torque DODGE RAM 2002 Service Repair Manual

DIAGNOSIS AND TESTING
WHEEL INSPECTION
Inspect wheels for:
²Excessive run out
²Dents or cracks
²Damaged wheel lug nut holes
²Air Leaks from any area or surface of the rim
NOTE: Do not attempt to repair a wheel by hammer-
ing, heating or welding.
If a wheel is damaged an original equipment
replacement wheel should be used. When obtaining
replacement wheels, they should be equivalent in
load carrying capacity. The diameter, width, offset,
pilot hole and bolt circle of the wheel should be the
same as the original wheel.
WARNING: FAILURE TO USE EQUIVALENT REPLACE-
MENT WHEELS MAY ADVERSELY AFFECT THE
SAFETY AND HANDLING OF THE VEHICLE. USED
WHEELS ARE NOT RECOMMENDED. THE SERVICE
HISTORY OF THE WHEEL MAY HAVE INCLUDED
SEVERE TREATMENT OR VERY HIGH MILEAGE. THE
RIM COULD FAIL WITHOUT WARNING.
STANDARD PROCEDURE - DUAL REAR WHEEL
INSTALLATION
Dual rear wheels use a special heavy duty lug nut
wrench. It is recommended to remove and install dual
rear wheels only when the proper wrench is available.
The wrench is also use to remove wheel center caps for
more information refer to Owner's Manual.
The tires on both wheels must be completely raised
off the ground when tightening the lug nuts. This
will ensure correct wheel centering and maximum
wheel clamping.
A two piece flat face lug nut with right-hand
threads is used for retaining the wheels on the hubs
(Fig. 20).The dual rear wheel lug nuts should be tightened
according to the following procedure:
²Place two drops of oil to the interface of the nut/
washer (Fig. 20) before installing on the wheel stud.
NOTE: Do not use more then two drops of oil on
the nut/washer, since the center caps attach in this
area.
²Tighten the wheel lug nuts in the numbered
sequential pattern until they are snug tight. Then
tighten lug nut to specified torque following same
number sequence, (Refer to 22 - TIRES/WHEELS/
WHEELS - SPECIFICATIONS).
²Tighten lug nuts in same numbered sequence a
second time to the specified torque. This will ensure
that the wheels are thoroughly mated.
²Check lug nut specified torque after 100 miles
(160 kilometers). Also after 500 miles (800 kilome-
ters) of vehicle operation.
NOTE: Wheel lug nuts should be tightened to spec-
ified torque at every maintenance interval thereafter.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Lug Nut
BR2500 (8 Stud Wheel)180 135 Ð
Lug Nut
BR3500 (8 Stud Dual
Wheel)195 145 Ð
Fig. 20 Oil Location
1 - PLACE TWO DROPS OF OIL HERE
BR/BETIRES/WHEELS 22 - 11
WHEELS (Continued)

BODY
TABLE OF CONTENTS
page page
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS . 2
DIAGNOSIS AND TESTING - WIND NOISE . . . 3
SPECIFICATIONS
WELD LOCATIONS.....................4
STRUCTURAL ADHESIVE LOCATIONS.....44
BODY SEALER LOCATIONS.............47
BODY GAP AND FLUSH MEASUREMENTS . . 56
BODY OPENING DIMENSIONS...........60TORQUE SPECIFICATIONS.............61
DECKLID/HATCH/LIFTGATE/TAILGATE.......63
DOOR - FRONT.........................68
DOOR - CARGO.........................77
EXTERIOR.............................86
HOOD................................100
INSTRUMENT PANEL SYSTEM............105
INTERIOR.............................118
PAINT................................129
SEATS...............................131
STATIONARY GLASS....................145
WEATHERSTRIP/SEALS..................151
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE AN OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
²AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL ± BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
²DO 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.
²Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
²Always have a fire extinguisher ready for use
when welding.
²Disconnect the negative (-) cable clamp from
the battery when servicing electrical components
that are live when the ignition is OFF. Damage to
electrical system can result.
²Do not use abrasive chemicals or compounds
on painted surfaces. Damage to finish can result.
²Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
to finish or color can result.
²Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
BR/BEBODY 23 - 1

TORQUE SPECIFICATIONS
BODY COMPONENTS
Description N´m Ft. lbs. In. lbs.
Ash receiver flame
shield screws2Ð20
Bench seat back latch
bolts25 18 Ð
Bench seat back to
cushion pivot bolt25 18 Ð
Bench seat front anchor
bolt54 40 Ð
Bench seat rear inboard
anchor nut40 30 Ð
Bench seat rear
outboard anchor nut54 40 Ð
Bench seat riser front
bolts54 40 Ð
Bench seat riser rear
inboard nuts40 30 Ð
Bench seat riser rear
outboard nuts54 40 Ð
Bench seat slider bolts 10 Ð 89
Bench seat/front seat
track to frame bolt25 18 Ð
Bench seat/inboard belt
buckle anchor bolt40 30 Ð
Bench seat/rear seat
track to frame bolt25 18 Ð
Cab mounting bolts 81 60 Ð
Cargo box frame bolts 54 40 Ð
Cargo door hinge bolts 28 21 Ð
Cargo door lower latch
nuts28 21 Ð
Cargo door lower striker
screws28 21 Ð
Cargo door upper larch
bolts23 17 Ð
Cargo door upper striker
bolts23 17 Ð
Cargo door vent window
latch to glass screws5Ð44
Center seat armrest
latch cover fastener4Ð35
Center seat armrest/
console bolts20 15 Ð
DOOR OPENING AND QUARTER GLASS OPENING
Ð CLUB CAB
A. 1284.8 MM D. 1235.4 MM G. 436.2 MM
B. 1190.3 MM E. 582.6 MM H. 440.5 MM
C. 1546.3 MM F. 538.8 MM J. 426.8 MM
CARGO DOOR QUARTER GLASS OPENING
E. 484.14 MM H. 427.28 MM
F. 456.83 MM J. 418.38 MM
G 424.97 MM
BR/BEBODY 23 - 61
BODY (Continued)

(14) Inspect for air bubbles. Small bubbles can be
pierced with a sharp pin and smoothed out.
(15) Install outer belt weatherstrip (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR OUTER BELT
WEATHERSTRIP - INSTALLATION).
(16) Install glass run weatherstrip (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR GLASS RUN
WEATHERSTRIP - INSTALLATION).
DOOR
REMOVAL
(1) Remove cowl trim panel (Refer to 23 - BODY/
INTERIOR/COWL TRIM COVER - REMOVAL).
(2) Disengage door wire harness connector of
instrument panel harness and push door harness
through access hole in pillar.
(3) Remove hidden bolts attaching door hinge to
hinge pillar from behind cowl panel (Fig. 2).
(4) Using a grease pencil or equivalent, mark the
outline of the door hinges on the hinge pillar to aid
installation.
(5) Support door on a suitable lifting device.
(6) Remove bolts attaching lower door hinge to
hinge pillar (Fig. 3).
(7) While holding door steady on lift, remove bolts
attaching upper door hinge to hinge pillar.
(8) Separate door from vehicle.
INSTALLATION
(1) While holding door steady on lift, position door
at A-pillar.
(2) Align hinges using reference marks.
(3) Install bolts attaching upper door hinge to
hinge pillar.
(4) Install bolts attaching lower door hinge to
hinge pillar (Fig. 3).
(5) Install hidden bolts attaching door hinge to
hinge pillar from behind cowl panel (Fig. 2).
(6) Align door to achieve equal spacing on all sides
and flush across the gaps.
(7) Tighten hinge bolts to 28 N´m (21 ft. lbs.)
torque.
(8) Route harness through door and engage door
wire harness connector.
(9) Install cowl trim panel (Refer to 23 - BODY/IN-
TERIOR/COWL TRIM COVER - INSTALLATION).
ADJUSTMENTS
ADJUSTMENT - FRONT DOOR FORE/AFT
Fore/aft (lateral) door adjustment is done by loos-
ening the hinge to cowl screws one hinge at a time.
Then move the door to the correct position.
(1) Support the door with a padded floor jack.
Fig. 1 B-Pillar Applique
1A = Club Cab - Up/Down
1B = Quad Cab - Up/Down
2 = Adhesion Strip
3A = Club Cab - For/Aft
3B = Quad Cab - For/Aft
4 = Rear Edge Locator
Fig. 2 Door Hinge Hidden Bolt
1 - HINGE
2 - DOOR HINGE SCREW
3 - AÐPILLER
4 - DOOR
BR/BEDOOR - FRONT 23 - 69
APPLIQUE (Continued)

(2) Loosen the hinge to cowl screws, if necessary,
refer to the front door hinge removal/installation pro-
cedure for hinge fastener location. Move the door to
the correct fore/aft position.
(3) Tighten the hinge to cowl screws.
(4) Remove the floor jack from the door.
ADJUSTMENT - FRONT DOOR UP/DOWN
Up/down door adjustment is done by loosening the
hinge to cowl fasteners at both hinges. Then move
the door to the correct position.
(1) Support the door with a padded floor jack.
(2) Loosen hinge to cowl fasteners at both hinges.
Move the door to the correct up/down position.
(3) Tighten the hinge to cowl fasteners.
(4) Remove the floor jack from the door.
ADJUSTMENT - FRONT DOOR IN/OUT
In/out door adjustment is done by loosening the
hinge to door fasteners. Then move the door to the
correct position.
(1) Support the door with a padded floor jack.
(2) Loosen the applicable hinge to door fasteners.
Move the door to the correct in/out position.
(3) If necessary, loosen the other hinge to door fas-
teners and move the door to the correct in/out posi-
tion.(4) Tighten the hinge to door fasteners.
(5) Remove the floor jack from the door.
DOOR GLASS
REMOVAL
(1) Remove the door waterdam (Refer to 23 -
BODY/DOOR - FRONT/WATERDAM - REMOVAL).
(2) Remove inner door belt weatherstrip (Refer to
23 - BODY/WEATHERSTRIP/SEALS/FDR INNER
BELT WEATHERSTRIP - REMOVAL).
(3) Align door glass lift plate to access holes in
inner door panel.
(4) Loosen bolts attaching front lower run channel
to inner door panel.
(5) Remove nuts attaching door glass to lift plate
(Fig. 4).
(6) Separate glass from lift plate.
(7) Lift glass upward and out of opening at top of
door.
INSTALLATION
(1) Position in door.
(2) Insert glass in lift plate.
CAUTION: Do not exceed 11 N´m (8 ft. lbs.) torque
when tightening the nuts that attach the glass to
the lift plate.
(3) Install nuts attaching glass to lift plate (Fig. 4).
Tighten nuts to 9 N´m (80 in. lbs.) torque.
(4) Tighten bolts attaching front lower run channel
to inner door panel.
Fig. 3 Door
1 - DOOR
2 - AÐPILLER
3 - LOWER DOOR HINGE
4 - SCREW
5 - UPPER DOOR HINGE
Fig. 4 Door Glass
1 - GLASS LIFT PLATE
2 - GLASS
3 - NUT
4 - REGULATOR ARM LOWER CHANNEL
23 - 70 DOOR - FRONTBR/BE
DOOR (Continued)

HINGE
REMOVAL
(1) Remove cowl trim panel (Refer to 23 - BODY/
INTERIOR/COWL TRIM COVER - REMOVAL).
(2) Remove hidden bolt attaching door hinge to
hinge pillar (Fig. 2).
(3) Support door on a suitable lifting device.
(4) Using a grease pencil or equivalent, mark the
outline of the door hinge on the hinge pillar to aid
installation.
(5) Remove bolts attaching door hinge to hinge pil-
lar (Fig. 3).
(6) Remove nut and bolt attaching door hinge to
door end frame (Fig. 8).
(7) Separate door hinge from vehicle.
INSTALLATION
(1) If necessary, paint replacement door hinge
before installation.
(2) Position hinge on door end frame.
(3) Align hinge using reference marks.
(4) Install nuts and bolts attaching door hinge to
door end frame. Tighten nuts and bolts to 28 N´m (21
ft. lbs.) torque.
(5) Install bolts attaching door hinge to hinge pil-
lar. Tighten bolts to 28 N´m (21 ft. lbs.) torque.(6) Install hidden bolt attaching door hinge to
hinge pillar. Tighten bolt to 28 N´m (21 ft. lbs.)
torque.
(7) Remove support.
(8) Install cowl trim panel (Refer to 23 - BODY/IN-
TERIOR/COWL TRIM COVER - INSTALLATION).
INSIDE HANDLE ACTUATOR
REMOVAL
(1) Remove the door waterdam (Refer to 23 -
BODY/DOOR - FRONT/WATERDAM - REMOVAL).
(2) Raise the window to the closed position.
(3) Remove the screws attaching the actuator to
the door (Fig. 9).
INSTALLATION
(1) Install the screws attaching the actuator to the
door.
(2) Test handle for proper operation.
(3) Install the door waterdam (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION).
LATCH
REMOVAL
(1) Remove the door waterdam (Refer to 23 -
BODY/DOOR - FRONT/WATERDAM - REMOVAL).
(2) Disengage clips attaching lock and latch rods to
door latch.
(3) Disconnect power door lock/latch connector, if
equipped (Fig. 10).
(4) Remove screws attaching door latch to door end
panel (Fig. 11).
(5) Separate door latch/lock from door.
Fig. 8 Door Hinge
1 - UPPER HINGE
2 - LOWER HINGE
3 - STUD
4 - HINGE PILLAR
5 - DOOR
6 - STUD
Fig. 9 Front Door Inside Handle Actuator
1 - INSIDE HANDLE
2 - ACTUATOR
23 - 72 DOOR - FRONTBR/BE

INSTALLATION
(1) Position door latch/lock in door.
(2) Install screws attaching door latch to door end
panel. Tighten screws to 10 N´m (89 in. lbs.) torque.
(3) Connect power door lock/latch connector, if
equipped.(4) Engage clips attaching lock and latch rods to
door latch.
(5) Install the door waterdam (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION).
ADJUSTMENTS
ADJUSTMENT - FRONT DOOR LATCH
(1) Insert a 4-mm (5/32-in) hex-wrench through
the elongated hole in the door end frame near the
latch striker opening (Fig. 12).
(2) Loosen torx head screw on the side of the latch
linkage.
(3) Lift upward on outside door handle and release
it.
(4) Tighten torx head screw on latch.
(5) Verify latch operation.
LATCH STRIKER
REMOVAL
(1) Mark outline of striker base on B-pillar with a
grease pencil or equivalent to aid installation.
(2) Remove screws attaching striker to B-pillar
(Fig. 13).
(3) Separate striker from vehicle.
INSTALLATION
(1) Position striker on vehicle and align with refer-
ence marks.
(2) Install screws attaching striker to B-pillar.
Tighten screws to 28 N´m (21 ft. lbs.) torque. (Fig.
13) .
Fig. 10 Power Lock/Latch Connector
1 - INSIDE HANDLE - TO - LATCH ROD
2 - LOCK KNOB - TO - LATCH ROD
3 - POWER LATCH CONNECTOR
4 - LOCK CYLINDER - TO - LATCH ROD
5 - OUTSIDE HANDLE - TO - LATCH ROD
Fig. 11 Front Door Latch
1 - OUTSIDE HANDLE - TO - LATCH ROD
2-LATCH
3 - INSIDE HANDLE - TO - LATCH ROD
4 - LOCK CYLINDER - TO - LATCH ROD
5 - LOCK KNOB - TO - LATCH ROD
Fig. 12 DOOR LATCH ADJUSTMENT
1 - HEX WRENCH
BR/BEDOOR - FRONT 23 - 73
LATCH (Continued)

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)