Dodge Ram Truck 1500-2500-3500. Manual — part 1911

SPECIFICATIONS

TORQUE CHART

TORQUE SPECIFICATIONS

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

1500 Series

Lug Nut 9/16 X 18 with

60° Cone

LD

129

95

—

2500 Series

Lug Nut 9/16 X 18 with

60° Cone

HD SRW

197

145

—

3500 Series

Lug Nut 9/16 X 18 with

Flat Washer

HD DRW

210

155

—

STUDS

REMOVAL

1. Raise and support the vehicle.

2. Remove the wheel and tire assembly.

3. Remove the brake caliper, caliper adapter and

rotor, (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/ROTORS - REMOVAL).

4. Remove the wheel speed sensor from the hub.

5. Press the stud from the hub using special tool

C-4150A (1).

6. Remove the stud (2) from the hub (1) through the

backing plate access hole (3).

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TIRES/WHEELS

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INSTALLATION

1. Install the new stud (2) into the hub flange (1).

2. Install three proper sized washers onto the stud,

then install lug nut with the flat side of the nut
against the washers.

3. Tighten the lug nut until the stud is pulled into the

hub flange. Verify that the stud is properly seated
into the flange.

4. Remove the lug nut and washers.

5. Install the brake rotor, caliper adapter, and caliper,

(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTORS - INSTALLATION).

6. Install the wheel speed sensor.

7. Install the wheel and tire assembly, use new lug nut on the stud or studs that were replaced.

8. Remove the support and lower the vehicle.

WHEEL COVER

REMOVAL

NOTE: The hub caps must be removed before raising the vehicle off the ground.

NOTE: You must use the flat end of the hub/cap remover/installer combination tool to pry off the wheel
skins. Insert the flat tip completely and using a back and forth motion, loosen the wheel skin. repeat this
procedure around the tire until the wheel skin pops off.

1. On 2500/3500 single rear wheel (SRW) models, insert a hub/cap remover/installer combination tool using the

blade on the end of the tool to pry the cap off in a back and forth motion.

2. On 3500 models with dual rear wheels (DRW), you must first remove the hub caps. The hub/cap remover/in-

staller combination tool must be inserted in the pry off notch of the rear hub caps.

3. Position the hub/cap remover/installer combination tool and pull out on the tool firmly. The cap should come off.

4. The wheel skins can now be removed from the wheel.

5. On 3500 models front hub caps use the hub/cap remover/installer combination tool to pry off the cap in a back

and forth motion. The wheel skins can now be removed.

INSTALLATION

REAR

1. Install one 1 1/2 in. valve stem extension on each rear inner wheel.

NOTE: A 3/8 in. drive 10mm deep wheel socket with a 10 in. or greater extension can be used to remove the
existing valve stem cap and install the extension.

2. Install one 1 in. valve stem extension on each outer wheel.

3. Align the cooling windows of the wheel skin with the cooling windows of the wheel. Seat one side of the wheel

skin’s retainer onto the wheel. Using a rubber mallet, strike thew wheel skin on the outer circumference. Strike at
several locations around the circumference until the skin is fully seated.

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TIRES/WHEELS

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NOTE: The wheel skin and the hub cap are fully seated when there is a consistent gap between the skin/cap
and the wheel.

4. Tug on the hub/cap wheel skin to ensure that they are properly installed.

FRONT

1. Align the valve stem with the notch in the wheel skin.

2. Seat on side of the wheel skin’s wire retainer on to the wheel.

3. Using a rubber mallet, strike the opposite side of the wheel skin until the skin is properly seated.

NOTE: The wheel skin and the hub cap are fully seated when there is a consistant gap between the skin/
cap and the wheel.

4. Tug on the hub cap/wheel skin to ensure that they are properly installed.

SPARE TIRE

DESCRIPTION

SPARE / TEMPORARY TIRE

The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the
first opportunity, then reinstalled. Do not exceed speeds of 50 M.P.H. when using the temporary spare tire. Refer to
Owner’s Manual for complete details.

FULL SIZE, SPARE WHEEL WITH MATCHING TIRE

The spare is a full usage wheel with a matching tire, It can be used within the (posted legal) speed limits or distance
limitations as of the rest of the vehicles four tires. Refer to Owner’s Manual for complete details.

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TIRES/WHEELS

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BODY

TABLE OF CONTENTS

page

page

BODY

WARNING

SAFETY PRECAUTIONS AND WARNINGS

. . . 1

DIAGNOSIS AND TESTING

WATER LEAKS

. . . . . . . . . . . . . . . . . . . . . . . . 1

WIND NOISE

. . . . . . . . . . . . . . . . . . . . . . . . . . 3

STANDARD PROCEDURE

BODY LUBRICATION

. . . . . . . . . . . . . . . . . . . . 3

HEAT STAKING

. . . . . . . . . . . . . . . . . . . . . . . . 3

BUZZ, SQUEAK & RATTLE

. . . . . . . . . . . . . . . 4

PLASTIC BODY PANEL REPAIR

. . . . . . . . . . . 5

SPECIFICATIONS - TORQUE

. . . . . . . . . . . . . . 13

SPECIAL TOOLS

BODY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

TAILGATE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

DOOR - FRONT

. . . . . . . . . . . . . . . . . . . . . . . . . 26

DOORS - REAR

. . . . . . . . . . . . . . . . . . . . . . . . . 52

EXTERIOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

HOOD

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

INSTRUMENT PANEL

. . . . . . . . . . . . . . . . . . . . 122

INTERIOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

PAINT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

SEATS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

STATIONARY GLASS

. . . . . . . . . . . . . . . . . . . . 203

SUNROOF - SERVICE INFORMATION

. . . . . . . 213

WEATHERSTRIP/SEALS

. . . . . . . . . . . . . . . . . . 238

BODY STRUCTURE

. . . . . . . . . . . . . . . . . . . . . 257

BODY

WARNING

SAFETY PRECAUTIONS AND WARNINGS

WARNING: Use an osha approved breathing filter when spraying paint or solvents in a confined area. Per-
sonal injury can result.

•

Avoid prolonged skin contact with petroleum or alcohol – based cleaning solvents. Personal injury can
result.

•

Do not stand under a hoisted vehicle that is not properly supported on safety stands. Personal injury can
result.

CAUTION: When holes must be drilled or punched in an inner body panel, verify depth of space to the outer
body panel, electrical wiring, or other components. Damage to 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.

DIAGNOSIS AND TESTING

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

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BODY

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