Removal DODGE RAM 1500 1998 2.G Workshop Manual

INSTALLATION
(1) Position the run channels into the door and
engage the upper screws into the keyhole slots.
(2) Install the lower screws and tighten to 10 N´m
(89 in. lbs.).
(3) Tighten the upper screws to 10 N´m (89 in.
lbs.).
(4) Stuff the glass run weatherstrip into the chan-
nels.
(5) Verify correct window operation.
(6) Install the window regulator. (Refer to 23 -
BODY/DOORS - REAR/WINDOW REGULATOR -
INSTALLATION)
HINGE
REMOVAL
NOTE: It is not necessary to remove the door to
replace the hinges if they are replaced one at a
time.
NOTE: The epoxy coated washers should not be
removed from the hinge. If the washers are
removed the door may have to be re-adjusted.
(1) Open the front door
UPPER HINGE
(1) Using a grease pencil or equivalent, mark the
position of the hinge on the door and b-pillar.
(2) Remove the nut and bolt attaching the hinge to
the door.
(3) Remove the three bolts attaching the hinge to
the b-pillar and remove the hinge.
LOWER HINGE
(1) Using a grease pencil or equivalent, mark the
position of the hinge on the door and b-pillar.
(2) Remove the lower b-pillar trim. (Refer to 23 -
BODY/INTERIOR/B-PILLAR LOWER TRIM -
REMOVAL)
(3) Remove the nut and bolt attaching the hinge to
the door.
(4) Remove the two bolts attaching the hinge to
the b-pillar.
(5) From the inside of the vehicle remove the
remaining bolt attaching the hinge to the b-pillar
and remove the hinge.
INSTALLATION
UPPER HINGE
(1) Install the hinge to door washers, if there were
removed previously, nut and bolt and tighten to 28
N´m (21 ft. lbs.).
(2) Install the three hinge to b-pillar bolts and
tighten to 28 N´m (21 ft. lbs.).
(3) Adjust the door if needed. (Refer to 23 - BODY/
DOORS - REAR/DOOR - ADJUSTMENTS)
LOWER HINGE
(1) Install the hinge and install the b-pillar bolts.
(2) Tighten the bolts to 28 N´m (21 ft. lbs.).
(3) Install the hinge to door washers, if there were
removed previously, nut and bolt and tighten to 28
N´m (21 ft. lbs.).
(4) Adjust the door if needed. (Refer to 23 - BODY/
DOORS - REAR/DOOR - ADJUSTMENTS)
(5) Install the lower b-pillar trim. (Refer to 23 -
BODY/INTERIOR/B-PILLAR LOWER TRIM -
INSTALLATION)
INSIDE HANDLE ACTUATOR
REMOVAL
(1) Remove the screw and remove the inside han-
dle. (Fig. 5)
(2) Remove the door trim panel. (Refer to 23 -
BODY/DOORS - REAR/TRIM PANEL - REMOVAL)
(3) Disconnect the latch actuator rod. (Fig. 6)
(4) Remove the nuts and remove the remote han-
dle actuator.
Fig. 4 REAR RUN CHANNEL
1 - REAR RUN CHANNEL
2 - SCREW LOCATIONS
DRDOORS - REAR 23 - 31
GLASS RUN CHANNEL (Continued)

INSTALLATION
(1) Install the remote handle actuator and install
the nuts.
(2) Tighten the nuts to 10 N´m (89 in. lbs.).
(3) Connect the latch actuator rod.
(4) Install the door trim panel. (Refer to 23 -
BODY/DOORS - REAR/TRIM PANEL - INSTALLA-
TION)
(5) Install the inside handle and install the bolt.(6) Tighten the bolt to 9 N´m (80 in. lbs.).
LATCH
REMOVAL
(1) Raise the window to the full up position.
(2) Remove the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - REMOVAL)
(3) Disconnect the actuator rods.
(4) Remove the bolts. (Fig. 7)
(5) Disconnect the electrical connector and remove
the latch.
INSTALLATION
(1) Connect the electrical connector and install the
latch assembly.
(2) Install the bolts and tighten to 10 N´m (89 in.
lbs.).
(3) Connect the actuator rods.
(4) Adjust the latch as needed. (Refer to 23 -
BODY/DOORS - REAR/LATCH - ADJUSTMENTS)
(5) Install the waterdam. (Refer to 23 - BODY/
DOORS - REAR/WATERDAM - INSTALLATION)
Fig. 5 INSIDE HANDLE ACTUATOR
1 - TRIM PANEL OPENING
2 - INSIDE LATCH HANDLE
3 - BOLT
Fig. 6 REMOTE HANDLE ACTUATOR
1 - NUTS (2)
2 - LATCH ACTUATOR ROD
3 - HANDLE REMOTE
Fig. 7 LATCH ASSEMBLY
1 - DOOR
2 - ELECTRICAL CONNECTOR
3 - LATCH ASSEMBLY
4 - BOLTS
23 - 32 DOORS - REARDR
INSIDE HANDLE ACTUATOR (Continued)

ADJUSTMENTS
ADJUSTMENT
(1) Locate access hole and remove the mylar tape
covering it. (Fig. 8)
(2) Insert a 5/32-inch hex-wrench through hole and
into adjustment screw. Loosen screw.
(3) Operate outside handle several times to release
any restriction because of mis-alignment.
(4) Tighten adjustment screw to 3 N´m (30 in.
lbs.).
(5) Test handle for proper operation.
LATCH STRIKER
REMOVAL
(1) Using a grease pencil or equivalent, mark the
position of the striker.
(2) Remove the bolts and remove the striker.
INSTALLATION
(1) Install the striker and install the bolts.
(2) Tighten the bolts to 28 N´m (21 ft. lbs.).
(3) Adjust the striker if needed. (Refer to 23 -
BODY/DOOR - FRONT/LATCH STRIKER - ADJUST-
MENTS)
ADJUSTMENTS
ADJUSTMENT
(1) Using a grease pencil or equivalent, mark the
position of the striker to aid in adjustment.
(2) Loosen the striker bolts.
(3) Change the striker position to adjust the rear
gap and flush measurement. (Refer to 23 - BODY/BODY STRUCTURE/GAP AND FLUSH - SPECIFI-
CATIONS)
(4) Tighten the bolts to 28 N´m (21 ft. lbs.).
TRIM PANEL
REMOVAL
(1) Remove the window crank, if equipped. (Fig.
10)
(2) Remove the interior handle. (Refer to 23 -
BODY/DOORS - REAR/INSIDE HANDLE ACTUA-
TOR - REMOVAL)
(3) Remove the screw near the inside handle. (Fig.
9)
CAUTION: Trim panel is attached to the door using
hooks molded into the panel. Do not pull the trim
panel straight off or damage to the panel and/or
power switch assembly may occur.
(4) Lift the trim panel up off the belt seal and
attachment hooks and separate the panel from the
door slightly.
(5) Disconnect the power window switch electrical
connector, if equipped, and remove the trim panel.
INSTALLATION
(1) Position the trim panel onto the lower hooks
and connect the power window switch electrical con-
nector, if equipped.
(2) Position the remaining trim panel attachment
hooks into the door panel and seat the trim panel
into the belt seal fully.
(3) Install the screw near the inside handle.
Fig. 8 LATCH ADJUSTMENT SCREW - TYPICAL
1 - DOOR LATCH
2 - MYLAR TAPE
3 - ADJUSTMENT SCREW
Fig. 9 TRIM PANEL
1 - DOOR
2 - ELECTRICAL CONNECTOR
3 - ATTACHMENT HOOKS
4 - SCREW
5 - TRIM PANEL
DRDOORS - REAR 23 - 33
LATCH (Continued)

(4) Install the interior handle. (Refer to 23 -
BODY/DOORS - REAR/INSIDE HANDLE ACTUA-
TOR - INSTALLATION)
(5) Install the window crank, if equipped.
WATERDAM
REMOVAL
(1) Remove the inside handle actuator. (Refer to 23
- BODY/DOORS - REAR/INSIDE HANDLE ACTUA-
TOR - REMOVAL)
(2) Remove the speaker. (Refer to 8 - ELECTRI-
CAL/AUDIO/SPEAKER - REMOVAL)
(3) Separate the waterdam from the inner door
panel and off of the latch linkages.
INSTALLATION
(1) Position the wire harness and actuator rods
through the holes in the waterdam.
(2) Secure the waterdam to the inner door panel.
(3) Install the speaker. (Refer to 8 - ELECTRICAL/
AUDIO/SPEAKER - INSTALLATION)
(4) Install the inside handle actuator. (Refer to 23 -
BODY/DOORS - REAR/INSIDE HANDLE ACTUA-
TOR - INSTALLATION)
WINDOW REGULATOR -
POWER
REMOVAL
(1) Remove the waterdam. (Refer to 23 - BODY/
DOORS - REAR/WATERDAM - REMOVAL)
(2) Remove the window switch from the door trim
panel and reconnect it to the door wire harness.(3) Raise the window to the position shown and
remove the two nuts attaching the glass to the win-
dow regulator. (Fig. 11)
(4) Remove the stabilizer nut.
(5) Disengage the door glass from the regulator lift
plate and position into the full up position.
(6) Secure the glass in the up position using a
wood wedge or equivalent.
(7) Lower the regulator.
(8) Disconnect the electrical connector. (Fig. 12)
(9) Remove the lower regulator bolt and loosen the
upper two. (Fig. 12)
(10) Slide the regulator up and out of the keyhole
slots in the door panel.
(11) Remove the regulator through the hole in the
inner door panel.
INSTALLATION
(1) Install the regulator through the hole in the
inner door panel.
(2) Position the regulator bolts into the keyhole
slots and slide into place.
(3) Install the lower regulator bolt and tighten all
three to 10 N´m (89 in. lbs.).
(4) Connect the electrical connector.
(5) Position the stabilizer, install the nut and
tighten to 10 N´m (89 in. lbs.).
(6) Raise the regulator to the position shown in
(Fig. 11).
(7) Remove the glass support and connect to the
regulator lift plate.
(8) Install the glass nuts and tighten to 10 N´m
(89 in. lbs.).
(9) Disconnect the window switch and install into
the door trim panel.
Fig. 10 WINDOW CRANK REMOVAL TOOL
1 - WINDOW CRANK REMOVAL TOOL
2 - WINDOW CRANK
Fig. 11 GLASS POSITIONING
1 - SIGHT WINDOW
2 - STABILIZER NUT
3 - GLASS LIFT PLATE
23 - 34 DOORS - REARDR
TRIM PANEL (Continued)

(10) Install the waterdam. (Refer to 23 - BODY/
DOORS - REAR/WATERDAM - INSTALLATION)
WINDOW REGULATOR -
MANUAL
REMOVAL
(1) Remove the waterdam. (Refer to 23 - BODY/
DOORS - REAR/WATERDAM - REMOVAL)
(2) Reinstall the window handle and raise the win-
dow to the position shown and remove the nuts. (Fig.
11 )
(3) Remove the stabilizer nuts. (Fig. 13)
(4) Disengage the door glass from the regulator lift
plate and position into the full up position.
(5) Secure the glass in the up position using a
wood wedge or equivalent.
(6) Lower the regulator.
(7) Remove the two back regulator bolts and
loosen the front two.
(8) Slide the regulator up and out of the keyhole
slots in the door panel.
(9) Remove the regulator through the hole in the
inner door panel.
INSTALLATION
(1) Install the regulator through the hole in the
inner door panel.
(2) Position the regulator bolts into the keyhole
slots and slide into place.
(3) Install the back regulator bolts and tighten all
four to 10 N´m (89 in. lbs.).
(4) Position the stabilizer, install the nuts and
tighten to 10 N´m (89 in. lbs.).
(5) Using the window handle raise the regulator to
the position shown in (Fig. 11).
(6) Remove the glass support and connect to the
regulator lift plate.
(7) Install the glass nuts and tighten to 10 N´m
(89 in. lbs.).
(8) Disconnect the window switch and install into
the door trim panel.
(9) Using the window handle raise the regulator to
the position shown in (Refer to 23 - BODY/DOORS -
REAR/WATERDAM - INSTALLATION)
Fig. 12 WINDOW REGULATOR MOTOR
1 - REGULATOR BOLTS
2 - REGULATOR MOTOR
3 - ELECTRICAL CONNECTOR.
Fig. 13 WINDOW REGULATOR - MANUAL
1 - DOOR
2 - REGULATOR BOLTS (4)
3 - STABILIZER NUTS (2)
4 - REGULATOR
DRDOORS - REAR 23 - 35
WINDOW REGULATOR - POWER (Continued)

EXTERIOR
TABLE OF CONTENTS
page page
BODY SIDE MOLDINGS
REMOVAL.............................36
INSTALLATION.........................36
BODY ISOLATORS
REMOVAL.............................36
INSTALLATION.........................37
CARGO BOX
REMOVAL.............................37
INSTALLATION.........................37
CARGO BOX - TIE DOWN
REMOVAL.............................38
INSTALLATION.........................38
COWL GRILLE
REMOVAL.............................38
INSTALLATION.........................38
EXTERIOR NAME PLATES
REMOVAL.............................38
INSTALLATION.........................38
FRONT FENDER
REMOVAL.............................39
INSTALLATION.........................39
FUEL FILL DOOR
REMOVAL.............................39
INSTALLATION.........................39GRILLE
REMOVAL.............................40
INSTALLATION.........................40
GRILLE FRAME
REMOVAL.............................40
INSTALLATION.........................40
FRONT WHEELHOUSE SPLASH SHIELD
REMOVAL.............................41
INSTALLATION.........................41
REAR WHEELHOUSE SPLASH SHIELD
REMOVAL.............................41
INSTALLATION.........................41
SIDE VIEW MIRROR
REMOVAL.............................41
INSTALLATION.........................42
UPPER RADIATOR CROSSMEMBER
REMOVAL.............................42
INSTALLATION.........................42
SIDE VIEW MIRROR GLASS
REMOVAL.............................42
INSTALLATION.........................43
REAR FENDER
REMOVAL.............................44
INSTALLATION.........................44
BODY SIDE MOLDINGS
REMOVAL
NOTE: Body side moldings are attached to the body
panels with adhesive tape.
(1) Apply a length of masking tape on the body
panel, parallel to the top edge of the molding and to
one end to use as a guide for installation, if neces-
sary.
(2) If temperature is below 21ÉC (70ÉF) warm
molding with a heat lamp or gun. Do not exceed 52ÉC
(120ÉF) when heating molding.
(3) Using a trim stick C-4755 or equivalent,
remove and discard the molding from the outside of
the body panel.
INSTALLATION
(1) Thoroughly clean all residue from the body side
molding attachment area of the body panel.(2) Wipe area with a clean lint free cloth moist-
ened with a 50% solution of water and alcohol and
wipe dry immediately with a dry lint free cloth.
(3) Apply new body side molding using the guide
tape on the body panel and apply consistent and uni-
form pressure of approximately 40 p.s.i. over the
entire surface of the molding.
BODY ISOLATORS
REMOVAL
(1) Loosen all cab to frame mounting bolts (six
standard cab, eight quad cab). (Fig. 1)
(2) Remove the mounting bolts and rebound cush-
ions
(3) Using a floor jack and block of wood under the
cab sill, lift the body to gain access to the isolators.
(4) Remove the isolators.
(5) Install new isolators and repeat steps one
through 4, for the opposite side.
23 - 36 EXTERIORDR

INSTALLATION
(1) For the rear isolators install the rebound cush-
ions, washers, reinforcement plates and bolts. (Fig. 1)
(2) Install the remaining rebound cushions and
bolts.
(3) Tighten the bolts to 81 N´m (60 ft. lbs.).
CARGO BOX
REMOVAL
(1) Disconnect the fuel fill hose and vent hose.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL TANK - REMOVAL)
(2) Disconnect the tail lamp wire harness.
(3) Remove the cargo box bolts. (Fig. 2) or (Fig. 3)
(4) Remove the cargo box.
INSTALLATION
(1) Install the cargo box and install the bolts.
(2) Tighten the bolts to 108 N´m (80 ft. lbs.).
(3) Connect the fuel fill and vent hoses. (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL TANK
- INSTALLATION)
(4) Connect the tail lamp wire harness.
Fig. 1 BODY ISOLATORS - TYPICAL
1 - CAB SILL
2 - ISOLATORS
3 - REBOUND CUSHION
4 - WASHER (REAR ISOLATOR ONLY)
5 - BOLTS
6 - REINFORCEMENT PLATE (REAR ISOLATOR ONLY)
Fig. 2 SHORT CARGO BOX
1 - CARGO BOX
2 - FRAME
3 - BOLTS (3 PER SIDE)
Fig. 3 LONG CARGO BOX
1 - CARGO BOX
2 - FRAME
3 - BOLTS (4 PER SIDE)
DREXTERIOR 23 - 37
BODY ISOLATORS (Continued)

CARGO BOX - TIE DOWN
REMOVAL
(1) Remove the bolts and remove the tie down
cleat. (Fig. 4)
INSTALLATION
(1) Install the tie down cleat and install the bolts.
(2) Tighten the bolts to 34 N´m (25 ft. lbs.).
COWL GRILLE
REMOVAL
(1) Remove the wiper arms. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER ARMS -
REMOVAL)
(2) Disconnect the washer hose.
(3) Remove the hood seal.
(4) Remove the six push pin fasteners from the
front of the grille. (Fig. 5)
(5) Remove the two rear corner screws and remove
the grilles.
INSTALLATION
(1) Install the grill and install the two rear corner
screws.
(2) Install the six push pin fasteners along the
front of the grille.
(3) Install the hood seal.
(4) Connect the washer hose.(5) Install the wiper arms. (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER ARMS - INSTAL-
LATION)
EXTERIOR NAME PLATES
REMOVAL
NOTE: Exterior name plates are attached to body
panels with adhesive tape.
(1) Apply a length of masking tape on the body,
parallel to the top edge and one end of the name
plate to use as a guide for installation, if necessary.
(2) If temperature is below 21ÉC (70ÉF) warm
emblem with a heat lamp or gun. Do not exceed 52ÉC
(120ÉF) when heating name plate.
(3) Using a trim stick C-4755 or equivalent,
remove and discard the name plate.
INSTALLATION
(1) Thoroughly clean all residue from the name
plate attachment area of the body panel.
(2) Wipe area with a clean lint free cloth moist-
ened with a 50% solution of water and alcohol and
wipe dry immediately with a dry lint free cloth.
(3) Remove protective cover from adhesive tape on
back of name plate.
(4)
Position name plate properly on the body panel.
(5) Apply consistent and uniform pressure over the
entire surface of the name plate, with palm of hand.
(6) If temperature is below 21ÉC (70ÉF) warm
emblem with a heat lamp or gun to assure adhesion.
Do not exceed 52ÉC (120ÉF) when heating name
plate.
Fig. 4 TIE DOWN CLEAT
1 - BOLTS (2)
2 - CLEAT
Fig. 5 COWL GRILLE
1 - PUSH PIN FASTENERS (6)
2 - COWL GRILLE
3 - SCREWS (2)
23 - 38 EXTERIORDR

FRONT FENDER
REMOVAL
(1) Remove the antenna, if equipped. (Refer to 8 -
ELECTRICAL/AUDIO/ANTENNA BODY & CABLE -
REMOVAL)
(2) Remove the battery tray, if required. (Refer to 8
- ELECTRICAL/BATTERY SYSTEM/TRAY -
REMOVAL)
(3) Remove the cowl grille. (Refer to 23 - BODY/
EXTERIOR/COWL GRILLE - REMOVAL)
(4) Remove the headlamp unit. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - REMOVAL)
(5) Remove the wheelhouse splash shield. (Refer to
23 - BODY/EXTERIOR/FRONT WHEELHOUSE
SPLASH SHIELD - REMOVAL)
(6) Remove the inside and lower bolts. (Fig. 6)
(7) Remove the two bolts below the headlamp.
(8) Remove the hinge support bolt at the cowl.
(9) Remove the three bolts along the fender rail.
INSTALLATION
(1) Install the three bolts along the upper fender
rail and tighten to 9 N´m (80 in. lbs.).
(2) Install the upper hinge support bolt at the cowl
and tighten to 17 N´m (13 ft. lbs.).
(3) Install the two bolts below the headlamp and
tighten to 9 N´m (80 in. lbs.).(4) Install the inside and lower bolts and tighten
to 17 N´m (13 ft. lbs.).
(5) Check the fender positioning and adjust as
required by adding shims. (Refer to 23 - BODY/
BODY STRUCTURE/GAP AND FLUSH - SPECIFI-
CATIONS)
(6) Install the wheelhouse splash shield. (Refer to
23 - BODY/EXTERIOR/FRONT WHEELHOUSE
SPLASH SHIELD - INSTALLATION)
(7) Install the headlamp unit. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - INSTALLATION)
(8) Install the cowl grille. (Refer to 23 - BODY/EX-
TERIOR/COWL GRILLE - INSTALLATION)
(9) Install the battery tray, if required. (Refer to 8
- ELECTRICAL/BATTERY SYSTEM/TRAY -
INSTALLATION)
(10) Install the antenna, if required. (Refer to 8 -
ELECTRICAL/AUDIO/ANTENNA BODY & CABLE -
INSTALLATION)
FUEL FILL DOOR
REMOVAL
(1) Open fill door and remove the bolts. (Fig. 7)
(2) Remove the door.
INSTALLATION
(1) Install the fuel fill door.
(2) Install the bolts and tighten to 9 N´m (80 in.
lbs.).
Fig. 6 FRONT FENDER
1 - HOOD HINGE SUPPORT BOLT (1)
2 - HOOD HINGE
3 - INNER BOLT (1)
4 - FRONT BOLTS (2)
5 - LOWER BOLT INSERT
6 - FENDER
7 - UPPER BOLTS (3)
Fig. 7 FUEL FILL DOOR
1 - FUEL FILL DOOR
2 - BOLTS (2)
DREXTERIOR 23 - 39

GRILLE
REMOVAL
(1) Open the hood.
(2) Remove the six lower screws. (Fig. 8)
(3) Remove the six upper nuts and separate the
grille from the grille frame.
INSTALLATION
(1) Position the grille onto the grille frame.
(2) Install the six upper nuts.
(3) Install the six lower screws.
GRILLE FRAME
REMOVAL
(1) Remove the grille. (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL)
(2) Remove the screws and remove the grille
frame. (Fig. 9)
INSTALLATION
(1) Install the grille frame and install the six
screws.
(2) Install the grille. (Refer to 23 - BODY/EXTERI-
OR/GRILLE - INSTALLATION)
Fig. 8 GRILLE
1 - NUTS (6)
2 - HOOD
3 - GRILLE
4 - GRILLE FRAME
5 - SCREWS (6)
Fig. 9 GRILLE FRAME
1 - HOOD
2 - GRILLE FRAME
3 - SCREWS (6)
23 - 40 EXTERIORDR