DODGE RAM 2001 Service Repair Manual

CHECK
REMOVAL
(1) Remove cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(2) Remove the bolts attaching the door check to
the cab C-pillar.
(3) Remove the nuts attaching the door check to
the cargo door (Fig. 2).
(4) Remove the door check through the access hole
in the cargo door.
INSTALLATION
(1) Position the door check in the cargo door
through the access hole.
(2) Install the nuts attaching the door check to the
cargo door (Fig. 2).
(3) Install the bolts attaching the door check to the
cab C-pillar.
(4) Install cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
DOOR
REMOVAL
(1) Using a grease pencil or equivalent, mark the
position of the hinge on the door.
(2) Remove the cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(3) Remove the cargo door check strap from the
cab C-pillar (Refer to 23 - BODY/DOOR - CARGO/
CHECK - REMOVAL).(4) Using the access hole in the cargo door inner
panel, disengage the speaker wire from the speaker
and route the wire through the door.
(5) Support the cargo door on a suitable device.
(6) Remove the bolts attaching the hinges to the
cargo door (Fig. 3).
INSTALLATION
(1) Support the cargo door on a suitable device.
(2) Using the alignment marks, position the door
at the hinge.
(3) Install the bolts attaching the hinges to the
cargo door (Fig. 3). Tighten the bolts to 28 N´m (21
ft. lbs.) torque.
(4) Route the speaker wire through the door and
using the access hole in the cargo door inner panel,
engage the speaker wire at the speaker.
(5) Install the cargo door check strap at the cab
C-pillar (Refer to 23 - BODY/DOOR - CARGO/
CHECK - INSTALLATION).
(6) Install the cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
ADJUSTMENT ± CARGO DOOR
CARGO DOOR FORE/AFT AND UP/DOWN
(1) As applicable, remove the C-pillar trim to
access the bolts attaching the cargo door to the C-pil-
lar.
(2) Support the door with a padded floor jack.
(3) Loosen the applicable C-pillar to hinge bolts
and move the door to the correct position.If neces-
sary, loosen the other C-pillar to hinge bolts and
move the door to the correct position.
(4) Tighten the bolts to 28 N´m (21 ft. lbs.) torque.
Fig. 2 Door Check
1 - CARGO DOOR
2 - DOOR CHECK
3 - CARGO DOOR INNER PANEL
Fig. 3 Cargo Door
1 - CARGO DOOR
2 - CARGO DOOR HINGE
23 - 78 DOOR - CARGOBR/BE

(5) If necessary, loosen the bolts attaching the
lower striker and move striker to the correct position.
(6)
If necessary, loosen the bolts attaching the upper
latch to the cargo door and move to the correct posi-
tion. (Fig. 4)
CARGO DOOR IN/OUT
(1) Loosen the applicable hinge to door fasteners
and move the door to the correct position.
(2) Tighten the bolts to 28 N´m (21 ft. lbs.) torque.
EXHAUST VENT
REMOVAL
(1) Using a trim stick, carefully pry bottom of vent
to disengage from door (Fig. 5).
(2) Separate vent from door.
INSTALLATION
(1) Position upper side of vent in door opening.
(2) Slide upward until tabs on top edge are in
place.
(3) Push the lower side of the vent towards the
door until the tabs snap into place.
(4) Ensure vent is fully seated.
HINGE
REMOVAL
(1) Remove cargo door (Refer to 23 - BODY/DOOR
- CARGO/DOOR - REMOVAL).(2) Remove quarter trim panel (Refer to 23 -
BODY/INTERIOR/QUARTER TRIM PANEL -
REMOVAL).
(3) Remove bolts attaching hinge to C-pillar (Fig.
6).
(4) Separate hinge from vehicle.
INSTALLATION
(1) Position hinge on vehicle.
(2) Install bolts attaching hinge to C-pillar (Fig. 6).
Tighten bolts to 28 N´m (21 ft. lbs.) torque.
(3) Install quarter trim panel (Refer to 23 - BODY/
INTERIOR/QUARTER TRIM PANEL - INSTALLA-
TION).
Fig. 4 CARGO DOOR UPPER LATCH
1 - UPPER LATCH
2 - ADJUSTMENT SLOTS
3 - CARGO DOOR
Fig. 5 Cargo Door Exhaust Vent
1 - CARGO DOOR
2 - EXHAUST VENT
Fig. 6 Cargo Door Hinge
1 - CARGO DOOR
2 - CAB
3 - UPPER HINGE
4 - LOWER HINGE
5 - DOOR CHECK
BR/BEDOOR - CARGO 23 - 79
DOOR (Continued)

(4) Install cargo door (Refer to 23 - BODY/DOOR -
CARGO/DOOR - INSTALLATION).
INSIDE HANDLE ACTUATOR
REMOVAL
NOTE: The cargo door inside handle actuator is
heat staked to the trim panel (Fig. 7).
(1) Remove cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(2) Disengage release cable from inside handle.
(3) Using a small file, drummel tool or die grinder,
remove the melted material securing the handle to
the trim panel.
(4) Separate the handle from the trim panel.
INSTALLATION
(1) Position the handle in the trim panel.
(2) Using a soldering gun, and using the additional
studs, heat stake the handle to the trim panel.
(3) Engage release cable to inside handle.
(4) Install cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
LATCH - LOWER
REMOVAL
(1) Remove cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(2) Peel back waterdam to access air exhauster.(3) Remove cargo door air exhauster (Refer to 23 -
BODY/DOOR - CARGO/AIR EXHAUSTER - REMOV-
AL).
(4) Disengage lower latch to shutface handle rod at
shutface handle (Fig. 8).
(5) Remove nuts attaching lower latch to cargo
door.
(6) Separate lower latch and latch rod from cargo
door.
INSTALLATION
(1) If installing a new replacement latch:
(a) Engage latch rod to latch rod retaining clip
in lower latch. Ensure ªwhiteº latch installation
pin is in the position closest to the latch release
lever (Fig. 9).
(2) If the latch was not replaced and the existing
latch is to be installed:
(a) Slide ªwhiteº latch installation pin to the
position closest to the latch release lever.
(3) Position lower latch and latch rod in cargo
door.
(4) Install nuts attaching lower latch to cargo door.
Tighten nuts to 12 N´m (9 ft. lbs.) torque (Fig. 8).
(5) Engage latch rod to latch rod retaining clip in
lower latch.
CAUTION: When engaging lower latch release rod
to shutface handle, ensure lower latch rod is
pushed all the way down before engaging to the
handle.
(6) Engage lower latch rod to shutface handle
(7) Cycle the shutface handle and verify latch
operation.
Fig. 7 Heat Staked Locations
1 - RELEASE CABLE
2 - HEAT STAKED LOCATIONS
3 - CARGO DOOR TRIM PANEL
4 - HEAT STAKED LOCATIONS
Fig. 8 Cargo Door Lower Latch
1 - LOWER LATCH TO HANDLE ROD
2 - LOWER CARGO DOOR LATCH
3 - CARGO DOOR
23 - 80 DOOR - CARGOBR/BE
HINGE (Continued)

(8) Install cargo door air exhauster (Refer to 23 -
BODY/DOOR - CARGO/AIR EXHAUSTER -
INSTALLATION).
(9) Reposition waterdam.
(10) Install cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
LATCH - UPPER
REMOVAL
(1) Remove cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(2) Using a grease pencil or equivalent, mark the
position of the bolts.
(3) Disengage upper latch release rod from shut-
face handle.
(4) Remove the bolts attaching upper latch to
cargo door (Fig. 10).
(5) Separate upper latch and latch rod from cargo
door.
INSTALLATION
(1) The new replacement latch is supplied with an
alignment set screw located in the lower mounting
hole of the upper cargo door latch. If a new is latch is
being installed, use the following procedure:
(a) Verify alignment set screw is fully seated in
latch.
(b) Engage latch rod to latch.
(c) Position latch in cargo door with alignment
set screw located in the lower hole.
(d) Align bolt with reference mark.(e) Install upper bolt. Tighten bolt to 23 N´m (17
ft. lbs.) torque.
(f) Engage latch rod to shutface handle.
(g) Remove alignment set screw from lower hole.
(h) Align lower bolt with reference mark.
(i) Install bolt in lower hole. Tighten bolt to 23
N´m (17 ft. lbs.) torque.
CAUTION: When engaging upper latch release rod
to shutface handle, ensure the latch rod is pushed
all the way up before engaging into the shutface
handle.
(2) If the latch was not replaced and the existing
latch is to be installed:
(a) Engage latch rod to latch.
(b) Position upper latch and latch rod in cargo
door.
(c) Align bolts with reference marks.
(d) Install the bolts attaching upper latch to
cargo door (Fig. 10). Tighten the bolts to 23 N´m
(17 ft. lbs.) torque.
(e) Engage upper latch release rod to shutface
handle.
(3) Cycle the shutface handle and verify latch
operation.
(4) Install cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
Fig. 9 Cargo Door Lower Latch Installation Pin
1 - LATCH ROD RETAINING CLIP
2 - SLOT
3 - CARGO DOOR LOWER LATCH
4 - INSTALLATION PIN
5 - LATCH RELEASE LEVER
Fig. 10 Cargo Door Upper Latch
1 - CARGO DOOR
2 - UPPER CARGO DOOR LATCH
3 - UPPER LATCH TO HANDLE ROD
4 - ALIGNMENT SET SCREW
BR/BEDOOR - CARGO 23 - 81
LATCH - LOWER (Continued)

LATCH STRIKER - LOWER
REMOVAL
(1) Using a grease pencil or equivalent, mark the
position of the lower striker on the sill.
(2) Remove the torx screws attaching the striker to
the sill (Fig. 11).
(3) Separate striker from sill.
INSTALLATION
(1) Using the alignment marks, position striker on
sill.
(2) Install the torx screws attaching the striker to
the sill (Fig. 11). Tighten screws to 28 N´m (21 ft.
lbs.) torque.
LATCH STRIKER - UPPER
REMOVAL
(1) Remove screws attaching striker trim cover to
roof.
(2) Remove bolts attaching striker to roof (Fig. 11).
(3) Separate upper striker from roof.
INSTALLATION
(1) Position upper striker on roof.
(2) Install bolts attaching striker to roof (Fig. 11).
Tighten bolts to 23 N´m (17 ft. lbs.) torque.(3) Install the screws attaching striker trim cover
to roof.
RELEASE CABLE
REMOVAL
(1) Remove cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(2) Disengage release cable from inside release
handle (Fig. 12).
(3) Peel back waterdam
(4) Disengage release cable from shutface door
handle (Fig. 13).
(5) Separate release cable from cargo door.
Fig. 11 Cargo Door Strikers
1 - UPPER STRIKER
2 - LOWER STRIKER
Fig. 12 Cargo Door Release Handle
1 - CARGO DOOR RELEASE CABLE
2 - CARGO DOOR RELEASE HANDLE
Fig. 13 Shutface Door Handle
1 - RELEASE CABLE
2 - SHUTFACE DOOR HANDLE
23 - 82 DOOR - CARGOBR/BE

INSTALLATION
(1) Position release cable in cargo door.
(2) Engage release cable to shutface door handle.
(3) Reposition waterdam
(4) Engage release cable to inside release handle.
(5) Install cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
SHUTFACE HANDLE
REMOVAL
(1) Remove cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(2) Peel back waterdam.
(3) Disengage upper and lower latch release rods
from shutface handle (Fig. 14).
(4) Disengage cargo door release cable.
(5) Remove screws attaching shutface handle to
cargo door (Fig. 15).
(6) Separate handle from cargo door.
INSTALLATION
(1) Position handle in cargo door.
(2) Install screws attaching shutface handle to
cargo door (Fig. 15).
(3) Engage cargo door release cable.
CAUTION: When engaging upper and lower latch
release rods to shutface handle, ensure the upper
latch rod is pushed all the way up and the lower
latch rod is pushed all the way down before engag-
ing into the shutface handle.
(4) Engage upper and lower latch release rods to
shutface handle.
(5) Cycle the shutface handle and verify operation.
(6) Reposition waterdam.
(7) Install cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
Fig. 14 Cargo Door Latch Rods
1 - UPPER LATCH ROD
2 - SHUTFACE HANDLE
3 - LOWER LATCH ROD
Fig. 15 Shutface Handle
1 - CARGO DOOR RELEASE CABLE
2 - CARGO DOOR
3 - SHUTFACE DOOR HANDLE
BR/BEDOOR - CARGO 23 - 83
RELEASE CABLE (Continued)

TRIM PANEL
REMOVAL
(1) Remove the screws attaching the cargo door
pull cup to the cargo door (Fig. 16).
(2) Remove the screw attaching the inside release
handle to the cargo door.
NOTE: The cargo door trim panel is secured to the
cargo door with spring clips and push-in fasteners
(Fig. 17).
(3) Using a trim panel removal tool, remove the
push-in fasteners attaching the trim panel to the
cargo door.
(4) Pull the trim panel outward to disengage the
spring clips.
(5) Separate the trim panel from the cargo door.
(6) Disengage the cargo door release cable from
the inside release handle (Fig. 18).
INSTALLATION
NOTE: When replacing door trim panel, installer
must replace the X-mas tree style pin 6506878aa.
(1) Engage the cargo door release cable to the
inside release handle (Fig. 18).
(2) Position the trim panel on the cargo door.(3) Align all fasteners and starting at the top of
the panel, push into place to secure.
(4) Install the screw attaching the inside release
handle to the cargo door.
(5) Install the screws attaching the cargo door pull
cup to the cargo door (Fig. 16).
Fig. 16 Cargo Door Trim Panel
1 - CARGO DOOR
2 - PUSH-IN FASTENER
3 - SPRING CLIP
4 - CARGO DOOR TRIM
5 - PULL CUP
6 - INSIDE HANDLE
Fig. 17 Cargo Door Trim Panel Fasteners
1 - CARGO DOOR TRIM PANEL
2 - SPRING CLIPS
3 - PUSH-IN FASTENERS
4 - INSIDE RELEASE HANDLE
Fig. 18 Cargo Door Release Cable
1 - CARGO DOOR RELEASE CABLE
2 - CARGO DOOR RELEASE HANDLE
23 - 84 DOOR - CARGOBR/BE

VENT WINDOW
REMOVAL
(1) Remove cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(2) Remove the screws attaching the latch to the
cargo door (Fig. 19).
(3) Remove the bolts attaching the vent glass to
the cargo door (Fig. 20).
(4) Remove the glass from the door.
(5) If necessary, remove the latch from the glass.
INSTALLATION
(1) If removed, install the latch to the glass.
Tighten the screw with 5 N´m (45 in. lbs.) torque.
(2) Center the glass in the cargo door opening.
(3) Install the bolts attaching the vent glass to the
cargo door.
(4) Install the screws attaching the latch to the
cargo door.
(5) Install cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
WATERDAM
REMOVAL
(1) Remove cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(2) Carefully peel waterdam from door (Fig. 21).
INSTALLATION
If a replacement waterdam is being applied, clean
cargo door inner panel with Mopar Super Clean or
equivalent.
(1) Position waterdam on cargo door and press into
place.
(2) install cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
Fig. 19 Cargo Door Quarter Glass Vent Window
Latch
1 - CARGO DOOR QUARTER GLASS
2-LATCH
Fig. 20 Cargo Door Quarter Glass Vent Window
1 - CARGO DOOR
2 - CARGO DOOR QUARTER GLASS
Fig. 21 Cargo Door Waterdam
1 - WATER DAM
2 - CARGO DOOR
BR/BEDOOR - CARGO 23 - 85

EXTERIOR
TABLE OF CONTENTS
page page
EXTERIOR
DESCRIPTION...........................86
OPERATION.............................86
BODY SIDE MOLDINGS
REMOVAL..............................87
INSTALLATION...........................87
BODY STRIPES AND DECALS
REMOVAL..............................87
INSTALLATION...........................87
TAPE STRIPE
REMOVAL..............................88
INSTALLATION...........................88
EXTERIOR NAME PLATES
REMOVAL..............................89
INSTALLATION...........................89
COWL GRILLE
REMOVAL..............................90
INSTALLATION...........................90
ROOF JOINT MOLDING
REMOVAL..............................91
INSTALLATION...........................91
GRILLE
REMOVAL..............................91
INSTALLATION...........................91
GRILLE FRAME
REMOVAL..............................91
INSTALLATION...........................92
FRONT END SPLASH SHIELDS
REMOVAL..............................92
INSTALLATION...........................92LEFT FRONT FENDER
REMOVAL..............................92
INSTALLATION...........................93
RIGHT FRONT FENDER
REMOVAL..............................94
INSTALLATION...........................94
FUEL FILL DOOR
REMOVAL..............................95
INSTALLATION...........................95
REAR FENDER
REMOVAL..............................95
INSTALLATION...........................95
REAR SPLASH SHIELD
REMOVAL..............................96
INSTALLATION...........................96
REAR WHEELHOUSE LINER
REMOVAL..............................96
INSTALLATION...........................96
CARGO BOX
REMOVAL..............................96
INSTALLATION...........................97
SIDE VIEW MIRROR
REMOVAL..............................97
INSTALLATION...........................97
SIDE VIEW MIRROR - LOW MOUNTED
REMOVAL..............................98
INSTALLATION...........................98
SIDE VIEW MIRROR GLASS
REMOVAL..............................98
INSTALLATION...........................98
EXTERIOR
DESCRIPTION
Exterior sheet metal components make up the
exterior of the vehicle. Some exterior metal systems
are welded assemblies, such as doors and hoods.
Some exterior trim items are made of composite.
OPERATION
The exterior is finished in various metal stampings
and composite moldings. These assemblies give the
vehicle a finished appearance and protect the occu-
pants from the elements. Some components are partof the energy absorbing system used to protect the
occupants in collisions. The exterior sheet metal is
repairable and adjustable for fit and finish. Welded
and bonded component systems are adjustable as a
system. Trim components made of composite are
stamped with the type of material used. Daimler-
Chrysler uses various fasteners to retain trim items.
At times, it is not possible to remove trim items
without damaging the fastener. If it is not possible to
remove an item without damaging a component, cut
or break the fasteners and use new ones when
installing the component.
23 - 86 EXTERIORBR/BE

BODY SIDE MOLDINGS
REMOVAL
(1) Warm the effected stick-on molding and body
metal to approximately 38ÉC (100ÉF) using a suitable
heat lamp or heat gun.
(2) Pull stick-on molding from painted surface
(Fig. 1) and (Fig. 2).
INSTALLATION
(1) Clean body surface with MOPARž Super Kleen
solvent or equivalent. Wipe surface dry with lint free
cloth.
(2) Apply a length of masking tape on the body,
parallel to the top edge of the molding to use as a
guide, if necessary.
(3) Remove protective cover from tape on back of
molding. Apply molding to body below the masking
tape guide (Fig. 1) and (Fig. 2).
(4) Remove masking tape guide and heat body and
molding, see step one. Firmly press molding to body
surface to assure adhesion.
BODY STRIPES AND DECALS
REMOVAL
(1) Warm the panel to approximately 38ÉC (100ÉF)
using a suitable heat lamp or heat gun.
(2) Peel decal from body panel using an even pres-
sure pull.(3) Remove adhesive residue from body panel
using a suitable adhesive removing solvent.
INSTALLATION
The painted surface of the body panel to be covered
by a decal must be smooth and completely cured
before decal can be applied. Ripples and feather edg-
ing will read through if surface is not properly pre-
pared. Clean all residue from surface.
(1) Peel paper backing away from decal exposing
adhesive back of decal.
(2) Apply soap solution liberally to adhesive back
of decal.
Fig. 1 Body Side Moldings
Fig. 2 Body Side MoldingsÐDual Wheel
BR/BEEXTERIOR 23 - 87