Dodge Sprinter. Manual — part 307

will ensure correct wheel centering and maximum
wheel clamping.

Before installing the wheel to the wheel ring flange

make sure that all the cone washers are installed on
the wheel flange ring (Fig. 20).

The dual rear wheel lug nuts should be tightened

according to the following procedure:

• Install the inner wheel to the hub assembly.

• Install the outer wheel Make sure the valve

stems line up with each when aligning the
wheels (Fig. 21).

• Install the cone washers for the outer wheel

before installing the lug nuts (Fig. 22).

• Tighten the wheel lug nuts in the numbered

sequential pattern until they are snug tight. Then
tighten lug nuts to specified torque following same
number sequence, (Refer to 22 - TIRES/WHEELS/
WHEELS - SPECIFICATIONS).

• Tighten lug nuts in same numbered sequence a

second time to the specified torque. This will ensure
that the wheels are thoroughly mated.

• Check lug nut specified torque after 100 miles

(160 kilometers). Also after 500 miles (800 kilome-
ters) of vehicle operation.

NOTE: Wheel lug nuts should be tightened to spec-
ified torque at every maintenance interval thereafter.

REMOVAL

(1) Raise and support the vehicle.
(2) Remove the wheel lug studs (SRW) (Fig. 24).
(3) Remove the lug nuts (DRW) On vehicles with

dual rear wheels do not pry off the front hub
cap the lug nuts must be removed in order to
remove the hub cap. (Fig. 23).

Fig. 20 WHEEL RING FLANGE CONE WASHERS

1 - WHEEL STUD
2 - CONE WASHER

Fig. 21 DUAL REAR WHEEL

1 - VALVE STEMS
2 - LUG NUTS

Fig. 22 (DRW) WHEEL CONE WASHERS

1 - CONE WASHER
2 - LUG STUD

22 - 14

TIRES/WHEELS

VA

(4) Remove the wheel and tire assembly.

INSTALLATION

(1) Install the wheel and tire assembly to the vehi-

cle.

(2) Install the wheel lug studs (SRW) (Fig. 24) and

tighten

to

specification

(Refer

to

22

-

TIRES/

WHEELS - SPECIFICATIONS) See specification
table for model variations.

(3) Install the hub cap to the wheel then install

snugly the lug nuts to hold the hub cap to the wheel
(DRW) (Fig. 23).

(4) Install the wheel lug nuts (DRW) and tighten

to specification (Refer to 22 - TIRES/WHEELS -
SPECIFICATIONS) See specification table for model
variations.

(5) Lower the vehicle.

Fig. 23 FRONT TIRE (DRW)

1 - HUB CAP
2 - LUG NUT WITH HUB CAP HOLD DOWNS

Fig. 24 WHEEL REMOVAL / INSTALLATION

1 - VEHICLE
2 - LUG/STUD
3 - TIRE & WHEEL ASSEMBLY

VA

TIRES/WHEELS

22 - 15

BODY

TABLE OF CONTENTS

page

page

BODY

WARNING

SAFETY PRECAUTIONS AND WARNINGS

. . . 1

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - WATER LEAKS

. 1

DIAGNOSIS AND TESTING - WIND NOISE

. . . 2

STANDARD PROCEDURE

STANDARD PROCEDURE - PLASTIC BODY

PANEL REPAIR . . . . . . . . . . . . . . . . . . . . . . . . 3

STANDARD PROCEDURE - BUZZ, SQUEAK

& RATTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . 11

DOOR - FRONT

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

DOORS - REAR

. . . . . . . . . . . . . . . . . . . . . . . . . . 23

DOORS - SLIDING

. . . . . . . . . . . . . . . . . . . . . . . . 35

EXTERIOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

HOOD

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

INSTRUMENT PANEL

. . . . . . . . . . . . . . . . . . . . . 55

INTERIOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

PAINT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

SEATS

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

STATIONARY GLASS

. . . . . . . . . . . . . . . . . . . . . 84

WEATHERSTRIP/SEALS

. . . . . . . . . . . . . . . . . . . 90

BODY STRUCTURE

. . . . . . . . . . . . . . . . . . . . . . . 91

BODY

WARNING

SAFETY PRECAUTIONS AND WARNINGS

WARNING: USE AN OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A

CONFINED

AREA.

PERSONAL

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 compo-
nents. 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 sol-

vents 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

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. Cen-
trifugal 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 pres-
sure washing or hard driving rain (severe) condi-
tions.

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

VA

BODY

23 - 1