Dodge Dakota (R1). Manual — part 555
FUEL TANK SKID PLATE
REMOVAL
(1) Position a support under the skid plate.
(2) Remove the nuts that attach the skid plate to
the fuel tank crossmember and the frame crossmem-
ber (Fig. 11).
(3) Remove the screws that attach the skid plate
to the support bracket and the frame side rail.
(4) Remove the support and the skid plate from
the vehicle.
INSTALLATION
(1) Position and support the skid plate under the
fuel tank.
(2) Install the nuts to attach the skid plate to the
fuel tank crossmember and the frame crossmember.
Tighten the nuts with 41 N·m (30 ft. lbs.) torque.
(3) Install the screws to attach the skid plate to
the frame side rail and the support bracket. Tighten
the screws with 23 N·m (200 in. lbs.) torque.
(4) Remove the support from under the skid plate.
TRAILER HITCH
REMOVAL
(1) Support trailer hitch on a suitable lifting
device.
(2) Remove fasteners attaching trailer wiring con-
nector to trailer hitch, if equipped.
(3) Remove bolts attaching trailer hitch to frame
rails (Fig. 12).
(4) Separate trailer hitch from vehicle.
INSTALLATION
(1) Position trailer hitch on vehicle.
(2) Install the bolts attaching trailer hitch to
frame rails and remove lifting device. Tighten to 108
N·m (80 ft. lbs.) torque.
(3) Install fasteners attaching trailer wiring con-
nector to trailer hitch, if equipped.
Fig. 11 Fuel Tank Skid Plate—4WD
1 - SKID PLATE SUPPORT BRACKET
2 - SCREW
3 - FUEL TANK
4 - FUEL TANK CROSSMEMBER
5 - FRAME CROSSMEMBER
6 - LOCK NUT
7 - SCREW
8 - SKID PLATE
9 - U-NUT
10 - FRAME RAIL
Fig. 12 Trailer Hitch
1 - FRAME
2 - TRAILER HITCH
13 - 12
FRAME & BUMPERS
AN
VALANCE PANEL
REMOVAL
(1) Remove
nuts
attaching
valance
panel
to
bracket (Fig. 13).
(2) Disengage license plate lamp harness connec-
tor.
(3) Separate valance panel from cargo box.
INSTALLATION
(1) Position valance panel on cargo box.
(2) Engage license plate lamp harness connector.
(3) Install nuts attaching valance panel to bracket
.
TRANSFER CASE SKID PLATE
REMOVAL
(1) Hoist and support vehicle on safety stands.
(2) Remove bolts attaching skid plate to crossmem-
bers (Fig. 14).
(3) Separate skid plate from vehicle.
INSTALLATION
(1) Position skid plate on vehicle.
(2) Install bolts attaching skid plate to crossmem-
bers. (Fig. 14) Tighten to 23 N·m (17 ft. lbs.) torque.
(3) Remove safety stands and lower vehicle.
Fig. 13 Valance Panel
1 - BRACKET
2 - VALANCE PANEL
3 - FRAME
4 - BRACKET
Fig. 14 Transfer Case Skid Plate
1 - TRANSMISSION CROSSMEMBER
2 - TORSION BAR CROSSMEMBER
3 - FRAME
4 - U-NUT
5 - TRANSFER CASE SKID PLATE
AN
FRAME & BUMPERS
13 - 13
FRAME & BUMPERS
TABLE OF CONTENTS
page
page
FRAME-R1
FRAME SERVICE. . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 2
FRONT AXLE SKID PLATE-R1
FUEL TANK SKID PLATE R-1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MANUAL TRANSMISSION CROSSMEMBER-R-1
AUTOMATIC TRANSMISSION CROSSMEMBER
FRAME-R1
DESCRIPTION
R-1 trucks have a ladder-type frame with Box-sec-
tion front rails, dropped center section and open-
channel side rails in the rear.
Cross members attached to the frame side rails
with rivets, welds or bolts form a ladder-type con-
struction. The cab is isolated from the frame with
rubber load cushions and through-bolts. The cargo
box or bed is attached to the frame with bolts.
The frame is designed to absorb and dissipate flex-
ing and twisting due to acceleration, braking, corner-
ing and road surface variances without bending when
subjected to normal driving conditions. The frame is
the mounting platform for the following systems and
components:
• Front and rear suspension systems.
• Engine and transmission assembly.
• Steering gear and linkage.
• Exhaust system and heat shields.
• Fuel cell and fuel line tubing.
• Front end sheet metal and radiator closure
panel.
• Skid plates.
• Passenger cab.
• Cargo box or bed.
• Spare tire winch.
• Front and rear bumper systems.
R-1 trucks utilize a modified four wheel drive AN
frame setup for two wheel drive only. This system
produces the excellent strength characteristics of a
four wheel drive frame, only in a two wheel drive
form. However similar, the R-1 truck frame is not
interchangeable with its AN predecessor. Different
components/systems are as follows:
• Transmission support crossmember.
• Engine support crossmember.
• Driveline angle.
STANDARD PROCEDURE - FRAME SERVICE
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT. BEFORE PROCEEDING WITH FRAME
REPAIR INVOLVING GRINDING OR WELDING, VER-
IFY THAT VEHICLE FUEL SYSTEM IS NOT LEAKING
OR IN CONTACT WITH REPAIR AREA, PERSONAL
INJURY CAN RESULT. DO NOT ALLOW OPEN
FLAME TO CONTACT PLASTIC BODY PANELS.
FIRE
OR
EXPLOSION
CAN
RESULT.
WHEN
WELDED FRAME COMPONENTS ARE REPLACED,
100% PENETRATION WELD MUST BE ACHIEVED
DURING
INSTALLATION.
IF
NOT,
DANGEROUS
OPERATING CONDITIONS CAN RESULT. STAND
CLEAR OF CABLES OR CHAINS ON PULLING
EQUIPMENT
DURING
FRAME
STRAIGHTENING
OPERATIONS, PERSONAL INJURY CAN RESULT.
DO NOT VENTURE UNDER A HOISTED VEHICLE
THAT IS NOT SUPPORTED ON SAFETY STANDS,
PERSONAL INJURY CAN RESULT.
CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect. Do not drill holes in top
or bottom frame rail flanges, frame rail failure can
result. Do Not use softer than Grade 5 bolts to
replace production fasteners, loosening or failure
can result. When using heat to straighten frame
components do not exceed 566°C (1050°F), metal
fatigue can result. Welding the joints around riveted
cross members and frame side rails can weaken
frame.
R1
FRAME & BUMPERS
13a - 1
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