DODGE RAM 2002 Service Repair Manual

LOCK CYLINDER
REMOVAL
(1) Remove outside door handle (Refer to 23 -
BODY/DOOR - FRONT/EXTERIOR HANDLE -
REMOVAL).
(2) Remove clip securing lock cylinder to outside
door handle (Fig. 14).
(3) Pull lock cylinder from door handle.
INSTALLATION
(1) Position lock cylinder in door handle.
(2) Install clip securing lock cylinder to outside
door handle.
(3) Install outside door handle (Refer to 23 -
BODY/DOOR - FRONT/EXTERIOR HANDLE -
INSTALLATION).
SIDE VIEW MIRROR FLAG
REMOVAL
(1) Remove door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL)
(2) Remove flag door seal.
(3) Remove nuts attaching mirror flag cover to
door frame (Fig. 15).
(4) Separate flag cover from door.
Fig. 13 Front Door Latch Striker
1 - RETAINING PLATE
2 - SCREW
3 - STRIKER
4 - SPACERFig. 14 Door Lock Cylinder
1 - DOOR HANDLE
2 - LOCK CYLINDER
3 - LOCK CYLINDER RETAINER
4 - LOCK RETAINING CLIP
Fig. 15 Mirror Flag Cover
1 - NUT
2 - DOOR
3 - FLAG COVER ASSEMBLY
23 - 74 DOOR - FRONTBR/BE
LATCH STRIKER (Continued)

INSTALLATION
(1) Position flag cover on door.
(2) Install nuts attaching mirror flag cover to door
frame.
(3) Install flag door seal.
(4) Install door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - INSTALLATION)
TRIM PANEL
REMOVAL
(1) Roll window down.
(2) Remove window crank (Fig. 16), if equipped.
(3) Remove screw attaching trim panel to outside
mirror frame.
(4) Remove screws attaching pull cup to door (Fig.
17).
(5) Using a trim panel removal tool, disengage
clips around perimeter of trim panel, attaching trim
panel to door.
(6) While holding bottom of trim panel away from
door, simultaneously lift upward and inboard.
(7) Disengage power mirror switch connector, if
equipped.
(8) Disengage power window/lock switch connec-
tors from switch panel, if equipped (Fig. 18).
(9) Separate trim panel from door.
INSTALLATION
NOTE: When replacing door trim panel, installer
must replace the X-mas tree style pin 6506878aa.
(1) Engage power mirror switch connector, if
equipped.
(2) Engage power window/lock switch connectors to
switch panel, if equipped.
Fig. 16 Window CrankÐTypical
1 - WINDOW CRANK REMOVAL TOOL
2 - WINDOW CRANK
Fig. 17 Door Trim Panel
1 - SCREW
2 - SCREW
3 - TRIM PANEL
4 - DOOR LOCK BUTTON
5 - POWER WINDOW HARNESS
6 - POWER MIRROR HARNESS
7 - POWER MIRROR
8 - POWER MIRROR CONTROL
Fig. 18 Power Window/Lock Switch Panel
1 - ELECTRICAL CONNECTOR
2 - POWER WINDOW/LOCK SWITCH PANEL
3 - WIRE HARNESS
BR/BEDOOR - FRONT 23 - 75
SIDE VIEW MIRROR FLAG (Continued)

(3) Position trim panel on door.
(4) Engage clips around perimeter of trim panel,
attaching trim panel to door.
(5) Install screws attaching pull cup to door.
(6) Install screw attaching trim panel to outside
mirror frame.
(7) Install window crank, if equipped.
WATERDAM
REMOVAL
(1) Remove door trim panel (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL).
(2) Peel waterdam away from adhesive around
perimeter of inner door panel (Fig. 19).
INSTALLATION
(1) Position and align water dam with adhesive
around perimeter of inner door panel.
(2) Press water dam onto inner door panel to
secure.
(3) Install door trim panel (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - INSTALLATION).
WINDOW REGULATOR
REMOVAL
(1) Remove the door waterdam (Refer to 23 -
BODY/DOOR - FRONT/WATERDAM - REMOVAL).
(2) Remove nuts attaching door glass to window
regulator.(3) Remove glass from door or move glass to full
up position and secure glass to door with tape.
(4) Disengage power window motor wire connector
from door harness, if equipped.
(5) Remove bolts attaching window regulator to
inner door panel.
(6) Separate window regulator from door panel
(Fig. 20).
(7) Extract window regulator through access hole
in inner door panel.
INSTALLATION
(1) Position window regulator in door through
access hole.
(2) Install bolts attaching window regulator to
inner door panel.
(3) Engage power window motor wire connector to
door harness, if equipped.
(4) Install glass in lift plate.
(5) Install the door waterdam (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION).
Fig. 19 Door Water Dam
1 - WATER DAM
2 - DOOR
Fig. 20 Door Glass Window Regulator
1 - DOOR ASSEMBLY
2 - WINDOW REGULATOR ASSEMBLY
3 - DOOR GLASS ASSEMBLY
4 - WINDOW REGULATOR
23 - 76 DOOR - FRONTBR/BE
TRIM PANEL (Continued)

DOOR - CARGO
TABLE OF CONTENTS
page page
AIR EXHAUSTER
REMOVAL.............................77
INSTALLATION.........................77
CHECK
REMOVAL.............................78
INSTALLATION.........................78
DOOR
REMOVAL.............................78
INSTALLATION.........................78
ADJUSTMENTS
ADJUSTMENT - CARGO DOOR..........78
EXHAUST VENT
REMOVAL.............................79
INSTALLATION.........................79
HINGE
REMOVAL.............................79
INSTALLATION.........................80
INSIDE HANDLE ACTUATOR
REMOVAL.............................80
INSTALLATION.........................80
LATCH - LOWER
REMOVAL.............................80
INSTALLATION.........................80
LATCH - UPPER
REMOVAL.............................81INSTALLATION.........................81
LATCH STRIKER - LOWER
REMOVAL.............................82
INSTALLATION.........................82
LATCH STRIKER - UPPER
REMOVAL.............................82
INSTALLATION.........................82
RELEASE CABLE
REMOVAL.............................82
INSTALLATION.........................82
SHUTFACE HANDLE
REMOVAL.............................83
INSTALLATION.........................83
TRIM PANEL
REMOVAL.............................83
INSTALLATION.........................84
VENT WINDOW
REMOVAL.............................85
INSTALLATION.........................85
WATERDAM
REMOVAL.............................85
INSTALLATION.........................85
AIR EXHAUSTER
REMOVAL
(1) Remove cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(2) Peel back waterdam.
(3) Remove push-in fastener attaching air
exhauster to cargo door inner panel (Fig. 1).
(4) Separate air exhauster from cargo door.
INSTALLATION
(1) Position air exhauster in cargo door.
(2) Engage air exhauster upper tabs with cargo
door inner panel.
(3) Install push-in fastener attaching air exhauster
to cargo door inner panel (Fig. 1).
(4) Reposition waterdam.
(5) Install cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
Fig. 1 Cargo Door Air Exhauster
1 - CARGO DOOR
2 - PUSHÐIN FASTENER
3 - DOOR EXHAUSTER
4-TAB
BR/BEDOOR - CARGO 23 - 77

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).
ADJUSTMENTS
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-
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

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.
(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.
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)

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).
(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.
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)

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.
(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 mountinghole 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.
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)

(4) Install cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
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.
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).
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
23 - 82 DOOR - CARGOBR/BE
LATCH - UPPER (Continued)

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).
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.
Fig. 13 Shutface Door Handle
1 - RELEASE CABLE
2 - SHUTFACE DOOR HANDLE
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)