door lock DODGE RAM 1500 1998 2.G Repair Manual

OPERATION
Fuel is returned through the fuel pump module
and back into the fuel tank through the fuel filter/
fuel pressure regulator. A separate fuel return line
from the engine to the tank is not used.
The fuel tank assembly consists of: the fuel tank,
fuel pump module assembly, fuel pump module lock-
nut/gasket, and fuel tank check valve (refer to Fuel
Tank Check Valve for information).
A fuel filler/vent tube assembly using a pressure/
vacuum, 1/4 turn fuel filler cap is used. The fuel
filler tube contains a flap door located below the fuel
fill cap.
Also to be considered part of the fuel system is the
evaporation control system. This is designed to
reduce the emission of fuel vapors into the atmo-sphere. The description and function of the Evapora-
tive Control System is found in Emission Control
Systems.
Both fuel filters (at bottom of fuel pump module
and within fuel pressure regulator) are designed for
extended service. They do not require normal sched-
uled maintenance. Filters should only be replaced if
a diagnostic procedure indicates to do so.
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE
Use following procedure if the fuel injector
rail is, or is not equipped with a fuel pressure
test port.
(1) Remove fuel fill cap.
Fig. 1 FUEL DELIVERY COMPONENTS
1 - FUEL TANK 8 - LDP FRESH AIR FILTER
2 - CHECK VALVE 9 - LEAK DETECTION PUMP
3 - LIQUID EXPANSION CHAMBER 10 - EVAP CANISTERS (2)
4 - FUEL FILTER / FUEL PRESSURE REGULATOR 11 - FUEL TANK STRAPS (2)
5 - QUICK-CONNECT FITTING AND FUEL LINE (TO ENGINE) 12 - CHECK VALVE
6 - EVAP LINE CONNECTION 13 - FUEL PUMP MODULE LOCK RING
7 - LEAK DETECTION PUMP FRESH AIR LINE 14 - FUEL PUMP MODULE
14 - 2 FUEL DELIVERY - GASDR
FUEL DELIVERY - GAS (Continued)

(15) Install air duct to air box.
(16) Connect battery cable to battery.
(17) Start engine and check for leaks.
5.7L V-8
(1) If fuel injectors are to be installed, refer to Fuel
Injector Removal/Installation.
(2) Clean out fuel injector machined bores in
intake manifold.
(3) Apply a small amount of engine oil to each fuel
injector o-ring. This will help in fuel rail installation.
(4) Position fuel rail/fuel injector assembly to
machined injector openings in intake manifold.
(5) Guide each injector into intake manifold. Be
careful not to tear injector o-rings.
(6) Pushrightside of fuel rail down until fuel
injectors have bottomed on shoulders. Pushleftfuel
rail down until injectors have bottomed on shoulders.
(7) Install 4 fuel rail holdown clamps and 4 mount-
ing bolts. Refer to Torque Specifications.
(8) Position spark plug cable tray and cable assem-
bly to intake manifold. Snap 4 cable tray retaining
clips into intake manifold.
(9) Install all cables to spark plugs and ignition
coils.
(10) Connect electrical connector to throttle body.
(11) Install electrical connectors to all 8 ignition
coils. Refer to Ignition Coil Removal/Installation.
(12) Connect electrical connector to throttle body.
(13) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 17). Push con-
nector onto injector (1) and then push and lock red
colored slider (2). Verify connector is locked to injec-
tor by lightly tugging on connector.
(14) Connect fuel line latch clip and fuel line to
fuel rail. Refer to Quick-Connect Fittings.
(15) Install air resonator to throttle body (2 bolts).
(16) Install flexible air duct to air box.
(17) Connect battery cable to battery.
(18) Start engine and check for leaks.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of a plastic material.
Its main functions are for fuel storage and for place-
ment of the fuel pump module, and (if equipped) cer-
tain ORVR components.
OPERATION
All models pass a full 360 degree rollover test
without fuel leakage. To accomplish this, fuel and
vapor flow controls are required for all fuel tank con-
nections.Two check (control) valves are mounted into the
top of the fuel tank. Refer to Fuel Tank Check Valve
for additional information.
An evaporation control system is connected to the
fuel tank to reduce emissions of fuel vapors into the
atmosphere. When fuel evaporates from the fuel
tank, vapors pass through vent hoses or tubes to a
charcoal canister where they are temporarily held.
When the engine is running, the vapors are drawn
into the intake manifold. Certain models are also
equipped with a self-diagnosing system using a Leak
Detection Pump (LDP) and/or an On-Board Refueling
Vapor Recovery (ORVR) system. Refer to Emission
Control System for additional information.
REMOVAL- EXCEPT DIESEL
Fuel Tank Draining
WARNING: THE FUEL SYSTEM MAY BE UNDER
CONSTANT FUEL PRESSURE EVEN WITH THE
ENGINE OFF. THIS PRESSURE MUST BE
RELEASED BEFORE SERVICING FUEL TANK.
Two different procedures may be used to drain fuel
tank: through the fuel fill fitting on tank, or using
the DRBtscan tool. Due to a one-way check valve
installed into the fuel fill opening fitting at the tank,
the tank cannot be drained conventionally at the fill
cap.
The quickest draining procedure involves removing
the rubber fuel fill hose.
As an alternative procedure, the electric fuel pump
may be activated allowing tank to be drained at fuel
rail connection. Refer to DRB scan tool for fuel pump
activation procedures. Before disconnecting fuel line
at fuel rail, release fuel pressure. Refer to the Fuel
System Pressure Release Procedure for procedures.
Attach end of special test hose tool number 6541,
6539, 6631 or 6923 at fuel rail disconnection (tool
number will depend on model and/or engine applica-
tion). Position opposite end of this hose tool to an
approved gasoline draining station. Activate fuel
pump and drain tank until empty.
If electric fuel pump is not operating, fuel must be
drained through fuel fill fitting at tank. Refer to fol-
lowing procedures.
(1) Release fuel system pressure.
(2) Raise vehicle.
(3) Thoroughly clean area around fuel fill fitting
and rubber fuel fill hose at tank.
(4) If vehicle is equipped with 4 doors and a 6 foot
(short) box, remove left-rear tire/wheel.
(5) Loosen clamp (Fig. 23) and disconnect rubber
fuel fill hose at tank fitting. Using an approved gas
holding tank, drain fuel tank through this fitting.
DRFUEL DELIVERY - GAS 14 - 17
FUEL RAIL (Continued)

(5) Position APPS assembly to bottom of battery
tray and install 3 bolts. Refer to Torque Specifica-
tions.
(6) Install wheelhouse liner. Refer to Body.
(7)The 5.7L V-8 engine is equipped with a
fully electronic accelerator pedal position sen-
sor. If equipped with a 5.7L, also perform the
following 3 steps:
(a) Connect negative battery cable to battery.
(b) Turn ignition switch ON, but do not crank
engine.
(c) Leave ignition switch ON for a minimum of
10 seconds. This will allow PCM to learn electrical
parameters.
(d) The DRB IIItScan Tool may also be used to
learn electrical parameters. Go to the Miscella-
neous menu, and then select ETC Learn.
(8) If the previous step is not performed, a Diag-
nostic Trouble Code (DTC) will be set.
(9) If necessary, use DRB IIItScan Tool to erase
any Diagnostic Trouble Codes (DTC's) from PCM.
CRANKSHAFT POSITION
SENSOR
DESCRIPTION
3.7L V-6
The Crankshaft Position (CKP) sensor is mounted
into the right rear side of the cylinder block. It is
positioned and bolted into a machined hole.
4.7L V-8
The Crankshaft Position (CKP) sensor is mounted
into the right rear side of the cylinder block. It is
positioned and bolted into a machined hole.
5.7L V-8
The Crankshaft Position (CKP) sensor is mounted
into the right rear side of the cylinder block. It is
positioned and bolted into a machined hole.
OPERATION
3.7L V-6
Engine speed and crankshaft position are provided
through the CKP (Crankshaft Position) sensor. The
sensor generates pulses that are the input sent to the
Powertrain Control Module (PCM). The PCM inter-
prets the sensor input to determine the crankshaft
position. The PCM then uses this position, along with
other inputs, to determine injector sequence and igni-
tion timing.
Fig. 3 APPS REMOVE / INSTALL
1 - BOTTOM OF BATTERY TRAY
2 - ELECTRICAL CONNECTOR
3 - APPS
4 - SWING-DOWN DOOR
5 - CABLE (TO PEDAL)
6 - CABLE RELEASE TAB
Fig. 4 APPS CABLE
1 - APPS LEVER
2 - BALL SOCKET
3 - SWING-DOWN DOOR
4 - CABLE CLIP
5 - CABLE
DRFUEL INJECTION - GAS 14 - 23
ACCELERATOR PEDAL POSITION SENSOR (Continued)

FUEL TANK
DESCRIPTION - DIESEL
The fuel tank is similar to the tank used with gas-
oline powered models. The tank is equipped with a
separate fuel return line and a different fuel tank
module for diesel powered models. A fuel tank
mounted, electric fuel pump is not used with diesel
powered models. Refer to Fuel Tank Module for addi-
tional information.
REMOVAL - DIESEL
Fuel Tank Draining
Due to a one-way check valve installed into the
fuel fill opening fitting at the tank, the tank cannot
be drained conventionally at the fill cap.
(1) Raise vehicle.
(2) If vehicle is equipped with 4 doors and a 6 foot
(short) box, remove left-rear tire/wheel.
(3) Thoroughly clean area at top of fuel tank
around fuel tank module.
(4) Remove rubber cap from auxiliary fitting on
top of tank module (Fig. 19).
(5) Drain fuel tank by attaching drain hose from
an approved draining station to auxiliary fitting on
top of tank module (Fig. 19).
Tank Removal
(1) Loosen clamp and disconnect rubber fuel fill
hose at tank.
(2) Support tank with a hydraulic jack.
(3) Remove 2 fuel tank strap nuts (Fig. 20) and
remove both tank support straps.
(4) Carefully lower tank a few inches and discon-
nect fuel pump module electrical connector (Fig. 19)
at top of tank. To disconnect electrical connector:
Push upward on red colored tab to unlock. Push on
black colored tab while removing connector.
(5) Disconnect fuel supply and return lines at fuel
tank module (Fig. 19). Refer to Quick-Connect Fit-
tings for procedures.
(6) Continue to lower tank for removal.
(7) If fuel tank is to be replaced, remove fuel tank
module from tank. Refer to Fuel Tank Module
Removal/Installation procedures.INSTALLATION - DIESEL
(1) If fuel tank is to be replaced, install fuel tank
module into tank. Refer to Fuel Tank Module Remov-
al/Installation procedures.
(2) Position fuel tank to hydraulic jack.
(3) Raise tank until positioned near body.
(4) Connect fuel tank module electrical connector
at top of tank.
(5) Connect fuel supply and return lines to tank
module.
(6) Continue raising tank until positioned snug to
body.
(7) Install and position both tank support straps.
Install 2 fuel tank strap nuts and tighten.Tighten
rear strap nut first.Refer to Torque Specifications.
(8) Remove hydraulic jack.
(9) Connect rubber fill hose to fuel fill tube and
tighten clamp.
(10) Install tire / wheel (if necessary).
(11) Lower vehicle.
(12) Fill fuel tank with fuel.
(13) Start engine and check for fuel leaks near top
of module.
Fig. 19 FUEL TANK MODULE - DIESEL
1 - TOP OF FUEL TANK
2 - AUX. FITTING
3 - ELEC. CONNECTOR
4 - FUEL TANK MODULE (TOP)
5 - LOCKNUT
6 - FUEL SUPPLY LINE
7 - FUEL RETURN LINE
14 - 62 FUEL DELIVERY - DIESELDR

(8) For columns without tilt remove the bracket to
gain access to the ignition switch mounting screws.
(Fig. 10)
(9) Disconnect the electrical connector at rear of
ignition switch (Fig. 11).
(10) Remove ignition switch mounting screw.
(11) Using a small screwdriver, push on locking
tab and remove switch from steering column.
INSTALLATION
The ignition key must be in the key cylinder for
cylinder removal. The key cylinder must be removed
first before installing ignition switch.
(1) Before installing ignition switch, rotate the slot
in the switch to the ON position.(2) Connect the electrical connector to rear of the
ignition switch. Make sure that locking tabs are fully
seated into wiring connector.
(3) Position switch to column and install the
mounting screw. Tighten screw to 3 N´m (26 in. lbs.).
(4) Install the tilt lever bracket mounting screws.
Tighten screws to 4.5 N´m (40 in. lbs.).
(5) If the column is non-tilt install the bracket.
Tighten screws to 4.5 N´m (40 in. lbs.) (Fig. 10)
(6) Position the wire retainer into the tilt lever
bracket.
(7) Reconnect the lower clockspring connectors.
(8) Install the key cylinder.
(9) Install steering column upper and lower
shrouds.
(10) Enable the airbag system. (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/DRIVER AIRBAG - INSTAL-
LATION).
KEY-IN IGNITION SWITCH
DESCRIPTION
The key-in ignition switch is integral to the igni-
tion switch, which is mounted on the left side of the
steering column. It closes a path to ground for the
Central Timer Module (CTM) when the ignition key
is inserted in the ignition key cylinder and the driver
door ajar switch is closed (driver door is open). The
key-in ignition switch opens the ground path when
the key is removed from the ignition key cylinder.
The ground path is also opened when the driver door
ajar switch is open (driver door is closed).
The key-in ignition switch cannot be repaired and,
if faulty or damaged, the entire ignition switch must
be replaced, (Refer to 19 - STEERING/COLUMN/IG-
NITION SWITCH - REMOVAL).
DIAGNOSIS AND TESTING - IGNITION SWITCH
AND KEY LOCK CYLINDER
ELECTRICAL DIAGNOSIS
For ignition switch electrical schematics, refer to
Ignition Switch in the appropriate section of Electri-
cal Wiring Diagrams.
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO
ROTATE)
(Refer to 19 - STEERING/COLUMN/IGNITION
SWITCH - DIAGNOSIS AND TESTING).
Fig. 10 IGNITION SWITCH WITHOUT TILT
1 - Ignition Switch Mounting Screws
2 - Non-Tilt Mounitng Bracket Screws
Fig. 11 IGNITION SWITCH
1 - Ignition Switch
2 - Ignition Switch Mounting Screws
DRCOLUMN 19 - 11
IGNITION SWITCH (Continued)

(14) Position overdrive piston retainer on trans-
mission case and align bolt holes in retainer, gasket
and case (Fig. 187). Then install and tighten retainer
bolts to 17 N´m (13 ft. lbs.) torque.
(15) Install new seals on overdrive piston.
(16) Stand transmission case upright on bellhous-
ing.
(17) Position Guide Ring 8114-1 on outer edge of
overdrive piston retainer.
(18) Position Seal Guide 8114-3 on inner edge of
overdrive piston retainer.
(19) Install overdrive piston in overdrive piston
retainer by: aligning locating lugs on overdrive piston
to the two mating holes in retainer.
(a) Aligning locating lugs on overdrive piston to
the two mating holes in retainer.
(b) Lubricate overdrive piston seals with Mopart
Door Ease, or equivalent.
(c) Install piston over Seal Guide 8114-3 and
inside Guide Ring 8114-1.
(d) Push overdrive piston into position in
retainer.
(e) Verify that the locating lugs entered the lug
bores in the retainer.PISTONS
DESCRIPTION
There are several sizes and types of pistons used in
an automatic transmission. Some pistons are used to
apply clutches, while others are used to apply bands.
They all have in common the fact that they are
round or circular in shape, located within a smooth
walled cylinder, which is closed at one end and con-
verts fluid pressure into mechanical movement. The
fluid pressure exerted on the piston is contained
within the system through the use of piston rings or
seals.
OPERATION
The principal which makes this operation possible
is known as Pascal's Law. Pascal's Law can be stated
as: ªPressure on a confined fluid is transmitted
equally in all directions and acts with equal force on
equal areas.º
PRESSURE
Pressure (Fig. 188) is nothing more than force
(lbs.) divided by area (in or ft.), or force per unit
area. Given a 100 lb. block and an area of 100 sq. in.
on the floor, the pressure exerted by the block is: 100
lbs. 100 in or 1 pound per square inch, or PSI as it is
commonly referred to.
Fig. 187 Aligning Overdrive Piston Retainer
1 - PISTON RETAINER
2 - GASKET
3 - RETAINER BOLTS
Fig. 188 Force and Pressure Relationship
DRAUTOMATIC TRANSMISSION - 48RE 21 - 239
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued)

(43) Remove the park pawl rod and e-clip (Fig. 31).
(44) Remove the park pawl rod guide snap-ring
(Fig. 31).
(45) Remove the park pawl rod guide (Fig. 31).
(46) Remove the park pawl pivot shaft, park pawl,
and spring (Fig. 31).
(47) Remove the manual selector shaft (Fig. 31).
(48) Remove the manual selector shaft seal.
(49) Remove the dipstick tube seal.
CLEANING
The use of crocus cloth is permissible where neces-
sary, providing it is used carefully. When used on shafts,
or valves, use extreme care to avoid rounding off sharp
edges. Sharp edges are vital as they prevent foreign
matter from getting between the valve and valve bore.
Do not reuse oil seals, gaskets, seal rings, or O-rings
during overhaul. Replace these parts as a matter of
course. Also do not reuse snap rings or E-clips that are
bent or distorted. Replace these parts as well.
Lubricate transmission parts with MopartATF +4,
Automatic Transmission Fluid, during overhaul and
assembly. Use petroleum jelly, MopartDoor Ease, or
Ru-Glyde to prelubricate seals, O-rings, and thrust
washers. Petroleum jelly can also be used to hold
parts in place during reassembly.Clean the case in a solvent tank. Flush the case
bores and fluid passages thoroughly with solvent.
Dry the case and all fluid passages with compressed
air. Be sure all solvent is removed from the case and
that all fluid passages are clear.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will stick
to case surfaces and transmission components and
circulate throughout the transmission after assem-
bly. A sufficient quantity of lint can block fluid pas-
sages and interfere with valve body operation.
INSPECTION
Inspect the case for cracks, porous spots, worn
bores, or damaged threads. Damaged threads can be
repaired with Helicoil thread inserts. However, the
case will have to be replaced if it exhibits any type of
damage or wear.
ASSEMBLY
(1) Clean and inspect all components. Replace any
components which show evidence of excessive wear
or scoring.
(2) Install the cooler filter bypass valve.
(3) Torque the bypass valve to specification. The
valve uses a tapered pipe thread and excessive
torque can damage the transmission case. Tighten
the cooler filter bypass valve to 4.5 N´m (40 in.lbs.).
(4) Install a new selector shaft seal using Seal
Installer 8253 (Fig. 32).
Fig. 31 Manual Shaft/Park Lock Components
1 - GUIDE
2 - SNAP-RING
3 - SHAFT
4 - SPRING
5 - PARK PAWL
6 - MANUAL SHAFT/LEVER
7 - PARK ROD
Fig. 32 Install Selector Shaft
1 - SEAL
2 - TOOL 8253
21 - 326 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

BODY
TABLE OF CONTENTS
page page
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS . 1
DIAGNOSIS AND TESTING - WIND NOISE . . . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY
LUBRICATION.........................3
STANDARD PROCEDURE - HEAT STAKING . . 3
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR........................3
STANDARD PROCEDURE - BUZZ, SQUEAK
& RATTLE...........................11
SPECIFICATIONS - TORQUE..............12SPECIAL TOOLS
BODY..............................14
TAILGATE..............................15
DOOR - FRONT.........................18
DOORS - REAR.........................28
EXTERIOR.............................36
HOOD.................................46
INSTRUMENT PANEL.....................49
INTERIOR..............................62
PAINT.................................73
SEATS................................75
STATIONARY GLASS.....................86
WEATHERSTRIP/SEALS...................91
BODY STRUCTURE......................95
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE AN OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
²AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL ± BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
²DO NOT STAND UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
²Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
²Always have a fire extinguisher ready for use
when welding.
²Disconnect the negative (-) cable clamp from
the battery when servicing electrical components
that are live when the ignition is OFF. Damage to
electrical system can result.²Do not use abrasive chemicals or compounds
on painted surfaces. Damage to finish can result.
²Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
to finish or color can result.
²Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not
always seal water tight under all conditions. At
times, side glass or door seals will allow water to
enter the passenger compartment during high pres-
sure washing or hard driving rain (severe) condi-
tions. Overcompensating on door or glass
adjustments to stop a water leak that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After completing
a repair, water test vehicle to verify leak has stopped
before returning vehicle to use.
DRBODY 23 - 1

ROAD TESTING WIND NOISE
(1) Drive the vehicle to verify the general location
of the wind noise.
(2) Apply 50 mm (2 in.) masking tape in 150 mm
(6 in.) lengths along weatherstrips, weld seams or
moldings. After each length is applied, drive the vehi-
cle. If noise goes away after a piece of tape is applied,
remove tape, locate, and repair defect.
POSSIBLE CAUSE OF WIND NOISE
²Moldings standing away from body surface can
catch wind and whistle.
²Gaps in sealed areas behind overhanging body
flanges can cause wind-rushing sounds.
²Misaligned movable components.
²Missing or improperly installed plugs in pillars.
²Weld burn through holes.
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY LUBRICATION
All mechanisms and linkages should be lubricated
when necessary. This will maintain ease of operation
and provide protection against rust and excessive
wear. The weatherstrip seals should be lubricated to
prolong their life as well as to improve door sealing.
All applicable exterior and interior vehicle operat-
ing mechanisms should be inspected and cleaned.
Pivot/sliding contact areas on the mechanisms should
then be lubricated.
(1) When necessary, lubricate the operating mech-
anisms with the specified lubricants.
(2) Apply silicone lubricant to a cloth and wipe it
on door seals to avoid over-spray that can soil pas-
senger's clothing.
(3) Before applying lubricant, the component
should be wiped clean. After lubrication, any excess
lubricant should be removed.
(4) The hood latch, latch release mechanism, latch
striker, and safety latch should be lubricated period-
ically.
(5) The door lock cylinders should be lubricated
twice each year (preferably autumn and spring).
²Spray a small amount of lock cylinder lubricant
directly into the lock cylinder.
²Apply a small amount to the key and insert it
into the lock cylinder.
²Rotate it to the locked position and then back to
the unlocked position several times.
²Remove the key. Wipe the lubricant from it with
a clean cloth to avoid soiling of clothing.
STANDARD PROCEDURE - HEAT STAKING
(1) Remove trim panel.(2) Bend or move the trim panel components at
the heat staked joints. Observe the heat staked loca-
tions and/or component seams for looseness.
(3) Heat stake the components.
(a) If the heat staked or component seam loca-
tion is loose, hold the two components tightly
together and using a soldering gun with a flat tip,
melt the material securing the components
together. Do not over heat the affected area, dam-
age to the exterior of the trim panel may occur.
(b) If the heat staked material is broken or miss-
ing, use a hot glue gun to apply new material to
the area to be repaired. The panels that are being
heat staked must be held together while the apply-
ing the glue. Once the new material is in place, it
may be necessary to use a soldering gun to melt
the newly applied material. Do not over heat the
affected area, damage to the exterior of the trim
panel may occur.
(4) Allow the repaired area to cool and verify the
repair.
(5) Install trim panel.
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR
There are many different types of plastics used in
today's automotive environment. We group plastics in
three different categories: Rigid, Semi-Rigid, and
Flexible. Any of these plastics may require the use of
an adhesion promoter for repair. These types of plas-
tic are used extensively on DaimlerChrysler Motors
vehicles. Always follow repair material manufactur-
er's plastic identification and repair procedures.
Rigid Plastics:
Examples of rigid plastic use: Fascias, Hoods,
Doors, and other Body Panels, which include SMC,
ABS, and Polycarbonates.
Semi-Rigid Plastics:
Examples of semi-rigid plastic use: Interior Panels,
Under Hood Panels, and other Body Trim Panels.
Flexible Plastics:
Examples of flexible plastic use: Fascias, Body
Moldings, and upper and lower Fascia Covers.
Repair Procedure:
The repair procedure for all three categories of
plastics is basically the same. The one difference is
the material used for the repair. The materials must
be specific for each substrate, rigid repair material
for rigid plastic repair, semi-rigid repair material for
semi-rigid plastic repair and flexible repair material
for flexible plastic repair.
DRBODY 23 - 3
BODY (Continued)

CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION
PC/ABS PC/ABS ALLOY GERMAX, BAY BLENDS,
PULSEDOORS, INSTRUMENT
PANELS
PPO POLYPHENYLENE OXIDE AZDEL, HOSTALEN,
MARLEX, PRFAX, NORYL,
GTX, PPOINTERIOR TRIM, DOOR
PANELS, SPLASH SHIELDS,
STEERING COLUMN
SHROUD
PPO/PA POLYPHENYLENE/
POLYAMIDPPO/PA, GTX 910 FENDERS, QUARTER
PANELS
PR/FV FIBERGLASS REINFORCED
PLASTICFIBERGLASS, FV, PR/FV BODY PANELS
PS POLYSTYRENE LUSTREX, STYRON, PS DOOR PANELS, DASH
PANELS
RTM RESIN TRANSFER
MOLDING COMPOUNDRTM BODY PANELS
SMC SHEET MOLDED
COMPOUNDSMC BODY PANELS
TMC TRANSFER MOLDING
COMPOUNDTMC GRILLES
UP UNSATURATED
POLYESTER
(THERMOSETTING)SMC, BMC, TMC, ZMC, IMC,
XSMC, UPGRILLE OPENING PANEL,
LIFTGATES, FLARESIDE
FENDERS, FENDER
EXTENSIONS
EEBC ETHER/ESTER BLOCKED
CO-POLYMEREEBC BUMPERS
EEBC/PBTP EEBC/POLYBUTYLENE
TEREPTHALATEEEBC, PBTP, BEXLOY BUMPER, ROCKER PANELS
EMPP ETHYLENE MODIFIED
POLYPROPYLENEEMPP BUMPER COVERS
EPDM ETHYLENE/
PROPROPYLENE DIENE
MONOMEREPDM, NORDEL, VISTALON BUMPERS
EPM ETHYLENE/
PROPROPYLENE CO-
POLYMEREPM FENDERS
MPU FOAM POLYURETHANE MPU SPOILERS
PE POLYETHYLENE ALATHON, DYLAN,
LUPOLEN, MARLEX-
PP POLYPROPYLENE
(BLENDS)NORYL, AZDEL, MARLOX,
DYLON, PRAVEXINNER FENDER, SPOILERS,
KICK PANELS
PP/EPDM PP/EPDM ALLOY PP/EPDM SPOILERS, GRILLES
PUR POLYURETHANE COLONELS, PUR, PU FASCIAS, BUMPERS
PUR/PC PUR/PC ALLOY TEXIN BUMPERS
PVC POLYVINYL CHLORIDE APEX, GEON, VINYLITE BODY MOLDINGS, WIRE
INSULATION, STEERING
WHEELS
RIM REACTION INJECTED
MOLDED POLYURETHANERIM, BAYFLEX FRONT FASCIAS, MODULAR
WINDOWS
DRBODY 23 - 5
BODY (Continued)