tailgate DODGE RAM 2001 Service User Guide

Connector Name/Number Color Location Fig.
Right Front Wheel Speed Sensor BK Right Fender Side Shield 17
Right Headlamp BL At Headlamp N/S
Right License Lamp BK At Rear Bumper 21
Right Outboard Clearance Lamp BK Behind Front of Headliner 20
Right Outboard Headlamp At Headlamp N/S
Right Outboard Identification Lamp BK Behind Front of Headliner 20
Right Park/Turn Signal Lamp BK At Lamp N/S
Right Power Mirror BK In Door 19
Right Rear Fender Lamp On Fender 21
Right Rear Speaker Bottom of Right B Pillar 18
Right Remote Radio Switch Steering Wheel N/S
Right Speed Control Switch Steering Wheel N/S
Right Tail/Stop Turn Signal Lamp BK At Rear Bumper 21
Right Tweeter Right A Pillar N/S
Right Visor/Vanity Lamp BK Right A-Pillar N/S
Seat Belt Switch Above Left Rear Speaker 18
Tailgate Lamp On Tailgate 21
Throttle Position Sensor Throttle Body 4,5,9
Trailer Tow Connector BK On Trailer Hitch 21
Transmission Solenoid Assembly BK Side of Transmission 13
Under Hood Lamp BK Underside of Hood 15
Vehicle Speed Control Servo BK Below Battery 16
Washer Fluid Level Switch At Reservoir 16
Water In Fuel Sensor BK Bottom of Fuel Filter/Water
Separator10
Windshield Washer Pump BK Bottom of Washer Fluid Reservior 16
Wiper Motor BK Center Rear Engine Compartment 14
BR/BE8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 7
CONNECTOR/GROUND LOCATIONS (Continued)

Splice Number Location Fig.
S301 Body Harness, Left Side Instrument Panel 10
S302 Body Harness, Left Side Instrument Panel 10
S303 Body Harness, Left Side Instrument Panel 10
S304 Body Harness, Left Side Instrument Panel 10
S305 Body Harness, Right Side Instrument Panel N/S
S306 Body Harness, Left Side Instrument Panel 10
S307 Body Harness, Left Cowl 10
S308 Body Harness, Left Cowl 10
S310 At Left Body Ground N/S
S311 At Left Body Ground N/S
S313 Left Rear Frame Rail 11
S314 Left Rear Frame Rail N/S
S315 Left Rear Frame Rail 11
S316 Left Rear Frame Rail 11
S317 Left Rear Frame Rail 11
S318 In T/O to Trailer Tow 11
S319 In T/O to Left Rear Lamps 11
S320 In T/O to Trailer Tow 11
S321 In T/O to Left Rear Lamps 11
S322 Overhead Console Harness, At Roof Lamps 9
S323 Overhead Console Harness, At Roof Lamps 9
S324 Overhead Console Harness, At Roof Lamps 9
S325 Overhead Console Harness, At Roof Lamps 9
S326 Overhead Console Harness, At Roof Lamps 9
S327 Power Seat Harness, Near Switch N/S
S328 Power Seat Harness, Near T/O to Body Wiring N/S
S329 Door Harness, Near Left Door Near Grommet N/S
S330 Door Harness, Near Right Door Near Grommet N/S
S331 Chassis Harness, Near T/O to Fuel Pump Module 11
S332 Body Harness, Left Side Instrument Panel 10
S333 Power Seat Harness, Near T/O to Passenger Seat Jumper N/S
S335 Power Seat harness, Near T/O to Body Wiring N/S
S336 Power Seat Harness, Under Passenger Seat N/S
S337 Power Seat Harness, Under Passenger Seat N/S
S340 Overhead Console Harness, At Roof Lamps 9
S401 Tail/Stop/Turn and Back-up Lamp Harness, Near T/O to Left Back-up Lamp N/S
S402 Tail/Stop/Turn and Back-up Lamp Harness, Near T/O to Right Back-up Lamp N/S
S404 Fender Lamp Harness, Near T/O to Tailgate Lamp N/S
S406 Fender Lamp Harness, Near T/O to Tailgate Lamp N/S
BR/BE8W-95 SPLICE LOCATIONS 8W - 95 - 3
SPLICE LOCATIONS (Continued)

BODY
TABLE OF CONTENTS
page page
BODY
DESCRIPTION............................1
WARNING...............................1
DIAGNOSIS AND TESTING..................2
WATER LEAKS..........................2
WIND NOISE...........................3
SPECIFICATIONS.........................4
DECKLID/HATCH/LIFTGATE/TAILGATE........62
DOOR - FRONT..........................67DOOR - CARGO.........................77
EXTERIOR..............................86
HOOD.................................99
INSTRUMENT PANEL SYSTEM.............104
INTERIOR.............................118
PAINT................................129
SEATS................................131
STATIONARY GLASS.....................145
WEATHERSTRIP/SEALS..................152
BODY
DESCRIPTION ± PUSH-IN FASTENERS
DaimlerChrysler Corporation uses many different
types of push-in fasteners to secure the interior and
exterior trim to the body. Most of these fasteners can
be reused to assemble the trim during various repair
procedures. At times, a push-in fastener cannot be
removed without damaging the fastener or the com-
ponent it is holding. If it is not possible to remove a
fastener without damaging a component or body, cut
or break the fastener and use a new one when
installing the component. Never pry or pound on a
plastic or pressed-board trim component. Using a
suitable fork-type prying device, pry the fastener
from the retaining hole behind the component being
removed. When installing, verify fastener alignment
with the retaining hole by hand. Push directly on or
over the fastener until it seats. Apply a low-force pull
to the panel to verify that it is secure.
When it is necessary to remove components to ser-
vice another, it should not be necessary to apply
excessive force or bend a component to remove it.
Before damaging a trim component, verify hidden
fasteners or captured edges holding the component in
place.
DESCRIPTION ± LOCK CYLINDERS
Ignition, door, deck lid, and rear hatch lock cylin-
ders are all codable to the key. Lock barrels, tum-
blers, and tumbler springs are available to allow the
technician to change replacement locks cylinders to
match the customer's original key set. See the appro-
priate section in this manual for lock cylinder
removal. See the Moparž catalogue for part numbers
and lock coding procedures.
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE A OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
AVOID PROLONGED SKIN CONTACT WITH PETRO-
LEUM OR ALCOHOL ± BASED CLEANING SOL-
VENTS. PERSONAL INJURY CAN RESULT.
DO 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.
Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
Always have a fire extinguisher ready for use when
welding.
Disconnect the negative (-) cable clamp from the
battery when servicing electrical components that
are live when the ignition is OFF. Damage to electri-
cal system can result.
Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning solvents
on painted or upholstered surfaces. Damage to fin-
ish or color can result.
Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
BR/BEBODY 23 - 1

CARGO BOX
CARGO BOX
DESCRIPTION GAP FLUSH
M Fuel Filler Door to Box 3.0 +/- 0.75 0.0 +/- 3.0
N Cab to Box Character Line U/D N/A 0.0 +/- 3.0
O Cargo to Box (side) 31.0 +/- 3.0 5.0 +/- 2.5
P Cab to Box at Centerline 34.0 +/- 3.0 N/A
Q Box to Tailgate U/D N/A 1.0 +/- 1.5
R Tailgate to Bumper 43.0 +/- 3.0 N/A
S Box to Tailgate 6.0 +/- 1.5 1.0 +/- 1.5
T Box to Tailgate 1.0 +/- 1.0 4.0 +/- 1.5
BR/BEBODY 23 - 59
BODY (Continued)

DECKLID/HATCH/LIFTGATE/TAILGATE
TABLE OF CONTENTS
page page
APPLIQUE
REMOVAL..............................62
INSTALLATION...........................62
CHECK CABLE
REMOVAL..............................62
INSTALLATION...........................63
DECALS
REMOVAL..............................63
INSTALLATION...........................63
HANDLE ESCUTCHEON
REMOVAL..............................63
INSTALLATION...........................63
LATCH
REMOVAL..............................64INSTALLATION...........................64
LATCH HANDLE
REMOVAL..............................65
INSTALLATION...........................65
LATCH STRIKER
REMOVAL..............................65
INSTALLATION...........................65
SLAM BUMPER
REMOVAL..............................66
INSTALLATION...........................66
TAILGATE
REMOVAL..............................66
INSTALLATION...........................66
APPLIQUE
REMOVAL
(1) Apply a length of masking tape on the body,
parallel to the top edge of the applique to use as a
guide, if necessary.
(2) Warm the tailgate applique and tailgate metal
to approximately 38ÉC (100ÉF) using a suitable heat
lamp or heat gun.
(3) Pull applique from tailgate (Fig. 1).
INSTALLATION
(1) Remove adhesive tape residue from painted
surface of tailgate.
(2) If applique is to be reused, remove tape residue
from applique. Clean back of applique with
MOPARž, Super Kleen solvent or equivalent. Wipe
molding dry with lint free cloth. Apply new body side
molding (two sided adhesive) tape to back of appli-
que.
(3) Clean tailgate surface with MOPARž, Super
Kleen solvent or equivalent. Wipe surface dry with
lint free cloth. An adhesion promoter must be applied
to ensure proper applique adhesion.
(4) Remove protective cover from tape on back of
applique. Apply applique to body below the masking
tape guide (Fig. 1).
(5) Remove masking tape guide and heat tailgate
and applique, see step one. Firmly press applique to
tailgate to assure adhesion.
CHECK CABLE
REMOVAL
(1) Open tailgate.
(2) Pry lock tab outward to clear stud head on
cargo box (Fig. 2).
(3) Push cable end forward until stud head is in
clearance hole portion of cable end.
(4) Separate cable end from stud.
(5) Remove screw attaching cable to tailgate.
(6) Separate check cable from tailgate.
Fig. 1 Tailgate Applique
1 - TAILGATE
2 - TAILGATE
3 - ADHESIVE TAPE
4 - APPLIQUE
23 - 62 DECKLID/HATCH/LIFTGATE/TAILGATEBR/BE

INSTALLATION
(1) Position check cable on tailgate.
(2) Install screw attaching small end of cable to
tailgate.
(3) Position large end of cable onto stud head and
slide downward to secure lock tab.
DECALS
REMOVAL
(1) Warm the panel to approximately 38ÉC (100ÉF)
using a suitable heat lamp or heat gun.
(2) Peel tape stripe from body panel using an even
pressure pull.
(3) Remove adhesive residue from body panel
using a suitable adhesive removing solvent.
INSTALLATION
(1) Clean painted body surface with Moparž Super
Clean solvent or equivalent and a lint free cloth.
(2) Remove protective cover from back side of
decal.
(3) Position decal properly on body.
(4) Press decal firmly to body with palm of hand.
(5) If temperature is below 21ÉC (70ÉF) warm decal
with a heat lamp or gun to assure adhesion. Do not
exceed 65ÉC (150ÉF) when heating emblem.
HANDLE ESCUTCHEON
REMOVAL
(1) Lift and hold tailgate latch release handle.
(2) Using a trim stick (C±4755), pry bottom of
escutcheon outward to disengage clips.
(3) Rotate escutcheon upward to disengage clip
above release handle.
(4) Push escutcheon downward from behind to
clear handle.
(5) Separate escutcheon from tailgate (Fig. 3).
INSTALLATION
(1) Insert upper ends of escutcheon into handle
opening.
(2) Lift escutcheon upward from behind release
handle.
(3) Press bottom of escutcheon inward to engage
clips.
Fig. 2 Tailgate Check
1 - TAILGATE STRIKER
2 - SCREW DRIVER
3 - TAILGATE CHECK CABLE
4 - LOCK TAB
Fig. 3 Tailgate Handle Escutcheon
1 - TAILGATE
2 - HANDLEÐTOÐRIGHT LATCH CONTROL ROD
3 - ESCUTCHEON
4 - LATCH ROD RETAINER
5 - HANDLEÐTOÐLATCH CONTROL ROD AND RETAINER
6 - HANDLE
BR/BEDECKLID/HATCH/LIFTGATE/TAILGATE 23 - 63
CHECK CABLE (Continued)

LATCH
REMOVAL
(1) Remove tailgate latch handle escutcheon (Refer
to 23 - BODY/DECKLID/HATCH/LIFTGATE/TAIL-
GATE/HANDLE ESCUTCHEON - REMOVAL).
(2) Open tailgate.
(3) Disengage linkage rod from latch handle.
(4) Remove screws attaching latch to tailgate (Fig.
4).
(5) Separate latch from tailgate.
(6) Pull latch and linkage rod from tailgate (Fig.
5).
INSTALLATION
(1) Position latch and linkage rod in tailgate.
(2) Install upper screw attaching latch to tailgate.
(3) Install lower screw attaching check cable and
latch to tailgate.
(4) Engage linkage rod to latch handle.
Fig. 4 Tailgate Latch
1 - SPACER
2 - CHECK CABLE
3-LATCH
4 - LINKAGE ROD5 - HANDLE ESCUTCHEON
6 - LATCH HANDLE
Fig. 5 Tailgate Latch and Linkage Rod
1 - SILENCER
2 - LATCH ASSEMBLY
3 - LINKAGE ROD
23 - 64 DECKLID/HATCH/LIFTGATE/TAILGATEBR/BE

(5) Install tailgate latch handle escutcheon (Refer
to 23 - BODY/DECKLID/HATCH/LIFTGATE/TAIL-
GATE/HANDLE ESCUTCHEON - INSTALLATION).
LATCH HANDLE
REMOVAL
(1) Remove tailgate latch handle escutcheon (Refer
to 23 - BODY/DECKLID/HATCH/LIFTGATE/TAIL-
GATE/HANDLE ESCUTCHEON - REMOVAL).
(2) Disengage clips holding linkage rods to latch
handle.
(3) Separate linkage rods from handle.
(4) Remove screws attaching latch handle to tail-
gate (Fig. 6).
(5) Separate latch handle from tailgate.
INSTALLATION
(1) Position latch handle in tailgate.
(2) Install screws attaching latch handle to tail-
gate.
(3) Install linkage rods to latch handle.
(4) Engage clips to linkage rods.
(5) Install tailgate latch handle escutcheon.
LATCH STRIKER
REMOVAL
(1) Open tailgate.
(2) Mark outline of striker on cargo box jamb to
aid installation.
(3) Using a Torx drive wrench, remove striker and
washer from cargo box (Fig. 7).
INSTALLATION
(1) Position striker and washer on jamb using
alignment outline as reference and install with Torx
drive wrench.
Fig. 6 Tailgate Latch Handle
1 - SCREW
2 - TAILGATE
3 - HANDLE ASSEMBLYFig. 7 Tailgate Striker
1 - TAILGATE STRIKER
2 - CARGO BOX
BR/BEDECKLID/HATCH/LIFTGATE/TAILGATE 23 - 65
LATCH (Continued)

SLAM BUMPER
REMOVAL
(1) Open tailgate.
(2) Remove screw holding slam bumper to cargo
box (Fig. 8).
(3) Separate slam bumper from vehicle.
INSTALLATION
(1) Position slam bumper on vehicle.
(2) Install screw holding slam bumper to cargo
box.
(3) Close tailgate and verify operation.
TAILGATE
REMOVAL
(1) Open tailgate.
(2) Disconnect tailgate marker light harness, if
equipped.
(3) Remove tailgate check cables (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
CHECK CABLE - REMOVAL).
(4) Close tailgate until the notch in the right hand
collar aligns with the pivot pin.
(5) Slip tailgate hinge collar from pivot pins.
(6) Slide tailgate to the right and separate left
hand collar from the pivot pin.
(7) Separate tailgate from vehicle.
INSTALLATION
(1) Position tailgate collar on left hand pivot pin
and slide tailgate to the left.
(2) Raise tailgate until the notch in the right hand
collar aligns with the pivot pin.
(3) Install tailgate check cables (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
CHECK CABLE - INSTALLATION).
(4) Connect tailgate marker light harness, if
equipped.
Fig. 8 Tailgate Slam Bumper
1 - CARGO BOX
2 - SLAM BUMPER
3 - TAILGATE
23 - 66 DECKLID/HATCH/LIFTGATE/TAILGATEBR/BE

INSTALLATION - WHEEL COVERS
(1) Install cover on wheel by hand only (Fig. 20).
(2) Install and torque wheel nuts to 135 N´m (100
lb. ft.).
(3) Install nut caps, if equipped using lug wrench,
do not over tighten.
(4) Remove release liner from removal instructions
label and install label next to jacking instructions
label. Surface must be clean and flat for proper adhe-
sion of label.
EXTERIOR
INSPECTIONÐBODY SEALING
Visually inspect the following seals during the nor-
mal recommended wash. Look for areas where water
may have entered the vehicle.
²Door and window seals
²Windshield
²Backlight
INSPECTION - FIT AND FINISH
(1) Remove all protective coatings/covers.
²Remove protective film from body moldings.
(2) Make sure body is free from paint chips,
scratches, sags, run, dirt or corrosion. Touch up any
minor paint chips and scratches as required.
(3) Ensure that moldings and stripes are aligned
properly.
²Ensure that moldings and stripes are present
and securely fastened to the body.NOTE: Painted-on accent strips require a unique
paint for touch-ups.
(4) Check that the door panels have even gaps and
fit well with adjacent body panels (Fig. 21).
(5) Check that the tailgate has even gaps and fits
well with adjacent panels (Fig. 22).
Fig. 20 WHEEL COVER
Fig. 21 DOOR ALIGNMENT
Fig. 22 TAILGATE ALIGNMENT
30 - 10 NEW VEHICLE PREPARATIONBR/BE
UNDER VEHICLE (Continued)