Index Dodge Dodge Ram Truck 1500-2500-3500 - service repair manual 2005 year

Content .. 1916 1917 1918 1919 ..

Dodge Ram Truck 1500-2500-3500. Manual - part 1918

DOOR - FRONT

TABLE OF CONTENTS

page

page

DOOR

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

. . . . . . . . . . . . . . . . . . . . . . . . . 27

. . . . . . . . . . . . . . . . . . . . . . . . 27

DOOR GLASS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

. . . . . . . . . . . . . . . . . . . . . . . . . 32

EXTERIOR HANDLE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

. . . . . . . . . . . . . . . . . . . . . . . . . 33

GLASS RUN CHANNEL

FRONT-ALL MODELS

. . . . . . . . . . . . . . . . . . 34

. . . . . . . . . . . . . . . . . . . . . 34

REAR-STANDARD CAB

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

FRONT-ALL MODELS

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

. . . . . . . . . . . . . . . . . . . . . 36

REAR-STANDARD CAB

. . . . . . . . . . . . . . . . . 36

HINGE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

. . . . . . . . . . . . . . . . . . . . . . . . . 37

INTERIOR HANDLE ACTUATOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

. . . . . . . . . . . . . . . . . . . . . . . . . 38

LATCH

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

. . . . . . . . . . . . . . . . . . . . . . . . . 40

. . . . . . . . . . . . . . . . . . . . . . . . 41

LATCH STRIKER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

. . . . . . . . . . . . . . . . . . . . . . . . . 42

. . . . . . . . . . . . . . . . . . . . . . . . 42

LOCK CYLINDER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

. . . . . . . . . . . . . . . . . . . . . . . . . 43

TRIM PANEL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

. . . . . . . . . . . . . . . . . . . . . . . . . 45

WATERDAM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

. . . . . . . . . . . . . . . . . . . . . . . . . 46

WINDOW REGULATOR - POWER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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

WINDOW REGULATOR - MANUAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

. . . . . . . . . . . . . . . . . . . . . . . . . 50

SIDE VIEW MIRROR FLAG

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

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

DOOR

REMOVAL

1. Disconnect and isolate the negative battery cable.

2. Disconnect the door wire harness connector (5)

from the body wire harness (7).

3. Using a grease pencil or equivalent, mark the loca-

tion of the door hinges (2 and 6) on the door (4).

NOTE: The epoxy bonded washers do not need to
be separated from the hinges. If the washers are
removed, the door may need to be re-adjusted.

4. Support the door with a suitable lifting device and

remove the two nuts (1) and two bolts (8) that
secure the door to the hinges.

5. Carefully remove the door from the hinges.

6. If required, remove the two studs (3) from the door.

23 - 26

DOOR - FRONT

DR/DH

INSTALLATION

1. If removed, install the two studs (3) into the door

(4).

2. Carefully position the door onto the hinges (2 and

6) and support the door with a suitable lifting
device.

NOTE: If the epoxy bonded washers are separated
from the hinges, the door may need to be
adjusted.

3. If removed, install the epoxy bonded washers.

4. Loosely install the two nuts (1) and the two bolts

(8) that secure the door to the hinges.

5. Align the door to the hinges using the reference

marks made during the removal procedure and
tighten the nuts and bolts to 28 N·m (21 ft. lbs.).

6. Connect the door wire harness (5) to the body wire harness (7).

7. Reconnect the negative battery cable.

8. If necessary, adjust the door (Refer to 23 - BODY/DOOR-FRONT - ADJUSTMENTS).

ADJUSTMENTS

NOTE: For quad cab vehicles, it is recommended that you adjust the rear door before adjusting the front
door. (Refer to 23 - BODY/DOORS - REAR/DOOR - ADJUSTMENTS)

•

Door adjustment measurements should be taken from stationary or welded body panels like the roof,
rocker or quarter panels.

•

During adjustment procedures, it is recommended that all the hinge fasteners be loosened except for the
upper most fasteners. Adjustments can be made using the upper bolts to hold the door with final torque
of the fasteners occurring after correct door positioning is achieved.

•

A suitable body sealant should be used when removing or moving the hinges.

FORE/AFT

NOTE: Fore/aft (lateral) door adjustment is done
by loosening the hinge to the hinge pillar fasten-
ers one hinge at a time and moving the door to
the correct position.

1. Support the door with a suitable lifting device.

2. Loosen the upper (4) and lower (3) hinge to hinge

pillar fasteners. (Refer to 23 - BODY/DOOR -
FRONT/HINGE - REMOVAL)

3. Adjust the door to the correct position. (Refer to 23

- BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECIFICATIONS)

4. Tighten the upper hinge bolt (1) to hinge pillar to 28

N·m (21 ft. lbs.).

5. Tighten the lower hinge bolt (2) to hinge pillar to 28

N·m (21 ft. lbs.).

6. Tighten the remaining hinge to hinge pillar bolts (3)

and (4) to 28 N·m (21 ft. lbs.).

DR/DH

DOOR - FRONT

23 - 27

UP/DOWN

NOTE: Up/down door adjustment is done by loos-
ening either the hinge to the hinge pillar fasteners
or the hinge to door fasteners and moving the
door to the correct position.

NOTE: When adjustment of the door requires the
loosening of the door to hinge fasteners, it will be
necessary to separate the epoxy bonded washers
with a chisel or other suitable tool.

NOTE: When the up/down adjustments are done
correctly, the top of the door is positioned over
flush to the roof. (Refer to 23 - BODY/BODY
STRUCTURE/GAP AND FLUSH - SPECIFICATIONS)

1. Support the door with a suitable lifting device.

2. Loosen the latch striker bolts (3). (Refer to 23 -

BODY/DOOR

-

FRONT/LATCH

STRIKER

-

REMOVAL)

3. If necessary, Loosen the hinge to door fasteners

(1) and (8). (Refer to 23 - BODY/DOOR - FRONT/
DOOR - REMOVAL)

4. If necessary, loosen the hinge to hinge pillar fasten-

ers (3) and (4). (Refer to 23 - BODY/DOOR -
FRONT/HINGE - REMOVAL)

23 - 28

DOOR - FRONT

DR/DH

5. Adjust the door to the correct position. (Refer to 23

- BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECIFICATIONS)

6. Tighten the door to hinges fasteners to 28 N·m (21

ft. lbs.).

7. Tighten the upper hinge bolt (1) to hinge pillar to 28

N·m (21 ft. lbs.).

8. Tighten the lower hinge bolt (2) to hinge pillar to 28

N·m (21 ft. lbs.).

9. Tighten the remaining hinge to hinge pillar bolts (3)

and (4) to 28 N·m (21 ft. lbs.).

10. Tighten the latch striker bolts. (Refer to 23 -

BODY/DOOR

-

FRONT/LATCH

STRIKER

-

INSTALLATION)

DR/DH

DOOR - FRONT

23 - 29

Content .. 1916 1917 1918 1919 ..