DODGE RAM 2002 Service Repair Manual

(11) Secure wire harness tie-downs to wheelhouse.
(12) Install power distribution center to wheel-
house.
(13) Install battery tray (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/TRAY - INSTALLATION).
(14) Install coolant overflow bottle (V-10 ONLY).
(15) Install air cleaner (DIESEL ONLY).
(16) Install front bumper (Refer to 13 - FRAMES
& BUMPERS/BUMPERS/FRONT BUMPER -
INSTALLATION).
RIGHT FRONT FENDER
REMOVAL
(1) Remove front bumper (Refer to 13 - FRAMES
& BUMPERS/BUMPERS/FRONT BUMPER -
REMOVAL).
(2) Disconnect and isolate battery negative cable.
(3) Remove auxiliary battery and tray on right
side, if equipped.
(4) Disengage wire harness tie-downs from wheel-
house.
(5) Disconnect wiring harness to headlamp connec-
tor.
(6) Disconnect wiring harness to airbag sensor and
remove airbag sensor from wheelhouse.
(7) Remove front wheelhouse liner (Fig. 13) (Refer
to 23 - BODY/EXTERIOR/FRONT END SPLASH
SHIELDS - REMOVAL).
(8) Disengage air conditioning tubing from inner
fender clips.
(9) Remove bolts attaching front fender to cowl
reinforcement (Fig. 15).
(10) Remove bolts attaching front fender to radia-
tor closure panel.(11) Remove bolts attaching bottom of front fender
to rocker panel lower flange (Fig. 17).
(12) Open right door.
(13) Remove bolt attaching front fender to hinge
pillar mounting bracket (Fig. 17).
(14) Remove bolts attaching top of fender to radia-
tor closure panel (Fig. 17).
(15) Separate right front fender from vehicle.
INSTALLATION
(1) Position fender on vehicle.
(2) Install bolts attaching top of fender to radiator
closure panel.
(3) Install bolt attaching front fender to hinge pil-
lar mounting bracket.
(4) Install bolts attaching bottom of front fender to
rocker panel lower flange.
(5) Install bolts attaching front fender to radiator
closure panel.
(6) Install bolts attaching front fender to cowl rein-
forcement.
(7) Secure air conditioning tubing to inner fender
clips.
(8) Install front wheelhouse liner (Refer to 23 -
BODY/EXTERIOR/FRONT END SPLASH SHIELDS
- INSTALLATION).
(9) Install airbag sensor and connect wiring har-
ness to airbag sensor.
(10) Connect wiring harness to headlamp connec-
tor.
(11) Secure wire harness tie-downs to wheelhouse.
(12) Install auxiliary battery tray and battery on
right side, if equipped.
(13) Connect battery negative cable.
(14) Install front bumper (Refer to 13 - FRAMES
& BUMPERS/BUMPERS/FRONT BUMPER -
INSTALLATION).
Fig. 16 Left Fender to Radiator Closure Panel
Fasteners
1 - LEFT FENDER
2 - RADIATOR CLOSURE PANEL
Fig. 17 Right Front Fender
1 - RADIATOR CLOSURE PANEL
2 - RIGHT FENDER
23 - 94 EXTERIORBR/BE
LEFT FRONT FENDER (Continued)

FUEL FILL DOOR
REMOVAL
(1) Open fuel fill door.
(2) Remove bolts attaching fuel fill door to cargo
box quarter panel (Fig. 18).
(3) Separate fuel fill door from vehicle.
INSTALLATION
(1) Separate fuel fill door on cargo box.
(2) Install bolts attaching fuel fill door to cargo box
quarter panel.
REAR FENDER
REMOVAL
(1) Open fuel fill door, left side only.
(2) Remove screws attaching fuel fill neck to rear
fender opening.
(3) Remove tail lamp. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/TAIL LAMP UNIT
- REMOVAL)
(4) Remove nuts attaching rear fender to cargo box
side panel through tail lamp opening.
(5) Remove the identification lamps. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
OUTBOARD IDENTIFICATION LAMP - REMOVAL)
(6) Remove bolts attaching bottom of fender to
cargo box forward of rear wheel.
(7) Remove bolts attaching bottom of fender to
cargo box rearward of rear wheel.
(8) Remove rear wheelhouse splash shields (Refer
to 23 - BODY/EXTERIOR/REAR WHEELHOUSE
SPLASH SHIELD - REMOVAL).(9) Remove rear wheelhouse liner, if equipped
(Refer to 23 - BODY/EXTERIOR/REAR WHEEL-
HOUSE SPLASH SHIELD - REMOVAL).
(10) Remove nuts attaching front of rear fender to
cargo box from behind side panel forward of wheel-
house.
(11) Remove screws attaching access panel to top
of wheelhouse.
(12) Remove nuts attaching rear fender to cargo
box through access hole in top of wheelhouse.
(13) Separate rear fender from cargo box side
panel (Fig. 19).
INSTALLATION
Ensure the retainers are in good condition.
(1) Position rear fender on cargo box side panel.
(2) Using access hole in top of wheelhouse, install
nuts attaching rear fender to cargo box.
(3) Install screws attaching access panel to top of
wheelhouse.
(4) From behind side panel forward of wheelhouse,
install nuts attaching front of rear fender to cargo
box.
(5) Install rear wheelhouse liners if equipped,
(Refer to 23 - BODY/EXTERIOR/REAR WHEEL-
HOUSE SPLASH SHIELD - INSTALLATION).
(6) Install rear wheelhouse splash shields (Refer to
23 - BODY/EXTERIOR/REAR WHEELHOUSE
SPLASH SHIELD - INSTALLATION).
(7) Install bolts attaching bottom of fender to cargo
box rearward of rear wheel.
(8) Install bolts attaching bottom of fender to cargo
box forward of rear wheel.
(9) Install identification lamps. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/OUT-
BOARD IDENTIFICATION LAMP -
INSTALLATION)
Fig. 18 Fuel Fill Door
1 - CARGO BOX
2 - FUEL FILL DOOR
Fig. 19 Rear Fender - Dual Wheels
1 - RETAINER
2 - FENDER (DUAL WHEEL)
BR/BEEXTERIOR 23 - 95

(10) Using tail lamp opening, install nuts attach-
ing rear fender to cargo box side panel.
(11) Install tail lamp. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/TAIL LAMP UNIT
- INSTALLATION)
(12) Install screws attaching fuel fill neck to rear
fender opening.
REAR SPLASH SHIELD
REMOVAL
(1) Remove screws holding rear splash shield to
rear wheel opening lip (Fig. 20).
(2) Remove push in fasteners holding rear splash
shield to rear wheelhouse.
(3) Separate splash shield from vehicle.
INSTALLATION
(1) Position splash shield in wheelhouse opening.
(2) Install plastic rivets holding rear splash shield
to rear wheelhouse.
(3) Install plastic rivets holding rear splash shield
to rear wheel opening lip.
REAR WHEELHOUSE LINER
REMOVAL
(1) Remove plastic rivets attaching rear wheel-
house liner to rear wheel opening lip (Fig. 21).
(2) Remove plastic rivets attaching rear wheel-
house liner to rear wheelhouse.
(3) Separate rear wheelhouse liner form vehicle.
INSTALLATION
(1) Position rear wheelhouse liner in wheelhouse
opening.
(2) Install plastic rivets attaching rear wheelhouse
liner to rear wheelhouse.
(3) Working front to rear, install plastic rivets
attaching rear wheelhouse liner to rear wheel open-
ing lip.
Fig. 20 REAR SPLASH SHIELDS
1 - FUEL FILLER DOOR
2 - REAR FENDER
3 - REAR SECTION REAR WHEEL HOUSE LINER
4 - PUSH IN FASTENERS
Fig. 21 Rear Wheelhouse Liner
1 - FENDER
2 - WHEEL HOUSELINER
3 - PLASTIC RIVET
23 - 96 EXTERIORBR/BE
REAR FENDER (Continued)

CARGO BOX
REMOVAL
CAUTION: The bolts attaching the cargo box to the
frame are specially coated to provide a locking action.
These bolts are not reusable and must be replaced
each time the cargo box is removed or replaced.
(1) Open fuel fill door.
(2) Remove screws attaching fuel fill neck adaptor
to cargo box side wall.
(3) Separate fuel fill neck from cargo box.
(4) Disengage tail lamp wire connector from main
body harness at left rear frame rail.
(5) Remove bolts attaching cargo box to frame rails
(Fig. 22).
(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.
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

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).
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
CAUTION: It is important to make sure the motor is
square to the glass holder (attaching fingers) prior
to glass holder attachment, otherwise the glass
holder could be installed incorrectly causing poor
retention and possible repeat failure.
(1) Position the new mirror glass holder to the
mirror assembly.
NOTE: Position the mirror glass holder so that the
moisture drain hole on the mirror glass holder
assembly is facing downward.
(2) Align the mirror glass holder's attaching fin-
gers to the mirror motor housing.
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)

NOTE: Ensure that the protective rubber cover of
the mirror motor housing is positioned correctly
around the bottom of the fingers area.
(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 attaching fingers to the correspond-
ing fingers on the housing assembly. One or more
clicks may be heard when finger engagement takes
place.
(4) Verify retention of the mirror glass holder
assembly by gently pulling outward on the mirror
glass holder.
BR/BEEXTERIOR 23 - 99
SIDE VIEW MIRROR GLASS (Continued)

HOOD
TABLE OF CONTENTS
page page
HINGE
REMOVAL............................100
INSTALLATION........................100
HOOD
REMOVAL............................101
INSTALLATION........................101
ADJUSTMENTS
ADJUSTMENT.......................101
LATCH
REMOVAL............................102
INSTALLATION........................102
ADJUSTMENTS
ADJUSTMENT.......................102
LATCH RELEASE CABLE
REMOVAL............................103INSTALLATION........................103
LATCH STRIKER
REMOVAL............................103
INSTALLATION........................103
ADJUSTMENTS
ADJUSTMENT.......................103
SAFETY LATCH
REMOVAL............................104
INSTALLATION........................104
SILENCER PAD
REMOVAL............................104
INSTALLATION........................104
HINGE
REMOVAL
(1) Open hood and support the side that requires
hinge replacement.
(2) Mark all bolt and hinge attachment locations
with a grease pencil or equivalent to provide refer-
ence marks for installation.
(3) Remove nuts attaching hood to hinge (Fig. 1).
(4) Remove bolts attaching hood hinge to cowl.
(5) Separate hinge from vehicle.
INSTALLATION
(1)If necessary, paint new hinge before installation.
(2) Position hinge on vehicle.
(3) Align all marks
(4) Install bolts attaching hood hinge to cowl.
(5) Install nuts attaching hood to hinge.
Fig. 1 Hood Hinge
1 - HOOD
2 - COWL
3 - HINGE
23 - 100 HOODBR/BE

HOOD
REMOVAL
(1) Disconnect the under hood lamp wire connec-
tor.
(2) Disconnect the air temperature sensor wire
connector, if equipped.
(3) Mark all bolt and hinge attachment locations
with a grease pencil or equivalent to provide refer-
ence marks for installation.
(4) Remove top nuts attaching hood to hinge and
loosen bottom nuts until they can be removed by
hand (Fig. 2).
(5) With assistance of a helper at the opposite side
of the vehicle to support the hood, remove the bottom
nuts. Separate the hood from the vehicle.
INSTALLATION
(1) With assistance of a helper, position hood on
vehicle loosely install bottom nuts.
Align all marks, install top nuts and tighten bot-
tom nuts. The hood should be aligned to 5 mm (0.2
in.) gap to the front fenders and flush across the top
surfaces along fenders.
(2) Connect the air temperature sensor wire con-
nector, if equipped.
(3) Connect the under hood lamp wire connector.
ADJUSTMENTS
ADJUSTMENT
(1) Loosen the hinge arm-to-hood panel bolts at
each side of the vehicle.(2) Loosen the hood latch screws.
(3) Close the hood. Adjust the fore/aft position.
(4) Raise the hood. Tighten the hinge arm-to-hood
panel bolts.
(5) Tighten the latch screws.
(6) Lower the hood. Inspect clearance between the
hood and the cowl cover.
Fig. 2 Hood
1 - HOOD
2 - HOOD HINGE
3 - FENDER
BR/BEHOOD 23 - 101

LATCH
REMOVAL
(1) Remove bolts attaching hood latch to radiator
closure panel crossmember (Fig. 3).
(2) Separate hood latch from crossmember.
(3) Disconnect release cable from hood latch.
INSTALLATION
(1) Connect release cable to hood latch.
(2) Position hood latch on crossmember.
(3) Install bolts attaching hood latch to radiator
closure panel crossmember.
ADJUSTMENTS
ADJUSTMENT
(1) Loosen the hood latch screws.
(2) Move the latch to the correct location and
lightly tighten the screws.
(3) Close the hood slowly and observe the latching
operation.
(4) As necessary, re-adjust the latch position and
tighten the screws.
Fig. 3 Hood Latch
1 - LATCH ASSEMBLY
2 - CABLE
3 - SCREW
4 - LATCH ASSEMBLY5 - HOOD SECONDARY SKID PLATE
6 - PUSHÐIN FASTENER
7 - CABLE
23 - 102 HOODBR/BE

LATCH RELEASE CABLE
REMOVAL
(1) Remove hood latch (Refer to 23 - BODY/HOOD/
LATCH - REMOVAL).
(2) Disconnect release cable from hood latch.
(3) Detach the release cable from the retainer clips
in the engine compartment.
(4) Separate the release cable grommet from the
dash panel hole.
(5) From the inside of the vehicle, remove the
screws attaching the hood release handle to the bot-
tom of the instrument panel (Fig. 4).
(6) Pull/route the hood release cable through the
dash panel hole and remove it via the inside of the
vehicle.
INSTALLATION
NOTE: If replacement hood latch is also being
installed, ensure that it is thoroughly lubricated.
(1) From inside the vehicle, pull/route the hood
release cable through the dash panel hole and into
the engine compartment.
(2) Install the hood release handle.
(3) Install the cable grommet in the dash panel
hole.
(4) Attach the release cable to the retainer clips in
the engine compartment.
(5) Attach release cable to hood latch.
(6) Install hood latch (Refer to 23 - BODY/HOOD/
LATCH - INSTALLATION).
(7) Test the hood latch release cable for proper
operation.
LATCH STRIKER
REMOVAL
(1) Open hood.
(2) Remove bolts attaching hood latch striker to
hood (Fig. 5).
(3) Separate hood latch striker from hood.
INSTALLATION
(1) Position hood latch striker on hood.
(2)
Install bolts attaching hood latch striker to hood.
ADJUSTMENTS
ADJUSTMENT
(1) Open the hood.
(2) Loosen the latch striker screws.
(3) Slowly close the hood and observe the latching
operation.As necessary, re-adjust the striker position.
Tighten the screws.
Fig. 4 Hood Release Handle
1 - INSTRUMENT PANEL
2 - HOOD RELEASE HANDLE
3 - HOOD RELEASE CABLE
BR/BEHOOD 23 - 103