DODGE RAM SRT-10 2006 Service Repair Manual

CLEANING
CAUTION: Do not use caustic cleaners to clean the charge air cooler. Damageto the charge air cooler will
result.
NOTE: If internal debris cannot be removed from the cooler, the charge air cooler MUST be replaced.
1. If the engine experiences a turbocharger failure or any other situationwhere oil or debris get into the charge air
cooler, the charge air cooler must be cleaned internally.
2. Position the charge air cooler so the inlet and outlet tubes are vertical.
3. Flush the cooler internally with solvent in the direction opposite of normal air flow.
4. Shake the cooler and lightly tap on the end tanks with a rubber mallet to dislodge trapped debris.
5. Continue flushing until all debris or oil are removed.
6. Rinse the cooler with hot soapy water to remove any remaining solvent.
7. Rinse thoroughly with clean water and blow dry with compressed air.
INSPECTION
Visually inspect the charge air cooler for cracks, holes, or damage. Inspect the tubes, fins, and welds for tears,
breaks, or other damage. Replace the charge air cooler if damage is found.
Pressure test the charge air cooler, using Charge Air Cooler Tester Kit No.3824556. This kit is available through
Cummins
Service Products. Instructions are provided with the kit.
INSTALLATION
1. Position the charge air cooler. Install the bolts and
tighten to 2 Nꞏm (17 in. lbs.) torque.

2. Install the air intake system tubes to the charge air
cooler. With the clamps in position, tighten the
clamps to 11 Nꞏm (95 in. lbs.) torque.
3. Install the transmission auxiliary cooler (if
equipped) (Refer to 7 - COOLING/TRANSMIS-
SION/TRANS COOLER - INSTALLATION).
4. Install the A/C condenser (if A/C equipped) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/A/C CONDENSER - INSTALLATION).
Recharge A/C system (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE).
5. Connect the battery negative cables.
6. Start engine and check for boost system leaks.

FRAME & BUMPERS
TABLE OF CONTENTS
page page
FRAMES & BUMPERS
SPECIFICATIONS
TORQUE .................................... 2
FRONT AIR DAM
REMOVAL ..................................... 3
INSTALLATION ................................ 3
FRONT BUMPER
REMOVAL ..................................... 4
INSTALLATION ................................ 4
FRONT FASCIA
REMOVAL ..................................... 5
INSTALLATION ................................ 6
REAR BUMPER
REMOVAL ..................................... 7
INSTALLATION ................................ 8
FASCIA-FRONT SRT-10
REMOVAL ..................................... 9
INSTALLATION ................................ 11
FASCIA-REAR SRT-10
REMOVAL .................................... 14
INSTALLATION ............................... 15
FRAME
WARNING
WARNINGS ................................ 17
STANDARD PROCEDURE
HYDROFORM FENDER RAIL REPAIR ........ 18REAR FRAME H-SECTION REPLACEMENT . . . 27
SPECIFICATIONS
WELD PROCESS ........................... 33
FRAME DIMENSIONS ....................... 34
TORQUE ................................... 45
FRONT CROSSMEMBER
REMOVAL .................................... 46
INSTALLATION ............................... 48
FRONT SKID PLATE
REMOVAL .................................... 50
INSTALLATION ............................... 51
FRONT TOW HOOK ASSEMBLY
REMOVAL .................................... 52
INSTALLATION ............................... 53
TRANSMISSION CROSSMEMBER
REMOVAL .................................... 54
INSTALLATION ............................... 56
TRAILER HITCH
REMOVAL .................................... 58
INSTALLATION ............................... 60
TRANSFER CASE SKID PLATE
REMOVAL .................................... 62
INSTALLATION ............................... 63

FRAMES & BUMPERS
SPECIFICATIONS
TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION Nꞏm Ft. Lbs.
Front bumper center bracket nuts 95 70
Front bumper stud plate nuts 95 70
License plate hitch reinforcement bolts 54 40
Rear bumper support bracket stud plate nuts 54 40
Rear bumper support bracket to hitch bolts 54 40
Rear bumper to hitch bolts 54 40

FRONT AIR DAM
REMOVAL
1. Remove the two outboard screws.
2. Remove the three middle screws and remove the air dam.
INSTALLATION
1. Position the air dam onto the bumper and seat the carrot type fasteners fully.
2. Starting at the center screw install the three middle screws.
3. Install the two outboard screws.

FRONT BUMPER
REMOVAL
1. Using a grease pencil or equivalent, mark the posi-
tion of the bumper support bracket (5) on the frame
rail tip (7) to aid installation.
2. Disconnect the fog lamp electrical connector at the
left frame rail.
3. Support the bumper with a suitable lifting device.
4. Remove the bumper support bracket (5) nuts and
bolts (8 and 9) and remove bumper.
INSTALLATION
1. Install the bumper onto the frame rails (7) and posi-
tion the wheelhouse splash shield into the support
brackets (4).
2. Install the bolts and nuts (8 and 9).
3. Line up the bumper with the marks made previ-
ously and tighten the bolts and nuts to 95 Nꞏm (70
ft. lbs.).
4. Check and adjust the bumper alignment as neces-
sary (Refer to 23 - BODY/BODY STRUCTURE/
GAP AND FLUSH - SPECIFICATIONS).

FRONT FASCIA
REMOVAL
ST/SLT/SLT+
1. Remove the two screws (4) at each trailing edge of
the fascia.
2. Remove the four push pin fasteners (5) from the
upper edge of the close out panel.
3. Using a trim stick (special tool #C-4755) or equiv-
alent, carefully release the six lower clips and
remove the close out panel.
4. Using a trim stick or equivalent, carefully remove
the step pad (1).
5. Remove and discard the four push pin fasteners
(5) and remove the fascia.
SPORT
1. Raise and support the vehicle (Refer to LUBRICA-
TION & MAINTENANCE/HOISTING - STANDARD
PROCEDURE).

2. Remove the three screws (3) at each trailing edge
of the fascia.
3. Remove the five lower screws (8).
4. Remove and discard the four upper push pins (7).
5. Using a trim stick (special tool #C-4755) or equiv-
alent, carefully release the six lower clips and
remove the close out panel.
6. Using a trim stick or equivalent, carefully remove
the step pad (1).
7. Spread the fascia (2) out at the wheels and remove
from the vehicle.
INSTALLATION
ST/SLT/SLT+
NOTE: The left and right inboard bumper to
bracket attachments must be secured before
installing the fascia and step pad.
1. Install the fascia.
2. Position the close out panel and seat the 6 lower
clips fully.
3. Install four new upper push pin fasteners (5).
4. Position the step pad (1) onto the fascia (2) and
fully seat the attachment clips.
5. Align the fascia to the fender with a 19 mm (0.75
inch) gap and install the two screws at each trailing
edge of the fascia.
SPORT
NOTE: The left and right inboard bumper to
bracket attachments must be secured before
installing the fascia and step pad.
1. Position the fascia (2) onto the bumper.
2. Position the step pad (1) onto the fascia (2) and
fully seat the attachment clips.
3. Install four new upper push pin fasteners (7).
4. Install the five lower screws (8).
5. Install the three screws (3) at each trailing edge of
the fascia.

REAR BUMPER
REMOVAL
1. Raise and support the vehicle (Refer to LUBRICA-
TION & MAINTENANCE/HOISTING - STANDARD
PROCEDURE).
2. Remove the license plate.
3. Remove the bolts behind the plate.
4. Disconnect the license plate light electrical connec-
tors.
5. Disconnect the trailer light connector electrical con-
nection (if equipped).
6. Remove the two bolts along the front upper edge
of the bumper near the frame tips.
7. Support the bumper with a suitable lifting device.
8. Remove the bolts attaching the bumper support
brackets (4) to the trailer hitch (1).