Dodge Ram Truck 1500-2500-3500. Manual — part 1443

SERVICE SLEEVE ASSEMBLY

NOTE: Two sleeve halves are included with each
kit. Modifications as follow, are necessary to cre-
ate the correct sleeve assembly for each applica-
tion.

1. On 4X2 models, the

9

lower

9

sleeve (1) is made by

cutting off the tab (5) and cutting out a notch (4) in
the bottom sleeve portion. Round the corners of
the cut out to keep stress cracks from forming. On
4X4 models the

9

lower

9

sleeve is used as provided.

2. On both 4X2 and 4X4 models cut off the front tab

(2) on the upper sleeve portion (1).

3. The sleeve halves are shipped slightly oversized to

allow custom fitting to each replacement frame rail
tip. It is necessary to grind the mating surfaces to
achieve the desired snug fit into the replacement
tip (rail tube has increasing height rearward of the
cut line). Once the two sleeve halves are fitted,
bevel the edges 25° - 30°.

NOTE: Scribing a line 2 mm from the cut edge and
then grinding back to the mark will simplify the
bevel creation process and accuracy.

4. Remove any burrs at the beveled edges.

5. Using the Weld Process Specifications table (Refer

to 13 - FRAME & BUMPERS/FRAME - SPECIFI-
CATIONS - WELDING), weld the two halves of the
repair sleeve together.

6. Clean the welds of any flux and other impurities

and grind smooth before proceeding with the instal-
lation of the sleeve.

7. Find the centerline of the sleeve and scribe a cen-

terline mark (1). Mark two additional lines (4) 2 mm
(0.08 in.) on either side of the centerline mark to
help ensure the required 4 mm - 6 mm (0.16 in. -
0.24 in.) weld root gap.

13 - 22

FRAME & BUMPERS

DR/DH

HYDROFORM FENDER RAIL REPAIR

CAUTION: This repair procedure assumes damage to the right or left hydroform fender rail (1). Prior to any
repairs, the vehicle must be mounted on the appropriate frame repair equipment (“frame rack”), checked
with three dimensional measuring equipment, and necessary pull corrections made. If damage exists in the
hydroform fender rail, or cab beyond the area covered by this service procedure after dimensional correc-
tions are made, the hydroform must be replaced in its entirety. Refer to 23 - BODY/BODY STRUCTURE/
WELD LOCATIONS - SPECIFICATIONS, when replacing the entire hydroform.

CAUTION: Inspect the tire winch assembly for damage. If any one or more of the following are evident,
replace the winch assembly.

•

Indications of cracked or bulging plastic.

•

Housing flanges are bent or cracked.

•

If winch was loose before repair.

•

If the rivet heads are separated from the housing in any way.

1. Before proceeding with this repair procedure review the required service warnings and precautions (Refer to 13

- FRAME & BUMPERS/FRAME - WARNING).

DR/DH

FRAME & BUMPERS

13 - 23

2. Disconnect and isolate the battery negative cable.

3. Remove the front wheelhouse splash shield (Refer

to 23 - BODY/EXTERIOR/FRONT WHEELHOUSE
SPLASH SHIELD - REMOVAL).

4. Remove the fender (Refer to 23 - BODY/EXTERI-

OR/FRONT FENDER - REMOVAL).

5. Remove the A/C condenser, if required (Refer to 24

- HEATING & AIR CONDITIONING/PLUMBING/A/C
CONDENSER - REMOVAL).

6. Remove the A/C lines, if required. Refer to the

Heating and Air Conditioning section of the manual
for recommended procedures.

7. Remove the radiator assembly (4) (Refer to 7 -

COOLING/ENGINE/RADIATOR - REMOVAL).

13 - 24

FRAME & BUMPERS

DR/DH

8. Remove the air cleaner and support bracket (1 - if

required) (Refer to 9 - ENGINE/AIR INTAKE SYS-
TEM/AIR CLEANER ELEMENT - REMOVAL).

9. Remove the integrated power module (Refer to 8 -

ELECTRICAL/POWER

DISTRIBUTION/INTE-

GRATED POWER MODULE - REMOVAL).

10. Remove the bolts and position aside the wire har-

ness and grounds, if required.

DR/DH

FRAME & BUMPERS

13 - 25