mirror DODGE RAM 2001 Service Service Manual

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

(6) Using a suitable lifting device, separate cargo
box from vehicle.
INSTALLATION
(1) Using a suitable lifting device, position cargo
box on vehicle.
(2) Installnewbolts attaching cargo box to frame
rails. Tighten bolts to 54 N´m (40 ft. lbs.) torque.
(3) Engage tail lamp wire connector to main body
harness at left rear frame rail.
(4) Install fuel fill neck.
SIDE VIEW MIRROR
REMOVAL
(1) Remove door trim panel (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL).
(2) Remove mirror flag door seal (Fig. 23).
(3) Disengage power mirror wire connector from
door harness, if equipped (Fig. 24).
(4) Remove nuts attaching sideview mirror to door
frame (Fig. 25).
(5) Separate harness grommet form door frame, if
equipped.
(6) Separate sideview mirror from vehicle.
INSTALLATION
(1) Position sideview mirror on door.
(2) Install harness grommet in door frame, if
equipped.
(3) Install nuts attaching sideview mirror to door
(Fig. 25).
(4) Engage power mirror wire connector to har-
ness, if equipped (Fig. 24).
(5) Install mirror flag door seal (Fig. 23).
(6) Install door trim panel (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - INSTALLATION).
Fig. 22 Cargo Box
1 - CARGO BOX
2 - FRAME
3 - BOLT
4 - AXLE
5 - BOLT
Fig. 23 Mirror Flag Door Seal
1 - MIRROR
2 - MIRROR FLAG SEAL
Fig. 24 Sideview MirrorÐPower
1 - POWER MIRROR
2 - NUT
3 - CONNECTOR
BR/BEEXTERIOR 23 - 97
CARGO BOX (Continued)

SIDE VIEW MIRROR - LOW
MOUNTED
REMOVAL
(1) Remove bolts attaching lower support legs to
outer door panel.
(2) Remove bolts attaching upper support arms to
outer door panel (Fig. 26).
(3) Separate mirror from door.
INSTALLATION
(1) Position mirror on door.
(2) Place insulation washers between support
frame and door panel
(3) Install bolts attaching upper support arms to
outer door panel.
(4) Install bolts attaching lower support legs to
outer door panel.
SIDE VIEW MIRROR GLASS
REMOVAL
WARNING: ALWAYS WEAR EYE AND HAND PRO-
TECTION WHEN SERVICING THE MIRROR ASSEM-
BLY. FAILURE TO OBSERVE THESE WARNINGS
MAY RESULT IN PERSONAL INJURY FROM BRO-
KEN GLASS.
(1) Carefully pull/pry the broken glass holder from
the mirror assembly.
(2) Disconnect the heated mirror electrical connec-
tors from the terminals on the mirror glass holder, if
equipped.
INSTALLATION
(1) Position the new mirror glass holder to the
mirror assembly.
(2) Align the mirror glass holder's attaching fin-
gers to the mirror motor housing.
NOTE: ENSURE THAT THE MOISTURE DRAIN HOLE
ON THE MIRROR GLASS HOLDER ASSEMBLY IS
FACING DOWNWARD.
(3) Using one hand, firmly press the mirror glass
holder assembly into place while at the same time
supporting the housing assembly from the backside
with the other hand.
NOTE: PRESSURE MUST BE APPLIED EQUALLY
OVER THE CENTER PORTION OF THE MIRROR TO
ENGAGE THE MIRROR GLASS HOLDER'S ATTACH-
ING FINGERS TO THE CORRESPONDING FINGERS
ON THE HOUSING ASSEMBLY. ONE OR MORE
CLICKS MAY BE HEARD WHEN FINGER ENGAGE-
MENT TAKES PLACE.
(4) Verify retention of the mirror glass holder
assembly by gently pulling outward on the mirror
glass holder.
Fig. 25 Sideview Mirror
1 - MIRROR
2 - NUT
3 - DOOR
Fig. 26 Low Mounted Side View Mirror
1 - FLAG COVER
2 - MIRROR
3 - WASHER
4 - NUTSERT
5 - WASHER
6 - NUTSERT
23 - 98 EXTERIORBR/BE
SIDE VIEW MIRROR (Continued)

INTERIOR
TABLE OF CONTENTS
page page
INTERIOR
CAUTION..............................118
A-PILLAR GRAB HANDLE
REMOVAL.............................119
INSTALLATION..........................119
A-PILLAR TRIM
REMOVAL.............................119
INSTALLATION..........................119
COWL TRIM COVER
REMOVAL.............................119
INSTALLATION..........................120
B-PILLAR TRIM
REMOVAL.............................120
INSTALLATION..........................120
REAR CLOSURE PANEL TRIM
REMOVAL.............................120
INSTALLATION..........................121
REAR FLOOR STOWAGE TRAY
REMOVAL.............................121
INSTALLATION..........................121
DOOR SILL TRIM
REMOVAL.............................121
INSTALLATION..........................121
SHIFT BOOT - MANUAL TRANSMISSION
REMOVAL.............................122
INSTALLATION..........................122
4WD FLOOR SHIFT BOOT
REMOVAL.............................122
INSTALLATION..........................122
CENTER CONSOLE
REMOVAL.............................122INSTALLATION..........................122
CARPETS AND FLOOR MATS
REMOVAL.............................123
INSTALLATION..........................123
ASSIST HANDLE
REMOVAL.............................124
INSTALLATION..........................124
COAT HOOK
REMOVAL.............................124
INSTALLATION..........................125
HEADLINER
REMOVAL.............................125
INSTALLATION..........................125
BODY VENT
REMOVAL.............................126
INSTALLATION..........................126
REAR VIEW MIRROR
REMOVAL.............................126
INSTALLATION..........................126
SUN VISOR
REMOVAL.............................127
INSTALLATION..........................127
QUARTER TRIM PANEL
REMOVAL.............................127
INSTALLATION..........................128
C-PILLAR TRIM
REMOVAL.............................128
INSTALLATION..........................128
INTERIOR
CAUTION
CAUTION: Do not attempt to remove interior trim
panels/moldings without first removing the neces-sary adjacent panels. To avoid damaging the pan-
els, ensure that all the screws and clips are
removed before attempting to remove an interior
trim panel/molding. Trim panels are somewhat flex-
ible but can be damaged if handled improperly.
23 - 118 INTERIORBR/BE

BODY VENT
REMOVAL
(1) Open door.
(2) Pull outward at top of vent to disengage clips
attaching vent to door jamb (Fig. 16).
(3) Separate vent from door jamb.
INSTALLATION
(1) Position vent from in jamb.
(2) Press vent inward to engage clips.
REAR VIEW MIRROR
REMOVAL
(1) If equipped, disconnect mirror harness wire
connector (Fig. 17).
(2) Loosen the mirror base setscrew (Fig. 18).
(3) Slide the mirror base upward and off the
bracket.
INSTALLATION
(1) Position the mirror base at the bracket and
slide it downward onto the support bracket.
(2) Tighten the setscrew 1 N´m (15 in. lbs.) torque.
(3) If equipped, connect mirror harness wire con-
nector.
INSTALLATION - REARVIEW MIRROR
SUPPORT BRACKET
(1) Mark the position for the mirror bracket on the
outside of the windshield glass with a wax pencil.
(2) Clean the bracket contact area on the glass.
Use a mild powdered cleanser on a cloth saturated
with isopropyl (rubbing) alcohol. Finally, clean the
glass with a paper towel dampened with alcohol.
(3) Sand the surface on the support bracket with
fine grit-sandpaper. Wipe the bracket surface clean
with a paper towel.
Fig. 16 Body Vent
1 - BÐPILLAR
2 - DOOR STRIKER
3 - BODY VENT
Fig. 17 Rearview Mirror Connector
1 - CONNECTOR
2 - MIRROR
3 - SCREW
Fig. 18 Rearview Mirror
1 - REARVIEW MIRROR
2 - WINDSHIELD GLASS
3 - SUPPORT BRACKET
4 - SCREW
23 - 126 INTERIORBR/BE

(4) Apply accelerator to the surface on the bracket
according to the following instructions:
(a) Crush the vial to saturate the felt applicator.
(b) Remove the paper sleeve.
(c) Apply accelerator to the contact surface on
the bracket.
(d) Allow the accelerator to dry for five minutes.
(e) Do not touch the bracket contact surface
after the accelerator has been applied.
(5) Apply adhesive accelerator to the bracket con-
tact surface on the windshield glass. Allow the accel-
erator to dry for one minute. Do not touch the glass
contact surface after the accelerator has been
applied.
(6) Install the bracket according to the following
instructions:
(a) Apply one drop of adhesive at the center of
the bracket contact-surface on the windshield
glass.
(b) Apply an even coat of adhesive to the contact
surface on the bracket.
(c) Align the bracket with the marked position
on the windshield glass.
(d) Press and hold the bracket in place for at
least one minute.
NOTE: Verify that the mirror support bracket is cor-
rectly aligned, because the adhesive will cure rap-
idly.
(7) Allow the adhesive to cure for 8-10 minutes.
Remove any excess adhesive with an alcohol-damp-
ened cloth.
(8) Allow the adhesive to cure for an additional
8-10 minutes before installing the mirror.
SUN VISOR
REMOVAL
(1) Remove screws attaching sunvisor to roof (Fig.
19).
(2) If equipped, disengage lighted vanity mirror
connector.
(3) Separate sunvisor from roof.
(4) Remove screw attaching sun visor hook to roof.
(5) Separate sunvisor hook from roof.
INSTALLATION
(1) Position sunvisor hook on roof.
(2) Install screw attaching sunvisor hook to roof.
(3) Position sunvisor on roof.
(4) If equipped, engage lighted vanity mirror con-
nector.
(5) Install screws attaching sunvisor to roof (Fig.
19).
QUARTER TRIM PANEL
REMOVAL
(1) Remove rear seat. (Refer to 23 - BODY/SEATS/
REAR SEAT - REMOVAL)
(2) Remove door sill cover as necessary to clear
quarter trim.
(3) Remove lower seat belt anchor bolt (Fig. 20).
(4) Remove seat belt tuning loop anchor bolt.
(5) Disengage clips attaching quarter trim panel
from quarter panel.
(6) Route seat belt webbing through opening in
quarter trim panel and remove panel from vehicle.
Fig. 19 Sunvisor
1 - BODY
2 - CLIP
3 - SUNVISOR
Fig. 20 Quarter Trim Panel Ð Club Cab
1 - TURNING LOOP COVER
2 - BELT ASSEMBLY
3 - TRIM PANEL
BR/BEINTERIOR 23 - 127
REAR VIEW MIRROR (Continued)

WINDSHIELD
DESCRIPTION
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.
URETHANE ADHESIVES ARE APPLIED AS A SYS-
TEM. USE GLASS CLEANER, GLASS PREP SOL-
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND
PINCH WELD (FENCE) PRIMER PROVIDED BY THE
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL
INTEGRITY COULD BE COMPROMISED.
DAIMLERCHRYSLER 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.
BE SURE TO REFER TO THE URETHANE MANU-
FACTURER'S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
ALWAYS 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.
OPERATION
The windshield is attached to the window frame
with urethane adhesive. The urethane adhesive is
applied cold and seals the surface area between the
window opening and the glass. The primer adheres
the urethane adhesive to the windshield.
It is difficult to salvage a windshield during the
removal operation. The windshield is part of the
structural support for the roof. The urethane bonding
used to secure the windshield to the fence is difficultto cut or clean from any surface. If the moldings are
set in urethane, it would also be unlikely they could
be salvaged. Before removing the windshield, check
the availability of the windshield and moldings from
the parts supplier.
REMOVAL
(1) Remove inside rear view mirror. (Refer to 23 -
BODY/INTERIOR/REAR VIEW MIRROR - REMOV-
AL).
(2) Remove cowl grill. (Refer to 23 - BODY/EXTE-
RIOR/COWL GRILLE - REMOVAL).
(3) With doors open, remove windshield molding
(Fig. 7). Pull outward on molding beginning at the
bottom of A-pillars using pliers.
(4) Cut urethane bonding from around windshield
using a suitable sharp cold knife (C-4849). A pneu-
matic cutting device can be used but is not recom-
mended (Fig. 8).
(5) 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,
Fig. 7 Windshield Moldings
1 - WINDSHIELD
2 - WINDSHIELD MOLDING
23 - 148 STATIONARY GLASSBR/BE

(11) Slowly lower windshield glass to the fence
opening guiding the lower corners into proper posi-
tion. Beginning at the bottom and continuing to the
top, push glass onto fence along the A-Pillars. Push
windshield inward to the fence at the bottom corners
(Fig. 13).
(12) Push windshield upward, snug with roof and
ratchet up the adjustable support brackets. Discard
tab from support spacer.
(13) Using clean water, lightly mist the support
spacers.
(14) Clean excess urethane from exterior with
MOPARž Super Clean or equivalent.
(15) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)
masking tape spaced 250 mm (10 in.) apart to hold
molding in place until urethane cures.
(16) Install cowl grill. (Refer to 23 - BODY/EXTE-
RIOR/COWL GRILLE - INSTALLATION).
(17) Install rear view mirror support bracket.
(Refer to 23 - BODY/INTERIOR/REAR VIEW MIR-
ROR - INSTALLATION).
(18) Install rear view mirror. (Refer to 23 - BODY/
INTERIOR/REAR VIEW MIRROR - INSTALLA-
TION).
(19) After urethane has cured, remove tape strips
and water test windshield to verify repair.
Fig. 11 Position Urethane Compression Spacer
1 - URETHANE COMPRESSION SPACER
2 - FENCE
Fig. 12 Applicator Tip
1 - APPLICATOR TIP
Fig. 13 Lower Windshield Into Position
1 - COMPRESSION SPACER
2 - WINDSHIELD
3 - ADJUSTABLE SUPPORT SPACERS
23 - 150 STATIONARY GLASSBR/BE
WINDSHIELD (Continued)

INSTALLATION
(1) Press door glass run weatherstrip into channel
around window opening (Fig. 4).
(2) Install inner door belt weatherstrip. (Refer to
23 - BODY/WEATHERSTRIP/SEALS/FRONT DOOR
INNER BELT WEATHERSTRIP - INSTALLATION)
FRONT DOOR INNER BELT
WEATHERSTRIP
REMOVAL
(1) Remove door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL)
(2) Lift inner door belt weatherstrip upward (Fig.
5).
(3) Separate inner door belt weatherstrip from
door.
INSTALLATION
(1) Position inner door belt weatherstrip on door.
(2) Press inner door belt weatherstrip downward
to seat.
(3) Install door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - INSTALLATION)
FRONT DOOR OUTER BELT
WEATHERSTRIP
REMOVAL
(1) Roll door glass down.
(2) Remove mirror. (Refer to 23 - BODY/EXTERI-
OR/SIDE VIEW MIRROR - REMOVAL)
(3) Using a hook tool inserted into the end of the
belt weatherstrip, lift upward.(4) Separate outer door belt weatherstrip from
door (Fig. 6).
INSTALLATION
(1) Position outer door belt weatherstrip on door.
(2) Press weatherstrip downward to seat.
(3) Install mirror. (Refer to 23 - BODY/EXTERI-
OR/SIDE VIEW MIRROR - INSTALLATION)
FRONT DOOR UPPER CORNER
SEAL
REMOVAL
(1) Remove the push-in fasteners attaching the
upper corner seal to the front door (Fig. 7).
(2) Separate the upper corner seal from the door.
INSTALLATION
(1) Position the upper corner seal on the door.
(2) Install the push-in fasteners attaching the
upper corner seal to the front door (Fig. 7).
FRONT DOOR SECOND
WEATHERSTRIP
REMOVAL
(1) Remove the push-in fasteners attaching the
secondary seal to the inner door panel.
(2) Separate the secondary seal from the inner
door panel (Fig. 8).
Fig. 5 Inner Door Belt Weatherstrip
1 - DOOR
2 - INNER BELTLINE WEATHERSEAL
Fig. 6 Outer Door Belt Weatherstrip
1 - OUTER BELTLINE WATHERSTRIP
2 - DOOR
23 - 154 WEATHERSTRIP/SEALSBR/BE
FRONT DOOR GLASS RUN WEATHERSTRIP (Continued)

(1) The relay common feed terminal cavity (30) is
connected to fused battery feed. There should be bat-
tery voltage at the cavity for relay terminal 30 at all
times. If OK, go to Step 2. If not OK, repair the open
circuit to the fuse in the PDC as required.
(2) The relay normally closed terminal (87A) is not
used in this application. Go to Step 3.
(3) The relay normally open terminal cavity (87) is
connected to the compressor clutch coil. There should
be continuity between this cavity and the A/C com-
pressor clutch relay output circuit cavity of the com-
pressor clutch coil wire harness connector. If OK, go
to Step 4. If not OK, repair the open circuit as
required.
(4) The relay coil battery terminal (86) is con-
nected to the fused ignition switch output (run/start)
circuit. There should be battery voltage at the cavity
for relay terminal 86 with the ignition switch in the
On position. If OK, go to Step 5. If not OK, repair the
open circuit to the fuse in the junction block as
required.
(5) The coil ground terminal cavity (85) is switched
to ground through the Powertrain Control Module
(PCM). There should be continuity between this cav-
ity and the A/C compressor clutch relay control cir-
cuit cavity of the PCM wire harness connector C
(gray) at all times. If not OK, repair the open circuit
as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cover from the Power Distribution
Center (PDC) (Fig. 17).(3) Refer to the label on the PDC for compressor
clutch relay identification and location.
(4) Unplug the compressor clutch relay from the
PDC.
INSTALLATION
(1) Install the compressor clutch relay by aligning
the relay terminals with the cavities in the PDC and
pushing the relay firmly into place.
(2) Install the PDC cover.
(3) Connect the battery negative cable.
(4) Test the relay operation.
A/C HEATER CONTROL
DESCRIPTION
Both the heater-only and a/c heater systems use a
combination of electrical and vacuum controls. These
controls provide the vehicle operator with a number
of setting options to help control the climate and
comfort within the vehicle. Refer to the owner's man-
ual in the vehicle glove box for more information on
the features, use, and suggested operation of these
controls.
OPERATION
The heater-only or a/c heater control panel is
located to the right of the instrument cluster on the
instrument panel. The control panel contains a rota-
ry-type temperature control knob, a rotary-type mode
control switch knob, and a rotary-type blower motor
speed switch knob. On models with the optional
heated mirror system, a momentary push button
switch and indicator lamp are located near the bot-
Fig. 16 COMPRESSOR CLUTCH RELAY
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 17 POWER DISTRIBUTION CENTER
1 - COVER
2 - POWER DISTRIBUTION CENTER
24 - 18 CONTROLSBR/BE
A/C COMPRESSOR CLUTCH RELAY (Continued)