remove seats DODGE RAM 2001 Service Service Manual

EXTENSION HOUSING
BUSHING AND SEAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove rear propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Using a suitable pry tool or slide-hammer
mounted screw, remove the extension housing seal.
(4) Using Remover 8158, remove bushing from
extension housing.
INSTALLATION
(1) Clean fluid residue from sealing surface and
inspect for defects.
(2) Position replacement bushing in extension
housing with fluid port in bushing aligned with slot
in housing.
(3) Using Installer 8157, drive bushing into hous-
ing until installer seats against case.
(4) Using Installer D-163, install seal in extension
housing (Fig. 96).
(5) Install propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - INSTALLATION)
(6) Verify proper transfer case fluid level.
(7) Lower vehicle.
Plug, Extension - C-293-3
Tool Set - L-4518
Cup - 8148
Installer, Pump Housing Seal - 7888
Fig. 96 Install Rear Seal in Extension Housing
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL D-163
21 - 850 TRANSFER CASE - NV231HDBR/BE
EXTENSION HOUSING BUSHING AND SEAL (Continued)

INSTALLATION
(1) Install new front output seal in front case with
Installer Tool 8143-A as follows:
(a) Place new seal on tool. Garter spring on seal
goes toward interior of case.
(b) Start seal in bore with light taps from ham-
mer (Fig. 101). Once seal is started, continue tap-
ping seal into bore until installer tool seats against
case.
(2) Install companion flange seal on front shaft
(Fig. 102).
(3) Install companion flange on front shaft (Fig.
103). Then install and tighten flange nut to 176-271
N´m (130-200 ft. lbs.) torque.(4) Install propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - INSTALLATION)
SHIFT LEVER
REMOVAL
(1) Shift transfer case into 2H.
(2) Remove transfer case shifter knob cap.
(3) Remove nut holding shifter knob to shift lever.
(4) Remove shifter knob.
(5) Remove the shift boot from the shifter bezel.
(6) Remove the bolts securing the shifter mecha-
nism to the floor pan along the driver's side of the
transmission tunnel (Fig. 104).
(7) Raise and support the vehicle.
(8) Loosen adjusting trunnion lock bolt and slide
shift rod out of trunnion. If rod lacks enough travel
to come out of trunnion, push trunnion out of shift
lever.
(9) Remove the nuts holding the shifter mecha-
nism to the underside of the floor pan.
(10) Separate shift lever mechanism from the vehi-
cle.
Fig. 101 Front Output Seal Installation
1 - INSTALLER 8143-A
2 - TRANSFER CASE
Fig. 102 Installing Flange Seal On Front Shaft
1 - FRONT OUTPUT SHAFT
2 - FLANGE SEAL
Fig. 103 Installing Companion Flange On Front
Shaft
1 - COMPANION FLANGE
21 - 852 TRANSFER CASE - NV231HDBR/BE
FRONT OUTPUT SHAFT SEAL (Continued)

EXTENSION HOUSING
BUSHING AND SEAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove rear propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Using a suitable pry tool or slide-hammer
mounted screw, remove the extension housing seal.
(4) Using Remover 8158, remove bushing from
extension housing.
INSTALLATION
(1) Clean fluid residue from sealing surface and
inspect for defects.
(2) Position replacement bushing in extension
housing with fluid port in bushing aligned with slot
in housing.
(3) Using Installer 8157, drive bushing into hous-
ing until installer seats against case.
(4) Using Installer D-163, install seal in extension
housing (Fig. 97).
(5) Install propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - INSTALLATION)
(6) Verify proper transfer case fluid level.
(7) Lower vehicle.
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL
The fill and drain plugs are both in the rear case
(Fig. 98).
(1) Raise vehicle.
(2) Position drain pan under transfer case.
(3) Remove drain and fill plugs and drain lubri-
cant completely.
(4) Install drain plug. Tighten plug to 41-54 N´m
(30-40 ft. lbs.).
(5) Remove drain pan.
(6) Fill transfer case to bottom edge of fill plug
opening with MopartATF +4, type 9602, Automatic
Transmission fluid.
(7) Install and tighten fill plug to 41-54 N´m
(30-40 ft. lbs.).
(8) Lower vehicle.
Plug, Extension - C-293-3
Tool Set - L-4518
Cup - 8148
Installer, Pump Housing Seal - 7888
Fig. 97 Install Rear Seal in Extension Housing
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL D-163
BR/BETRANSFER CASE - NV241LD 21 - 885
TRANSFER CASE - NV241LD (Continued)

EXTENSION HOUSING
BUSHING AND SEAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove rear propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Using a suitable pry tool or slide-hammer
mounted screw, remove the extension housing seal.
(4) Using Remover 8155, remove bushing from
extension housing (Fig. 98).
INSTALLATION
(1) Clean fluid residue from sealing surface and
inspect for defects.
(2) Position replacement bushing in extension
housing with fluid port in bushing aligned with slot
in housing.
(3) Using Installer 8156, drive bushing into hous-
ing until installer seats against case (Fig. 99).
(4) Using Installer 8154, install seal in extension
housing (Fig. 100).
(5) Install propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - INSTALLATION)
(6) Verify proper transfer case fluid level.
(7) Lower vehicle.
Installer, Bearing - 5062
Installer, Bushing - 5066
Installer, Pump Housing Seal - 7888
Remover, Bearing - L-4454
Cup - 8148
Fig. 98 Extension Housing Bushing Removal
1 - REMOVER 8155
2 - EXTENSION HOUSING BUSHING
BR/BETRANSFER CASE - NV241HD 21 - 921
TRANSFER CASE - NV241HD (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

(4) Install the screws attaching the console to
mounting brackets.
(5) Install the transmission shifter boot, (Refer to
23 - BODY/INTERIOR/SHIFT BOOT - INSTALLA-
TION).
(6) Install the transfer case shifter boot, if
equipped. (Refer to 23 - BODY/INTERIOR/SHIFT
BOOT - INSTALLATION).
(7) Install cup holder in console, if equipped.
CARPETS AND FLOOR MATS
REMOVAL
STANDARD CAB
(1) Remove seat (Refer to 23 - BODY/SEATS/SEAT
- BENCH SEAT - REMOVAL) or(Refer to 23 - BODY/
SEATS/SEAT - SPLIT BENCH - REMOVAL).
(2) Remove door sill covers (Refer to 23 - BODY/
INTERIOR/DOOR SILL TRIM - REMOVAL).
(3) Remove cowl trim covers (Refer to 23 - BODY/
INTERIOR/COWL TRIM COVER - REMOVAL).
(4) Remove center console, if equipped.(Refer to 23
- BODY/INTERIOR/CENTER CONSOLE -
REMOVAL)
(5) If not equipped with a center console remove
the transfer case shifter boot (Refer to 23 - BODY/IN-
TERIOR/SHIFT BOOT/TRANSFER CASE - REMOV-
AL).
(6) Remove rear stowage tray (Refer to 23 - BODY/
INTERIOR/REAR FLOOR STOWAGE TRAY -
REMOVAL).
(7) Remove rear closure panel trim (Refer to 23 -
BODY/INTERIOR/REAR CLOSURE PANEL TRIM -
REMOVAL).
(8) Fold carpet or mat toward center of cab.
(9) Remove carpet or mat through door opening
(Fig. 11).
QUAD/CLUB CABS
(1) Remove front and rear seats. (Refer to 23 -
BODY/SEATS/SEAT - BENCH SEAT - REMOVAL)
or(Refer to 23 - BODY/SEATS/SEAT - SPLIT BENCH
- REMOVAL) and (Refer to 23 - BODY/SEATS/REAR
SEAT - REMOVAL)
(2) Remove door sill covers (Refer to 23 - BODY/
INTERIOR/DOOR SILL TRIM - REMOVAL).
(3) Remove center console, if equipped.(Refer to 23
- BODY/INTERIOR/CENTER CONSOLE -
REMOVAL)
(4) If not equipped with a center console remove
the transfer case shifter boot (Refer to 23 - BODY/IN-
TERIOR/SHIFT BOOT/TRANSFER CASE - REMOV-
AL).
(5) Remove emergency jack tool kit.(6) Remove rear seat belt buckles. (Refer to 8 -
ELECTRICAL/RESTRAINTS/SEAT BELT BUCKLE -
REMOVAL)
(7) Remove rear closure panel trim (Refer to 23 -
BODY/INTERIOR/REAR CLOSURE PANEL TRIM -
REMOVAL).
(8) Remove C-pillar trim panels. (Refer to 23 -
BODY/INTERIOR/C-PILLAR TRIM - REMOVAL)
(9) Remove the quarter trim panels. (Refer to 23 -
BODY/INTERIOR/QUARTER TRIM PANEL -
REMOVAL)
(10) Fold carpet or mat toward center of cab.
(11) Remove carpet or mat through door opening.
INSTALLATION
STANDARD CAB
(1) Position carpet or mat in vehicle and align all
holes (Fig. 11).
(2) Install rear closure panel trim (Refer to 23 -
BODY/INTERIOR/REAR CLOSURE PANEL TRIM -
INSTALLATION).
(3) Install rear stowage tray (Refer to 23 - BODY/
INTERIOR/REAR FLOOR STOWAGE TRAY -
INSTALLATION).
(4) Install the transfer case shifter boot if not
equipped with a center console. (Refer to 23 - BODY/
INTERIOR/SHIFT BOOT/TRANSFER CASE -
INSTALLATION)
(5) Install the center console, if equipped. (Refer to
23 - BODY/INTERIOR/CENTER CONSOLE -
INSTALLATION)
(6) Install cowl trim covers (Refer to 23 - BODY/
INTERIOR/COWL TRIM COVER - INSTALLATION).
Fig. 11 Floor Carpet or Mat
1 - CARPET OR MAT
2 - FLOOR PAN
3 - REAR/INNER SEAT MOUNT
4 - POWER SEAT HARNESS
BR/BEINTERIOR 23 - 123
CENTER CONSOLE (Continued)

(7) Install door sill covers (Refer to 23 - BODY/IN-
TERIOR/DOOR SILL TRIM - INSTALLATION).
(8) Install seat, (Refer to 23 - BODY/SEATS/SEAT
- INSTALLATION) or (Refer to 23 - BODY/SEATS/
SEAT/SPLIT BENCH - INSTALLATION).
QUAD/CLUB CABS
(1) Position carpet or mat in vehicle.
(2) Install quarter trim panels. (Refer to 23 -
BODY/INTERIOR/QUARTER TRIM PANEL -
INSTALLATION)
(3) Install rear seat belt buckles.
(4) Install the C-pillar trim panels, if equipped.
(Refer to 23 - BODY/INTERIOR/C-PILLAR TRIM -
INSTALLATION)
(5) Install rear closure panel trim (Refer to 23 -
BODY/INTERIOR/REAR CLOSURE PANEL TRIM -
INSTALLATION).
(6) Install the rear seat belt buckles. (Refer to 8 -
ELECTRICAL/RESTRAINTS/SEAT BELT BUCKLE -
INSTALLATION)
(7) Install emergency jack tool kit.
(8) Install the transfer case shifter boot if not
equipped with a center console. (Refer to 23 - BODY/
INTERIOR/SHIFT BOOT/TRANSFER CASE -
INSTALLATION)
(9) Install the center console, if equipped. (Refer to
23 - BODY/INTERIOR/CENTER CONSOLE -
INSTALLATION)
(10) Install floor shift boot, if equipped.
(11) Install cowl trim covers (Refer to 23 - BODY/
INTERIOR/COWL TRIM COVER - INSTALLATION).
(12) Install door sill covers (Refer to 23 - BODY/
INTERIOR/DOOR SILL TRIM - INSTALLATION).
(13) Install front and rear seats. (Refer to 23 -
BODY/SEATS/SEAT - BENCH SEAT - INSTALLA-
TION) or (Refer to 23 - BODY/SEATS/SEAT - SPLIT
BENCH - INSTALLATION) and (Refer to 23 - BODY/
SEATS/REAR SEAT - INSTALLATION)
ASSIST HANDLE
REMOVAL
(1) Disengage tabs attaching assist handle end
covers to assist handle.
(2) Remove screws attaching overhead assist han-
dle to roof rail (Fig. 12).
(3) Separate overhead assist handle from vehicle.
INSTALLATION
(1) Position assist handle on vehicle.
(2) Install screws attaching overhead assist handle
to roof rail (Fig. 12).
(3) Install tabs attaching assist handle end covers
to assist handle.
COAT HOOK
REMOVAL
(1) Insert a small flat blade into the tip of the
hook.
(2) Carefully pry outward to separate the coat
hook from coat hook base.
(3) Pull coat hook out of roof panel (Fig. 13).
Extended cab shown, standard cab similar.
Fig. 12 Overhead Assist Handle
1 - CAB ASSEMBLY
2 - SCREW
3 - ASSIST HANDLE
4 - TRIM COVER
Fig. 13 Coat HookÐClub/Quad Cab
1 - COAT HOOK
23 - 124 INTERIORBR/BE
CARPETS AND FLOOR MATS (Continued)

(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)

INSTALLATION
(1) Position trim panel in vehicle and route seat
belt webbing through opening in quarter trim panel.
(2) Open quarter vent window.
(3) Position trim panel on quarter panel and
engage clips on upper portion of panel.
(4) Engage clips attaching lower portion of quarter
trim panel to quarter panel.
(5) Install lower seat belt anchor bolt.
(6) Install door sill cover as necessary.
(7) Install rear seat. (Refer to 23 - BODY/SEATS/
REAR SEAT - INSTALLATION)
C-PILLAR TRIM
REMOVAL
(1) Remove rear floor stowage tray. (Refer to 23 -
BODY/INTERIOR/REAR FLOOR STOWAGE TRAY -
REMOVAL)
(2) Remove door sill cover as necessary to clear
C-pillar trim.
(3) Remove bolt attaching seat belt anchor to floor.
(4) Unsnap turning loop, push cover up and
remove bolt attaching turning loop to C-pillar.(5) Remove seat belt exit plug.
(6) Disengage clips attaching C-pillar trim to
upper C-pillar.
(7) Separate C-pillar trim from C-pillar.
(8) Route seat belt webbing through opening in
C-pillar trim.
INSTALLATION
(1) Route seat belt webbing through opening in
C-pillar trim.
(2) Position C-pillar trim at C-pillar.
(3) Starting at the top, engage clips attaching
C-pillar trim to upper C-pillar.
(4) Install seat belt exit plug.
(5) Install bolt attaching turning loop to C-pillar
and position turning loop cover. Snap turning loop
cover into place.
(6) Install bolt attaching seat belt anchor to floor.
(7) Install door sill cover.
(8) Install rear floor stowage tray. (Refer to 23 -
BODY/INTERIOR/REAR FLOOR STOWAGE TRAY -
INSTALLATION)
23 - 128 INTERIORBR/BE
QUARTER TRIM PANEL (Continued)

INSTALLATION
(1) Align console lid with console. Verify lid tension
spring is in position.
(2) Install hinge pin.
(3) Position trim bezel on lid and snap into place.
CENTER SEAT ARMREST/
CONSOLE
REMOVAL
(1) Remove bolts on driver and passenger seat
inboard seat tracks.
(2) Separate center section.
INSTALLATION
(1) Position and align center section on driver and
passenger seat inboard seat tracks.
(2) Install bolts. Tighten to 19.5 N´m (14 ft. lbs.)
torque.
CENTER SEAT ARMREST/
LATCH COVER
REMOVAL
(1) With the seat back fully forward, move the
driver's seat to a full forward position.
(2) Place the center arm rest in a full up position.
(3) Remove the fastener securing the cover to the
inertia latch.
(4) Disengage the front edge of the cover, then
lower the arm rest.
(5) Remove the inertia latch cover by pulling the
cover rearwards (Fig. 1).
INSTALLATION
(1) Slide the inertia latch cover onto the latch arm.
(2) Raise the armrest, then engage the front edge
of the cover.
(3) Install the lower strap into the center armrest's
lower track (Fig. 2).
(4) Slide back the armrest trim to visually ensure
the lower strap is properly installed.
(5) Slowly cycle the armrest to ensure the strap
moves freely in the track.
(6) Install the upper strap into the center arm-
rest's upper track (Fig. 3).
(7) Slowly cycle the armrest to ensure the strap
moves freely in the track.
(8) Secure the armrest inertia latch cover and
tighten the fastener to 4N´m (35 in. lbs.).
Fig. 1 Armrest Inertia Latch Cover
1 - INERTIA LATCH COVER
Fig. 2 Inertia Latch Cover Lower Strap Installation
23 - 132 SEATSBR/BE
CENTER CONSOLE LID (Continued)