DODGE RAM 2001 Service Repair Manual

QUAD CAB
QUAD CAB
DESCRIPTION GAP FLUSH
A Door to Windshield Molding N/A 2.0 +/- 2.0
B Front Door to Roof 5.0 +/- 1.5 0.0 +/- 1.0
C Rear Door to Roof 5.0 +/- 1.0 0.0 +/- 1.0
D Rear Door Glass to Rear Door (top) 5.0 +/- 1.0 3.25 +/- 1.5
E Rear Door Glass to Rear Door (rear) 5.0 +/- 2.0 3.25 +/- 1.5
F Rear Door to Quarter 5.5 +/- 1.0 0.0 +/- 1.0
G Rear Door Glass to Rear Door (bottom) 5.0 +/- 1.5 N/A
H Front Door to Rear Door 5.0 +/- 1.0 0.0 +/- 1.0
I Rear Door Glass to Rear Door (front) in-line within +/- 1.0
Rear Door Glass to Front Door N/A 3.25 +/- 1.5
J Door to Hood/Fender 5.0 +/- 1.0 0.0 +/- 1.0
K Grille to Headlamp 6.0 +/- 3.0 N/A
L Grille to Fender 5.0 +/- 0.75 1.0 +/- 0.5
23 - 58 BODYBR/BE
BODY (Continued)

CARGO BOX
CARGO BOX
DESCRIPTION GAP FLUSH
M Fuel Filler Door to Box 3.0 +/- 0.75 0.0 +/- 3.0
N Cab to Box Character Line U/D N/A 0.0 +/- 3.0
O Cargo to Box (side) 31.0 +/- 3.0 5.0 +/- 2.5
P Cab to Box at Centerline 34.0 +/- 3.0 N/A
Q Box to Tailgate U/D N/A 1.0 +/- 1.5
R Tailgate to Bumper 43.0 +/- 3.0 N/A
S Box to Tailgate 6.0 +/- 1.5 1.0 +/- 1.5
T Box to Tailgate 1.0 +/- 1.0 4.0 +/- 1.5
BR/BEBODY 23 - 59
BODY (Continued)

BODY OPENING DIMENSIONS
WINDSHIELD OPENING
DOOR OPENING Ð REGULAR CAB
BACKLITE OPENING
DOOR OPENING Ð QUAD CAB
23 - 60 BODYBR/BE
BODY (Continued)

TORQUE SPECIFICATIONS
BODY COMPONENTS
Description N´m Ft.
lbs.In. lbs.
Bench seat front anchor
bolt54 40 Ð
Bench seat rear inboard
anchor nut40 30 Ð
Bench seat rear outboard
anchor nut54 40 Ð
Bench seat, rear seat
track to frame bolt25 18 Ð
Bench seat, front seat
track to frame bolt25 18 Ð
Bench seat, inboard
belt/buckle anchor bolt40 30 Ð
Bench seat back to
cushion pivot bolt25 18 Ð
Bench seat slider bolts 10 7 Ð
Cab mounting bolt 81 60 Ð
Front shoulder belt upper
anchor bolt39 28 Ð
Front belt buckle inboard
anchor nut45 33 Ð
Front belt retractor
anchor bolt39 28 Ð
Front shoulder belt lower
anchor bolt39 28 Ð
Front shoulder belt lower
anchor bolt45 33 Ð
Door hinge to A-pillar bolt 28 21 Ð
Door latch screw 11 8 Ð
Door latch striker screw 28 21 Ð
Door glass to lift plate
screw97Ð
Sliding backlite
latch/keeper screws1.5 Ð 15
Split bench seat front
anchor bolt54 40 Ð
Split bench seat rear
inboard anchor nut40 30 Ð
Split bench seat rear
outboard anchor nut54 40 Ð
Split bench seat track to
frame bolt25 18 Ð
Split bench seat back to
cushion pivot bolt25 18 Ð
DOOR OPENING AND QUARTER GLASS OPENING
Ð CLUB CAB
A. 1284.8 MM D. 1235.4 MM G. 436.2 MM
B. 1190.3 MM E. 582.6 MM H. 440.5 MM
C. 1546.3 MM F. 538.8 MM J. 426.8 MM
CARGO DOOR QUARTER GLASS OPENING
E. 484.14 H. 427.28
F. 456.83 J. 418.38
G 424.97
BR/BEBODY 23 - 61
BODY (Continued)

DECKLID/HATCH/LIFTGATE/TAILGATE
TABLE OF CONTENTS
page page
APPLIQUE
REMOVAL..............................62
INSTALLATION...........................62
CHECK CABLE
REMOVAL..............................62
INSTALLATION...........................63
DECALS
REMOVAL..............................63
INSTALLATION...........................63
HANDLE ESCUTCHEON
REMOVAL..............................63
INSTALLATION...........................63
LATCH
REMOVAL..............................64INSTALLATION...........................64
LATCH HANDLE
REMOVAL..............................65
INSTALLATION...........................65
LATCH STRIKER
REMOVAL..............................65
INSTALLATION...........................65
SLAM BUMPER
REMOVAL..............................66
INSTALLATION...........................66
TAILGATE
REMOVAL..............................66
INSTALLATION...........................66
APPLIQUE
REMOVAL
(1) Apply a length of masking tape on the body,
parallel to the top edge of the applique to use as a
guide, if necessary.
(2) Warm the tailgate applique and tailgate metal
to approximately 38ÉC (100ÉF) using a suitable heat
lamp or heat gun.
(3) Pull applique from tailgate (Fig. 1).
INSTALLATION
(1) Remove adhesive tape residue from painted
surface of tailgate.
(2) If applique is to be reused, remove tape residue
from applique. Clean back of applique with
MOPARž, Super Kleen solvent or equivalent. Wipe
molding dry with lint free cloth. Apply new body side
molding (two sided adhesive) tape to back of appli-
que.
(3) Clean tailgate surface with MOPARž, Super
Kleen solvent or equivalent. Wipe surface dry with
lint free cloth. An adhesion promoter must be applied
to ensure proper applique adhesion.
(4) Remove protective cover from tape on back of
applique. Apply applique to body below the masking
tape guide (Fig. 1).
(5) Remove masking tape guide and heat tailgate
and applique, see step one. Firmly press applique to
tailgate to assure adhesion.
CHECK CABLE
REMOVAL
(1) Open tailgate.
(2) Pry lock tab outward to clear stud head on
cargo box (Fig. 2).
(3) Push cable end forward until stud head is in
clearance hole portion of cable end.
(4) Separate cable end from stud.
(5) Remove screw attaching cable to tailgate.
(6) Separate check cable from tailgate.
Fig. 1 Tailgate Applique
1 - TAILGATE
2 - TAILGATE
3 - ADHESIVE TAPE
4 - APPLIQUE
23 - 62 DECKLID/HATCH/LIFTGATE/TAILGATEBR/BE

INSTALLATION
(1) Position check cable on tailgate.
(2) Install screw attaching small end of cable to
tailgate.
(3) Position large end of cable onto stud head and
slide downward to secure lock tab.
DECALS
REMOVAL
(1) Warm the panel to approximately 38ÉC (100ÉF)
using a suitable heat lamp or heat gun.
(2) Peel tape stripe from body panel using an even
pressure pull.
(3) Remove adhesive residue from body panel
using a suitable adhesive removing solvent.
INSTALLATION
(1) Clean painted body surface with Moparž Super
Clean solvent or equivalent and a lint free cloth.
(2) Remove protective cover from back side of
decal.
(3) Position decal properly on body.
(4) Press decal firmly to body with palm of hand.
(5) If temperature is below 21ÉC (70ÉF) warm decal
with a heat lamp or gun to assure adhesion. Do not
exceed 65ÉC (150ÉF) when heating emblem.
HANDLE ESCUTCHEON
REMOVAL
(1) Lift and hold tailgate latch release handle.
(2) Using a trim stick (C±4755), pry bottom of
escutcheon outward to disengage clips.
(3) Rotate escutcheon upward to disengage clip
above release handle.
(4) Push escutcheon downward from behind to
clear handle.
(5) Separate escutcheon from tailgate (Fig. 3).
INSTALLATION
(1) Insert upper ends of escutcheon into handle
opening.
(2) Lift escutcheon upward from behind release
handle.
(3) Press bottom of escutcheon inward to engage
clips.
Fig. 2 Tailgate Check
1 - TAILGATE STRIKER
2 - SCREW DRIVER
3 - TAILGATE CHECK CABLE
4 - LOCK TAB
Fig. 3 Tailgate Handle Escutcheon
1 - TAILGATE
2 - HANDLEÐTOÐRIGHT LATCH CONTROL ROD
3 - ESCUTCHEON
4 - LATCH ROD RETAINER
5 - HANDLEÐTOÐLATCH CONTROL ROD AND RETAINER
6 - HANDLE
BR/BEDECKLID/HATCH/LIFTGATE/TAILGATE 23 - 63
CHECK CABLE (Continued)

LATCH
REMOVAL
(1) Remove tailgate latch handle escutcheon (Refer
to 23 - BODY/DECKLID/HATCH/LIFTGATE/TAIL-
GATE/HANDLE ESCUTCHEON - REMOVAL).
(2) Open tailgate.
(3) Disengage linkage rod from latch handle.
(4) Remove screws attaching latch to tailgate (Fig.
4).
(5) Separate latch from tailgate.
(6) Pull latch and linkage rod from tailgate (Fig.
5).
INSTALLATION
(1) Position latch and linkage rod in tailgate.
(2) Install upper screw attaching latch to tailgate.
(3) Install lower screw attaching check cable and
latch to tailgate.
(4) Engage linkage rod to latch handle.
Fig. 4 Tailgate Latch
1 - SPACER
2 - CHECK CABLE
3-LATCH
4 - LINKAGE ROD5 - HANDLE ESCUTCHEON
6 - LATCH HANDLE
Fig. 5 Tailgate Latch and Linkage Rod
1 - SILENCER
2 - LATCH ASSEMBLY
3 - LINKAGE ROD
23 - 64 DECKLID/HATCH/LIFTGATE/TAILGATEBR/BE

(5) Install tailgate latch handle escutcheon (Refer
to 23 - BODY/DECKLID/HATCH/LIFTGATE/TAIL-
GATE/HANDLE ESCUTCHEON - INSTALLATION).
LATCH HANDLE
REMOVAL
(1) Remove tailgate latch handle escutcheon (Refer
to 23 - BODY/DECKLID/HATCH/LIFTGATE/TAIL-
GATE/HANDLE ESCUTCHEON - REMOVAL).
(2) Disengage clips holding linkage rods to latch
handle.
(3) Separate linkage rods from handle.
(4) Remove screws attaching latch handle to tail-
gate (Fig. 6).
(5) Separate latch handle from tailgate.
INSTALLATION
(1) Position latch handle in tailgate.
(2) Install screws attaching latch handle to tail-
gate.
(3) Install linkage rods to latch handle.
(4) Engage clips to linkage rods.
(5) Install tailgate latch handle escutcheon.
LATCH STRIKER
REMOVAL
(1) Open tailgate.
(2) Mark outline of striker on cargo box jamb to
aid installation.
(3) Using a Torx drive wrench, remove striker and
washer from cargo box (Fig. 7).
INSTALLATION
(1) Position striker and washer on jamb using
alignment outline as reference and install with Torx
drive wrench.
Fig. 6 Tailgate Latch Handle
1 - SCREW
2 - TAILGATE
3 - HANDLE ASSEMBLYFig. 7 Tailgate Striker
1 - TAILGATE STRIKER
2 - CARGO BOX
BR/BEDECKLID/HATCH/LIFTGATE/TAILGATE 23 - 65
LATCH (Continued)

SLAM BUMPER
REMOVAL
(1) Open tailgate.
(2) Remove screw holding slam bumper to cargo
box (Fig. 8).
(3) Separate slam bumper from vehicle.
INSTALLATION
(1) Position slam bumper on vehicle.
(2) Install screw holding slam bumper to cargo
box.
(3) Close tailgate and verify operation.
TAILGATE
REMOVAL
(1) Open tailgate.
(2) Disconnect tailgate marker light harness, if
equipped.
(3) Remove tailgate check cables (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
CHECK CABLE - REMOVAL).
(4) Close tailgate until the notch in the right hand
collar aligns with the pivot pin.
(5) Slip tailgate hinge collar from pivot pins.
(6) Slide tailgate to the right and separate left
hand collar from the pivot pin.
(7) Separate tailgate from vehicle.
INSTALLATION
(1) Position tailgate collar on left hand pivot pin
and slide tailgate to the left.
(2) Raise tailgate until the notch in the right hand
collar aligns with the pivot pin.
(3) Install tailgate check cables (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
CHECK CABLE - INSTALLATION).
(4) Connect tailgate marker light harness, if
equipped.
Fig. 8 Tailgate Slam Bumper
1 - CARGO BOX
2 - SLAM BUMPER
3 - TAILGATE
23 - 66 DECKLID/HATCH/LIFTGATE/TAILGATEBR/BE

DOOR - FRONT
TABLE OF CONTENTS
page page
APPLIQUE
REMOVAL..............................67
INSTALLATION...........................67
DOOR
REMOVAL..............................68
INSTALLATION...........................68
ADJUSTMENTS..........................68
DOOR GLASS
REMOVAL..............................69
INSTALLATION...........................69
EXTERIOR HANDLE
REMOVAL..............................70
INSTALLATION...........................70
GLASS RUN CHANNEL
REMOVAL..............................70
INSTALLATION...........................70
HINGE
REMOVAL..............................70
INSTALLATION...........................71
INSIDE HANDLE ACTUATOR
REMOVAL..............................71
INSTALLATION...........................71LATCH
REMOVAL..............................72
INSTALLATION...........................72
ADJUSTMENTS..........................72
LATCH STRIKER
REMOVAL..............................73
INSTALLATION...........................73
LOCK CYLINDER
REMOVAL..............................73
INSTALLATION...........................73
SIDE VIEW MIRROR FLAG
REMOVAL..............................74
INSTALLATION...........................74
TRIM PANEL
REMOVAL..............................74
INSTALLATION...........................74
WATERDAM
REMOVAL..............................75
INSTALLATION...........................75
WINDOW REGULATOR
REMOVAL..............................75
INSTALLATION...........................76
APPLIQUE
REMOVAL
(1) Using a heat lamp, warm B-pillar to 38É C
(100É F).
(2) Remove glass run weatherstrip (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR GLASS RUN
WEATHERSTRIP - REMOVAL).
(3) Remove outer belt weatherstrip (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR OUTER BELT
WEATHERSTRIP - REMOVAL).
(4) Using an even pressure pull, peel B-pillar
applique away from the B-pillar.
INSTALLATION
Installation equipment needed:
²Lint free applicator cloth
²six inch applicator squeegee
²Piercing pin
(1) Clean B-pillar using Mopar Super Kleen or
equivalent.
(2) Wipe surface with a lint free cloth.
(3) Using a heat gun, warm surface to 22É C (70É
F).(4) Fold down, up/down locator tab (1a or 1b) (Fig.
1)along crease.
(5) Remove carrier from adhesion strip (2).
(6) Using up/down locator tab (1a or 1b) and fore/
aft locator tab (3a or 3b), position the applique on the
upper portion of the B-pillar.
(7) Using the lower edge locator (4), position the
applique on the lower portion of the B-pillar.
(8) Verify the applique is positioned correctly and
press the adhesion strip (2) to the door to tempo-
rarily secure it in place.
(9) Remove the carrier for the applique.
(10) Holding the applique from the surface, apply
firm downward pressure with a six inch applicator
squeegee. Ensure the lower rear edge (4) is aligned
correctly.
(11) Wrap edges around door to at least a 90É
angle.
(12) Remove premask by pulling in a firm contin-
uous manner from top down at 180É.
(13) Complete wrapping applique around the door
edges.
(14) Inspect for air bubbles. Small bubbles can be
pierced with a sharp pin and smoothed out.
BR/BEDOOR - FRONT 23 - 67