Dodge Ram Truck 1500-2500-3500. Manual — part 1914
PATCHING PANELS
An 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 degrees to expose a larger bonding area
on the outer side. This will allow for an increased rein-
forcement areas.
PANEL PATCH FABRICATIONS
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 reinforce-
ment 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.
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PANEL PATCH INSTALLATION
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 sur-
faces.
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 sand-
wiched between the panel and squares.
12. Position patch in cutout against support squares
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.
14. Apply a coat of adhesive to the exposed ends of
the support squares.
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15. Install screws to hold the patch to support
squares. Tighten screws until patch surface is
flush with panel surface.
16. Allow adhesive to cure, and remove all screws.
17. Using a 125 mm (5 in.) 24 grit disc grinder, grind
a 50 mm (2 in.) to 75 mm (3 in.) wide and 2 mm
(0.080 in.) deep path across the gaps around the
patch. With compressed air, blow dust from
around patch.
18. Apply adhesive backed nylon mesh (dry wall tape)
over gaps around patch.
19. Mix enough adhesive to cover the entire patch
area.
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20. Apply adhesive over the mesh around patch, and
smooth epoxy with a wide spreader to reduce fin-
ish 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 - TORQUE
Torque specifications
Description
N·m
Ft. Lbs.
In. Lbs.
A-pillar trim/grab handle bolts
6
—
55
Body Isolator/cab bolts
81
60
—
Cargo box bolts
108
80
—
Cargo box tie down/cleat bolts
34
25
—
Center seat assembly nuts*
25
18
—
Center seat cushion/hinge bolts*
20
15
—
Center seat back hinge to storage bin bolts*
25
18
—
Center seat back free pivot hinge bolt*
25
18
—
Center seat back inertia hinge pivot bolt*
10
—
89
Center seat inertia hinge to seat back bolts*
25
18
—
Fender bolts - front lower
9
—
80
Fender bolts - lower inside
17
13
—
Fender to hinge support bolts
11
8
—
Fender to upper fender rail bolts
9
—
80
Footmans loop bolts
12
9
—
Front center seat nuts*
25
18
—
Front door glass lift plate nuts
10
—
89
Front door hinge to a-pillar nuts
28
21
—
Front door hinge to door nuts/bolts
28
21
—
Front door inside handle bolt
9
—
80
Front door latch adjustment screw
3
—
30
Front door latch assembly bolts
10
—
89
Front door latch striker bolts
28
21
—
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