grease DODGE RAM 1500 1998 2.G Manual Online

INSTALLATION
FRONT RUN CHANNEL
(1) Install the channel, position the screws in the
door panel slots and slide into place.
(2) Tighten the screws to 10 N´m (89 in. lbs.).
(3) Install the window regulator. (Refer to 23 -
BODY/DOOR - FRONT/WINDOW REGULATOR -
INSTALLATION)
REAR RUN CHANNEL
(1) On quad cab models, install the channel and
slide the upper screw into the slot.
(2) Install the lower screw and tighten both upper
and lower screws to 10 N´m (89 in. lbs.).
(3) On standard cab models, install the channel
and install the screws.
(4) Tighten the screws to 10 N´m (89 in. lbs.).
BOTH CHANNELS
(1) Stuff the glass run weatherstrip into the chan-
nels.
(2) Verify correct window operation.
(3) Install the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION)
HINGE
REMOVAL
(1) Remove the door. (Refer to 23 - BODY/DOOR -
FRONT/DOOR - REMOVAL)
(2) Using a grease pencil or equivalent, mark the
hinge location and remove the bolts.
INSTALLATION
(1) Install the hinges and bolts.
(2) Tighten bolts to 28 N´m (21 ft. lbs.).
(3) Install the door. (Refer to 23 - BODY/DOOR -
FRONT/DOOR - INSTALLATION)
INSIDE HANDLE ACTUATOR
REMOVAL
(1) Remove the screw and remove the inside han-
dle. (Fig. 7)
(2) Remove the door trim panel. (Refer to 23 -
BODY/DOOR - FRONT/TRIM PANEL - REMOVAL)
(3) Disconnect the latch actuator rod. (Fig. 8)
(4) Remove the nuts and remove the remote han-
dle actuator.
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.
Fig. 7 INSIDE HANDLE ACTUATOR
1 - BOLT
2 - HANDLE
3 - TRIM PANEL OPENING
Fig. 8 REMOTE HANDLE ACTUATOR
1 - DOOR
2 - LATCH ASSEMBLY
3 - LATCH ACTUATOR ROD
4 - NUTS (2)
5 - HANDLE REMOTE
23 - 22 DOOR - FRONTDR
GLASS RUN CHANNEL (Continued)

(4) Install the door trim panel. (Refer to 23 -
BODY/DOOR - FRONT/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. 9)
(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/DOOR - FRONT/LATCH - ADJUSTMENTS)
(5) Install the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/LATCH - INSTALLATION)
ADJUSTMENTS
ADJUSTMENT
(1) Locate access hole and remove the mylar tape
covering it. (Fig. 10)
(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)
Fig. 9 LATCH ASSEMBLY
1 - DOOR
2 - ELECTRICAL CONNECTOR
3 - LATCH ASSEMBLY
4 - BOLTS
Fig. 10 LATCH ADJUSTMENT SCREW - TYPICAL
1 - DOOR LATCH
2 - MYLAR TAPE
3 - ADJUSTMENT SCREW
DRDOOR - FRONT 23 - 23
INSIDE HANDLE ACTUATOR (Continued)

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.).
LOCK CYLINDER
REMOVAL
(1) Remove the exterior handle. (Refer to 23 -
BODY/DOOR - FRONT/EXTERIOR HANDLE -
REMOVAL)
(2) Remove the clip and remove the lock cylinder
lever and switch, if equipped.
(3) Remove the screw and remove the lock cylin-
der. (Fig. 11)
INSTALLATION
(1) Install the lock cylinder and install the screw.
(2) Install the lock cylinder switch, if equipped,
lever and retaining clip.
(3) Install the exterior handle. (Refer to 23 -
BODY/DOOR - FRONT/EXTERIOR HANDLE -
INSTALLATION)
TRIM PANEL
REMOVAL
(1) Remove the window crank, if equipped. (Fig.
13)
(2) Remove the interior handle. (Refer to 23 -
BODY/DOOR - FRONT/INSIDE HANDLE ACTUA-
TOR - REMOVAL)
(3) Remove the screws at the mirror flag and near
the inside handle. (Fig. 12)
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) Install the window switch into the trim panel,
if equipped.
(2) Position the trim panel onto the lower hooks
and connect the power window switch electrical con-
nector, if equipped.
(3) Position the remaining trim panel attachment
hooks into the door panel and seat the trim panel
into the belt seal fully.
(4) Install the screws near the inside handle and
at the mirror flag.
Fig. 11 LOCK CYLINDER
1 - LOCK CYLINDER
2 - EXTERIOR HANDLE
3 - SCREW
4 - LOCK SWITCH WIRE HARNESS
Fig. 12 TRIM PANEL ASSEMBLY
1 - SCREW INSERT (2)
2 - SCREWS (2)
3 - DOOR TRIM PANEL
4 - LOWER SCREWS (3)
5 - ATTACHMENT HOOKS
23 - 24 DOOR - FRONTDR
LATCH STRIKER (Continued)

DOORS - REAR
TABLE OF CONTENTS
page page
DOOR
REMOVAL.............................28
INSTALLATION.........................28
ADJUSTMENTS
ADJUSTMENT........................28
DOOR GLASS
REMOVAL.............................30
INSTALLATION.........................30
EXTERIOR HANDLE
REMOVAL.............................30
INSTALLATION.........................30
GLASS RUN CHANNEL
REMOVAL.............................30
INSTALLATION.........................31
HINGE
REMOVAL.............................31
INSTALLATION.........................31
INSIDE HANDLE ACTUATOR
REMOVAL.............................31
INSTALLATION.........................32
LATCH
REMOVAL.............................32INSTALLATION.........................32
ADJUSTMENTS
ADJUSTMENT........................33
LATCH STRIKER
REMOVAL.............................33
INSTALLATION.........................33
ADJUSTMENTS
ADJUSTMENT........................33
TRIM PANEL
REMOVAL.............................33
INSTALLATION.........................33
WATERDAM
REMOVAL.............................34
INSTALLATION.........................34
WINDOW REGULATOR - POWER
REMOVAL.............................34
INSTALLATION.........................34
WINDOW REGULATOR - MANUAL
REMOVAL.............................35
INSTALLATION.........................35
DOOR
REMOVAL
(1) Disconnect the door wire harness electrical con-
nector at the b-pillar. (Fig. 1)
(2) Using a grease pencil or equivalent, mark the
outline of the door hinges on the door to aid in instal-
lation.
(3) Support the door with a suitable lifting device.
NOTE: The epoxy bonded washers should not be
seperated from the hinge. If the washers are
removed the door may have to be re-adjusted.
(4) Remove the nuts and bolts attaching the door
hinges to the door.
INSTALLATION
(1) Support the door with a suitable lifting device
and install the door onto the hinges.
(2) Install the bolts, nuts and washers, if there
were removed previously, and tighten to 28 N´m (21
ft. lbs.).
(3) Connect the electrical connector.(4) Adjust the door as necessary. (Refer to 23 -
BODY/DOORS - REAR/DOOR - ADJUSTMENTS)
ADJUSTMENTS
ADJUSTMENT
NOTE: For vehicles equipped with four doors, it is
recommended that you adjust the rear door before
adjusting the front door.
²Door adjustment measurements should be
taken from stationary or welded body panels like
the roof, rocker or quarter panels.
²During adjustment procedures, it is recom-
mended that all the hinge fasteners be loosened
except for the upper most fasteners. Adjustments
can be made using the upper fasteners to hold the
door with final torque of the fasteners occurring
after correct door positioning is achieved.
23 - 28 DOORS - REARDR

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)

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)

HOOD
TABLE OF CONTENTS
page page
HINGE
REMOVAL.............................46
INSTALLATION.........................46
HOOD
REMOVAL.............................46
INSTALLATION.........................47
LATCH
REMOVAL.............................47
INSTALLATION.........................47LATCH RELEASE CABLE/HANDLE ASSEMBLY
REMOVAL.............................47
INSTALLATION.........................47
LATCH STRIKER / SECONDARY CATCH
REMOVAL.............................47
INSTALLATION.........................48
SUPPORT CYLINDER
REMOVAL.............................48
INSTALLATION.........................48
HINGE
REMOVAL
NOTE: It is not necessary to remove the hood to
replace one or both hinges. The hinges can be
replaced one at a time.
(1) Remove the cowl grille. (Refer to 23 - BODY/
EXTERIOR/COWL GRILLE - REMOVAL)
(2) Using a grease pencil or equivalent, mark the
position of the hinge on the hood.
(3) Remove the fender support bolt. (Fig. 1)
(4) Remove the support cylinder. (Refer to 23 -
BODY/HOOD/SUPPORT CYLINDER - REMOVAL)
(5) Remove the hood nuts.
(6) Remove the wheelhouse splash shield. (Refer to
23 - BODY/EXTERIOR/FRONT WHEELHOUSE
SPLASH SHIELD - REMOVAL)
(7) From inside the fender, remove the two hinge
bolts. (Fig. 2)
(8) Slide the hinge forward and remove from the
fender rail.
INSTALLATION
(1) Install the hinge and slide back into position
on the fender rail.
(2) From inside the fender, install the two hinge
bolts and tighten to 20 N´m (15 ft. lbs.).
(3) Install the hood nuts and line up the marks
made previously.
(4) Tighten the nuts to 23 N´m (17 ft. lbs.).
(5) Install the support cylinder. (Refer to 23 -
BODY/HOOD/SUPPORT CYLINDER - INSTALLA-
TION)
(6) Install the fender support bolt and tighten to
11 N´m (8 ft. lbs.).(7) Check hood fit and adjust if required. (Refer to
23 - BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECIFICATIONS)
(8) Install the cowl grille. (Refer to 23 - BODY/EX-
TERIOR/COWL GRILLE - INSTALLATION)
(9) Install the wheelhouse splash shield. (Refer to
23 - BODY/EXTERIOR/FRONT WHEELHOUSE
SPLASH SHIELD - INSTALLATION)
HOOD
REMOVAL
(1) Open the hood.
(2) Using a grease pencil or equivalent, mark the
position of the hinges on the hood.
(3) Remove the hood hinge nuts and remove the
hood.
Fig. 1 HINGE/FENDER BOLT
1 - FENDER
2 - FENDER SUPPORT BOLT
3 - HINGE
23 - 46 HOODDR

(4) Remove the grille. (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL)
(5) Remove the hood lamp and ambient tempera-
ture sensor.
INSTALLATION
(1) Install the hood lamp and ambient temperature
sensor.
(2) Install the grille. (Refer to 23 - BODY/EXTERI-
OR/GRILLE - INSTALLATION)
(3) Install the hood and install the nuts.
(4) Line up the marks made previously and
tighten the nuts to 23 N´m (17 ft. lbs.).
(5) Check the hood fit and adjust if required.
(Refer to 23 - BODY/BODY STRUCTURE/GAP AND
FLUSH - SPECIFICATIONS)
LATCH
REMOVAL
(1) Open the hood.
(2) Using a grease pencil or equivalent, mark the
position of the latch on the radiator crossmember.
(3) Remove the bolts. (Fig. 3)
(4) Disconnect the hood latch cable and remove the
latch.
INSTALLATION
(1) Connect the hood latch cable.
(2) Install the latch lining up the marks made pre-
viously and install the bolts.
(3) Tighten the bolts to 11 N´m (8 ft. lbs.).
(4) Check hood fit and adjust if required. (Refer to
23 - BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECIFICATIONS)
LATCH RELEASE CABLE/
HANDLE ASSEMBLY
REMOVAL
(1) Remove the hood latch. (Refer to 23 - BODY/
HOOD/LATCH - REMOVAL)
(2) Remove the batter tray. (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/TRAY - REMOVAL)
(3) Disconnect the three cable push pin fasteners.
(4) From inside the cab loosen the two handle
screws and disconnect the handle from the instru-
ment panel bracket.
(5) Separate the grommet at the cowl panel and
remove cable through the cab.
INSTALLATION
(1) Route the cable/handle assembly through the
cowl panel and install the grommet.
(2) Position the handle onto the instrument panel
bracket and tighten the screws.
(3) Route the cable along the fender rails and
install the three push pin fasteners.
(4) Install the latch. (Refer to 23 - BODY/HOOD/
LATCH - INSTALLATION)
(5) Install the battery tray. (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/TRAY - INSTALLATION)
LATCH STRIKER /
SECONDARY CATCH
REMOVAL
(1) Disconnect and remove the secondary release
handle. (Fig. 4)
(2) Remove the two bolts and remove the striker/
catch assembly.
Fig. 2 HINGE
1 - A-PILLAR
2 - HINGE
3 - BOLTS (2)
Fig. 3 LATCH
1 - HOOD LATCH
2 - HOOD LATCH CABLE
3 - BOLTS (2)
DRHOOD 23 - 47
HOOD (Continued)

WINDSHIELD
WARNING
WINDSHIELD SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
²URETHANE ADHESIVES ARE APPLIED AS A
SYSTEM. USE GLASS CLEANER, GLASS PREP
SOLVENT, GLASS PRIMER, PVC (VINYL) PRIMER
AND PINCH WELD (FENCE) PRIMER PROVIDED BY
THE ADHESIVE MANUFACTURER. IF NOT, STRUC-
TURAL INTEGRITY COULD BE COMPROMISED.
²DAIMLERCHRYSLER DOES NOT RECOMMEND
GLASS ADHESIVE BY BRAND. TECHNICIANS
SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVES
THAT THEIR MANUFACTURES WARRANT WILL
RESTORE A VEHICLE TO THE REQUIREMENTS OF
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
THAT PRIMERS AND CLEANERS ARE COMPATIBLE
WITH THE PARTICULAR ADHESIVE USED.
²BE SURE TO REFER TO THE URETHANE MAN-
UFACTURER'S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
²VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
²SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
²ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
REMOVAL
(1) Remove inside rear view mirror. (Refer to 23 -
BODY/INTERIOR/REAR VIEW MIRROR -
REMOVAL).
(2) Remove cowl grill. (Refer to 23 - BODY/EXTE-
RIOR/COWL GRILLE - REMOVAL).(3) Remove the a-pillar weatherstrip retainer.
(Refer to 23 - BODY/WEATHERSTRIP/SEALS/A-
PILLAR WEATHERSTRIP RETAINER - REMOVAL)
(4) Remove the a-pillar trim panels. (Refer to 23 -
BODY/INTERIOR/A-PILLAR TRIM - REMOVAL)
(5) Remove the headliner and from the inside of
the vehicle, cut the upper urethane bonding from
around windshield upper edge using a suitable sharp
cold knife (C-4849). A pneumatic cutting device can
be used but is not recommended. (Refer to 23 -
BODY/INTERIOR/HEADLINER - REMOVAL)
(6) From the outside of the vehicle, cut urethane
bonding from the remaining sides of the windshield
using a suitable sharp cold knife (C-4849). A pneu-
matic cutting device can be used but is not recom-
mended.
(7) Separate windshield from vehicle.
INSTALLATION
WARNING: Allow the urethane at least 24 hours to
cure before returning the vehicle to use.
CAUTION: Roll down the left and right front door
glass and open the rear glass slider (if available)
before installing windshield to avoid pressurizing
the passenger compartment if a door is slammed
before urethane is cured. Water leaks can result.
The windshield fence should be cleaned of most of
its old urethane bonding material. A small amount of
old urethane, approximately 1-2 mm in height,
should remain on the fence. Do not grind off or com-
pletely remove all old urethane from the fence, the
paint finish and bonding strength will be adversely
affected.
(1) Place replacement windshield into windshield
opening and position glass in the center of the open-
ing against the support spacers. Mark the outside
surface of the glass at the support spacers with a
grease pencil or pieces of masking tape and ink pen
to use as a reference for installation. Remove replace-
ment windshield from windshield opening (Fig. 5).
(2) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart (Fig. 6).
(3) Clean inside of windshield with MOPAR Glass
Cleaner and lint-free cloth.
(4) Apply clear glass primer 25 mm (1 in.) wide
around perimeter of windshield and wipe with a new
clean and dry lint- free cloth.
(5) Apply black-out primer onto the glass using the
windshield molding as a guide. The primer should be
15 mm (5/8 in.) wide on the top and sides of the glass
23 - 88 STATIONARY GLASSDR

If the friction surfaces are oily, inspect the shaft
and nose area of the A/C compressor for oil. Remove
the felt from the front cover. If the felt is saturated
with oil, the shaft seal is leaking and the A/C com-
pressor must be replaced.
Check the pulley bearing for roughness or exces-
sive leakage of grease. Replace the pulley and clutch
plate, if required.
INSTALLATION
(1) Install the clutch field coil and snap ring.
(2) Install the screw and retainer on the clutch coil
lead wire harness on the compressor front housing.
Tighten screw to 2.2 N´m (20 in. lbs.).
(3) Align the rotor assembly squarely on the front
compressor housing hub.
(4) Install the rotor bearing assembly with the
installer (Special Tool C-6871 or equivalent) (Fig. 8).
Thread the installer on the shaft, then turn the nut
until the rotor assembly is seated.
(5) Install the external front housing snap ring
with snap ring pliers. The bevel side of the snap ring
must be facing outward. Press the snap ring to make
sure it is properly seated in the groove.
CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch fail-
ure and severe damage to the front housing of the
compressor.
(6) Install the original clutch shims on the com-
pressor shaft.
(7) Install the clutch plate. Install the shaft hex
nut and tighten to 15±20 N´m (11±15 ft. lbs.).
(8) Check the clutch air gap with a feeler gauge
(Fig. 9). If the air gap does not meet specifications,
add or subtract shims as required (Refer to 24 -
HEATING & AIR CONDITIONING - SPECIFICA-
TIONS).
Fig. 6 Clutch Coil Lead Wire Harness - Typical
1 - COIL
2 - COIL WIRE
3 - RETAINER SCREW
Fig. 7 Clutch Field Coil Snap Ring Remove - Typical
1 - COIL
2 - SNAP RING PLIERS
Fig. 8 Clutch Pulley Install - Typical
1 - ROTOR BEARING ASSEMBLY
2 - INSTALLER
24 - 12 CONTROLSDR
A/C COMPRESSOR CLUTCH/COIL (Continued)