (2).

11. Install the right cowl trim panel. Refer to PANEL, COWL TRIM, INSTALLATION.
12. Install the glove box to the instrument panel. Refer to GLOVE BOX, INSTRUMENT PANEL,
INSTALLATION.


13. Connect the headliner wire harness connector (2) located at the A-pillar and secure the harness push pin
(1) fully.
14. Install the right side hush panel.


NOTE: Left side shown in the illustration, right side similar.
15. Install the right instrument panel side cover.


16. Install the right A-pillar trim. Refer to PANEL, A-PILLAR TRIM, WITH GRAB HANDLE,
INSTALLATION.
Fig. 427: Instrument Panel To Center Of Floor Panel Bolt

17. Install the two bolts (1) that secure the instrument panel to the center of the floor panel.
19. Install the brake sled to I/P bolts.


20. Install the floor console, if equipped. Refer to CONSOLE, FLOOR, INSTALLATION and
Fig. 429: Left Side Of Instrument Panel To Dash Panel Bolts


21. Install the three bolts that secure the left side of the instrument panel to the dash panel.
22. Tighten the bolts to 12 N.m (9 ft. lbs.)

23. Connect the headliner wire harness connector (2) located at the A-pillar and secure the harness push pin
(1) fully.



24. Install the left instrument panel side cover fully engaging the retainer clips.

25. Install the left A-pillar trim. Refer to PANEL, A-PILLAR TRIM, WITH GRAB HANDLE,
INSTALLATION.
26. Install the steering column as necessary. Refer to COLUMN, INSTALLATION .
Fig. 433: Installing Park Release Lever

27. Install the manual park release lever (2) and install the bolts (1).


28. Install the trim panel (1) covering the manual park release lever to the instrument panel and seat fully.
29. Install the hood release lever.
Refer to CABLE, HOOD RELEASE, INSTALLATION.

Fig. 435: Park Release Handle And Link

30. Connect the park brake release lever link (2).

Fig. 436: Instrument Panel Wire Harness Connector

31. Connect the instrument panel wire harness connector (2) located above the brake pedal to the bulkhead
wire harness connector (1).
32. Install the steering column opening cover. Refer to COVER, STEERING COLUMN OPENING,
INSTALLATION.


33. Install the left cowl trim panel. Refer to PANEL, COWL TRIM, INSTALLATION.
34. Install the front seat assembly. Refer to SEAT, FRONT, INSTALLATION or SEAT, FRONT
CENTER, INSTALLATION .
INTERIOR
CAUTION
CAUTION
CAUTION: Do not attempt to remove interior trim panels or moldings without first
removing the necessary adjacent trim panels or moldings. To avoid
damaging the trim panels, ensure that all the fasteners are removed or
disengaged before attempting to remove interior trim panels or moldings.
Trim panels are somewhat flexible but can be damaged if handled
improperly.
BEZEL, CENTER CONSOLE
REMOVAL
REMOVAL


1. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, remove shift bezel trim ring (1).
Fig. 439: Shift Bezel

2. Remove the rubber mat and remove the screws (1).

3. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, remove shift bezel (1).
INSTALLATION
INSTALLATION

1. Position the shift bezel (2) in place and seat the retaining tabs fully.
2. Install the screws (1) and install the rubber mat.

3. Position the trim ring (1) into place and seat the retaining tabs fully.
BIN, STORAGE
REMOVAL
REMOVAL
STORAGE BIN


1. Remove the six bolts (4) that secure the storage bin (3) to the floor panel and remove the storage bin.
REAR STORAGE COMPARTMENT
Fig. 443: Rear Storage Compartment

1. Remove the three bolts (2) that secure the rear storage compartment (1) to the floor panel and remove the
storage compartment from the rear cab trim panel.

INSTALLATION
INSTALLATION
STORAGE BIN

1. Position the storage bin (3) in the floor panel and install the six bolts (4).
REAR STORAGE COMPARTMENT
Fig. 445: Rear Storage Compartment

1. Position the rear storage compartment (1) onto the rear cab trim panel and install the three bolts (2).
CARPET, FLOOR
REMOVAL
REMOVAL
Fig. 446: Floor Carpet

NOTE: Carpet for quad can model shown in the illustration, regular cab similar.
NOTE: The floor mat hook is serviced separately from the carpet, do not replace the
carpet do to a broken floor mat hook.
1. Remove the front seats. Refer to SEAT, FRONT, REMOVAL or SEAT, FRONT CENTER,
REMOVAL .
2. If equipped, remove the floor console. Refer to CONSOLE, FLOOR, REMOVAL and CONSOLE,
3. If equipped, remove the storage bins. Refer to BIN, STORAGE, REMOVAL.
4. If equipped, remove the rear sub-woofer. Refer to SPEAKER, REMOVAL .
5. Remove the lower B-pillar trim panels. Refer to PANEL, B-PILLAR TRIM, LOWER, REMOVAL or
PANEL, B-PILLAR TRIM, UPPER, REMOVAL.

6. Remove the jack assemblies.

7. Remove the nine push pin fasteners (2) on the quad cab models.
8. Remove the carpet (1) from the vehicle.

9. If required, separate the seat belts from the floor on both sides. Refer to SEAT BELT, REMOVAL .
10. Remove the rear storage bin carpet (1), if equipped.
INSTALLATION
INSTALLATION


1. Install the rear storage bin carpet (1), if equipped.

2. If required, install the seatbelts to the floor. Refer to SEAT BELT, INSTALLATION .

NOTE: Carpet for quad cabmodel shown in the illustration, regular cab similar.

3. Position the carpet (1) into the vehicle.

4. On quad cab models, install the nine push-pin fasteners (2) that secure the carpet to the floor panel.
5. Install the lower B-pillar trim panels. Refer to PANEL, B-PILLAR TRIM, LOWER,
INSTALLATION or PANEL, B-PILLAR TRIM, UPPER, INSTALLATION.
6. If equipped, install the sub-woofers. Refer to SPEAKER, INSTALLATION .
7. Install the storage bins, if equipped. Refer to BIN, STORAGE, INSTALLATION.
8. If equipped, install the floor console. Refer to CONSOLE, FLOOR, INSTALLATION and
9. Install the front seats. Refer to SEAT, FRONT, INSTALLATION or SEAT, FRONT CENTER,
INSTALLATION .
CONSOLE, FLOOR
REMOVAL
REMOVAL
Fig. 450: Side Trim Covers

1. Remove the side trim covers (1).


2. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, remove shift bezel trim ring (1) and the
shift cable cover (2).

3. Remove the screws (1).

4. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, remove shift bezel (1).

Fig. 453: Shift Cable End

5. Separate the shift cable end (2) from the shifter.

6. Release the clip and separate the shift cable housing (1) from the shifter assembly.
Fig. 454: Console

7. Remove the screws (1, 3 and 4).

Fig. 455: Electrical Connectors To Console

8. Disconnect the power outlet electrical connector, if equipped.

9. Disconnect the electrical connectors (1, 2 and 3) and remove the console.
INSTALLATION
INSTALLATION

Fig. 456: Console

1. Position the floor console inside the vehicle and over the support brackets.
Fig. 457: Electrical Connectors To Console

2. Connect the power outlet electrical connector, if equipped.

3. Connect the electrical connectors (1, 2 and 3).
Fig. 458: Shift Cable End


4. Position the shift cable back into place and secure the housing to the shifter assembly (1).
5. Seat the cable end onto the shifter stud (2) fully.

6. Position the shift bezel (2) in place and seat the retaining tabs fully.
7. Install the screws (1).


8. Install the shift cable cover (2) and seat the retaining clips fully.
9. Position the trim ring (1) into place and seat the retaining tabs fully.
Fig. 461: Console

10. Install the screws (3) and tighten to 7 N.m (62 in. lbs.).
11. Install the screws (1) and tighten to 7 N.m (62 in. lbs.).
12. Install the screws (4).

Fig. 462: Side Trim Covers

13. Position the side trim (1) into place and seat the clips fully (2).
CONSOLE, FLOOR, LID
REMOVAL
REMOVAL
Fig. 463: Floor Console Lid Screws & Connectors

1. Disconnect the negative battery cable.

2. Remove the center console rear panel (back of the center console) to access the console lid hinge.
3. Disconnect both connectors (3).
4. Loosen the guide screws (2).
5. Remove the three screws securing the hinge to the rear of the center console.
INSTALLATION
INSTALLATION

Fig. 464: Floor Console Lid Screws & Connectors

1. Seat the center console lead. Guide the latch onto the guide pins on the back of the center console.
2. Install three bolts (1) to secure latch to the console.
3. Tighten the adjuster guide screws (2).
4. Attach the connectors (3).
CONSOLE, OVERHEAD, FRONT
DESCRIPTION
DESCRIPTION

Fig. 465: Overhead Console Assembly

A front overhead console is standard factory-installed equipment on this model. All overhead consoles are
equipped with two reading and courtesy lamps (2). On vehicles equipped with a power sunroof, the overhead
console will contain a three button switch (1) directly between the two reading and courtesy lamps. The front
overhead console will contain a two button switch (5) on vehicles equipped with rear power sliding glass, and a
three button HomeLink® transceiver switch (4) - if equipped. On vehicles equipped with automatic climate
control an infrared temperature sensor is located between the two switch banks.
NOTE: The overhead console reading lamp switches, bulb holders and wiring harness
are serviced only as a unit and are not available individually for service.
An overhead console (1) is available on this vehicle and may include many of the following components:
Front map/reading lamps (2)

HomeLink® transceiver (3) - if equipped
Compass module - if equipped
Power sunroof switch - if equipped
Power sliding glass switch - if equipped
REMOVAL
REMOVAL

Fig. 466: Overhead Console Assembly


2. Using your fingertips, grasp the sides of the overhead console and pull straight down evenly to disengage
the four snap clips.
Fig. 467: Overhead Console Harness Connectors

3. Lower the overhead console from the headliner far enough to access the wire harness connectors.
4. Disconnect the reading lamp wire harness connector (1).
5. Disconnect the sunroof switch wire harness connector, if equipped.
6. Disconnect the inferred temperature sensor wire harness connector (4), if equipped.
7. Disconnect the power sliding glass wire harness connector (2), if equipped.

8. Disconnect the Homelink® transceiver wire harness connector (3), if equipped.

9. Remove the overhead console from the vehicle.
INSTALLATION
INSTALLATION
Fig. 468: Overhead Console Harness Connectors

1. Position the overhead console near the mounting location on the headliner and connect the wire harness
connectors.
2. Connect the reading lamp wire harness connector (1).
3. If equipped, connect the sunroof switch wire harness connector.
4. If equipped, connect the inferred temperature sensor wire harness connector (4).
5. If equipped, connect the power sliding glass wire harness connector (2).
6. If equipped, connect the Homelink® transceiver wire harness connector (3).
7. Align the snap clips on the overhead console housing with their receptacles (5) in the overhead console
bracket.
8. Push upward firmly and evenly on the sides of the overhead console housing over the snap clip locations
until the snap clips are fully engaged with the receptacles in the overhead console bracket.
9. Reconnect the battery negative cable.
EXHAUSTER
REMOVAL
REMOVAL

Fig. 469: Removing/Installing Body Vent

1. Remove the rear cab trim panel. Refer to PANEL, CAB BACK TRIM, REMOVAL.
2. Disengage the retaining tabs (1) that secure the body vent (3) to the cab back panel (2).
3. Remove the vent through the opening in the cab back panel.
INSTALLATION
INSTALLATION
Fig. 470: Removing/Installing Body Vent

1. Position the body vent (3) into the opening of the cab back panel (2).
2. Install the body vent into the cab back panel and fully engage the retaining tabs (1).
3. Install the rear cab trim panel. Refer to PANEL, CAB BACK TRIM, INSTALLATION.

HEADLINER
REMOVAL
REMOVAL
STANDARD CAB
Fig. 471: Visor Support Screws

CAUTION: Hands should be clean or clean cloth gloves used when handling the
headliner to avoid damage to the headliner.
1. Remove the A-pillar trim. Refer to PANEL, A-PILLAR TRIM, WITH GRAB HANDLE,
REMOVAL.
2. Remove the upper B-pillar trim. Refer to PANEL, B-PILLAR TRIM, UPPER, REMOVAL.
3. Remove the screws and remove the visor supports.
4. Remove the screws (2) and remove the visors (1). Disconnect the electrical connectors, if equipped.

Fig. 472: Coat Hook

5. Using a small flat bladed tool, open the coat hook screw cover (2) and remove the screws and coat hooks.
Fig. 473: CHMSL Wiring Electrical Connector

6. Disconnect the CHMSL wiring electrical connector.

Fig. 474: Electrical Connectors

7. Remove the instrument panel side trim covers and disconnect the electrical connectors (1).
8. Separate the support push pin fasteners (2).
Fig. 475: A-Pillar Wiring And Clips

9. Disconnect the A-pillar wiring and clips (3).

10. Remove the headliner.
QUAD/CREW/MEGA CAB

Fig. 476: Visor Support Screws

1. Remove the windshield. Refer to WINDSHIELD, REMOVAL.

2. Remove the upper B-pillar trim. Refer to PANEL, B-PILLAR TRIM, UPPER, REMOVAL.
3. Remove the upper C-pillar trim, if equipped. Refer to PANEL, C-PILLAR TRIM, UPPER,
REMOVAL.


4. Disconnect the CHMSL wiring electrical connector.

5. Remove the instrument panel side trim covers and disconnect the electrical connectors (1).
6. Separate the support push pin fasteners (2).


7. Disconnect the A-pillar wiring and clips (3).

8. Disengage the sunroof trim ring if equipped.
Fig. 480: DVD Monitor & Screws

9. Remove the DVD monitor screws (2) and separate the monitor (1) from the roof, if equipped.

Fig. 481: DVD Housing Electrical Connectors

10. Disconnect the DVD housing electrical connectors (1), if equipped.

11. Remove the overhead console. Refer to CONSOLE, OVERHEAD, FRONT, REMOVAL.
Fig. 482: Sunroof Module Electrical Connector

12. Disconnect the sunroof module electrical connector (1) from the sunroof module takeout, if equipped.

Fig. 483: Body Harness At Left C-Pillar

13. Disconnect the electrical connector (1) from the body harness at the C-pillar left hand side.
14. Remove the body harness clip from the C-pillar inner left hand side, if equipped.
15. Disconnect the main harness from the body harness at the C-pillar inner right hand side.
Fig. 484: Headliner

16. Remove the headliner through the windshield opening.

17. Remove the visor outboard retainer from the body.

18. Remove the overhead console backing plate from the body taking care not to break the backing plate.
19. Remove the visor center support mounting clips.
20. Remove the coat hook mounting clips.
21. Remove the DVD mounting clips.
INSTALLATION
INSTALLATION
STANDARD CAB
Fig. 485: Headliner

NOTE: Quad cab shown in the illustration, standard cab is similar.
1. Position the coat hooks (5) onto the headliner and install the screws into the mounting clips.
2. Close the screw caps fully.
3. Position the visor supports (3) onto the headliner and install the screws into the mounting clips.
4. Install the overhead console (2). Refer to CONSOLE, OVERHEAD, FRONT, INSTALLATION.
5. Position the visors onto the headliner and install the screws (4) into the mounting clips.
6. Install the headliner through the front passenger door.
7. Lift the headliner into position and engage the visor center supports.


8. Position the wire harness on the A-pillar and seat the support clips (3) fully.

9. Connect the electrical connectors (1) and seat the support clip (2) fully.
10. Position the instrument panel side covers onto the instrument panel and seat fully.


11. Connect the CHMSL wiring electrical connector.

12. Install the floor console. Refer to CONSOLE, FLOOR, INSTALLATION and CONSOLE, FLOOR,
LID, INSTALLATION.
13. Install the upper B-pillar trim. Refer to PANEL, B-PILLAR TRIM, UPPER, INSTALLATION .
14. Install the A-pillar trim. Refer to PANEL, A-PILLAR TRIM, WITH GRAB HANDLE,
INSTALLATION.
QUAD/CREW/MEGA CAB

Fig. 489: Headliner

1. Install the DVD monitor to the headliner, if equipped.

2. Position the coat hooks (5) onto the headliner and install the screws into the mounting clips.
3. Close the screw caps fully.
4. Position the visor supports (3) onto the headliner and install the screws into the mounting clips.
5. Install the overhead console (2). Refer to CONSOLE, OVERHEAD, FRONT, INSTALLATION.
6. Position the visors onto the headliner and install the screws (4) into the mounting clips.
7. Install the headliner through the front passenger door.
8. Lift the headliner into position and engage the drivers side visor center support.
Fig. 490: Sunroof Module Electrical Connector

9. Connect the electrical connectors (1) for the sunroof module, if equipped.


10. Connect the CHMSL electrical connector (1).
Fig. 492: DVD Housing Electrical Connectors

11. Connect the DVD monitor electrical connectors (1), if equipped.

Fig. 493: Body Harness At Left C-Pillar

12. Connect the C-pillar electrical connectors (1).

13. Insert the passenger side coat hook.
14. Insert the passenger side visor center support.
15. Install the visor outboard screws.
16. Connect the body harness electrical connector and install the body clip right hand side.
17. Install the DVD unit mounting clips into the sheet metal.
18. Install the two remaining DVD screws.
19. Seat the sunroof trim ring if equipped.


20. Position the wire harness on the A-pillar and seat the support clips (3) fully.

21. Connect the electrical connectors (1) and seat the support clip (2) fully.
22. Position the instrument panel side covers onto the instrument panel and seat fully.
23. Install the upper C-pillar trim. Refer to PANEL, C-PILLAR TRIM, UPPER, INSTALLATION .
24. Install the upper B-pillar trim. Refer to PANEL, B-PILLAR TRIM, UPPER, INSTALLATION.
25. Install the windshield. Refer to WINDSHIELD, INSTALLATION.
LOAD FLOOR, NON-SLIDING
REMOVAL
REMOVAL

Fig. 496: Removing/Installing Rear Load Floor - Rear Fasteners

1. Move the rear seat cushion (1) to the up position.

2. Remove the two nuts (2) that secure the rear of the load floor (3) to the floor panel.
Fig. 497: Removing/Installing Rear Load Floor - Typical

3. Move the load floor (2) to the up position.

4. Remove the two bolts (3) that secure the load floor to the floor panel (1) and remove the load floor.
5. If required, remove the support cylinder (4).
INSTALLATION
INSTALLATION
Fig. 498: Removing/Installing Rear Load Floor - Typical

1. If removed, install the load floor support cylinder (4).

2. Position the load floor (2) into the vehicle and install the two bolts (3) that secure it to the floor panel (1).
Tighten the bolts to 40 N.m (30 ft. lbs.).

Fig. 499: Removing/Installing Rear Load Floor - Rear Fasteners

3. Move the load floor (3) to the down position and install the two nuts (2) that secure the load floor to the
floor panel. Tighten the nuts to 25 N.m (18 ft. lbs.).
4. Move the rear seat cushion (1) to the down position.
MIRROR, REARVIEW
REMOVAL
REMOVAL
Fig. 500: Identifying Button & Mirror Assembly

1. Twist the mirror assembly (2) clockwise and release the mirror from the aluminum button (1) attached to

the windshield.
INSTALLATION
INSTALLATION
Fig. 501: Installing Button & Mirror Assembly

1. Align indicator mark on mirror bracket (2) to the 12:00 position on the windshield mirror button (1).
2. Place mirror bracket (2) over windshield button (1).
3. Rotate mirror assembly 60 degrees counterclockwise to attach to the windshield.
NOTE: Rotate mirror until positive stop (detent) is felt.
REAR VIEW MIRROR MOUNTING BRACKET

Fig. 502: Rear View Mirror

1. Mark the position for the mirror mounting bracket (4) on the outside of the windshield glass (5) with a
wax pencil.
2. Clean the bracket contact area on the glass. Use a mild powdered cleanser on a cloth saturated with
isopropyl (rubbing) alcohol. Finally, clean the glass with a paper towel dampened with alcohol.
3. Sand the surface on the mounting bracket with a fine grit sandpaper. Wipe the mounting bracket surface
clean with a paper towel.
4. Apply accelerator to the surface on the mounting bracket according to the following instructions:
a. Crush the vial to saturate the felt applicator.
b. Remove the paper sleeve.
c. Apply accelerator to the contact surface on the mounting bracket.
d. Allow the accelerator to dry for five minutes.
e. Do not touch the bracket contact surface after the accelerator has been applied.
5. Apply adhesive accelerator to the bracket contact surface on the windshield glass. Allow the accelerator
to dry for one minute. Do not touch the glass contact surface after the accelerator has been applied.
6. Install the mounting bracket according to the following instructions:
a. Apply one drop of adhesive at the center of the bracket contact-surface on the windshield glass.
b. Apply an even coat of adhesive to the contact surface on the mounting bracket.
c. Align the mounting bracket with the marked position on the windshield glass.
d. Press and hold the mounting bracket in place for at least one minute.
NOTE: Verify that the mirror mounting bracket is correctly aligned, because the
adhesive will cure rapidly.
7. Allow the adhesive to cure for 8-10 minutes. Remove any excess adhesive with an alcohol-dampened
cloth.
8. Allow the adhesive to cure for an additional 8-10 minutes before installing the rear view mirror (3). Refer
to MIRROR, REARVIEW, INSTALLATION.
PANEL, A-PILLAR TRIM, WITH GRAB HANDLE
REMOVAL
REMOVAL


1. Using a small flat-bladed tool, carefully open the two fastener covers (3) located in the a-pillar trim panel
(2).
2. Remove the two bolts (4) that secure the a-pillar trim panel to the a-pillar (1) and remove the trim panel.
INSTALLATION
INSTALLATION


1. Position the locating tab of the A-pillar trim panel (2) into the slot located in the top of the instrument
panel.
2. Install the A-pillar trim panel onto the A-pillar (1) and install the two bolts (4). Tighten the bolts to 5 N.m
(44 in. lbs.).
3. Close the two fastener covers (3) located in the A-pillar trim panel.
PANEL, B-PILLAR TRIM, LOWER
REMOVAL
REMOVAL
STANDARD CAB

Fig. 505: Lower Trim

1. If equipped, remove the rear storage bin. Refer to BIN, STORAGE, REMOVAL.
2. Remove the lower seat belt anchor bolt (3).
3. Separate the forward clip.
4. Separate the remaining retaining clips and remove the lower trim (1).
QUAD CAB


1. Remove the front door cowl trim panel. Refer to PANEL, COWL TRIM, REMOVAL.
2. Remove the rear door scuff plate. Refer to PLATE, SCUFF, REAR DOOR SILL, REMOVAL.
3. Release the retaining clips and remove the trim panel(1).
INSTALLATION
INSTALLATION
STANDARD CAB

1. Position the lower trim (1) back into place and line up the retaining clips.
2. Seat the upper clips fully.
3. Seat the lower clips fully
4. Clip the forward foot into the sheet metal.
5. Install the lower seat belt anchor and tighten to 40 N.m (30 ft. lbs.).
6. If equipped, install the rear storage bin. Refer to BIN, STORAGE, INSTALLATION.
QUAD CAB


1. Position the trim (1) back and seat the clips fully.
2. Install the rear door scuff plate. Refer to PLATE, SCUFF, REAR DOOR SILL, INSTALLATION.
3. Install the front door cowl trim panel. Refer to PANEL, COWL TRIM, INSTALLATION.
PANEL, B-PILLAR TRIM, UPPER
REMOVAL
REMOVAL
STANDARD CAB

Fig. 509: B-Pillar Trim

1. Remove the lower B-pillar trim. Refer to PANEL, B-PILLAR TRIM, LOWER, REMOVAL .
2. Separate the turning loop cover (2) and remove the turning loop bolt.
3. Pull the upper trim (1) off and release the retaining clips.
QUAD CAB
Fig. 510: Upper B-Pillar Trim Panel

1. Remove the lower B-pillar trim. Refer to PANEL, B-PILLAR TRIM, LOWER, REMOVAL .

2. Using a small flat-bladed tool, carefully open the two fastener covers (2) located on the grab handle.
3. Remove the two bolts (3) that secure the grab handle to the B-pillar and remove the grab handle.
4. Separate the seat belt turning loop cover and remove the turning loop bolt.
5. Using a trim stick (special tool #C-4755, Trim Stick) or equivalent, disengage the retaining clips that
secure the upper trim (1) to the pillar and remove the trim panel.
6. Remove the seat belt from the trim.
INSTALLATION
INSTALLATION
STANDARD CAB
Fig. 511: B-Pillar Trim

1. Position the upper trim (1) back in place and seat the clips fully.
2. Install the turning loop bolt (2) and tighten to 40 N.m (30 ft. lbs.).
3. Install the turning loop cover.
4. Install the lower B-pillar trim. Refer to PANEL, B-PILLAR TRIM, LOWER, INSTALLATION .
QUAD CAB

Fig. 512: Upper B-Pillar Trim Panel

1. Position the seat belt through the hole in the trim.

5. Install the grab handle bolts and tighten to 5 N.m (44 in. lbs.).
6. Seat the grab handle bolt caps fully.
PANEL, C-PILLAR TRIM, LOWER
REMOVAL
REMOVAL
CREW CAB

Fig. 513: C-Pillar Trim

1. Remove the rear seat assembly. Refer to SEAT, REAR, REMOVAL or SEAT, MEGA CAB REAR,
REMOVAL.
2. Remove the seat belt anchor (4).
3. Separate the lower trim retaining clips from the pillar and the rear door scuff plate.
4. Remove the trim (2).
QUAD CAB


1. Remove the rear seat assembly. Refer to SEAT, REAR, REMOVAL and SEAT, MEGA CAB REAR,
REMOVAL.
4. Remove the seat belt (2) from the hole in the trim and remove the trim.
MEGA CAB
Fig. 515: Removing Lower Trim & Seat Belt Anchor

REMOVAL.
INSTALLATION
INSTALLATION
CREW CAB


1. Position the lower trim (2) into place and line up the clips to the pillar and rear door scuff plate.
2. Seat the retaining clips fully.
QUAD CAB

1. Position the seat belt (2) through the hold in the trim (3).

3. Seat the retaining clips fully.
MEGA CAB
Fig. 518: Removing Lower Trim & Seat Belt Anchor

3. Install the rear seat assembly. Refer to SEAT, REAR, INSTALLATION or SEAT, MEGA CAB
REAR, INSTALLATION.
PANEL, C-PILLAR TRIM, UPPER
REMOVAL
REMOVAL
CREW CAB


1. Remove the lower C-pillar trim (2). Refer to PANEL, C-PILLAR TRIM, LOWER, REMOVAL .
3. Pull the seat belt (3) through the trim and remove the trim.
QUAD CAB

1. Remove the lower C-pillar trim (3). Refer to PANEL, C-PILLAR TRIM, LOWER, REMOVAL .

2. Separate the turning loop cover (2) and remove the turning loop bolt.
MEGA CAB
Fig. 521: Turning Loop Bolt

1. Remove the lower C-pillar trim. Refer to PANEL, C-PILLAR TRIM, LOWER, REMOVAL .
2. Separate the turning loop cover and remove the turning loop bolt. Refer to ADJUSTER, SEAT BELT
TURNING LOOP, REMOVAL .
Fig. 522: Removing Upper Trim


3. Pull the upper trim off and release the retaining clips.
INSTALLATION
INSTALLATION
CREW CAB

1. Position the seat belt (3) through the hold in the trim (1).
3. Install the lower C-pillar trim (2). Refer to PANEL, C-PILLAR TRIM, LOWER, INSTALLATION .
QUAD CAB


4. Install the lower C-pillar trim (2). Refer to PANEL, C-PILLAR TRIM, LOWER, INSTALLATION .
MEGA CAB
Fig. 525: Removing Upper Trim

1. Position the upper trim back in place and seat the clips fully.

Fig. 526: Turning Loop Bolt

3. Install the lower C-pillar trim. Refer to PANEL, C-PILLAR TRIM, LOWER, INSTALLATION .
PANEL, CAB BACK TRIM
REMOVAL
REMOVAL
Fig. 527: Utility Hook


1. If equipped, remove the rear storage compartment. Refer to BIN, STORAGE, REMOVAL.
2. If equipped, using a (special tool #C-4755, Trim Stick) or equivalent, disengage the latch (1) for the
utility hook cover and open the cover to gain access to the screw (2) that secures the utility hook to the
rear cab back panel.
Fig. 528: CAB Back Panel

3. On two door models, remove the lower B-pillar trim panels. Refer to PANEL, B-PILLAR TRIM,
LOWER, REMOVAL .
4. On two door models, remove the lower seat belt anchor and remove the cab back panel (1).

Fig. 529: Rear CAB Back Panel

5. On four door models, remove the child seat tether straps from the rear cab back panel (2). Refer to
ANCHOR, CHILD SEAT, REMOVAL .
6. On four door models, remove the center seat belt trim bezel. Refer to RETRACTOR, SEAT BELT,
REMOVAL .
7. On four door models, remove the lower C-pillar trim panels. Refer to PANEL, C-PILLAR TRIM,
LOWER, REMOVAL .
8. On four door models, remove the push-pin fasteners (1 and 3) that secure the rear cab trim panel (2) to the
rear cab back panel and remove the trim panel.
INSTALLATION
INSTALLATION
Fig. 530: Rear Cab Back Panel

1. On four door models, position the rear cab trim panel (2) onto the rear cab back panel and install the
push-pin fasteners (1 and 3).
2. On four door models, install the lower C-pillar trim panels. Refer to PANEL, C-PILLAR TRIM,
LOWER, INSTALLATION .
3. On four door models, install the center seat belt trim bezel. Refer to RETRACTOR, SEAT BELT,
INSTALLATION .
4. On four door models, install the child seat tether straps. Refer to ANCHOR, CHILD SEAT,
INSTALLATION .

Fig. 531: CAB Back Panel

5. On two door models, position the rear cab trim panel (1) onto the rear cab back panel and install the
utility hooks.
Fig. 532: Utility Hook

6. Install the lower seat belt anchor. Refer to SEAT BELT, INSTALLATION .
7. With the utility hook cover (1) open, install the screws (2) and close the utility hook covers.
8. On two door models, install the lower B-pillar trim panels. Refer to PANEL, B-PILLAR TRIM,
LOWER, INSTALLATION .

9. If equipped, install the rear storage compartment. Refer to BIN, STORAGE, INSTALLATION.
PANEL, COWL TRIM
REMOVAL
REMOVAL
Fig. 533: Cowl Trim Panel

1. Using a (special tool #C-4755, Trim Stick)or equivalent, disengage the retaining tabs of the cowl trim
panel (1) from the retainer clips in the door sill.
2. Pull the cowl trim panel rearward and remove it from the vehicle.
INSTALLATION
INSTALLATION

Fig. 534: Cowl Trim Panel

1. Position the cowl trim panel (1) onto the door sill.
2. Push the cowl trim panel forward and then engage the retaining tabs that secure the sill trim panel to the
rear door sill.
PLATE, SCUFF, REAR DOOR SILL
REMOVAL
REMOVAL

Fig. 535: Rear Door Sill Scuff Plate

1. Using a trim stick (special tool #C-4755, Trim Stick) or equivalent, disengage the retaining tabs of the sill
trim panel (1) from the retainer clips in the rear door sill and remove the trim panel.
INSTALLATION
INSTALLATION
Fig. 536: Rear Door Sill Scuff Plate

1. Position the sill trim panel (1) onto the rear door sill.
2. Seat the retaining tabs that secure the sill trim panel to the rear door sill fully.
SUPPORT, VISOR
REMOVAL
REMOVAL

Fig. 537: Removing/Installing Visor Support

1. Using a trim stick (special tool #C-4755, Trim Stick) or equivalent, disengage the release clip (3) as
shown in the illustration and remove the sun visor support (1) from the headliner (2)
INSTALLATION
INSTALLATION
Fig. 538: Removing/Installing Visor Support

1. Position the sun visor support (1) through the headliner (2) and fully seat the base of the support to the
roof panel.
2. Engage the release clip (3).
VISOR

REMOVAL
REMOVAL
Fig. 539: Visor Support & Screws

CAUTION: When removing or installing the screws (1), be certain to avoid any wiring
or drain tube interference.
1. Separate the visor from the support (1) and remove the screws (2) that secure each sun visor to the roof
panel.

Fig. 540: Visor Retaining Tabs

2. Using a small flat bladed tool or equivalent, release the retaining tabs (1) and separate the visor from the
headliner.
3. If equipped, disconnect the wire harness connector for the illuminated vanity mirror.
INSTALLATION
INSTALLATION
Fig. 541: Visor Support & Screws

CAUTION: When removing or installing the screws (1), be certain to avoid any wiring
or drain tube interference.
1. If equipped, connect the wire harness connector for the illuminated vanity mirror.
2. Position the sun visor onto the headliner.
3. Install the screws (2) that secure each sun visor to the roof panel. Tighten the screws to 6 N.m (53 in.
lbs.).
PAINT
SPECIFICATIONS
SPECIFICATIONS

NOTE: Because of late model changes to the available paint colors. Refer to VEHICLE
CERTIFICATION LABEL, DESCRIPTION .
EXTERIOR COLORS
EXTERIOR COLOR CHRYSLER CODE
Black Clear Coat DX8
Bright White Clear Coat GW7
Deep Cherry Red Pearl Coat JRP
Maximum Steel Metallic Clear Coat KAR
True Blue Pearl Coat KBU
Blue Streak KCL
Western Brown Pearl Coat KEP
Prairie Pearl Coat KFA
Granite Crystal Pearl Coat LAU
Black Gold Pearl Coat LUG
Flame Red Clear Coat PR4
White Gold QWL
Bright Silver Metallic Clear Coat WS2
INTERIOR COLORS
INTERIOR COLOR CHRYSLER CODE
Black X9
Black/Diesel Gray X8
Canyon Brown/Light Frost Beige U1
Black/Cattle Tan XT
SEATS
WARNING
WARNING

Supplemental Restraint System (SRS), refer to RESTRAINTS - SERVICE
INFORMATION - 2500 HD & 3500 HD . Never attempt to repair the

WARNING: Refer to RESTRAINTS - SERVICE INFORMATION - 2500 HD & 3500 HD to

avoid serious or fatal injury during and following any seat belt or child
restraint anchor service. Carefully inspect all seat belts, buckles,
injury.
WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain
airbags, disable the Supplemental Restraint System (SRS). Refer to
RESTRAINTS - SERVICE INFORMATION - 2500 HD & 3500 HD before
attempting any Occupant Restraint Controller (ORC) diagnosis or service.
The ORC may contain a rollover sensor, which enables the system to
deploy the side SRS components in the event of a vehicle rollover event.
If an ORC containing a rollover sensor is accidentally rolled during
service while still connected to battery power, the side SRS components
will deploy. Disconnect and isolate the battery negative (ground) cable,
then wait two minutes for the system capacitor to discharge before
disable the SRS. Failure to take the proper precautions could result in
the Supplemental Restraint System (SRS). Refer to RESTRAINTS -
SERVICE INFORMATION - 2500 HD & 3500 HD before attempting any
steering wheel, steering column, airbag, seat belt tensioner, impact
sensor or instrument panel component diagnosis or service. Disconnect
and isolate the battery negative (ground) cable, then wait two minutes for
the system capacitor to discharge before performing further diagnosis or
service. This is the only sure way to disable the SRS. Failure to take the
proper precautions could result in accidental airbag deployment.


or tamper with its inflator Refer to RESTRAINTS - SERVICE
INFORMATION - 2500 HD & 3500 HD . Do not puncture, incinerate or bring
into contact with electricity. Do not store at temperatures exceeding 93° C

COVER, SEAT BACK, MEGA CAB REAR
REMOVAL
REMOVAL
1. Fold both rear seats flat.

2. Remove the filler panels from the rear seat to storage compartment.
3. Separate the J-straps at the bottom of the seat back.
4. Remove both hinge covers from the back section being worked on.
5. Remove the lower anchor for the center seat belt.
6. Disconnect the lower cable attachment from the seat back release.
7. Remove the four bolts and remove the seat back from the seat.
8. Mark the location of the cables at the cushion and remove.
9. Remove the upper cushion pivot bolts.
10. Remove the lower cushion pivot bolts.
11. Remove the cushion from the seat.
12. Remove the seat release/recline handle.
13. Separate the J-straps for the cover to the seat pan.
14. Remove the cover/cushion from the seat pan and separate the foam from the cover.
INSTALLATION
INSTALLATION
1. Place cover over the foam and install onto the seat pan.
2. Connect the J-straps to the pan.
3. Install the release/recliner handle.
4. Install the cushion assembly onto the seat assembly.
5. Install the lower cushion pivot bolts.
6. Install the upper cushion pivot bolts.
7. Install the cables at the cushion using the marks made during removal.
8. Install the seat back onto the seat and install the four bolts.
9. Connect the lower cable attachment for the seat back release.
10. Install the lower anchor for the center seat belt.
11. Install the hinge covers.
12. Connect the J-straps at the bottom of the seat back being worked on.

13. Install the filler panels.
COVER, SEAT CUSHION, FRONT
REMOVAL
REMOVAL
NOTE: While servicing seat assemblies, Refer to DESCRIPTION .
MANUAL
Fig. 542: Seat Back Cover Straps

1. Separate the seat back cover straps (2) from under the seat cushion.

Fig. 543: Side Shield Screws

2. Remove the side shield screws (2) in the back.
Fig. 544: Inboard Shield

3. Remove the inboard shield screw (1).

4. Remove the inboard side shield (2).

Fig. 545: Door Handle Clip Tool

5. Using a door handle clip tool (1) or equivalent, release the clip holding the handle (2) onto the seat and
remove the handle.
6. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, release the seven tabs and separate the
center bezel from the outboard side shield.
7. Pull the bezel rearward and release the front retaining tab.
Fig. 546: Outer Side Shield

8. Remove the screw (1).

9. Release the retaining clips (2) and remove the outer side shield.

Fig. 547: Recliner Rod

10. Separate the clip (1) and separate the recliner rod (2) from the lever.
11. Remove the push pin fastener (3).
Fig. 548: J-Straps

12. Separate the cover J-straps (1) from the sides and remove the foam/cover assembly.

Fig. 549: Hog Rings

13. Remove the 10 hog rings (2) and separate the cover (1) from the foam.
POWER WITHOUT VENTED SEAT

1. Remove the front seat. Refer to SEAT, FRONT, REMOVAL or SEAT, FRONT CENTER,
REMOVAL .
2. Separate the seat back cover straps (2) from under the seat cushion and disconnect the electrical
connectors (1).



4. Remove the inboard shield screw.

5. Remove the inboard side shield.

Fig. 553: Lumbar Switch Electrical Connector

CAUTION: Disconnect the lumbar control switch electrical connector beneath

the seat, prior to removing the power seat switch bezel from the seat.
Failure to follow these instructions can result in damage to the
lumbar control switch.
6. If equipped, disconnect the lumbar control switch electrical connector (1).
Fig. 554: Switch Bezel

7. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, release the seven tabs (3) and separate
the bezel (1) from the outboard side shield.

8. Pull the bezel (1) rearward and release the front retaining tab (2).
9. Disconnect the wire harness connectors from the power seat switch and memory seat switch, if equipped.


Fig. 556: J-Straps


Fig. 557: Hog Rings

POWER WITH VENTED SEAT

REMOVAL .
connectors (1).








NOTE: Power seat bezel shown in the illustration, manual seat bezel similar.



Fig. 564: Vented Seat Pad

12. Disconnect the vented seat bag (1) from the motor (2).

13. Disconnect the electrical connectors, if equipped.
Fig. 565: J-Straps

Fig. 566: Hog Rings



16. Pull the vent pad (1) through the foam.
INSTALLATION
INSTALLATION
MANUAL
Fig. 568: Hog Rings

1. Position the cover (1) onto the foam and install 10 new hog rings (2).

Fig. 569: J-Straps

2. Position the foam/cover assembly onto the seat cushion frame and secure the J-straps (1) on the sides.

3. Install the push pin fastener (3) and seat fully.

4. Install the recliner rod (1) and seat the retaining clip (2) fully.


5. Install the outer side shield and seat the clips (2) fully.
6. Install the screw (1).
Fig. 572: Recliner Handle

7. Position the bezel to the outboard side shield and engage the front retaining tab.
8. Seat the remaining tabs (3) fully.
9. Position the recliner handle (1) onto the splined shaft and seat fully.


10. Install the inboard shield (2) and install the screw (1).

11. Install the side shield screws (2) in the back.


12. Secure the seat back cover straps (2) to suspension mat.
POWER WITHOUT VENTED SEAT
Fig. 576: Hog Rings


Fig. 577: J-Straps




5. Connect the wire harness connectors to the power seat switch and memory seat switch, if equipped.
6. Position the bezel (1) back into place and secure the front tab (2).

8. If equipped, connect the lumbar switch electrical connector (1).





11. Secure the seat back cover straps (2).

12. Connect the electrical connectors (1).
13. Install the front seat. Refer to SEAT, FRONT, INSTALLATION or SEAT, FRONT CENTER,
INSTALLATION .
POWER WITH VENTED SEAT

1. Pull the vent pad (1) through the foam.

Fig. 585: Hog Rings

Fig. 586: J-Straps



4. Position the vented seat pad (2) onto the vent motor if equipped, and seat the clips fully.
5. Connect the electrical connectors, if equipped.










INSTALLATION .
COVER, SEAT CUSHION, REAR
REMOVAL
REMOVAL
Fig. 594: J-Straps


NOTE: It is not necessary to remove the rear seat assembly in order to remove the seat
cushion foam and cover.
1. Place the cushion into the up position.

2. Disconnect the seat cushion heat mat electrical connector, if equipped.
3. Release the J-straps (2) and remove the foam/cover (1) from the seat cushion frame.
Fig. 595: Seat Back Hog Rings

4. Roll the cover (3) off of the foam (1) and remove the hog rings (2).
5. Separate the cover from the foam.
6. Remove the seat cushion frame bolts and remove the seat cushion frame. Refer to DESCRIPTION .
INSTALLATION
INSTALLATION


NOTE: It is not necessary to remove the rear seat assembly in order to remove the seat
cushion foam and cover.
1. Install the seat cushion frame and install the seat cushion frame bolts. Refer to DESCRIPTION .
2. Tighten the seat cushion frame bolts to 55 N.m (41 ft. lbs.)
3. Position the cover (3) on to the foam (1) and install three new hog rings (2).
4. Position the foam and cover assembly over the seat cushion frame.
Fig. 597: J-Straps

5. Install the seat cushion foam/cover (1) over the seat cushion frame and secure the J-straps (2).

6. Connect the seat cushion heat mat electrical connector, if equipped.
COVER, SEAT CUSHION, MEGA CAB REAR
REMOVAL
REMOVAL
1. Fold both rear seats flat.

2. Remove the filler panels from the rear seat to storage compartment.
3. Separate the J-straps at the bottom of the seat back.
4. Remove both hinge covers from the back section being worked on.
5. Remove the lower anchor for the center seat belt.
6. Disconnect the lower cable attachment from the seat back release.
7. Remove the four bolts and remove the seat back from the seat.
8. Remove the screw and remove the seat back release bezel.
9. Mark the location of the release cables at the cushion and remove.
10. Remove the upper cushion pivot bolts.
11. Remove the lower cushion pivot bolts.
12. Remove the cushion from the seat.
13. Remove the seat release lever from the cushion.
14. Separate the J-straps securing the cover to the seat pan.
15. Remove the foam and cover from the seat pan.
16. Separate the foam from the cover.
INSTALLATION
INSTALLATION
1. Position the seat cushion foam into the cover.

2. Position the cushion assembly onto the seat pan.
3. Connect the J-straps securing the cover to the seat pan.
4. Install the seat release lever.
5. Install the cushion assembly onto the seat assembly.
6. Install the lower cushion pivot bolts.
7. Install the upper cushion pivot bolts.
8. Install the release cables using the marks created during removal.
9. Install the seat back release bezel and install the screw.
10. Install the seat back and install the four bolts.
11. Connect the lower cable attachment from the seat back release.

12. Install the lower anchor fro the center seat belt.
13. Install both hinge covers for the back section seat back.
14. Connect the J-straps at the bottom of the seat back.
15. Install the filler panels for the rear storage compartment.
SEAT, FRONT
DESCRIPTION
DESCRIPTION
Fig. 598: Two Way Manual Seat (Passenger Side) Component Location
1 - HEADREST 17 - WIRE HARNESS

2 - HEADREST SLEEVES 18 - CONNECTOR BRACKET
3 - SEAT BACK FOAM 19 - BRACKET SCREWS
20 - INVERTER ASSEMBLY SCREWS 10 N.m
4 - INNER SIDE SHIELD
(89 in. lbs.)
5 - SEAT BACK BOLTS 40 N.m (30 ft. lbs.) 21 - INVERTER ASSEMBLY
6 - CLIPS (4) 22 - CUSHION FRAME SCREWS (8)
7 - SEAT BACK FRAME 23 - CUSHION FRAME
8 - SUPPORT SPRING 24 - REMOTE ACTUATION LINK

9 - SIDE CUSHION SCREWS - REAR 25 - OUTER SIDE SHIELD

10 - SEAT CUSHION SUSPENSION MAT 26 - OUTER SIDE SHIELD SCREW
11 - BELT BUCKLE ASSEMBLY 27 - SWITCH BEZEL
12 - OUTER SIDE SHIELD 28 - MANUAL RECLINE HANDLE
13 - SIDE SHIELD SCREW 29 - CLIP RECLINER LEVER RETAINING
14 - BELT BUCKLE BOLT 50 N.m (37 ft. lbs.) 30 - SEAT CUSHION FOAM
15 - INNER SIDE SHIELD 31 - SEAT CUSHION COVER
16 - MANUAL ADJUSTER ASSEMBLY 32 - SEAT BACK COVER
Fig. 599: Six Way Power Seat (Driver Side) Component Location
1 - HEADREST 26 - INNER SIDE SHIELD

2 - HEADREST SLEEVE - SLAVE 27 - SIDE SHIELD MOUNTING BRACKET
3 - HEADREST SLEEVE - MASTER 28 - BRACKET SCREWS
4 - SEAT BACK FOAM/COVER 29 - SEAT POSITION SWITCH
5 - OUTER SIDE SHIELD - INBOARD 30 - MEMORY SWITCH SCREWS
6 - SEAT CUSHION VENT BAG 31 - MEMORY SWITCH
7 - SEAT BACK VENT BAG 32 - SWITCH BEZEL
8 - LUMBAR MOTOR BOLT 10 N.m (89 in. lbs.) 33 - LUMBAR SWITCH
9 - CLIPS (4) 34 - OUTER SIDE SHIELD
10 - SEAT BACK FRAME ASSEMBLY 35 - SIDE SHIELD MOUNTING BRACKET

11 - FOAM SUPPORT SCREWS 36 - MODULE BRACKET SCREWS

12 - PLASTIC FOAM SUPPORT 37 - MODULE BRACKET
13 - FOAM SUPPORT PUSH PINS 38 - HEATED SEAT MODULE
39 - WIRE HARNESS - LOWER POWER
14 - LUMBAR ASSEMBLY
HEAT/COOL
15 - DIAGONAL SUPPORT BRACE SCREWS (2) 40 - BRACKET SCREWS
16 - BACK FRAME DIAGONAL SUPPORT
41 - BRACKET
BRACE
17 - VENTED SEAT BACK BLOWER MOTOR 42 - MEMORY MODULE
18 - WIRE HARNESS - BACK POWER HEAT 43 - CUSHION FRAME
19 - DIAGONAL SUPPORT BRACE SCREW 44 - CUSHION FRAME SCREWS
20 - CLIPS 45 - 6 WAY POWER ADJUSTER ASSEMBLY
21 - LOWER BACK FRAME BRACE SCREWS
46 - BELT BUCKLE ASSEMBLY
(4)
22 - LOWER BACK FRAME BRACE 47 - INNER SIDE SHIELD
23 - SEAT BACK BOLTS 40 N.m (30 Ft. lbs.) 48 - BELT BUCKLE BOLT 50 N.m (37 Ft. lbs.)
24 - SEAT CUSHION SUSPENSION MAT 49 - SEAT CUSHION FOAM/COVER
25 - VENTED SEAT CUSHION BLOWER
MOTOR
REMOVAL
REMOVAL
DRIVER SIDE
Fig. 600: Trim Cover


1. Before proceeding with the following repair procedure, review all warnings and cautions. Refer to
SEATS, WARNING.
2. Remove the trim cover (1).

3. Disconnect the electrical connectors (1) and (2), if equipped.
Fig. 602: Mounting Bolts

4. Remove the front mounting bolts (1) from the driver side seat.

5. Remove the rear bolts (2) and remove the diver seat.
PASSENGER SIDE
Fig. 603: Jack Cover

SEATS, WARNING.
2. Carefully release the front clip and separate the jack cover (2) from the front of the riser (1).
3. Carefully pull the cover forward and release the rear hook from the rear of the riser (3).
Fig. 604: Electrical Connector

4. Disconnect the electrical connector (1), if equipped.
Fig. 605: Seat Bolts

5. Remove the front pasenger seat bolts (3).

6. Remove the center seat bolts (2), if equipped with the center seat.
7. Remove the rear bolts (1) and remove the passenger seat assembly.
Fig. 606: Rear Air Duct


8. Disconnect the rear air duct (1) by sliding the telescoping duct section, attached to the seat, rearward.
INSTALLATION
INSTALLATION
DRIVER SIDE

SEATS, WARNING.
2. Install the driver seat and loosely install the front bolts (1).
3. Loosely install the driver seat rear bolts (2).


4. Tighten the driver seat bolts to 47 N.m (35 ft. lbs.) using the sequence shown in the illustration.

5. Connect the electrical connectors (1 and 2), if equipped.

Fig. 610: Trim Cover

6. Install the trim cover (1) and seat the clip fully.
PASSENGER SIDE
Fig. 611: Rear Air Duct

SEATS, WARNING.
2. Position the passenger seat assembly into the vehicle and connect the air duct (1), if equipped.


3. Loosely install the passenger seat front bolts (3).

4. If equipped with the center seat, loosely install the bolts (2).
5. Loosely install the passenger seat rear bolts (1).

6. Tighten the passenger seat bolts to 47 N.m (35 ft. lbs.) using the sequence shown in the illustration.


Fig. 615: Jack Cover

8. Secure the jack cover rear hook on the rear riser (3).
9. Position the front of the side shield (2) on the front of the riser (1) and seat the clip fully.
SEAT, FRONT CENTER

DESCRIPTION
DESCRIPTION
Fig. 616: Center Seat (W/O Storage) Component Location

1 - SEAT BACK COVER 12 - HVAC DUCT SCREWS

2 - SEAT BACK FOAM 13 - HVAC DUCT
3 - SEAT BACK FRAME 14 - CUSHION FRAME
4 - TRAY 15 - CUSHION FRAME
5 - INNER LID 16 - CUSHION FOAM
6 - FOAM PAD - LID 17 - PIVOT SIDE SHIELD
7 - PIVOT SIDE SHIELD 18 - PIVOT DETENT GUIDE

8 - INERTIA LATCH BOLTS 25 N.m (18 Ft. lbs.) 19 - PIVOT BRACKET

9 - SCREW 20 - SCREW
10 - INERTIA LATCH BOLTS 25 N.m (18 Ft. lbs.) 21 - SEAT CUSHION COVER
11 - INERTIA LATCH ASSEMBLY
Fig. 617: Center Seat - W/Storage

1 - SEAT BACK FOAM/COVER 24 - INERTIA LATCH ASSEMBLY

2 - TRAY 25 - INERTIA LATCH BOLTS 25 N.m (18 Ft. lbs.)
3 - POWERPOINT CAP 26 - FOAM PAD
4 - 12V POWERPOINT 27 - CUSHION LINKAGE
5 - COIN HOLDER 28 - LINKAGE SCREWS (8)
6 - DIVIDER 29 - CUSHION FRAME
7 - REAR DIVIDER 30 - HVAC DUCT SCREWS
8 - BACK LID BEZEL 31 - HVAC DUCT
9 - PAD INSERT 32 - LOWER CUSHION COVER
10 - INNER LID 33 - SCREWS
11 - SCREWS 34 - CUSHION LATCH/HANDLE
12 - SCREWS 35 - CUSHION LINKAGE
13 - LID LATCH 36 - TRAY
14 - BACK HANDLE 37 - SCREWS

15 - FOAM PAD - LID 38 - SCREWS

16 - COVER 39 - SEAT CUSHION FOAM/COVER
17 - WIRE HARNESS 40 - SCREW
18 - HINGE SCREWS 41 - PIVOT SIDE SHIELD
19 - HINGE 42 - PIVOT BRACKET
20 - HINGE SCREWS 43 - PIVOT DETENT GUIDE
21 - PIVOT SIDE SHIELD 44 - SCREWS (6)
22 - INERTIA LATCH BOLTS 25 N.m (18 Ft.
45 - SEAT BACK FRAME
lbs.)
23 - SCREW

Fig. 618: Center Seat - W/Storage

1 - CENTER SEAT ASSEMBLY 15 - STORAGE BIN LID

2 - SHIELD PIVOT SCREWS (2) 16 - STORAGE COMPARTMENT HINGE

3 - PIVOT BRACKET 17 - LINKAGE SCREWS (6)

4 - STORAGE BIN DEVIDERS 18 - ARMREST BIN LID
5 - PIVOT DETENT GUIDE 19 - BIN LATCH SCREWS (2)
6 - COIN HOLDER 20 - STORAGE BIN
7 - INERTIA LATCH ASSEMBLY 21 - BIN LATCH
8 - PIVOT SIDE SHIELD 22 - BOLSTER
9 - INERTIA LATCH BOLTS 25 N.m (18 Ft. lbs.) 23 - BIN LATCH
24 - LINKAGE SCREWS (2)
lbs.)
11 - POWER OUTLET 25 - STORAGE COMPARTMENT HINGE
12 - POWER OUTLET CAP 26 - VENT
27 - ARMREST BEZEL
lbs.)
14 - ARMREST 28 - ARMREST BEZEL
REMOVAL
REMOVAL
Fig. 619: Center Seat Assembly Fasteners

1. Remove the front passenger seat assembly. Refer to SEAT, FRONT, REMOVAL or SEAT, FRONT
CENTER, REMOVAL.
2. Remove the fasteners (2) attaching the center seat assembly to the seat adjuster (1) and separate the center
seat.
INSTALLATION
INSTALLATION

Fig. 620: Center Seat Assembly Fasteners

1. Position the center seat assembly onto the passenger seat.

2. Install and tighten the fasteners (2).
3. Install the passenger seat assembly. Refer to SEAT, FRONT, INSTALLATION or SEAT, FRONT
CENTER, INSTALLATION .
SEAT, REAR
DESCRIPTION
DESCRIPTION
INDEX
DESCRIPTION FIGURE
CREW CAB
REAR BENCH SEAT - CREW CAB Refer to Fig. 621.
REAR 60% SEAT - CREW CAB Refer to Fig. 622.
REAR 40% SEAT - CREW CAB Refer to Fig. 623.
QUAD CAB
REAR BENCH SEAT - QUAD CAB Refer to Fig. 624.
REAR 60% SEAT - QUAD CAB Refer to Fig. 625.
REAR 40% SEAT - QUAD CAB Refer to Fig. 626.

Fig. 621: Rear Bench Seat - Crew Cab Component Location

1 - SEAT BACK FOAM/COVER 14 - SEAT BACK FRAME

2 - OUTER PIVOT COVER 15 - INNER COVER
3 - RISER COVER 16 - BACK PIVOT SPACER
4 - SEAT BACK PIVOT BOLT 28 N.m (21 ft. lbs.) 17 - OUTER PIVOT COVER SCREW
5 - INNER COVER SCREW 18 - LATCH ASSEMBLY
6 - LATCH ASSEMBLY 19 - INNER COVER SCREW
20 - SEAT BACK PIVOT BOLT 28 N.m (21 ft.
7 - OUTER PIVOT COVER SCREW
lbs.)
8 - INNER COVER 21 - RISER COVER
9 - CAB HOOK ISOLATOR 22 - OUTER PIVOT COVER
23 - SEAT CUSHION FRAME BOLTS 55 N.m (41
10 - PUSH PIN
ft. lbs.)
11 - HEADREST SLEEVE - SLAVE 24 - SEAT CUSHION FRAME
12 - HEADREST
ft. lbs.)
13 - HEADREST SLEEVE - MASTER 26 - SEAT CUSHION FOAM/COVER

Fig. 622: Rear 60% Seat - Crew Cab Component Location

1 - HEAT MAT - BACK 19 - STORAGE LID BOLT 18 N.m (13 ft. lbs.)
2 - SEAT BACK FOAM/COVER 20 - SEAT CUSHION FRAME
3 - ARMREST COVER 21 - STORAGE BIN LID
4 - ARMREST FOAM 22 - INNER COVER
5 - CUP HOLDER 23 - OUTER PIVOT COVER SCREW
6 - ARMREST CLOSE-OUT PANEL 24 - ARMREST DETENT ISOLATOR
7 - PIVOT ASSEMBLY 25 - LATCH ASSEMBLY
8 - CAB HOOK ISOLATOR 26 - ARMREST DETENT ISOLATOR
9 - PUSH PIN 27 - PIVOT ASSEMBLY
10 - HEADREST SLEEVE - SLAVE 28 - ARMREST PIVOT BOLTS (2)
11 - HEADREST 29 - OUTER PIVOT COVER
30 - SEAT BACK PIVOT BOLTS (2) 18 N.m (13
12 - HEADREST SLEEVE - MASTER
ft. lbs.)
13 - SEAT BACK FRAME 31 - INNER COVER SCREWS (2)
32 - SEAT CUSHION FRAME BOLTS (4) 55 N.m
14 - ARMREST SCREWS 28 N.m (21 ft. lbs.)
(41 ft. lbs.)
15 - ARMREST NUTS 28 N.m (21 ft. lbs.) 33 - STORAGE LID BOLT 28 N.m (21 ft. lbs.)
16 - INNER COVER 34 - RISER COVER
17 - LATCH ASSEMBLY 35 - SEAT CUSHION FOAM/COVER
18 - OUTER PIVOT COVER 36 - HEAT MAT - CUSHION

Fig. 623: Rear 40% Seat - Crew Cab Component Location

1 - OUTER PIVOT COVER - INBOARD 14 - SEAT CUSHION - FOAM/COVER

2 - LATCH ASSEMBLY 15 - HEAT MAT - CUSHION
3 - CAB HOOK ISOLATOR
ft. lbs.)
4 - PUSH PIN 17 - INNER COVER SCREW
5 - HEADREST SLEEVE - SLAVE
(41 ft. lbs.)
6 - HEADREST 19 - RISER COVER
7 - HEADREST SLEEVE - MASTER 20 - STORAGE LID BOLT 18 N.m (13 ft. lbs.)
8 - SEAT BACK FRAME 21 - STORAGE BIN LID
9 - INNER COVER 22 - SEAT CUSHION FRAME
10 - LATCH ASSEMBLY 23 - INNER COVER
11 - OUTER PIVOT COVER 24 - STORAGE LID BOLT 18 N.m (13 ft. lbs.)
12 - HEAT MAT - BACK 25 - OUTER PIVOT COVER SCREW
13 - SEAT BACK - FOAM/COVER

Fig. 624: Rear Bench Seat - Quad CAB

1 - SEAT BACK - FOAM/COVER 9 - SEAT BACK FRAME

2 - SEAT BACK PIVOT BOLT 28 N.m (21 ft. lbs.) 11 - LATCH ASSEMBLY
12 - SEAT BACK PIVOT BOLT 28 N.m (21 ft.
3 - LATCH ASSEMBLY
lbs.)
4 - CAB HOOK ISOLATOR (2)
ft. lbs.)
5 - CAB HOOK ISOLATOR PUSH PIN (4) 14 - SEAT CUSHION FRAME
ft. lbs.)
7 - HEADREST 16 - SEAT CUSHION FOAM/COVER

Fig. 625: Rear 60% Seat - Quad CAB

1 - SEAT BACK FOAM/COVER 8 - LATCH ASSEMBLY

2 - CAB HOOK ISOLATOR 9 - SEAT CUSHION FRAME
3 - PUSH PIN 10 - LATCH ASSEMBLY
ft. lbs.)
5 - HEADREST
(41 ft. lbs.)
6 - HEADREST SLEEVE - MASTER 13 - SEAT CUSHION FOAM/COVER
7 - SEAT BACK FRAME

Fig. 626: Rear 40% Seat - Quad CAB

1 - CAB HOOK ISOLATOR 8 - SEAT CUSHION FOAM/COVER

2 - PUSH PIN
(41 ft. lbs.)
ft. lbs.)
4 - HEADREST 11 - LATCH ASSEMBLY
5 - HEADREST SLEEVE - MASTER 12 - SEAT CUSHION FRAME
6 - SEAT BACK FRAME 13 - LATCH ASSEMBLY
7 - SEAT BACK FOAM/COVER
REMOVAL
REMOVAL


NOTE: 60/40 bench seat shown in the illustration, solid bench seat similar.
1. Disconnect the electrical connector (1), if equipped.
Fig. 628: Center Shoulder Belt

2. Remove the bolt (1) attaching the center shoulder belt (2) to the retractor and position the shoulder belt
out of the way.

Fig. 629: Rear Inner Belts & Buckles

3. Remove the rear outer bolts.

4. Remove the rear inner bolts (3) and buckles (2) as necessary.
Fig. 630: Front Mounting Bolts

5. Remove the front fasteners (1).

Fig. 631: CAB Hooks

6. Lift the seat assemblies up and separate the cab hooks (3) from the loops (1 and 2).
7. Remove the seat assemly from the vehicle.
INSTALLATION
INSTALLATION
Fig. 632: CAB Hooks


NOTE: 60/40 bench seat shown in the illustration, solid bench seat similar.
1. Position the rear seat assembly into the vehicle and secure the hooks (3) to the loops (1 and 2).
Fig. 633: Front Mounting Bolts

2. Install the front mounting bolts (1).
Fig. 634: Rear Inner Belts & Buckles

3. Install the remaining bolts (1, 4) and tighten all bolts to 47 N.m (35 ft. lbs.).

Fig. 635: Center Shoulder Belt

4. Position the shoulder belt (2) back into place and install the bolt (1).
5. Tighten the bolt to 23 N.m (17 ft. lbs.).

SEAT BACK, FRONT
REMOVAL

REMOVAL

REMOVAL .
connectors (1).





6. If equipped with manual seat, using a door handle clip tool (1) or equivalent, release the clip holding the
handle (2) onto the seat and remove the handle.







Fig. 644: Seat Cushion Suspension Mat

13. Release the seat cushion suspension mat (2) from the cross brace and separate the electrical connector (1).


14. On manual reclining seats, remove the clip (1) and separate the recliner rod (2) from the lever.
Fig. 646: Seat Back Assembly & Bolts

15. Remove the bolts (2) and remove the seat back assembly (1).
DISASSEMBLY
DISASSEMBLY
1. Remove the seat back. Refer to SEAT BACK, FRONT, REMOVAL .

Fig. 647: Side Shield

2. Separate the side shield from the seat back (2) and remove the side shields (1).
Fig. 648: Brace

3. Remove the two screws (1) and remove the brace (2).

Fig. 649: Headrest

4. Push in the buttons on both headrest sleeves, pull the headrest up and remove.
Fig. 650: J-Straps

5. Separate the J-straps (1 and 2) and pull cover up over frame.

Fig. 651: Headrest Sleeves

6. Position the foam aside and strike the bottom of the headrest sleeves (1) with a rubber mallet or
equivalent, and remove.
7. Remove the cover.
Fig. 652: Vented Seat Bag

8. Release the vented seat bag (1) from the vent motor (2) clips.
9. Remove the foam cushion from the seat back frame.

Fig. 653: Lumbar Motor

10. Disconnect the lumbar motor electrical connector (1) and remove the bolt (3).
Fig. 654: Lower Lumbar Mat

11. Separate the lower lumbar mat (1) from the clips (2).

Fig. 655: Lumbar Mat Side Wires

12. Release the lumbar mat side wires (3) by pulling out on the wire supports and then pulling them in.
13. Release the clips (2) and separate the vented seat motor from the lumbar support, if equipped.
14. Pull the upper support wires (1) down and release the lumbar mat from the seat back frame.
ASSEMBLY
ASSEMBLY
Fig. 656: Lumbar Mat Side Wires


1. Connect the upper support wires (1) to the seat back frame.
2. Secure the lumbar mat side wires (3).
3. Secure the vented seat motorclips (2) to the lumbar support, if equipped.
Fig. 657: Lower Lumbar Mat

4. Secure the lower lumbar mat (1) to the clips (2).
Fig. 658: Lumbar Motor

5. If equipped, position the lumbar motor (2) onto the seat back frame and install the bolt (3).
6. Tighten the bolt (3) to 10 N.m (89 in. lbs.).

Fig. 659: Vented Seat Bag

8. Position the vented seat bag (1) through the seat back support spring (3).
9. Position the vented seat bag (1) onto the vent motor (2) and seat the clips fully.
Fig. 660: J-Straps

10. Seat the foam and cover assembly over the seat back frame fully and secure the J-straps (1 and 2).

Fig. 661: Head Restraint Sleeves With Slave Sleeve

11. Install the new head restraint sleeves with slave sleeve (4) in the right position and master sleeve (3) in
the left position.
12. Press the lock buttons (2) on the sleeves and insert the head restraint tubes (1) into the head restraint
guide sleeves, ensuring proper forward facing orientation of the head restraint.

Fig. 662: Brace

13. Install the brace (2) and install the screws (1).
Fig. 663: Side Shield

14. Position the inner shields (1) back and seat the locator pin (2) fully.
15. Install the seat back. Refer to SEAT BACK, FRONT, INSTALLATION .
INSTALLATION
INSTALLATION

Fig. 664: Seat Back Assembly

1. Install the seat back (1) onto the seat cushion assembly and install the four bolts (2).
2. Tighten the bolts (2) to 40 N.m (30 ft. lbs.).

3. On manual reclining seats, install the recliner rod (2) onto the recliner lever and fully seat the clip (1).

Fig. 666: Seat Cushion Suspension Mat

4. Position the wire harness (1) through the suspension mat (2).
5. Secure the suspension mat (2) to the cross brace.






12. If equipped with manual seat, install the seat recline handle. Make sure the clip holding the handle is fully
engaged.



14. Install the side shield screws (2).


INSTALLATION .
SEAT BACK, REAR

REMOVAL
REMOVAL

REMOVAL.
2. Remove the screws (1) and remove the side shields (2).
Fig. 675: Seat Back Assembly & Bolt

3. Remove the bolts (1).

4. Remove the seat back assembly (2).

DISASSEMBLY
DISASSEMBLY
Fig. 676: Headrest

1. Remove the seat back. Refer to SEAT BACK, REAR, REMOVAL.

2. Press master and slave buttons on head restraint guides simultaneously and remove the headrests.
Fig. 677: J-Straps

3. Separate the J-straps (2).

Fig. 678: J-Straps & Hog Rings

4. Separate the J-strap (1).

5. Remove the two rear hog rings (2).
Fig. 679: Hooks, J-Straps & Hog Rings

6. Remove the two bolts (3).

7. Remove the two nuts (4).
8. Pull the bottom of the armrest out and away from the seat back.
9. Release the two top hooks (2) and remove the armrest.
10. Separate the remaining J-straps (1 and 5).

Fig. 680: Headrest Sleeves

11. Using pliers or equivalent, squeeze the locking tabs and remove the headrest sleeves.

12. Remove the foam and cover assembly.

13. Remove the hog rings (2) attaching the cover (3) to the foam (1).
CENTER ARM REST

Fig. 682: Armrest

1. Remove the pivot bolts (2) and separate the armrest (1) from the tray (3).

2. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, disengage the clips (1) and remove the
cup holder (2).

Fig. 684: Armrest Foam & Cover

3. Unzip the cover (1) and separate the foam and cover (2) from the armrest frame.
ASSEMBLY
ASSEMBLY

1. Position the cover (3) on to the foam (1) and install three new hog rings (2).
2. Position the foam and cover assembly over the seat back frame.

Fig. 686: Hooks, J-Straps & Hog Rings

3. Secure the J-straps (1 and 5)

4. Position the armrest into the seat cavity and secure the upper hooks (2).
5. Seat the armrest fully into the seat cavity and install the screws (3) and nuts (4).
6. Tighten the screws and nuts to 28 N.m (21 ft. lbs.)
Fig. 687: J-Straps & Hog Rings

7. Secure the J-strap (1).

8. Install two new rear hog rings (2).

Fig. 688: J-Straps

9. Secure the J-straps (2).
Fig. 689: Head Restraint Sleeves With Slave Sleeve


10. Install the new head restraint sleeves with slave sleeve (4) in the right position and master sleeve (3) in
the left position.
11. Press the lock buttons (2) on the sleeves and insert the head restraint tubes (1) into the head restraint
guide sleeves, ensuring proper forward facing orientation of the head restraint.
12. Install the seat back. Refer to SEAT BACK, REAR, INSTALLATION .
CENTER ARM REST
Fig. 690: Armrest Foam & Cover

1. Position the foam and cover (2) over the armrest frame and secure the zipper (1).


2. Position the cupholder (2) onto the armrest (3) and seat the four clips (1) fully.
Fig. 692: Armrest

3. Install the armrest assembly (1) onto the tray (3) and install the pivot brackets.
4. Install the pivot bolts and tighten to 28 N.m (21 ft. lbs.).
INSTALLATION
INSTALLATION
Fig. 693: Seat Back Assembly & Bolt

1. Position the seat back assembly (2) onto the seat latches and install the pivot bolts (1).

2. Tighten the bolts (1) to 28 N.m (21 ft. lbs.).

3. Install the side shields (2) and install the screws (1).
4. Install the rear seat assembly. Refer to SEAT, REAR, INSTALLATION or SEAT, MEGA CAB
REAR, INSTALLATION .
SEAT, MEGA CAB REAR
DESCRIPTION
DESCRIPTION
MEGA CAB FIGURE

REAR 60% SEAT - MEGA CAB Refer to Fig. 695.
REAR 40% SEAT - MEGA CAB Refer to Fig. 696.
REAR SEAT MOUNTING BRACKETS - MEGA
Refer to Fig. 697.
CAB

Fig. 695: Rear 60% Seat - Mega CAB

27 - REAR MOUNTING BRACKET BOLT 28

1 - SEAT BACK CUSHION/COVER ASSEMBLY
N.m (21 ft. lbs.)
28 - PIVOT LEG TO CUSHION BOLTS (2) 28
2 - ARMREST COVER
N.m (21 ft. lbs.)
3 - ARMREST FOAM 29 - CONNECTING ROD
4 - CUP HOLDER 30 - FRONT PIVOT MOUNTING LEG BRACKET
5 - CUP HOLDER SCREWS (2) 31 - STOW PIVOT BOLTS (2) 28 N.m (21 ft. lbs.)
32 - REAR MOUNTING BRACKET BOLTS (2)
6 - ARMREST BACK PANEL
28 N.m (21 ft. lbs.)
7 - ARMREST PIVOT ASSEMBLY 33 - PIVOT LEG TO CUSHION WASHERS (2)
8 - RETRACTOR COVER SCREWS (2) 34 - FRONT PIVOT MOUNTING LEG BRACKET
9 - RETRACTOR COVER 35 - SEAT CUSHION FRAME ASSEMBLY
36 - RECLINER HANDLE BRACKET SCREWS
10 - RETRACTOR
(2)
11 - HEADREST 37 - SIDE COVER SCREW
12 - CENTER HEADREST 38 - SEAT CUSHION FRAME SIDE COVER
13 - SCREWS (2) 39 - RECLINER - OUTBOARD
14 - HEADREST SLEEVE - SLAVE 40 - RETRACTOR BEZEL SCREW
N.m (21 ft. lbs.)

16 - SEAT BACK PANEL 42 - RECLINER COVER

17 - FOLD-TABLE CABLE ASSEMBLY 43 - SEAT BACK FRAME ASSEMBLY
18 - SEAT BACK TO RECLINER BOLTS (4) 48
44 - RECLINER COVER SCREWS
N.m (35 ft. lbs.)
19 - RECLINER COVER SCREWS 45 - RECLINER CABLE ASSEMBLY
20 - SCREWS 46 - RECLINER HANDLE
47 - ARMREST FRAME PIVOT BOLTS (2) 8 N.m
21 - RECLINER COVER
(71 in. lbs.)
48 - ARMREST PIVOT TO FRAME BOLTS (2) 8
22 - SCREW
N.m (71 in. lbs.)
23 - RECLINER - INBOARD 49 - SEAT BACK HEAT MAT
50 - SEAT CUSHION HEAT MAT
48 N.m (35 ft. lbs.)
25 - SEAT CUSHION FRAME SIDE COVER 51 - SEAT CUSHION/COVER ASSEMBLY
26 - SIDE COVER SCREW
Fig. 696: Rear 40% Seat - Mega CAB

1 - SEAT BACK CUSHION/COVER ASSEMBLY 20 - SCREW

2 - RECLINER COVER SCREWS 21 - RECLINER COVER
3 - RECLINER COVER 22 - SIDE COVER SCREW

4 - FOLD-TABLE CABLE ASSEMBLY 23 - SEAT CUSHION FRAME SIDE COVER

5 - HEADREST SLEEVE - SLAVE 24 - STOW PIVOT BOLTS (2) 28 N.m (21 ft. lbs.)
6 - HEADREST 25 - SEAT CUSHION FRAME SIDE COVER
7 - HEADREST SLEEVE - MASTER 26 - RECLINER CABLE ASSEMBLY
27 - RECLINER HANDLE BRACKET SCREWS
8 - SEAT BACK PANEL
(2)
9 - SCREWS (2) 28 - RECLINER HANDLE
29 - PIVOT LEG TO CUSHION BOLTS (2) 28
10 - SEAT BACK FRAME ASSEMBLY
N.m (21 ft. lbs.)
11 - SEAT BACK TO RECLINER BOLTS (4) 48
30 - FRONT PIVOT MOUNTING LEG BRACKET
N.m (35 ft. lbs.)
12 - RETRACTOR BEZEL SCREW 31 - SEAT CUSHION FRAME ASSEMBLY
13 - RECLINER - INBOARD 32 - RISER COVER ASSEMBLY
33 - RISER COVER SCREW
28 N.m (21 ft. lbs.)
34 - RISER COVER SCREWS (2)
48 N.m (35 ft. lbs.)
35 - PIVOT LEG TO BRACKET BOLTS (2) 28
16 - CONNECTING ROD
N.m (21 ft. lbs.)
36 - PIVOT LEG TO BRACKET WASHERS (2)
N.m (21 ft. lbs.)
18 - RECLINER - OUTBOARD 37 - SEAT CUSHION/COVER ASSEMBLY
19 - SCREWS

Fig. 697: Rear Seat Mounting Brackets - Mega CAB

13 - PIVOT LEG TO BRACKET BOLTS - 40 (2)

1 - FLIPPER PANEL BRACKET ASSEMBLY - 60
28 N.m (21 ft. lbs.)
14 - PIVOT LEG TO BRACKET WASHERS - 40
2 - MOUNTING NUTS (16) 28 N.m (21 ft. lbs.)
(2)
3 - FLIPPER PANEL SCREWS - 60 (11) 15 - SEAT BUCKLE ASSEMBLY INBOARD - 40
4 - CENTER ISOFIX TUBE ASSEMBLY 16 - BELT BUCKLE BOLT 47 N.m (35 ft. lbs.)
5 - FLIPPER PANEL - 60 17 - SEAT BUCKLE ASSEMBLY CENTER
18 - FLOOR MOUNTING BRACKET
6 - FLIPPER PANEL - 40
ASSEMBLY
19 - OUTBOARD ISOFIX TUBE ASSEMBLY -
7 - FLIPPER PANEL BRACKET ASSEMBLY - 40
40
20 - PIVOT LEG TO BRACKET WASHERS - 60
8 - OUTBOARD ISOFIX TUBE ASSEMBLY - 40
(2)
21 - PIVOT LEG TO BRACKET BOLTS - 60 (2)
9 - FLIPPER PANEL SCREWS - 40 (9)
28 N.m (21 ft. lbs.)
10 - RISER COVER ASSEMBLY 22 - RISER COVER SCREWS (2)
11 - RISER COVER SCREW 23 - RISER COVER SCREW
12 - RISER COVER SCREWS (2) 24 - RISER COVER ASSEMBLY
REMOVAL

REMOVAL
Fig. 698: Identifying Seat Back, Filler Panels & Rear Bolts
1. Fold the seat backs (2) forward.

2. Remove the filler panels (3).
3. Remove the rear bolts (1).

Fig. 699: Removing Front Bolts And Nut

4. Remove the front bolts (1) and nut (2).
Fig. 700: Removing/Installing Seat Assembly

5. Remove the seat assembly (1).

INSTALLATION
INSTALLATION
Fig. 701: Removing/Installing Seat Assembly

1. Install the seat assembly (1) into the vehicle and position over the front stud (2).
Fig. 702: Installing Nuts And Bolts


2. Install the nut (2) and bolts (1).

3. Tighten the fasteners to 47.5 N.m (35 ft. lbs.) using the sequence shown in the illustration.
Fig. 703: Identifying Seat Back, Filler Panels & Rear Bolts
4. Install the rear bolts and tighten to 47.5 N.m (35 ft. lbs.).
STATIONARY GLASS
BACKLITE
REMOVAL
REMOVAL
MANUAL

Fig. 704: Identifying Backlite Vent Glass

1. Slide the upper run channel (1) out of the window frame (2).
2. Slide the vent glass (3) upward to remove from the lower window frame (2).
3. Lower the glass (3) out of the upper window frame (2) and remove.
CREW/QUAD CAB

1. Remove the rear seats. Refer to SEAT, REAR, REMOVAL or SEAT, MEGA CAB REAR,
REMOVAL .
3. Separate the cable housing block from the lower left glass run channel and disconnect the left side cable
from the glass.

6. Disconnect the right side cable and remove the glass.
MEGA CAB

1. Tumble the rear seat assembly into the full down position.
from the glass.
INSTALLATION
INSTALLATION
MANUAL


1. Slide the vent glass (3) upper edge into window frame (2) and insert the lower edge into the lower
molding.
2. Position the upper run channel (1) into the window frame (2) and slide it into place.
3. Verify vent glass (3) operation.
CREW/QUAD CAB

1. Position the glass (3) and connect the right side cable.
molding.
3. Connect the left side cable to the glass and secure the cable housing block into the lower glass channel.

5. Install the rear seats. Refer to SEAT, REAR, INSTALLATION or SEAT, MEGA CAB REAR,
INSTALLATION .
MEGA CAB

molding.
BACKLITE, SLIDING
REMOVAL
REMOVAL
MANUAL


CREW/QUAD CAB

REMOVAL .
from the glass.

MEGA CAB

1. Tumble the rear seat assembly into the full down position.
from the glass.
INSTALLATION
INSTALLATION
MANUAL


molding.
3. Verify vent glass (3) operation.
CREW/QUAD CAB

molding.

5. Install the rear seats. Refer to SEAT, REAR, INSTALLATION or SEAT, MEGA CAB REAR,
INSTALLATION .
MEGA CAB

molding.
REGULATOR, BACKLITE GLASS
REMOVAL
REMOVAL

2. Remove the rear cab back panel. Refer to PANEL, CAB BACK TRIM, REMOVAL.

Fig. 716: Locating Backlite Glass Regulator Mounting Bolts

3. Disconnect the electrical connector to the power motor.

4. Remove the two mounting bolts (1).
Fig. 717: Identifying Glass Track, Vent Glass, Support Clips, And Regulator Assembly
5. Separate the cable housings from the glass track (1).

6. Disconnect the cable ends from the vent glass (2).
7. Separate the support clips (5) and remove the regulator assembly (3).

INSTALLATION
INSTALLATION
Fig. 718: Identifying Glass Track, Vent Glass, Support Clips, And Regulator Assembly
1. Connect the cable ends to the vent glass (2).

2. Install the cable housings into the glass tracks (1).
3. Fasten the support clips (5).
Fig. 719: Locating Backlite Glass Regulator Mounting Bolts


4. Install the 2 mounting bolts (1).

5. Connect the electrical connector to the power motor.
6. Install the rear cab back panel. Refer to PANEL, CAB BACK TRIM, INSTALLATION.
7. Connect the battery negative cable.
WINDSHIELD
WARNING
WARNING
WARNING: Do not operate the vehicle within 24 hours of windshield installation. It

takes at least 24 hours for urethane adhesive to cure. If it is not cured, the
windshield may not perform properly in an accident.
Urethane adhesives are applied as a system. Use glass cleaner,

glass prep solvent, glass primer, PVC (vinyl) primer and pinch weld
(fence) primer provided by the adhesive manufacturer. If not,
structural integrity could be compromised.
Chrysler LLC does not recommend glass adhesive by brand.
Technicians should review product labels and technical data sheets,
and use only adhesives that their manufactures warranty and will
restore a vehicle to the requirements of fmvss 212. Technicians
should also insure that primers and cleaners are compatible with the
particular adhesive used.
Be sure to refer to the urethane manufacturer's directions for curing
time specifications and do not use adhesive after its expiration date.
Vapors that are emitted from the urethane adhesive or primer could
cause personal injury or death. Use them in a well-ventilated area.
Skin contact with urethane adhesive should be avoided. Personal
injury or death may result.
Always wear eye and hand protection when working with glass.
CAUTION: Protect all painted and trimmed surfaces from coming in contact with
urethane or primers.
Be careful not to damage painted surfaces when removing moldings or

cutting urethane around windshield.
REMOVAL
REMOVAL


1. Remove inside rear view mirror (3). Refer to MIRROR, REARVIEW, REMOVAL.
Fig. 721: Removing/Installing Cowl Grille

2. Remove cowl grille (2). Refer to COVER, COWL PANEL, REMOVAL.

Fig. 722: Removing/Installing Door Opening Weatherstrips/Seals

3. Remove the A-pillar weatherstrip retainer (1).


4. Remove the A-pillar trim panels (2). Refer to PANEL, A-PILLAR TRIM, WITH GRAB HANDLE,
REMOVAL.
Fig. 724: Head Liner-Quad Cab

5. Lower the headliner (9) as needed and using windshield removal tool such as an extractor or equivalent,
start at the rear section of the glass and work around the parameter to remove urethane. A pneumatic
cutting device can be used but is not recommended. Refer to HEADLINER, REMOVAL.
6. Separate windshield from vehicle.
INSTALLATION
INSTALLATION

Fig. 725: Center Windshield And Mark At Support

WARNING: Allow the urethane at least 24 hours to cure before returning the vehicle
to use.
CAUTION: Roll down the left and right front door glass and open the rear glass slider
(if available) before installing windshield. This is to avoid pressurizing the
passenger compartment if a door is slammed before the urethane is cured.
The potential for water leaks can result.
The windshield fence should be cleaned of most of its old urethane bonding material. A small amount of old
urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove
all old urethane from the fence, the paint finish and bonding strength will be adversely affected.
1. Place replacement windshield (1) into windshield opening and position glass in the center of the opening
against the support spacers (3). Mark the outside surface of the glass at the support spacers (3) with a
grease pencil or pieces of masking tape and ink pen to use as a reference (2) for installation. Remove
replacement windshield from windshield opening.
Fig. 726: Work Surface Set Up

2. Position the windshield (1) inside up on a suitable work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks (3), placed parallel 75 cm (2.5 ft.) apart.
3. Clean inside of windshield with MOPAR® Glass Cleaner and lint-free cloth.
4. Apply clear glass primer 25 mm (1 in.) wide around perimeter of windshield and wipe with a new clean
and dry lint- free cloth.
5. Apply black-out primer onto the glass using the windshield molding as a guide. The primer should be 15
mm (5/8 in.) wide on the top and sides of the glass and 25 mm (1 in.) on the bottom of windshield. Allow
at least three minutes drying time.

Fig. 727: Center Windshield And Mark At Support

6. Locate NEW support spacers (3) on support brackets and adjust to lowest height.
Fig. 728: Locating Windshield Foam Support Spacers

7. Position seven new foam spacers (4 and 3) on the inside surface of the windshield, flush with the lower
and side edges.
8. Position three new foam spacers (1) on the inside surface of the windshield, at a minimum distance of 3
mm (0.12 in.) from the top edge of the windshield.

Fig. 729: Applicator TIP

9. The urethane bead should be shaped in a triangular cross-section, this can be achieved by notching the tip
of the applicator.
Fig. 730: Work Surface Set Up

10. Apply a 13 mm (1/2 in.) high and 10 mm (3/8 in.) wide bead of urethane around the perimeter of
windshield (2). At the top, apply the bead 7 mm (1/4 in.) inboard from the glass edge. On the other three
sides apply the bead 14 mm (0.55 in.) inboard from the glass edge.

Fig. 731: Lower Windshield Into Position

11. With the aid of a helper, position the windshield (2) over the windshield opening. Align the reference
marks at the bottom of the windshield to the support spacers (3).
12. Slowly lower windshield glass (2) to the fence opening guiding the lower corners into proper position.
Beginning at the bottom and continuing to the top, push glass (2) onto fence along the A-Pillars. Push
windshield (2) inward to the fence at the bottom corners.
13. Push windshield (2) upward, setting the windshield to roof gap to 1.5 mm (0.06 in.) to 3 mm (0.12 in.)
and ratchet up the adjustable support brackets.
14. Using clean water, lightly mist the support spacers (3).
15. Clean excess urethane from exterior with MOPAR® Super Clean or equivalent.
Fig. 732: Removing/Installing Cowl Grille

16. Install cowl grille (2). Refer to COVER, COWL PANEL, INSTALLATION.


17. Install rear view mirror support bracket (4). Refer to MIRROR, REARVIEW, INSTALLATION.
18. Install rear view mirror (3). Refer to MIRROR, REARVIEW, INSTALLATION.

19. Install the A-pillar trim (2). Refer to PANEL, A-PILLAR TRIM, WITH GRAB HANDLE,
INSTALLATION.

Fig. 735: Removing/Installing Head Liner - Quad CAB

20. Install the headliner (6). Refer to HEADLINER, INSTALLATION.
Fig. 736: Removing/Installing Door Opening Weatherstrips/Seals

21. Install the A-pillar weatherstrip retainer (1).

22. After urethane has cured, remove tape strips and water test windshield to verify repair.

SUNROOF
DESCRIPTION
DESCRIPTION
Fig. 737: Exploded View Of Sunroof Components

1 - MECHANISM COVERS (2) 10 - MOTOR FASTENERS (3)

2 - RIGHT HAND GLASS GUIDE 11 - SUNROOF MOTOR/MODULE ASSEMBLY

3 - GLASS FASTENERS (4) 12 - ALIGNMENT HOLE

4 - GLASS ASSEMBLY 13 - ASSEMBLY FASTENERS (8)
5 - DRAIN CHANNEL 14 - ALIGNMENT HOLE
6 - SUNSHADE 15 - WIND DEFLECTOR
7 - LEFT SUNROOF GLASS GUIDE 16 - GLASS GUIDE FOOT
8 - WIRE HARNESS 17 - WIND DEFLECTOR STRAP SCREWS (2)
9 - SUNROOF ASSEMBLY
The power sunroof system allows the sunroof to be opened, closed or placed in the vent position electrically by
actuating a switch in the overhead console. The sunroof will operate normally with the key in any position,
while the Accessory Delay system is active.
The sunroof glass panel tilts upward at the rear for ventilation and slides rearward under the roof when open.
The glass panel seals flush with the roof in the closed position to eliminate wind noise. The sunroof includes a
manual-sliding sunshade to cover the deep-tinted glass panel.
In addition to the standard power sunroof operation, this vehicle offers several additional features. There is an
express (one-touch) opening and closing feature as well as Excessive Force Limitation (EFL). The EFL function
detects obstacles trapped between the glass and the vehicle roof during a closing motion. Upon sensing an
obstacle the EFL function will reverse direction of the glass to allow removal of the obstacle.
The main components of the power sunroof system are:
The motor/module assembly

The power sunroof glass and frame assembly
The power sunroof switch
The manual sliding sunshade
The power sunroof system allows the sunroof to be opened, closed or placed in the vent position electrically by
actuating a switch in the overhead console. The sunroof will operate normally with the key in any position,
while the Accessory Delay system is active.
The sunroof glass panel tilts upward at the rear for ventilation and slides rearward under the roof when open.
The glass panel seals flush with the roof in the closed position to eliminate wind noise. The sunroof includes a
manual-sliding sunshade to cover the deep-tinted glass panel.
In addition to the standard power sunroof operation, this vehicle offers several additional features. There is an
express (one-touch) opening and closing feature as well as Excessive Force Limitation (EFL). The EFL function
detects obstacles trapped between the glass and the vehicle roof during a closing motion. Upon sensing an
obstacle the EFL function will reverse direction of the glass to allow removal of the obstacle.
The main components of the power sunroof system are:
The motor/module assembly

The power sunroof glass and frame assembly

The power sunroof switch

The manual-sliding sunshade
OPERATION
OPERATION
This vehicle has a vent, tilt and slide power sunroof system with express (one-touch) open and closing feature.
The sunroof system receives constant battery feed through a fuse in the Power Distribution Center (PDC). The
sunroof will operate normally with the key in the "RUN" or "ACCESSORY" position. If the sunroof is moving
when the key is turned to the START position (crank engine), all motions will stop. The sunroof will also stop a
requested motion if the key is turned "OFF".
A combination push-button and rocker switch module mounted in the overhead console controls sunroof
operation. The sunroof switch is a rocker design with a push button in the center of the two halves of the rocker.
Pressing the rocker towards the front of the car commands the sunroof closed. Pressing the rocker towards the
rear of the car commands the sunroof open. Pressing the center push button commands the sunroof up into the
vent position (Rear of sunroof glass raises above the vehicle roof with glass still covering the sunroof opening).
All switch commands operate with the glass starting in any position. for additional information. Refer to
SWITCH, SUNROOF, OPERATION .
An electronic control system, integral to the motor/module assembly, provides the express open and close
functions. During express opening, the sunroof glass panel will first open to the "Comfort Stop" position. A
second press of the "OPEN" button on the rocker switch will move the glass panel to the full open position.
Pressing the "close" end of the rocker switch moves the sunroof glass panel to the full closed position. During
express closing, anytime an obstacle is detected in the way of the glass, the motor will stop and reverse travel to
avoid pinching an occupant's finger, ice in the track, etc. This function is called Excessive Force Limitation
(EFL). There are two methods of overriding the EFL function.
1. When three EFL events occur without the glass being allowed to fully close, the next close attempt will
only move while the close switch is continuously actuated. This allows the sunroof to be forced closed if
multiple close attempts fail.
2. If the sunroof close switch is continuously actuated during an EFL event, through the reversal, and during
a two second wait time, then continuing to hold the close switch will cause the roof to move towards
close with the EFL protection disabled. This allows the sunroof to be forced closed if it is known that a
reversal will occur. This secondary EFL override may be necessary when known debris (ice blockage for
example) is preventing the glass panel from closing.
While in EFL override, the closing motion will cease if the sunroof switch is released at any time.
DIAGNOSIS AND TESTING - SUNROOF
For sunroof electrical system diagnosis and testing procedures. Refer to DIAGNOSIS AND TESTING .
WATER DRAINAGE AND WIND NOISE DIAGNOSIS

The sliding glass panel is designed to seal water entry with a snug fit between the roof and the seal. The fit can
be checked by inserting a business card or equivalent, between the roof and the seal. The piece of paper should
have some resistance when pulled out when the glass panel is in the closed position. The sunroof housing will
drain off a minimum amount of water. Excessive wind noise could result if the gap clearances are exceeded.
The sunroof glass panel may need to be adjusted. Refer to GLASS, SUNROOF, ADJUSTMENTS.
Adequate drainage is provided by a drain trough in the sunroof housing which encircles the sliding glass panel
and leads to drain hoses. If a wet headliner or other water leak complaints are encountered, before performing
any adjustments, first ensure that the drainage system is not plugged or disconnected. Use a pint container to
pour water into the sunroof housing drain trough. If water flow is restricted, use compressed air to blow out any
material plugging the drain system. Retest system again.
To further check for a disconnected drain hose:
NOTE: Care must be taken not to fold or kink the headliner upon removal.
1. Lower headliner as necessary to gain access to sunroof housing drain tubes. Refer to HEADLINER,
REMOVAL.
2. Repair as necessary.
CHANNEL, SUNROOF DRAIN
REMOVAL
REMOVAL
Fig. 738: Identifying Drain Channel Arm & Guide Mechanisms


1. Remove glass panel. Refer to GLASS, SUNROOF, REMOVAL.

2. Using pliers, disengage the drain channel arm (1) from the guide mechanisms (2) one at a time by
pushing the drain channel arm retaining tab through the retention hole located in the guide mechanism.Do
not use excessive force to remove.
CAUTION: Disengage the drain channel arms one at a time. Do not disengage
both sides at the same time.
CAUTION: Do not pull or pry the channel arms. Doing so will result in breaking
the channel arms. Only disengage the channel arms as shown in the
illustration.
Fig. 739: Drain Channel & Notches

3. Carefully slide the drain channel (1) forward to the notches (2) in the track asy. Pull up on one side to
disengage, repeat on the opposite side and remove the drain channel.
INSTALLATION
INSTALLATION

Fig. 740: Positioning Drain Channel Into Notches

1. Carefully position the drain channel (1) one side at a time into the notches (2) in the track assembly. Once
positioned, push down until it engages into the track assembly. Repeat steps on the opposite side and slide
the drain channel assembly rearward.
Fig. 741: Drain Channel Arms & Mechanism Holes

2. Install the drain channel arms (2) into the mechanism holes (1) one at a time.

CAUTION: Do not push the guide arms at the same time or you could break the
guide mechanism. Do not use excessive force to install.
3. Install the sunroof glass. Refer to GLASS, SUNROOF, INSTALLATION.
COVER, SUNROOF MECHANISM
REMOVAL
REMOVAL
Fig. 742: Mechanism Covers & Tabs

1. Move the glass panel to the full closed position.

2. Slide sunshade rearward to the open position.
3. Separate the mechanism covers (2) from the tabs (1) on the glass panel.

Fig. 743: Removing/Installing Mechanism Cover

4. Hold both mechanism covers down and open the sunroof fully.
5. Slide the mechanism covers (1) out the front of the guide in the frame (2).
INSTALLATION
INSTALLATION

1. With the sunroof in the open position, snap the mechanism cover (2) into the lower guide channel.

2. Hold down each cover and close the sunroof.

3. Snap the upper portion of the cover (2) into the retaining clips (1) on the glass panel between the locating
features.
DEFLECTOR, WIND
REMOVAL
REMOVAL
Fig. 745: Deflector Strap Screw

1. Open the sunroof fully.

2. Remove the strap screws (3) from the beam area (1) and release the strap (2).

Fig. 746: Removing/Installing Wind Deflector

3. Rotate the deflector up and remove springs (2) from the holes in the frame (1).
INSTALLATION
INSTALLATION
Fig. 747: Removing/Installing Wind Deflector

1. Position the deflector spring arms (2) into the holes of the frame (1).

Fig. 748: Deflector Strap Screw

2. Rotate the deflector down, attach the straps (2) and install the strap screws (1).
3. Verify sunroof operation and alignment.
GLASS, SUNROOF
ADJUSTMENTS
ADJUSTMENTS
Fig. 749: Mechanism Cover

1. Move the sunshade rearward to the open position.

2. Separate the mechanism covers (1) from the tabs on the glass panel by pulling the top edge of the cover
inboard from both sides.
Fig. 750: Glass Fasteners

3. Verify the sunroof glass panel is in the fully closed position.

4. Loosen the forward attaching screws (2) on each side enough to permit the front of the glass to adjust up
or down.
5. Adjust the front surface of the sunroof glass panel 0.00 mm to 2 mm (0.00 in. to 0.08 in.) below the top
surface of the roof.
6. Tighten the front glass panel attaching screws to 5.5 N.m (49 in. lbs.).
7. Loosen the rear screws (2) on each side enough to make the rear adjustment.
8. Adjust the rear surface of the sunroof glass panel 0.00 mm to 2 mm (0.00 in. to 0.08 in.) above the top
surface of the roof.
9. Tighten the rear glass panel attaching screws to 5.5 N.m (49 in. lbs.).
10. Check for proper fit by inserting a business card between the glass seal and roof. Slide the card around the
entire perimeter of the glass. The effort to slide the card should be uniform through the entire perimeter. If
the effort is not uniform, repeat the glass panel adjustment.

Fig. 751: Top Of Mechanism Cover

11. Locate the top of the mechanism cover by printed text (1).
Fig. 752: Mechanism Cover

12. Position the mechanism covers (1) over the glass tabs between the locating features and seat fully by
pushing the top edges of the cover outboard.
REMOVAL
REMOVAL
Fig. 753: Removing/Installing Mechanism Cover

1. Move the glass panel to the full closed position.

2. Slide sunshade rearward to the open position.
3. Separate the mechanism covers (2) from the tabs (1) on the glass panel.

4. Remove the glass panel screws (3).

5. Lift off glass panel and remove from vehicle.
INSTALLATION
INSTALLATION


1. Position glass panel on to mechanism lift arms.
CAUTION: Verify that the retaining tabs are located on the INSIDE of the guide
mechanism arms.
2. Start the attaching screws (3).

3. Connect a 12v power supply and verify that the sunroof is in the closed position.
4. Adjust sunroof glass to fit flush with roof line. Refer to GLASS, SUNROOF, ADJUSTMENTS.
5. Tighten the screws (3) to 3.5 N.m (30 in. lbs.).
6. Position the mechanism covers (2) over the glass tabs (1) between the locating features and seat fully.
GUIDE, SUNROOF, GLASS
REMOVAL
REMOVAL
Fig. 756: Identifying Drain Channel Arm & Guide Mechanisms

1. Open the sunroof into the "vent" position.

2. Turn off the ignition and disconnect the negative battery cable to disable the sunroof operation.

3. Remove the glass panel. Refer to GLASS, SUNROOF, REMOVAL.

4. Separate the drain channel arms (1) from the guide mechanisms (2) one at a time.
CAUTION: Disengage the drain channel arms one at a time. Do not disengage
both sides at the same time.
CAUTION: Do not pry the guide arms apart at the same time, damage to the
guide mechanism may occur.
5. Slide the drain channel rearward out of the way.
Fig. 757: Holding Locking Lever Out Of Notch

6. Using a small flat blade screwdriver, slightly lift and hold the locking lever (1) out of the notch (3) in the
track assembly.
7. Slide the glass guide/guide carriage assembly (2) rearward approximately 25-30 mm.

Fig. 758: Releasing Locking Lever

8. Push rearward at the front of the glass guide (2). The locking lever (1) can be released after 12mm of
rearward movement.
Fig. 759: Driving Wedge & Guide Carriage

9. Make sure the driving wedge (1) is not forward of the position shown in order to remain engaged with the
guide carriage (2).

Fig. 760: Glass Guide Foot & Track Assembly

10. Lift and rotate the glass guide out to release the glass guide foot (1) from the track assembly (2).
11. If necessary, repeat steps for the opposite side.
INSTALLATION
INSTALLATION
Fig. 761: Glass Guide Foot & Track Assembly

1. Insert the front foot (1) into the track assembly (2) and rotate inboard to engage.

Fig. 762: Glass Guide Bosses & Guide Carriage Foot

2. Align the opening between the glass guide bosses (1) with the guide carriage foot (2) and lower the glass
guide to engage.
Fig. 763: Pushing Glass Guide Into Driving Wedge

3. Push the glass guide (1) forward and engage into the driving wedge (2).
NOTE: The guide carriage assembly should move together with the glass guide. If
the guide carriage assembly does not move with the glass guide, repeat
the alignment procedure in step 2.

4. Continue pushing the guide carriage and glass guide forward until the locking lever (4) engages into the
track assembly notch (3).
Fig. 764: Drain Channel Arms & Mechanism Holes

5. Install the drain channel arms (2) into the mechanism holes (1) one at a time.
6. If necessary, repeat steps for the opposite side.
CAUTION: Do not push the guide arms at the same time or you could break the
guide mechanism. Do not use excessive force to install.
7. Re-connect the negative battery cable and turn the key to the accessory run position.
8. Cycle the mechanism through all of it's functions to verify proper operation.
9. Cycle the mechanism to the closed postion.
10. Install the glass as necessary. Refer to GLASS, SUNROOF, INSTALLATION.
11. Adjust the sunroof glass to fit flush with the roof line. Refer to GLASS, SUNROOF, ADJUSTMENTS.
12. Verify proper operation of the power sunroof system.
SUNROOF
REMOVAL
REMOVAL

Fig. 765: Removing/Installing Electrical Connector

WARNING: The Excessive Force Limitation (EFL) feature must be calibrated any time
a sunroof motor/module is replaced with a new component. Failure to
perform this procedure could result in vehicle damage and/or personal
injury.
NOTE: The EFL calibration procedure can be found in the service information. Refer to
MOTOR, SUNROOF, STANDARD PROCEDURE .
1. Remove the glass. Refer to GLASS, SUNROOF, REMOVAL.

3. Remove headliner. Refer to HEADLINER, REMOVAL.
4. Disconnect the sunroof wire harness electrical connector (1).

Fig. 766: Drain Tubes

5. Disconnect the four drain tubes (1) from sunroof housing.
Fig. 767: Removing/Installing Sunroof Assembly

6. With the aid of a helper, support the sunroof and remove the eight fasteners (2) attaching sunroof
assembly (1) to roof panel.

7. Remove the sunroof (1) from vehicle.
INSTALLATION
INSTALLATION
Fig. 768: Removing/Installing Sunroof Assembly

WARNING: The Excessive Force Limitation (EFL) feature must be calibrated any time
a sunroof motor/module is replaced with a new component. Failure to
perform this procedure could result in vehicle damage and/or personal
injury.
NOTE: The EFL calibration procedure can be found in the service information. Refer to
MOTOR, SUNROOF, STANDARD PROCEDURE .
1. Raise sunroof module assembly (1) and guide it carefully into position.
2. Hand start the eight screws (2).
3. Line up the locating holes and tighten the attaching screws (2) to 9 N.m (80 in. lbs.).

Fig. 769: Removing/Installing Electrical Connector

Fig. 770: Connecting Drain Tubes

5. Connect the drain tubes (1) to the sunroof.

6. Connect battery negative cable.
7. Install the glass. Refer to GLASS, SUNROOF, INSTALLATION.
8. Install the vehicle headliner. Refer to HEADLINER, INSTALLATION.
9. Perform the sunroof position calibration. Refer to MOTOR, SUNROOF, STANDARD PROCEDURE .
10. Verify proper operation of the power sunroof system.

SUNSHADE, SUNROOF
REMOVAL
REMOVAL
Fig. 771: Removing/Installing Drain Channel

1. Remove the drain channel. Refer to TUBE, SUNROOF DRAIN, REMOVAL.

2. Push up the front center of the sunshade (1) to pop out the front two feet.
Fig. 772: Removing/Installing Sunshade

3. Rotate the sunshade (2) so that the other feet (1) are removed from the guide track.
INSTALLATION
INSTALLATION
Fig. 773: Removing/Installing Sunshade

1. Verify the sunshade track is free of obstructions like the trim lace/ring.
2. Start with sunshade (2) at an angle with one foot (1) in the track.
3. Rotate the sunshade so the other rear foot is in the track as well as the 2 other feet (3) on the same side as
the first foot.

Fig. 774: Installing Sunshade

4. To insert the remaining two feet (2) apply force to the middle front of sunshade (3) and guide them into
the track.
5. Check that all the feet are in the right track and verify sunshade operation.
6. Install the drain channel. Refer to CHANNEL, SUNROOF DRAIN, INSTALLATION.
TRIM RING, SUNROOF
REMOVAL
REMOVAL
Fig. 775: Removing/Installing Trim Ring


1. Remove the headliner. Refer to HEADLINER, REMOVAL.

2. Remove the 12 nuts (1) and roll the trim ring off the headliner off the retaining flanges (2).
INSTALLATION
INSTALLATION
Fig. 776: Removing/Installing Trim Ring

1. Position trim ring support flanges (2) over the headliner and seat the trim ring fully.
2. Install the 12 nuts (1) onto the support studs.
TUBE, SUNROOF DRAIN
REMOVAL
REMOVAL
FRONT HOSES

Fig. 777: Front Drain Tube

1. Remove the instrument panel. Refer to PANEL, INSTRUMENT, REMOVAL.

3. Disconnect the drain hose from the sunroof housing (1).
4. Separate the lower tube from the grommet in the body (3).
5. Drain any liquid from hose connection, if necessary.
6. Release the clips (2) and remove the tube.
REAR HOUSING HOSE


REMOVAL .
NOTE: Front tube shown in the illustration, rear tube similar.
3. Disconnect the drain hose from the sunroof housing (1).

4. Drain any liquid from hose connection, if necessary.
5. Release the push pin fasteners (2) and separate the lower tube from the grommet in the body (3).
INSTALLATION
INSTALLATION
FRONT HOSES
Fig. 779: Sunroof Housing, Clips & Grommet

1. Position the lower portion through the grommet in the body (3).
2. Connect the new drain tube to the sunroof housing (1) and test drainage.
3. Position the tube support clips (2) and seat fully.
4. Install the instrument panel. Refer to PANEL, INSTRUMENT, INSTALLATION.
5. Install headliner. Refer to HEADLINER, INSTALLATION.
REAR HOUSING HOSE


NOTE: Front tube shown in the illustration, rear similar.
1. Install the rear tube and seat the push pin fasteners (2) fully.
2. Position the lower portion through the grommet in the body (3).
3. Connect the new drain tube to the sunroof housing (1) and test drainage.
4. Install the rear seats, if equipped. Refer to SEAT, REAR, INSTALLATION or SEAT, MEGA CAB
REAR, INSTALLATION .
5. Install headliner. Refer to HEADLINER, INSTALLATION.
WEATHERSTRIP/SEALS
CAUTION
CAUTION
Some body mounted weatherstrips are sealed to the body using a white mastic compound.
CAUTION: Door and Liftgate weatherstrip seals that use a white mastic sealant must
be replaced with a new weatherstrip and any mastic must be cleaned from
attachment flanges whenever the weatherstrip is removed.
CAUTION: Failure to follow these recommendations could result in damage or failure

to the part and the related parts.

SEAL, A-PILLAR
REMOVAL
REMOVAL

1. Open the appropriate door.

2. Carefully remove the A-pillar seal (1) from the retainers on the door sheet metal.
3. Remove the seal from the door.
INSTALLATION
INSTALLATION


1. Place the A-pillar seal (1) into position to the door.

2. Install the seal to the seal retainers on the door.
3. Close the door and verify a proper seal.
SEAL, B-PILLAR, LOWER
REMOVAL
REMOVAL



2. Carefully pry off the B-pillar seal (4) and remove from the retainers in the door.
INSTALLATION
INSTALLATION


1. Place the B-pillar seal (4) into position to the door.

2. Install the seal to the door engaging the retainers.
3. Close the door and verify proper seal.
SEAL, DOOR OPENING
REMOVAL
REMOVAL
FRONT DOOR SEAL

Fig. 785: Door Seals

1. Remove the cowl trim panel. Refer to PANEL, COWL TRIM, REMOVAL.
2. Remove the lower B-pillar trim panel. Refer to PANEL, B-PILLAR TRIM, LOWER, REMOVAL .
3. Separate the front door opening seal (2and 3) from the door opening flange.
REAR DOOR SEAL


1. Remove the lower B-pillar trim panel. Refer to PANEL, B-PILLAR TRIM, LOWER, REMOVAL .
2. Remove the lower C-pillar trim. Refer to PANEL, C-PILLAR TRIM, LOWER, REMOVAL .
3. Separate the rear door opening seal (1 and 7) from the door opening flange.
INSTALLATION
INSTALLATION
FRONT DOOR SEAL


1. Position the front door seal (2 and 3) to the bottom of the door opening, with bulb facing outboard,
starting the installation at the center of the lower flange. Press the seal onto the sill flange and work
around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to
avoid puckers or wrinkles.
3. Install the cowl trim panel. Refer to PANEL, COWL TRIM, INSTALLATION.
NOTE: When installing a new weatherstrip on the front door opening, remove the tear
strip starting at the splice and moving around the front of the door to the back
of the opening.
REAR DOOR SEAL


1. Position the rear door seal (1 and 7) to the bottom of the door opening, with bulb facing outboard, starting
the installation at the center of the lower flange. Press the seal onto the sill flange and work around the
perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid
puckers or wrinkles.
2. Install the lower C-pillar trim. Refer to PANEL, C-PILLAR TRIM, LOWER, INSTALLATION .
NOTE: When installing a new weatherstrip on the rear door opening, remove the tear
strip starting at the splice and moving around the back of the door to the front
of the opening.
WEATHERSTRIP, DOOR
REMOVAL
REMOVAL



2. If removing the rear door seal, using a trim stick or equivalent, remove the rear trim from the rear door.
3. Carefully remove the door seal (6) from the door retainers.
INSTALLATION
INSTALLATION


1. Position the door seal (6) to the door.

2. Install the door seal being sure to engage the retainers into the seal.
3. Secure the seal around the perimeter of the door.
4. If required, install the rear trim to the rear door.
5. Shut the door and verify proper seal.
WEATHERSTRIP, GLASS RUN
REMOVAL
REMOVAL


1. Remove the door glass. Refer to GLASS, DOOR, REMOVAL or GLASS, DOOR, REMOVAL.
2. Remove the inner belt molding (3).
3. Carefully pull the top of the window run seal (5) down and remove from the top of the door.
4. Pull the sides of the seal upward out of the door.
INSTALLATION
INSTALLATION


1. Insert the sides of the window run seal (5) into the door.
2. Firmly seat the top of the seal to the top of the door.
3. Install the door glass. Refer to GLASS, DOOR, INSTALLATION or GLASS, DOOR,
INSTALLATION.
WEATHERSTRIP, HEADER, ROOF
REMOVAL
REMOVAL

Fig. 793: Roof Header Seal

1. Carefully peel the roof header seal (2) from the roof.
2. Clean any access adhesive off of the seal trough.
INSTALLATION
INSTALLATION


1. Ensure that the roof header seal (2) trough is clean and free of debris.
2. Starting at the front firmly seat the seal into the trough and press down firmly to ensure proper adhesion
to the sheet metal.
WEATHERSTRIP, WINDSHIELD, A-PILLAR
REMOVAL
REMOVAL


1. Starting at the rear of the windshield weatherstrip (1) carefully peel the seal away from the sheet metal
working towards the front of the vehicle.
2. Remove the weatherstrip from the retainers along the side of the windshield.
3. Clean any access adhesive from the sheet metal.
INSTALLATION
INSTALLATION


1. Ensure the sheet metal is clean and free of debris.

2. Starting at the front of the windshield, install the windshield weatherstrip (1) to the vehicle.
3. Ensure to engage the retainers along the side of the windshield.
4. Continue to install the weatherstrip pressing down firmly to ensure proper adhesion.
WINCH
WARNING
WARNING
WARNING: Disconnect and isolate battery negative cable before attempting any
troubleshooting or repairs.
Do not disengage the clutch if the winch is under a load or wire rope
is under tension.
Do not route electrical cables across sharp edges.
Do not route electrical cables through or near moving parts.
Always wear heavy leather gloves when handling a wire rope.
Never let wire rope slip through your hands.
Always keep hands clear of wire rope, hook loop, hook and fairlead
opening during installation, operation, and when spooling in or out.

Always use supplied hook strap whenever spooling wire rope in or

out, during installation or operation.
Failure to follow these instructions may result in personal injury.
CAUTION: Do not leave the remote plugged into the winch when not in use. Leaving
the remote plugged in, may result in a dangerous condition and/or battery
drain.
Always make sure the clutch is fully engaged or disengaged.
DESCRIPTION
DESCRIPTION
The winch uses the electrical power from the vehicle charging system to power a motor that winds wire rope
into the winch drum by means of planetary gear reduction.
The winch assembly includes the following:
Motor: The winch motor is powered by the vehicle electrical system and features a thermal protection
switch that automatically stops the motor function in the power-in direction if the motor gets too hot.
Winch Drum: The winch drum allows the wire rope to be stored on the winch and transmits force to the
wire rope.
Wire Rope: The wire rope allows the winch to be connected to an anchor to provide a pulling force.
Fairlead: The fairlead consists of four rollers and acts as guide for the wire rope and minimizes damage
to the rope.
Automatic Brake: The winch is equipped with an automatic brake that will stop rotation of the winch
drum if the winch motor is stopped.
Clutch Lever: The clutch lever allows the winch drum to be disconnected from the winch motor to allow
the wire rope to be pulled from the winch by hand.
Remote Socket: The remote socket allows the remote control to be attached to the control pack to allow
the winch to function.
Remote Control: The remote control provides the interface between the winch operator and the winch.
The remote control provides the ability to power the winch in, out, and stop the winch.
OPERATION
OPERATION
Winch: The winch uses the electrical power from the vehicle charging system to power a motor that winds wire
rope into the winch drum via planetary gear reduction. By nature, a winch is capable of generating very high
forces and should be used with care. Do not operate the winch without reading and understanding the complete
winch owner's manual.

Low Voltage Interrupt: The winch is equipped with a device that will interrupt winch function if the vehicle
charging system voltage drops to a low level. The winch will not power-in or out for 30 seconds if this device is
tripped. If the interrupt is tripped, the vehicle should be operated at high idle for a few minutes to allow the
vehicle charging system to recover before continuing to winch.
Winch Motor Thermal Protection: The winch is equipped with a thermal protection device in the motor. If
the winch is operated for an excessive duration, the device may interrupt motor function to protect the winch
motor. During this time the winch will power-out but will not power-in. Allow the winch motor to cool for a
few minutes before continuing operation of the winch. The winch will resume normal function once the motor
cools.
Remote Control: To operate the winch, the toggle switch is pressed down to power the winch in and up to
power the winch out. The winch will stop if the switch is left in the neutral (center) position.
Clutch Lever: The clutch lever is used to allow free spooling of the winch drum. Rotate the clutch lever on the
winch to disengage the clutch.
DIAGNOSIS AND TESTING - WINCH
CONDITION POSSIBLE CAUSES CORRECTION

Winch does not hold the load. Faulty winch drum brake. Replace the winch assembly.
Refer to WINCH, REMOVAL.
Load exceeds rating for the winch. Refer to operators manual for the
correct line pull rating for the
winch.
Brake overheats and will not The wire rope is on the drum Remove all the wire rope and
hold the load. backwards. respool in the proper direction.
The wire rope is spool onto the drum The wire rope must always spool
in the wrong direction and working onto the drum as indicated by the
against the brake in the "power in" drum rotation label on the winch.
mode. Winches are equipped with an
automatic brake and WILL NOT
FUNCTION if the wire rope
spools in the opposite direction.
The wire rope spooling can
accidentally be reversed by running
the wire rope all the way out and
re-spooling in with the control
switch in the "power out" mode.
Load exceeds rating for winch Refer to operators manual for the
correct line pull rating for the
winch.
After a very long "power out" cycle, These winches are rated for
in excess of 50 feet under high loads, intermittent duty operations only.

the brake has overheated and needs a As the load is increased, the
cool down cycle of approximately 30 duration of power out cycles must
minutes. be reduced to limit the brake
temperature. Allow adequate time
for the brake to cool between uses
when performing extended power
out cycles.
Difficult to spool the wire rope Bent drum flanges or worn drum Rotate the drum while it is still on
off the drum by hand. bushings. the winch to see if the drum flanges
appear to be bent. If the flanges
appear to be bent, the winch will
have to be replaced.
Free spool clutch is damaged inside Replace winch.
the gear train. Refer to WINCH, REMOVAL.
Wire rope is bound up on the drum. Should the wire rope become
bound onto the drum, connect the
hook to a load, then by alternately
"powering in" then "powering out",
the wire rope will usually work
itself free.
WARNING:
Do not put your hands anywhere
near the wire rope when working
a bind free.
Winch is not mounted correctly, Check winch mounting and repair
causing the drum to bind. as necessary.
Winch lacks power or will not Faulty ground cable attachment to Verify that the ground cable is
run at all. the motor housing. correctly installed to the threaded
hole in the motor housing.
The vehicle battery is inadequate in Use a fully charged conventional
size, terminals are corroded, is automotive battery with a
defective or worn out, or is not fully minimum of 650 cold cranking
charged. amps rating to obtain peak
performance from the winch. Make
sure all terminals are clean and the
battery is fully charged. Replace
battery if necessary.
Faulty cable connections on battery Clean and tighten all terminals.
or motor terminals
Faulty power supply to the winch. Check for proper power supply.
Faulty remote control switch or cord. Check for faulty switch.
Replace the remote switch is
necessary.
When remote control switch is Low battery charge, corroded Use a fully charged conventional
activated, there is only a terminals, defective battery. automotive battery with a

"clicking" sound, and the minimum of 650 cold cranking

winch does not operate in amps rating to obtain peak
either "power in" or "power performance from the winch. Make
out" modes. sure all terminals are clean and the
Check for proper power supply.
Faulty ground cable attachment to Check for proper ground.
the motor housing.
Faulty motor armature, brushes, or Replace the motor.
water in the motor. Refer to MOTOR, WINCH,
REMOVAL.
Faulty control relay. Check and replace relays as
necessary.
Refer to RELAY, WINCH,
REMOVAL.
Winch runs slowly and lacks The wire rope is spool onto the drum The wire rope must always spool
power when pulling a load, in the wrong direction and working onto the drum as indicated by the
won't pull load, or stalls easily. against the brake in the "power in" drum rotation label on the winch.
mode. Winches are equipped with an
automatic brake and WILL NOT
FUNCTION if the wire rope spools
in the opposite direction. The wire
rope spooling can accidentally be
reversed by running the wire rope
all the way out and re-spooling in
with the control switch in the
"power out" mode.
When the remote control is One or more of the control pack Check and replace relays as
activated, the winch will relays is damaged necessary.
operate only in one direction. Refer to RELAY, WINCH,
REMOVAL.
The remote control switch is Check and replace switch as
damaged. necessary.
Power-out mode only. Tripped or damaged thermal switch Let motor cool for at least 30
minutes, then try to power-in again.
Check thermal switch.
Replace the motor if the thermal
switch is faulty.
Refer to MOTOR, WINCH,
REMOVAL.
Tripped or damaged Low Voltage Use a fully charged conventional
Interrupt (LVI) automotive battery with a
When the remote control is minimum of 650 cold cranking
activated, the winch will not amps rating to obtain peak
operate and no "clicking" performance from the winch. Make

sound is heard. sure all terminals are clean and the

Check LVI.
Replace the relay pack if the LVI is
faulty.
Refer to RELAY PACK,
WINCH, REMOVAL.
RELAY TEST
Relay Test
Fig. 797: Battery Cable Exploded View

1. Disconnect the red (+) battery cable (1).

Fig. 798: Removing/Installing Winch Assembly

2. Remove the winch assembly (2) as necessary to gain access to the relay pack and cover. Refer to
WINCH, REMOVAL.
Fig. 799: Identifying Power Cable Connections

3. Disconnect the three cables connected to the motor on the studs marked F1 (2), F2 (1) and A (3).

Fig. 800: Measuring Resistance Between Studs On Relay 1

4. Remove the nut and disconnect the terminal wire (1).

a. Measure the resistance between the two large studs on relay #1.
The resistance should be greater than 1 mega ohm.
b. Apply 12 volts to the small terminal (1) and apply ground to the small terminal (2).
Measure the resistance between the two large studs on relay #1.
The resistance should be less than 1 ohm.








8. If the resistance across any of the relays doesn't go from open to closed (mega ohms to tenths) then the
relay is bad and needs to be replaced. Refer to RELAY, WINCH, REMOVAL.
REMOTE SWITCH TEST
To check switch, follow the steps below to check for switch continuity.
Power-Out
a. Move switch to the power-out position.

Fig. 804: Switch Pins

b. Check for continuity between pins (1) and (4).

c. Check for continuity between pins (2) and (5).
Power-In
1. Move switch to the power-in position.
Fig. 805: Switch Pins


2. Check for continuity between pins (1) and (4).

3. Check for continuity between pins (2) and (3).
If there is no continuity, then the remote switch is bad and needs to be replaced.
THERMAL SWITCH TEST
The motor will not power-in if the thermal switch is open or if its terminals are in contact with the motor case.
The switch should normally open when the temperature at the motor brushes reaches 205+°C (400+°F).
If the Thermal Switch is suspected to be failing check the following:
1. Disconnect the switch.

2. Measure the resistance of the switch at the electrical connector.
3. If the switch is open at room temperature then replace the motor.
4. If the switch is closed then the switch is good.
5. Check for resistance between both terminals and the motor case.
6. If the resistance is less than 1 mega ohm then the winch is grounded, replace the motor. Refer to
MOTOR, WINCH, REMOVAL.
LOW VOLTAGE INTERRUPT (LVI) TEST
If the LVI is suspected to be failing check the following:
1. Check to make sure the battery has 10.5 to 12 volts.

2. If low, charge battery.
3. Wait for 30 seconds or more.
4. Check for a ground on pin 4.
5. If no ground then check control ground.
6. If ground good then replace the relay pack. Refer to RELAY PACK, WINCH, REMOVAL.
MOTOR TEST
If the motor is suspected to be failing check the following:
1. Disconnect the motor power connectors F1, F2 and A.

2. Measure the resistance between F1 and F2. Resistance should be less than 1 ohm.
3. Measure the resistance between A and ground. Resistance should be less than 1 ohm.
4. If the resistance is greater than 1 ohm the motor brushes could be worn or the internal wiring could be
burned. Replace the motor, refer to MOTOR, WINCH, REMOVAL.
POWER TEST
1. Check for a tight fit of all connections.

2. Using a volt meter, verify 12 ± 2 volts a the bus bar connecting relays #1 and #3.
MOTOR GROUND TEST
1. Check for continuity between the ground stud and the battery.
2. If no continuity then repair the ground cable from the batter to the motor.
RELAY PACK TEST
Fig. 806: Control Pack Connector

Measurement Resistance Voltage

Results Correction
between pins Ohms (V)
Yes Relay pack OK.
1. Check for any faulty relay or
motor electrical connections and
"4" to "5" 2 -
No repair if necessary.
2. Check for a faulty relay and
replace as necessary.
Yes Relay pack OK.
1. Check for any faulty relay or
"4" to "2" 2 -
No repair if necessary.
2. Check for a faulty relay and
replace as necessary.
Greater than Yes Relay pack OK.
"1" to "2" -
100K No Check for shorted Thermal Switch.
Yes Relay pack OK.
"1" to "3" - 12 1. Check for any faulty relay or

repair if necessary.
No
2. Check for faulty LV.
REMOVAL
REMOVAL

1. Disconnect and isolate battery negative (3) and positive (1) cables.

2. Remove the winch support bolts (1).
Fig. 809: Frame Bracket

3. Remove the lower frame bracket (2) bolts (6) and loosen the upper bolts (1).
Fig. 810: Frame Support Brackets

4. Support the winch using a jack or other suitable lift device.

5. Lift the winch assembly off the support brackets.
6. Pivot the frame support brackets (2) up and position out of the way.

7. Carefully lower the winch assembly out of the vehicle.
Fig. 811: Ground Cable Connection

8. Remove the nut and disconnect the ground cable (1) from the motor (2).

9. Disconnect the three cables connected to the motor on the studs marked F1 (2), F2 (1) and A (3).
10. Disconnect the thermal switch electrical connector.

Fig. 813: Coil Pack Clamps & Power Connections

11. Remove the clamps (2) and separate the coil pack from the motor.
Fig. 814: Removing/Installing Support Bracket

12. Remove the four winch mounting and roller bracket bolts (3).
13. Separate the mounting bracket assembly (1) from the winch assembly.

INSTALLATION
INSTALLATION

1. Position the winch (2) onto the support bracket (1) and install the bolts (3).
2. Tighten the bolts to 108 N.m (80 ft. lbs.)

Fig. 816: Coil Pack Clamps & Power Connections

3. Position the relay pack onto the motor and tighten the band clamps (2).
4. Connect the thermal switch electrical connector.

5. Connect the three cables connected to the motor on the studs marked F1 (2), F2 (1) and A (3).
6. Tighten the nuts to 7 N.m (60 in. lbs.).
Fig. 818: Ground Cable Connection


7. Install the ground cable and install the bolt (1).

8. Tighten the bolt to 14 N.m (10 ft. lbs.).
Fig. 819: Frame Bracket Install

9. Raise the winch assembly into position.

10. Pivot the frame support brackets (2) down under the winch mounting bracket (1).

11. Install the lower frame bracket bolt (6) and nut (4).
12. Check and adjust the bumper alignment as necessary. Refer to GAP AND FLUSH, SPECIFICATIONS.
13. Tighten the bolts and nuts to 95 N.m (70 ft. lbs.).


14. Install the winch mounting bolts (1) and tighten to 41 N.m (30 ft. lbs.)

15. Connect battery negative cable (3).

16. Verify the operation of the winch.
BRACKET

REMOVAL
REMOVAL

1. Remove the winch (2). Refer to WINCH, REMOVAL.

2. Remove the upper bolts (1) and remove the frame brackets (2).

Fig. 825: Roller, Shaft & Clips

3. Separate one of the roller shaft clips (1), remove the shaft (3) and the roller (4).

4. Remove the bolts (3) and separate the support bracket (1) from the winch assembly (2).
INSTALLATION
INSTALLATION


1. Install the support bracket (1) and install the bolts (3).

3. Position the wire rope through the roller opening and install the roller (4), shaft (3) and clip (1).


4. Install the frame bracket (2) and install the upper bolt (1) and nut (4) and hand tighten.

5. Install the winch (2). Refer to WINCH, INSTALLATION.
MOTOR, WINCH
DESCRIPTION
DESCRIPTION

Fig. 831: Identifying Motor Winch Components

1 - ARMATURE STUD/NUT 7 N.m (60 in. lbs.)

2 - MOTOR BOLTS (2) 9 N.m (82 in. lbs.)
3 - MOUNTING BAND CLAMPS
4 - GROUND CABLE
5 - GROUND BOLT 14 N.m (10 ft. lbs.)
6 - MOTOR COUPLER
7 - MOTOR DRIVE SHAFT
8 - FIELD STUDS/NUTS 7 N.m (60 in. lbs.)
The winch is driven on one end by a two direction electric motor powered by the vehicle electrical system. The
motor is internally protected by a thermal switch that is activated when the motor gets too hot to operate
efficiently.
Winch motor controls consist of a relay pack mounted to the motor, and a remote control connected to the relay
pack with a cord. The winch power source cables are connected to the relay pack which in turn feeds power to
the winch motor through electrical cable connections. The main function of the relay pack is to allow the
operator to switch the winch on and off in both directions. The winch relay pack also includes a Low Voltage
Interrupt (LVI) used to prevent winch operation in the event of battery power dropping below 10 volts.
REMOVAL
REMOVAL


1. Remove the winch assembly (2). Refer to WINCH, REMOVAL.

2. Separate one of the roller shaft clips (1), remove the shaft (3) and the roller (4).


3. Remove the bolts (3) and separate the support bracket (1) from the winch assembly (2).
Fig. 835: Relay Pack Cover

4. Remove the relay pack (1). Refer to RELAY PACK, WINCH, REMOVAL.

Fig. 836: Identifying Mounting Bolts And Motor

5. Stand winch assembly on the clutch end with the motor up to make it easier to align the motor coupler
and drive shaft.
6. Remove the two motor mounting bolts (1) and carefully lift the motor (2) off of the drum assembly.
INSTALLATION
INSTALLATION

Fig. 837: Identifying Motor Coupler

1. With the winch assembly (1) standing on the clutch side verify that the motor coupler (2) is centered in
the drive shaft opening (3).

Fig. 838: Identifying Mounting Bolts And Motor

2. Position the motor drive shaft into the motor coupler splines and install the motor (2).
3. Install the bolts (1) and tighten to 9 N.m (82 in. lbs.).


4. Install the relay pack (1). Refer to RELAY PACK, WINCH, INSTALLATION.

5. Install the support bracket (1) and install the bolts (3).


7. Position the wire rope through the roller opening and install the roller (4), shaft (3) and clip (1).

8. Install the winch assembly (2). Refer to WINCH, INSTALLATION.
RELAY PACK, WINCH
DESCRIPTION
DESCRIPTION

Fig. 843: Locating Relays

1 - RELAY #1
2 - RELAY #2
3 - RELAY #3
4 - RELAY #4
F2 - FIELD #2 LEAD
F1 - FIELD #1 LEAD
A - ARMATURE LEAD
Electrical operation of the control assembly consists of four heavy duty relays, a thermal-switch located on the
motor armature brush holder and a Low Voltage Interrupt (LVI) located in the control assembly. The thermal-
switch interrupts the power-in function and the LVI affects both the power-in and power-out functions and must
be reset by allowing the charging circuit voltage to rise above 10 volts for more than 30 seconds. The thermal
switch is reset only by allowing the winch motor to cool adequately (about 30 minutes). Relay number 1 and 3
control current flow through the field windings and relay number 2 and 4 supply current to the motor armature.
OPERATION
OPERATION

Fig. 844: Locating Relays

1 - RELAY #1
2 - RELAY #2
3 - RELAY #3
4 - RELAY #4
F2 - FIELD #2 LEAD
F1 - FIELD #1 LEAD
A - ARMATURE LEAD
In the power-out mode, relay number 2 and 3 are energized by the remote control switch. Current flows from
the positive battery terminal through relay number 3 then through the black motor cable to the number 2 and
number 1 field windings. From the black motor cable current then flows through solenoid number 2 to the
motor armature to ground.
In power-in mode, relay number 1 and 4 are energized. Current again flows from the battery positive cable, but
this time current flows through solenoid number 1 then through field winding number 1. Current flowing in the
reverse direction through the field windings cause the motor to turn in the opposite direction. From the red
motor cable current then flows through relay number 4 to the black cable going to the motor armature to
ground.

REMOVAL
REMOVAL

1. Disconnect and isolate battery negative cable (3).

2. Remove the winch assembly (2). Refer to WINCH, REMOVAL.

Fig. 847: Identifying Nuts, Battery Positive Cable & Bus Straps
3. Remove the nut and disconnect the red battery positive cable (1).
Fig. 848: Identifying Nuts And Control Wires

NOTE: Relay #4 shown in the illustration, all others similar.
4. Remove the control wire nuts (1) and disconnect the control wires (2) from each relay.
INSTALLATION

INSTALLATION

1. Install the control wires (2) to all the relays and install the nuts (1).

3. Install the red battery positive cable (1) and install the switch wire.
4. Install the nut and tighten to 10 N.m (85 in. lbs.).

5. Install the relay pack cover (1) and install the three screws (2).

6. Install the winch assembly (2). Refer to WINCH, INSTALLATION.


7. Connect the battery negative cable (3) and verify winch operation.
RELAY, WINCH
REMOVAL
REMOVAL


1. Remove the relay pack (1). Refer to RELAY PACK, WINCH, REMOVAL.
2. Remove the nuts (2 AND 3), disconnect the cables and remove the bus straps (4).

3. Remove the nuts (1) and disconnect the control wires (2).

Fig. 857: Identifying Relay And Retaining Tab

4. Slide the relay (1) out of the retaining tab (2) and remove.
INSTALLATION
INSTALLATION
Fig. 858: Identifying Relay And Retaining Tab


1. Slide the relay (1) into the retaining tab (2).

2. Install the control wires (2) and install the nuts (1).
4. Install the bus straps (4) and connect the cables.

5. Install the nuts (2 AND 3) and tighten to 9.5 N.m (85 in. lbs.).

6. Install the relay pack (1). Refer to RELAY PACK, WINCH, INSTALLATION.
ROLLERS, WIRE ROPE GUIDE
REMOVAL
REMOVAL
Fig. 862: Moving Clutch Lever To "Free Spool"


1. Move the clutch lever (2) to "Free Spool" and disengage the wire rope. Pull out a portion to give it some
slack.

2. Remove the clips (1).

3. Remove the roller axle rods (3) and remove the rollers (4) from the support bracket (2).
Fig. 864: Horizontal Rollers Bushings

4. Separate the bushings (1) from the rollers (2) and replace if necessary.

Fig. 865: Identifying Roller Axle Rods, Rollers, Clips & Support Bracket
5. Remove the clips (3).

6. Remove the roller axle rods (2) and remove the rollers (4) from the support bracket (1).
Fig. 866: Identifying Vertical Rollers & Bushings

7. Separate the bushings (2) from the rollers (1) and replace if necessary.
INSTALLATION

INSTALLATION
Fig. 867: Identifying Vertical Rollers & Bushings

1. Install the roller bushings (2) onto the rollers (1).
Fig. 868: Identifying Roller Axle Rods, Rollers, Clips & Support Bracket
2. Install the rollers (4) and install the axle rods (2).
3. Install the clips (3).

Fig. 869: Horizontal Rollers Bushings

4. Install the roller bushings (1) onto the rollers (2).

5. Install the roller axle rods (3) and install the rollers (4) onto the support bracket (2).
6. Install the clips (1).

Fig. 871: Engaging Clutch Lever

7. Store the winch hook on the most outboard loop of the tow hook.
8. Engage the clutch lever (2) and remove the slack from the wire rope.
ROPE, WIRE
REMOVAL
REMOVAL
Fig. 872: Moving Clutch Lever To "Free Spool"

1. Move the clutch lever (2) to "Free Spool" and disengage the wire rope. Pull out a portion to give it some
slack.

Fig. 873: Hook, Clip & Wire Rope

2. Remove the clip (2), pin (1) and remove the hook (5) from the wire rope (4).
Fig. 874: Identifying Wire Rope Connection, Bolt, Winch Drum & Rope
3. Pull the wire rope out and unwind the winch drum (1).
4. Remove the bolt (2) and remove the rope (3).
INSTALLATION
INSTALLATION

Fig. 875: Identifying Wire Rope Connection, Bolt, Winch Drum & Rope
WARNING: Always keep hands and clothing clear of the wire rope, hook and fairlead
opening during operation and when spooling. Failure to follow these
instructions may result in personal injury or death.
CAUTION: Wire rope must spool on the winch drum in the direction indicated.
1. Feed the new wire rope end (3) through the guide rollers.
2. Attach the flat side of the wire rope end (3) to the winch drum (1), apply red thread locker to the threads
and install the bolt (2).
3. Wrap the wire rope around the spool approximately one time, in the direction indicated on the spool.
4. Tighten the bolt to 3 N.m (25 in. lbs.).

Fig. 876: Engaging Clutch Lever

5. Arrange the wire rope so it will not kink or tangle when spooled.
6. Lock the winch drum by rotating the clutch lever (2) on the winch to "Engage."
NOTE: Always make sure the clutch is engaged or disengaged fully.
Fig. 877: Hook, Clip & Wire Rope

7. Connect the remote control to the socket.

8. Install the hook (5), the pin (1) and clip (2) to the end of the wire rope (4).
9. Keep the rope under light tension and spool the rope back onto the winch drum in even layers.
10. Stop frequently to tighten and straighten the layers as necessary.
11. Repeat this process until the winch hook (5) is the same distance from the winch as the full length of the
remote control.

12. Using the hook strap, walk the wire rope towards the guide rollers, carefully spooling in the remaining
wire rope by pulsing the remote control switch.
NOTE: If you do not have the hook strap, use a length of cord or similar when
handling the hook during servicing of the winch.
13. Store the winch hook on the most outboard loop of the tow hook and remove the slack from the wire
rope.
TIE RODS, WINCH MOTOR
REMOVAL
REMOVAL
1. Remove the winch assembly. Refer to WINCH, REMOVAL.

2. Remove the bolts and remove the damaged tie rod(s).
INSTALLATION
INSTALLATION
1. Install the tie rod(s) and install the bolts.

3. Install the winch assembly. Refer to WINCH, INSTALLATION.
BODY STRUCTURE
WARNING
SAFETY NOTICE
CAUTION: ALL SERVICE AND REBUILDING INSTRUCTIONS CONTAINED HEREIN

ARE APPLICABLE TO, AND FOR THE CONVENIENCE OF, THE
AUTOMOTIVE TRADE ONLY.
All rest and repair procedures on components or assemblies in con-

automotive applications should be repaired in accordance with
instructions supplied by the manufacturer of the total product.
Proper service and repair is important to the safe, reliable operation of all
motor vehicles. The service produces recommended and described in this
publication were developed for professional service personnel, and are
effective methods for performing vehicle repair. Following these
procedures will help ensure efficient economical vehicle performance and

service reliability. Some service procedures require the use of special

tools designed for specific procedures. These special tools should be
used as recommended throughout this publication.
Special attention should be exercised when working with spring-or

tension-loaded fasteners and devices such as E-Clips, Circlips, Snap
rings, etc., since careless removal may cause personal injury. Always wear
safety goggles when working on vehicles or vehicle components.
It is important to note that this publication contains various Cautions and

Warnings. These should be read carefully in order to minimize risk of
personal injury or the possibility that improper service methods may
damage the vehicle or render it unsafe. It is important to note that these
Cautions and Warnings cover only the situations and procedures Chrysler
Group LLC has encountered and recommended. Chrysler Group LLC
cannot possibly know, evaluate, and advise the service trade of all
conceivable ways in which service may be performed, or of the possible
hazards of each. Consequently, Chrysler has not undertaken any such
broad service review. Accordingly, anyone uses a service procedure or
tool that is not recommended in this publication must be certain that
neither personal safety, nor vehicle safety, will be jeopardized by the
service methods they select.
USE OF HEAT DURING REPAIR
WARNING: Chrysler Group LLC engineering's position on the use of heat during
collision repair is as follows:
Any body panel or frame component damaged which is to be

repaired and reused, must be repaired using the "cold straightening"
method. No heat may be used during the straightening process.
During rough straightening prior to panel replacement, damaged
panels or frame components may be heated to assist in body/frame
realignment. The application of heat must be constrained to the
parts which will be replaced and not allowed to affect any other
components.
This "no heat" recommendation is due to the extensive use of high

strength and advanced high strength steels in Chrysler Group LLC
products. High-strength materials can be substantially and negatively
affected from heat input which will not be obviously known to the repairer
or consumer.
Ignoring these recommendations may lead to serious compromises in the

ability to protect occupants in a future collision event, reduce the
engineered qualities and attributes, or decrease the durability and

reliability of the vehicle.
This statement supersedes any previously released information by the

Chrysler Group LLC.
GAP AND FLUSH
SPECIFICATIONS
SPECIFICATIONS
GAP AND FLUSH DIMENSIONS INDEX

DESCRIPTION FIGURE
REGULAR CAB Fig. 878
QUAD CAB Fig. 879
CREW CAB Fig. 880

Fig. 878: Regular CAB

All measurements are in millimeters.
O/F = Over Flush U/F = Under Flush

U/D = Up/Down F/A = Fore/Aft

DIMENSION DESCRIPTION GAP FLUSH
Hood O/F 7.0 @ center
7.0 +/- 2.0 transition to
1 Hood to grille (along top) to 5.5 @ corner to 1.0
4.5 after corner
around corner +/- 2.0
Headlamp O/F 4.0 +/-
2 Headlamp to hood 7.0 +/- 2.0
2.0
Parallel within 2.0 Parallel within 2.0
Side to side within 3.0 Side to side within 2.0
3 Fender to headlamp 2.5 +/- 2.0 Fender O/F 2.0 +/- 2.0
4 Fender to a-pillar 3.0 +/- 1.5 Fender O/F 0.75 +/- 1.5
Aperture O/F 1.5 +/-
5 Aperture to front door @ a-pillar 4.5 +/- 1.5
1.5
Front to back within Front to back within
1.5 1.5
6 Aperture to front door @ roof 4.5 +/- 1.5
1.5
1.5 1.5
7 Aperture to rear door @ roof 4.5 +/- 1.5
1.5
Front to back within
1.5
8 Box outer to fuel filler door 4.5 +/- 1.5 0.0 +/- 1.5
9 Cab to box 35.0 +/- 4.0 Cab O/F 6.0 +/- 4.0
Box outer O/F 0.5 +/-
10 Fender to front door 4.5 +/- 1.5
1.5
Top to bottom within Top to bottom within
1.5 1.5
11 Fascia to fender Net to 2.0 0.0 +/- 2.0
12 Headlamp to fascia 4.5 +/- 2.0 0.0 +/- 2.0


13 Grille to headlamp 3.7 +/- 2.0 -
Parallel within 2.0
Side to side within 3.0
14 Grille to fascia 3.5 +/- 2.0 -
Parallel within 2.0
15 Deflector to tailgate inner F/A 0.0 +2.0/- 0.0 -
Parallel within 2.0
16 Box cab to tailgate deflector - U/D 0.0 +/- 2.0
Fender U/D-U/F 0.75
17 Fender to hood @ cowl 4.5 +/- 1.5
+/-1.5
Parallel within 1.5 Cross/car 0.0 +/- 1.5
18 Fender to hood 4.5 +/- 1.5 Fender O/F 0.5 +/- 1.5
Parallel within 1.5
19 Wheel flare to fascia 1.0 +2.0/- 1.0 0.0 +/- 2.0
20 Fender to sill 4.5 +/- 1.5 Fender O/F 1.0 +/- 1.5
Parallel within 1.5
21 Sill to front door 6.0 +/- 1.5 Sill O/F 4.5 +/- 1.5
1.5 1.5
22 Cab to box 32.0 +/- 3.5 -
Parallel within 3.0
23 Box outer to tail lamp 2.5 +/- 2.0 0.0 +/- 2.0
Parallel within 2.0
24 Rear bumper to box outer F/A 30.4 +/- 5.0 +/- 1.5
U/D 26.0 +/- 3.0
Parallel within 4.0
25 Bumper to tailgate 33.4 +/- 3.0 -
Parallel within 4.0
Tail lamp O/F 1.5 +/-
26 Tail lamp to tailgate 5.0 +/- 2.0
2.0
Parallel within 2.0
27 Box outer to tailgate 5.0 +/- 1.5
1.5


Fig. 879: Quad CAB


NOTE: All measurements are in millimeters.
O/F = Over Flush U/D = Up/Down

U/F = Under Flush F/A = Fore/Aft
4.5 after corner
2 Headlamp to hood 7.0 +/- 2.0
2.0
3 Fender to headlamp 2.5 +/- 2.0 Fender O/F 2.0 +/- 2.0
Fender O/F 0.75 +/-
4 Fender to a-pillar 3.0 +/- 1.5
1.5
5 Aperture to front door @ a-pillar 4.5 +/- 1.5
1.5
1.5 1.5
6 Aperture to front door @ roof 4.5 +/- 1.5
1.5
1.5 1.5
7 Aperture to rear door @ roof 4.5 +/- 1.5
1.5
1.5
8 Quarter panel to rear door 4.5 +/- 1.5 0.0 +/- 1.5
Top to bottom within
1.5
9 Box outer to fuel filler door 4.5 +/- 1.5
1.5
10 Cab to box 35.0 +/- 4.0 Cab O/F 6.0+/- 4.0

11 Front door to rear door above belt 4.5 +/- 1.5 0.0 +/- 1.5
1.5
12 Front door to rear door below belt 4.5 +/- 1.5 Front door O/F 1.0
Between belt and
Parallel within 1.5
character line +/- 1.5
Parallel within 1.5
1.5
1.0 to 0.0 below
character line +/- 1.5
13 Fender to front door 4.5 +/- 1.5 Fender O/F 1.0 +/- 1.5
1.5 1.5
14 Fascia to fender Net to 2.0 0.0 +/- 2.0
15 Headlamp to fascia 4.5 +/- 2.0 0.0 +/- 2.0
16 Grille to headlamp 3.7 +/- 2.0 -
Parallel within 2.0
17 Grille to fascia 3.5 +/- 2.0 -
Parallel within 2.0
18 Deflector to tailgate inner F/A 0.0 +2.0/- 0.0 -
Parallel within 2.0
20 Cab to box 32.0 +/- 3.5 -
Parallel within 3.0
U/D alignment: 0 +/-
21 Front door belt to rear door belt -
2.0
Fender U/D-U/F 0.75
22 Fender to hood @ cowl 4.5 +/- 1.5
+/-1.5
Parallel within 1.5 Cross/car 0.0 +/- 1.5
23 Fender to hood 4.5 +/- 1.5 Fender O/F 0.5 +/- 1.5
Parallel within 1.5
24 Wheel flare to fascia 1.0 +2.0/- 1.0 0.0 +/- 2.0
25 Fender to sill 4.5 +/- 1.5 Fender O/F 1.0 +/- 1.5

Parallel within 1.5

26 Sill to front door 6.0 +/- 1.5 Sill O/F 4.5 +/- 1.5
1.5 1.5
27 Sill to rear door 6.0 +/- 1.5 Sill O/F 4.5 +/- 1.5
1.5 1.5
28 Box outer to tail lamp 2.5 +/- 2.0 0.0 +/- 2.0
Parallel within 2.0
29 Rear bumper to box outer F/A 30.4 +/- 5.0 +/- 1.5
U/D 26.0 +/- 3.0
Parallel within 4.0
30 Bumper to tailgate 33.4 +/- 3.0 -
Parallel within 4.0
31 Box outer to tailgate 5.0 +/- 1.5
1.5
Tail lamp O/F 1.5 +/-
32 Tail lamp to tailgate 5.0 +/- 2.0
2.0
Parallel within 2.0

Fig. 880: Crew CAB

NOTE: All measurements are in millimeters.
O/F = Over Flush U/D = Up/Down

U/F = Under Flush F/A = Fore/Aft

4.5 after corner
Headlamp to hood 7.0 +/- 2.0
2.0
2
Fender to headlamp 2.5 +/- 2.0 Fender O/F 2.0 +/- 2.0
3 Parallel within 2.0 Parallel within 2.0
Fender O/F 0.75 +/-
Fender to a-pillar 3.0 +/- 1.5
1.5
4
Aperture to front door @ a-pillar 4.5 +/- 1.5
1.5
Front to back within 1.5
1.5
Aperture to front door @ roof 4.5 +/- 1.5
1.5
1.5
Aperture to rear door @ roof 4.5 +/- 1.5
1.5
7
Quarter panel to rear door 4.5 +/- 1.5 0.0 +/- 1.5
8
1.5
9 Ram box to box outer 5.0 +/- 2.0 Flush +/- 2.0
Box Outer O/F 0.5 +/-
Box outer to fuel filler door 4.5 +/- 1.5
10 1.5
Cab to box 35.0 +/- 4.0 Cab O/F 6.0 +/- 4.0
11
Front door to rear door above belt 4.5 +/- 1.5 0.0 +/- 1.5

1.5
Front Door O/F 1.0
Front door to rear door below belt 4.5 +/- 1.5 Between belt and
Character line +/- 1.5
13
Top to bottom within 1.0 to 0.0 below
1.5 Character line +/- 1.5
Fender to front door 4.5 +/- 1.5 Fender O/F 1.0 +/- 1.5
14
1.5 1.5
Fascia to fender Net to 2.0 0.0 +/- 2.0
15
Headlamp to fascia 4.5 +/- 2.0 0.0 +/- 2.0
Grille to headlamp 3.7 +/- 2.0
17 Parallel within 2.0 -
Grille to fascia 3.5 +/- 2.0
18 Parallel within 2.0 -
Deflector to tailgate inner F/A 0.0 +2.0/- 0.0
19 -
Parallel within 2.0
Cab to box 32.0 +/- 3.5
21 -
Parallel within 3.0
U/D Alignment: 0 +/-
22 Front door belt to rear door belt -
2.0
Fender U/D-U/F 0.75
Fender to hood @ cowl 4.5 +/- 1.5
+/-1.5
23
Parallel within 1.5 Cross/Car 0.0 +/- 1.5
Fender to hood 4.5 +/- 1.5
24 Parallel within 1.5 Fender O/F 0.5 +/- 1.5
Wheel flare to fascia 1.0 +2.0/- 1.0 0.0 +/- 2.0
25
Fender to sill 4.5 +/- 1.5
26 Parallel within 1.5 Fender O/F 1.0 +/- 1.5
Sill to front door 6.0 +/- 1.5 Sill O/F 4.5 +/- 1.5


27 Front to back within 1.5
1.5
Sill to rear door 6.0 +/- 1.5 Sill O/F 4.5 +/- 1.5
28
1.5
Box outer to tail lamp 2.5 +/- 2.0
29 0.0 +/- 2.0
Parallel within 2.0
Rear bumper to box outer F/A 30.4 +/- 5.0 +/- 1.5
30
U/D 26.0 +/- 3.0
Parallel within 4.0
Bumper to tailgate 33.4 +/- 3.0
31 -
Parallel within 4.0
Box Outer O/F 1.5 +/-
Box outer to tailgate 5.0 +/- 1.5
1.5
32
Tail lamp to tailgate 5.0 +/- 2.0
Tail Lamp O/F 1.5 +/-
33 Parallel within 2.0
2.0

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2014 RAM 3500 HD Laramie

2014 ACCESSORIES AND EQUIPMENT Body-Interior & Exterior - Ram Pickup

2014 ACCESSORIES AND EQUIPMENT

Body-Interior & Exterior - Ram Pickup

WARNING: Use an Occupational Safety and Health Administration (OSHA) approved

avoid prolonged skin contact with petroleum or alcohol based

do not weld exterior panels unless combustible material on the

WARNING: To avoid potential physical injury, or damage to sensitive electronic

Thursday, November 16, 2017 18:37:54

accidental airbag deployment, possible damage to the Supplemental

WARNING: To avoid serious or fatal injury on vehicles equipped with the

Thursday, November 16, 2017 18:35:28 Page 2

WARNING: To avoid potential physical injury or damage to sensitive electronic

Thursday, November 16, 2017 18:35:28 Page 3

fastener is needed, replace it with the correct fasteners provided in the

USE OF HEAT DURING REPAIR

Any body panel or frame component damaged which is to be

This "no heat" recommendation is due to the extensive use of high

Ignoring these recommendations may lead to serious compromises in the

This statement supersedes any previously released information by the

Failure to follow these instructions may result in serious or fatal injury.

DIAGNOSIS AND TESTING

Thursday, November 16, 2017 18:35:28 Page 4

VISUAL INSPECTION BEFORE WATER LEAK TESTS

WATER LEAK TESTS

WATER LEAK DETECTION

Thursday, November 16, 2017 18:35:28 Page 5

MIRROR INSPECTION METHOD

BRIGHT LIGHT LEAK TEST METHOD

PRESSURIZED LEAK TEST METHOD

NOTE: GENERAL NOTES

Thursday, November 16, 2017 18:35:28 Page 6

Water Leak Conditions

REPAIR PROCEDURE FOR WINDSHIELD URETHANE

Mopar Glass Sealer

Potential Parts Required:

Molding, Windshield, Right (Only replace if damage occurs during removal)

TWO METHODS OF TESTING:

Thursday, November 16, 2017 18:35:28 Page 7

WINDSHIELD URETHANE SKIP REPAIR

Fig. 1: Identifying A-Pillar Windshield Molding

Fig. 2: Exposed Body Seam

Thursday, November 16, 2017 18:35:28 Page 8

REPAIR PROCEDURE FOR ROOF/BODY SEAMS

Paintable Clear Seam Sealer

Potential Parts Required:

Molding - Roof Ditch Right

Thursday, November 16, 2017 18:35:28 Page 9

Fig. 3: Roof Ditch Molding

REPAIR PROCEDURE FOR SUNROOF DRAIN SYSTEM

Thursday, November 16, 2017 18:35:28 Page 10

Fig. 4: Sunroof Drain Tubes

Fig. 5: Sunroof Drain Tube Grommets

Thursday, November 16, 2017 18:35:28 Page 11

REPAIR PROCEDURE FOR SUNROOF GLASS SYSTEM

Fig. 6: Checking Sunroof Glass Flushness

WATER ENTERING THE VEHICLE AT THE BACK GLASS AREA (C-PILLARS)

REPAIR PROCEDURE FOR CHMSL (3RD BRAKE LIGHT)

Mopar Glass Sealer

Thursday, November 16, 2017 18:35:28 Page 12

Fig. 7: Identifying Center High Mounted Stop Lamp Assembly

Fig. 8: Identifying Bead Of Heavy Bodied Sealer

REPAIR PROCEDURE FOR BACK-GLASS/POWER SLIDER

Thursday, November 16, 2017 18:35:28 Page 13

Accessories and Equipment Body-Interior & Exterior - Ram Pickup

Accessories and Equipment Body-Interior & Exterior - Ram Pickup