DODGE RAM SRT-10 2006 Service Repair Manual

STANDARD PROCEDURE
HYDROFORM FENDER RAIL REPAIR
CAUTION: This repair procedure assumes damage to the right or left hydroform fender rail (1). Prior to any
repairs, the vehicle must be mounted on the appropriate frame repair equipment (“frame rack”), checked
with three dimensional measuring equipment, and necessary pull corrections made. If damage exists in the
hydroform fender rail, or cab beyond the area covered by this service procedure after dimensional correc-
tions are made, the hydroform must be replaced in its entirety. Refer to 23 -BODY/BODY STRUCTURE/
WELD LOCATIONS - SPECIFICATIONS, when replacing the entire hydroform.
CAUTION: Inspect the tire winch assembly for damage. If any one or more of thefollowingareevident,
replace the winch assembly.
Indications of cracked or bulging plastic.
Housing flanges are bent or cracked.
If winch was loose before repair.
If the rivet heads are separated from the housing in any way.
1. Before proceeding with this repair procedure review the required service warnings and precautions (Refer to 13
- FRAME & BUMPERS/FRAME - WARNING).

2. Disconnect and isolate the battery negative cable.
3. Remove the front wheelhouse splash shield (Refer
to 23 - BODY/EXTERIOR/FRONT WHEELHOUSE
SPLASH SHIELD - REMOVAL).
4. Remove the fender (Refer to 23 - BODY/EXTERI-
OR/FRONT FENDER - REMOVAL).
5. Remove the A/C condenser, if required (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/A/C
CONDENSER - REMOVAL).
6. Remove the A/C lines, if required. Refer to the
Heating and Air Conditioning section of the manual
for recommended procedures.
7. Remove the radiator assembly (4) (Refer to 7 -
COOLING/ENGINE/RADIATOR - REMOVAL).

8. Remove the air cleaner and support bracket (1 - if
required) (Refer to 9 - ENGINE/AIR INTAKE SYS-
TEM/AIR CLEANER ELEMENT - REMOVAL).
9. Remove the integrated power module (Refer to 8 -
ELECTRICAL/POWER DISTRIBUTION/INTE-
GRATED POWER MODULE - REMOVAL).
10. Remove the bolts and position aside the wire har-
ness and grounds, if required.

11. Remove the upper radiator crossmember (4). (Refer to 23 - BODY/EXTERIOR/UPPER RADIATOR CROSS-
MEMBER - REMOVAL).
12. Remove the headlamp unit (5) (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP UNIT - REMOVAL).

13. Remove the front cab mount to the Front End Sheet Metal bracket (FESM) bolt (2).
14. Remove the bolts (5) attaching the lower radiator crossmember (6) to the hydroform fender rail (1).
CAUTION: Do not use any flame or plasma cutting equipment to cut the frame inthis procedure. The inac-
curate and high temperatures achieved during flame or plasma cutting willchange the metal characteristics
and may weaken the frame and/or repair location.

15. Using a reciprocating saw or equivalent, cut the fender rail and shotgun at a straight and square section of the
hydroform and remove.
16. Smooth and square the cut edges.
17. Using the damaged structure as a reference cut the service part at the same location as the first cut. Smooth
and square the cut edges.
NOTE: The repair structure should butt up to the remaining structure and provide the same overall vehicle
geometry.
18. Fabricate 51 mm (2.0 in.) long repair inserts using scrap from the old structure or the replacement part. It will
be necessary to split the inserts on each of their four sides to fit into the hydroform.
19. Remove any paint or e-coat from the inserts and also to the interior and exterior of the hydroforms.
20. Cut plug weld holes as described below.
On the upper rail, cut one 13 mm (0.5 in.) hole on each side of the rail, 25 mm (1.0 in.) from the butt joint of
the tubes.
On the lower rail, cut one 13 mm (0.5 in.) hole on the top and bottom sides of therail25mm(1.0in.)fromthe
butt joint of the tube.
On the lower rail, cut two 13 mm (0.5 in.) holes on the inner and outer sides oftherail25mm(1.0in.)from
the butt joint of the tube.
CAUTION: Shield the surrounding area and components from exposure to the welding spatter and heat.
21. Install the insert 1” into the replacement part and tack into place witha weld. (Refer to 13 - FRAME &
BUMPERS/FRAME - SPECIFICATIONS - WELDING)
22. Insert the service part into place and using the appropriate measuringequipment, verify the front end sheet
metal bracket’s location in all three (X,Y, and Z) planes of space.
23. Complete all 360° plug welds.
NOTE: Before the final welding, use three dimensional measuring equipment to ensure the part is in the
correct location. Verify that tap plate extrusion at the bottom of the vertical post lines up with the isolator
and hole in the frame perch mount. Also ensure the lower radiator closure tube is bolted into the forward
shotgun ends.
24. Complete welding by making a 360° butt weld around the fender rails.
25. Metal finish the exposed welds on the hydroforms.
26. Dress the welded area and apply corrosion resistant coatings inside and out.
a. Inside the rail, inject a creeping wax based rust inhibitor compound to the inside of the hydroforms ensuring
100% coverage including the mating face between the fender rail sections and insert such that corrosion
protection is restored in the internal cavity.
b. Apply a durable top coat to the outside of the repair area.

27. Install the front cab mount bolt (2) if previously removed and tighten to81Nꞏm(60ft.lbs.).
28. Install the lower radiator crossmember (6) bolts (5) and tighten to 28 Nꞏm ( 2 1 f t . l b s . ) .
29. Install the headlamp unit (Refer to 8 - ELECTRI-
CAL/LAMPS/LIGHTING - EXTERIOR/HEADLAMP
UNIT - INSTALLATION).

30. Install the upper radiator crossmember (4) (Refer to 23 - BODY/EXTERIOR/UPPER RADIATOR CROSSMEM-
BER - INSTALLATION).
31. Install the wire harness and ground if previously removed and install the bolts.
32. Install the integrated power module, if previously
removed (Refer to 8 - ELECTRICAL/POWER DIS-
TRIBUTION/INTEGRATED POWER MODULE -
INSTALLATION)

33. Install the air cleaner bracket and air cleaner (1),
if previously removed (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER ELEMENT -
INSTALLATION).
34. Install the radiator assembly (4) (Refer to 7 -
COOLING/ENGINE/RADIATOR - INSTALLATION).

35. Install the A/C lines, if previously removed. Refer
to the Heating and Air Conditioning section of the
manual for the recommended procedures.
36. Install the A/C condenser, if previously removed
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C CONDENSER - INSTALLATION).
37. Install the fender (Refer to 23 - BODY/EXTERI-
OR/FRONT FENDER - INSTALLATION).
38. Install the front wheelhouse splash shield. (Refer
to 23 - BODY/EXTERIOR/FRONT WHEELHOUSE
SPLASH SHIELD - INSTALLATION)
39. Reconnect the battery negative cable.
REAR FRAME H-SECTION REPLACEMENT
CAUTION: This procedure is designed to replace the H-section/spare tire support located at the rear of the
frame assembly. Prior to any cutting, the vehicle must be mounted on the appropriate frame repair equip-
ment (“frame rack”), checked with three dimensional measuring equipment, and the necessary pull correc-
tions made. If damage remains in the frame beyond the area covered by this service part after the pull, the
frame must be replaced in its entirety.
1. Before proceeding with this repair procedure review the required service warnings and precautions. (Refer to 13
- FRAME & BUMPERS/FRAME - WARNING)