Dodge Ram Truck 1500-2500-3500. Manual — part 1437
REMOVAL
WARNING: IF THE ENGINE WAS JUST TURNED
OFF, THE AIR INTAKE SYSTEM TUBES MAY BE
HOT.
1. Disconnect the battery negative cables.
2. Discharge the A/C system (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE) and remove the A/C condenser
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C CONDENSER - REMOVAL) (if A/C
equipped).
3. Remove the transmission auxiliary cooler (Refer to
7 - COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).
4. Remove intake air tubing from the charge air
cooler.
5. Remove the charge air cooler bolts. Pivot the
charge air cooler forward and up to remove.
CLEANING
CAUTION: Do not use caustic cleaners to clean the charge air cooler. Damage to the charge air cooler will
result.
NOTE: If internal debris cannot be removed from the cooler, the charge air cooler MUST be replaced.
1. If the engine experiences a turbocharger failure or any other situation where oil or debris get into the charge air
cooler, the charge air cooler must be cleaned internally.
2. Position the charge air cooler so the inlet and outlet tubes are vertical.
3. Flush the cooler internally with solvent in the direction opposite of normal air flow.
4. Shake the cooler and lightly tap on the end tanks with a rubber mallet to dislodge trapped debris.
5. Continue flushing until all debris or oil are removed.
6. Rinse the cooler with hot soapy water to remove any remaining solvent.
7. Rinse thoroughly with clean water and blow dry with compressed air.
INSPECTION
Visually inspect the charge air cooler for cracks, holes, or damage. Inspect the tubes, fins, and welds for tears,
breaks, or other damage. Replace the charge air cooler if damage is found.
Pressure test the charge air cooler, using Charge Air Cooler Tester Kit No. 3824556. This kit is available through
Cummins
T
Service Products. Instructions are provided with the kit.
11 - 34
EXHAUST SYSTEM
DR/DH
INSTALLATION
1. Position the charge air cooler. Install the bolts and
tighten to 2 N·m (17 in. lbs.) torque.
2. Install the air intake system tubes to the charge air
cooler. With the clamps in position, tighten the
clamps to 11 N·m (95 in. lbs.) torque.
3. Install
the
transmission
auxiliary
cooler
(if
equipped) (Refer to 7 - COOLING/TRANSMIS-
SION/TRANS COOLER - INSTALLATION).
4. Install the A/C condenser (if A/C equipped) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/A/C
CONDENSER
-
INSTALLATION).
Recharge A/C system (Refer to 24 - HEATING &
AIR
CONDITIONING/PLUMBING
-
STANDARD
PROCEDURE).
5. Connect the battery negative cables.
6. Start engine and check for boost system leaks.
DR/DH
EXHAUST SYSTEM
11 - 35
FRAME & BUMPERS
TABLE OF CONTENTS
page
page
FRAMES & BUMPERS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FRONT AIR DAM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . 2
FRONT BUMPER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . 2
FRONT FASCIA
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . . . . 4
REAR BUMPER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . 6
FASCIA-FRONT SRT-10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . . . . . . . 8
FASCIA-REAR SRT-10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
. . . . . . . . . . . . . . . . . . . . . . . . . 13
FRAME
. . . . . . . . . . . . . . . . . . . . . . . . . . 14
LIGHT DUTY FRONT FRAME RAIL TIP
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 15
REAR FRAME H-SECTION REPLACEMENT
. . . . . . . . . . . . . . . . . . . . . 38
. . . . . . . . . . . . . . . . . . 39
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
FRONT CROSSMEMBER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
. . . . . . . . . . . . . . . . . . . . . . . . . 48
FRONT SKID PLATE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
. . . . . . . . . . . . . . . . . . . . . . . . . 50
FRONT TOW HOOK ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
. . . . . . . . . . . . . . . . . . . . . . . . . 52
TRANSMISSION CROSSMEMBER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
. . . . . . . . . . . . . . . . . . . . . . . . . 55
TRAILER HITCH
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
. . . . . . . . . . . . . . . . . . . . . . . . . 58
TRANSFER CASE SKID PLATE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
. . . . . . . . . . . . . . . . . . . . . . . . . 61
FRAMES & BUMPERS
SPECIFICATIONS
TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION
N·m
Ft. Lbs.
Front bumper center bracket nuts
95
70
Front bumper stud plate nuts
95
70
License plate hitch reinforcement bolts
54
40
Rear bumper support bracket stud plate nuts
54
40
Rear bumper support bracket to hitch bolts
54
40
Rear bumper to hitch bolts
54
40
DR/DH
FRAME & BUMPERS
13 - 1
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