lock DODGE RAM 2002 Service Repair Manual

INSTRUMENT PANEL SYSTEM
TABLE OF CONTENTS
page page
INSTRUMENT PANEL SYSTEM
DESCRIPTION........................105
OPERATION..........................106
ASH RECEIVER
REMOVAL............................107
INSTALLATION........................107
CLUSTER BEZEL
REMOVAL............................108
INSTALLATION........................108
CUBBY BIN
REMOVAL............................108
INSTALLATION........................109
CUP HOLDER
REMOVAL............................109
INSTALLATION........................110
GLOVE BOX
REMOVAL
REMOVAL..........................110
DISASSEMBLY - GLOVE BOX...........110
ASSEMBLY - GLOVE BOX................111INSTALLATION........................111
GLOVE BOX LATCH STRIKER
REMOVAL............................111
INSTALLATION........................112
GLOVE BOX OPENING UPPER TRIM
REMOVAL............................112
INSTALLATION........................112
INSTRUMENT PANEL TOP COVER
REMOVAL............................113
INSTALLATION........................113
STEERING COLUMN OPENING COVER
REMOVAL............................113
INSTALLATION........................114
STORAGE BIN
REMOVAL............................114
INSTALLATION........................114
INSTRUMENT PANEL ASSEMBLY
REMOVAL............................115
INSTALLATION........................117
INSTRUMENT PANEL SYSTEM
DESCRIPTION
The instrument panel is located at the front of the
passenger compartment. This instrument panel is
molded from a blend of various plastics that are
mechanically attached to the vehicle. Colors are
molded into the plastic components to minimize
appearance degradation from scratches or abrasions.
The panel components are internally ribbed and riv-
eted to steel reinforcements for additional structural
integrity and dimensional stability. The instrument
panel surface components are designed to deform
upon impact without breaking. This type of construc-
tion provides improved energy absorption which, in
conjunction with the dual airbags and seat belts,
helps to improve occupant protection.
The top of the instrument panel is secured to the
top of the dash panel near the base of the windshield
using screws. An end bracket integral to each end of
the instrument panel structure is secured to each
cowl side inner panel with a screw. A stamped metal
bracket supports the center of the instrument panel
by securing it to the top of the floor panel transmis-
sion tunnel below the instrument panel with screws.
The instrument cluster, radio, heater-air conditioner
control, passenger airbag, glove box, electrical junc-tion block, Central Timer Module (CTM), accessory
switches, ash receiver, cigar lighter, accessory power
outlet, park brake release handle, inside hood release
handle, as well as numerous other components are
secured to and supported by this unit.
The instrument panel for this vehicle includes the
following major features:
²Cluster Bezel- This molded plastic bezel is
secured with snap clips to the instrument panel sup-
porting structure. It trims out the edges of the head-
lamp switch, instrument cluster, radio, heater-air
conditioner controls, passenger airbag on-off switch,
and the heated seat switches on vehicles so equipped.
On vehicles without the heated seat option, a small
storage cubby bin is provided in the cluster bezel.
This bezel also incorporates three completely adjust-
able panel outlets for the climate control system, and
fills the opening between the instrument cluster and
the top of the steering column where it passes
through the instrument panel.
²Cup Holder/Storage Bin- Vehicles equipped
with an automatic transmission feature a latching
fold-down, adjustable cup holder located on the lower
instrument panel between the glove box and the ash
receiver. Vehicles equipped with a manual transmis-
sion have a lighted storage bin on the instrument
panel in place of the cup holder.
BR/BEINSTRUMENT PANEL SYSTEM 23 - 105

²Glove Box- The hinged bin-type glove box in
the passenger side of the instrument panel features a
recessed paddle-operated latch handle. Three molded
hook formations on the lower edge of the glove box
door are engaged with and pivot on three hinge pins
integral to the lower edge of the instrument panel
support structure. The glove box door also serves as
the passenger side knee blocker. A honeycomb struc-
ture between the inner and outer glove box door pan-
els helps to absorb the impact load and distribute it
to the instrument panel structure.
²Steering Column Opening Cover- The steer-
ing column opening cover serves as the driver side
knee blocker. This molded plastic cover has an inte-
gral ribbed plastic liner concealed behind it, for
increased strength and integrity. The steering column
opening cover transfers impact loads to the instru-
ment panel structural support.
²Top Cover- The instrument panel top cover or
base trim is the molded, grained, and color impreg-
nated plastic outer skin of the instrument panel
structural support.
Hard wired circuitry connects the electrical compo-
nents on the instrument panel to each other through
the electrical system of the vehicle. These hard wired
circuits are integral to several wire harnesses, which
are routed throughout the vehicle and retained by
many different methods. These circuits may be con-
nected to each other, to the vehicle electrical system
and to the instrument panel components through the
use of a combination of soldered splices, splice block
connectors and many different types of wire harness
terminal connectors and insulators. Refer to the
appropriate wiring information. The wiring informa-
tion includes complete circuit diagrams, proper wire
and connector repair procedures, further details on
wire harness routing and retention, as well as pin-
out and location views for the various wire harness
connectors, splices, and grounds.
OPERATION
The instrument panel serves as the command cen-
ter of the vehicle, which necessarily makes it a very
complex unit. The instrument panel is designed to
house the controls and monitors for standard and
optional powertrains, climate control systems, audio
systems, safety systems, and many other comfort or
convenience items. When the components of the
instrument panel structural support are properly
assembled and secured in the vehicle they provide
superior instrument panel stiffness and integrity to
help reduce buzzes, squeaks, and rattles. This type of
construction also provides improved energy absorp-
tion which, in conjunction with the dual airbags and
seat belts, helps to improve occupant protection.The instrument panel is also designed so that all of
the various controls can be safely reached and the
monitors can be easily viewed by the vehicle operator
when driving, while still allowing relative ease of
access to each of these items for service. Modular
instrument panel construction allows all of the
gauges and controls to be serviced from the front of
the panel. In addition, most of the instrument panel
electrical components can be accessed without com-
plete instrument panel removal. However, if neces-
sary, the instrument panel can be removed from the
vehicle as an assembly.
The steering column opening cover with its inte-
gral knee blocker located on the driver side of the
instrument panel works in conjunction with the air-
bag system in a frontal vehicle impact to keep the
driver properly positioned for an airbag deployment.
In addition, removal of this component provides
access to the steering column mounts, the steering
column wiring, the Junction Block (JB) (removal of a
snap-fit fuse access panel on the left end of the
instrument panel allows access to the fuses and cir-
cuit breakers), the Central Timer Module (CTM), the
Infinity speaker filter choke and relay unit, much of
the instrument panel wiring, and the gear selector
indicator cable (automatic transmission).
In a frontal collision, the glove box door on the pas-
senger side of the instrument panel provides the
same function for the front seat passenger as the
knee blocker does for the driver. The glove box door
also incorporates a recessed latch handle. Removal of
the glove box provides access to the passenger airbag,
the glove box lamp and switch, the radio antenna
coaxial cable, the heating and air conditioning vac-
uum harness connector, and additional instrument
panel wiring.
Removal of the instrument panel cluster bezel
allows access to the headlamp switch, instrument
cluster, radio, passenger airbag on-off switch, heated
seat switches (if equipped), and the heating and air
conditioning control. Removal of the instrument clus-
ter allows access to the cluster illumination and indi-
cator bulbs, and more of the instrument panel
wiring. Complete instrument panel removal is
required for service of most components internal to
the heating and air conditioning system housing,
including the heater core and the evaporator.
See the owner's manual in the vehicle glove box for
more information on the features, use and operation
of all of the components and systems mounted on or
in the instrument panel.
23 - 106 INSTRUMENT PANEL SYSTEMBR/BE
INSTRUMENT PANEL SYSTEM (Continued)

CLUSTER BEZEL
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) If the vehicle is equipped with an automatic
transmission, turn the ignition switch to the Off posi-
tion (not Lock), set the parking brake, and place the
automatic transmission gear selector lever in the
Low position.
(3) If the vehicle is so equipped, set the tilt steer-
ing column in its lowest position.
(4) Using a trim stick or another suitable wide
flat-bladed tool, gently pry around the perimeter of
the cluster bezel to disengage the snap clips from
their receptacles in the instrument panel (Fig. 2).
(5) Remove the cluster bezel from the instrument
panel.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Position the cluster bezel to the instrument
panel (Fig. 2).
(2) Align the snap clips on the cluster bezel with
the receptacles in the instrument panel.
(3) Press firmly on the cluster bezel over each of
the snap clip locations until each of the snap clips is
fully engaged in its receptacle.
(4) Reconnect the battery negative cable.
CUBBY BIN
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cluster bezel from the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - REMOVAL).
(3) Remove the three screws that secure the cubby
bin to the instrument panel (Fig. 3).
(4) Remove the cubby bin from the instrument
panel.
Fig. 2 Cluster Bezel Remove/Install
1 - CLUSTER BEZEL
23 - 108 INSTRUMENT PANEL SYSTEMBR/BE

instrument panel just inboard of the glove box. Vehi-
cles equipped with a manual transmission have a
lighted storage bin installed on the instrument panel
in place of the fold-down cup holder.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Position the storage bin unit onto the instru-
ment panel (Fig. 10).
(2) Engage the illumination lamp and hood
retainer clip to the back of the instrument panel stor-
age bin unit.
(3) Raise and position the top of the storage bin to
the instrument panel.
(4) Install and tighten the two screws that secure
the top of the storage bin unit to the instrument
panel. Tighten the screws to 2.2 N´m (20 in. lbs.).
(5) Reinstall the cluster bezel onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - INSTALLATION).
(6) Reconnect the battery negative cable.
INSTRUMENT PANEL
ASSEMBLY
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
SEAT BELT TENSIONER, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG
SYSTEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS
THE ONLY SURE WAY TO DISABLE THE AIRBAG SYS-
TEM. FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.
(1)
Disconnect and isolate the battery negative cable.
(2) Remove the Airbag Control Module (ACM) and
bracket from the floor panel transmission tunnel.
(Refer to 8 - ELECTRICAL/RESTRAINTS/AIRBAG
CONTROL MODULE - REMOVAL).
(3) Remove the trim from the left and right cowl
side inner panels. (Refer to 23 - BODY/INTERIOR/
COWL TRIM COVER - REMOVAL).
(4) Remove the steering column opening cover
from the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - REMOVAL).
(5)
Remove the two screws that secure the inside
hood latch release handle to the instrument panel lower
reinforcement and lower the release handle to the floor.
(6)Disconnect the clockspring pigtail wire connector
from the instrument panel wire harness connector
located on the instrument panel lower reinforcement.
(7) If the vehicle is so equipped, disconnect the
overdrive lockout switch pigtail wire connector from
the instrument panel wire harness connector near
the instrument panel lower reinforcement.
(8) Remove the steering column from the vehicle,
but do not remove the driver airbag, the steering
wheel, or the switches from the column. Be certain
that the steering wheel is locked and secured from
rotation to prevent the loss of clockspring centering.
(Refer to 19 - STEERING/COLUMN - REMOVAL).
(9) From under the driver side of the instrument
panel, perform the following:
(a) Disengage the park brake release handle
linkage rod from the park brake mechanism on the
Fig. 10 Instrument Panel Storage Bin Remove/Install
1 - SCREWS
2 - STORAGE BIN (RAISED)
3 - STORAGE BIN (LOWERED)
BR/BEINSTRUMENT PANEL SYSTEM 23 - 115
STORAGE BIN (Continued)

left cowl side inner panel. (Refer to 5 - BRAKES/
PARKING BRAKE/RELEASE - REMOVAL).
(b) Disconnect the instrument panel wire har-
ness connector from the park brake switch on the
park brake mechanism.
(c) Disconnect the three connectors (one from the
body wire harness, and two from the headlamp and
dash wire harness) from the three connector recep-
tacles located closest to the dash panel on the back
of the Junction Block (JB).
(d) Remove the screw from the center of the
headlamp and dash wire harness to instrument
panel wire harness bulkhead connector and discon-
nect the connector.
(e) Disconnect the instrument panel wire har-
ness to door wire harness connector located directly
below the instrument panel wire harness to head-
lamp and dash wire harness bulkhead connector.
(f) If the vehicle is equipped with the Infinity
sound system option, disconnect the Infinity wire
harness connector from the instrument panel wire
harness connector that is secured to the outboard
side of the instrument panel wire harness to head-
lamp and dash wire harness bulkhead connector.(g) Disconnect the instrument panel wire har-
ness connector from the stop lamp switch.
(h) Disconnect the heater-A/C housing vacuum
harness connector from the heater-A/C control vac-
uum harness connector located near the left end of
the heater-A/C housing.
(10) From under the passenger side of the instru-
ment panel, disconnect the two halves of the radio
antenna coaxial cable connector.
(11) Loosen the right and left instrument panel
cowl side roll-down bracket screws about 13 mm
(0.50 inch) (Fig. 11).
(12) Remove the five screws that secure the top of
the instrument panel to the top of the dash panel,
removing the center screw last.
(13) Roll down the instrument panel and install a
temporary hook in the center hole on top of the
instrument panel. Secure the other end of the hook
to the center hole in the top of the dash panel. The
hook should support the instrument panel in its
rolled down position about 46 cm (18 inches) from
the dash panel.
(14) With the instrument panel supported in the
roll-down position, disconnect the instrument panel
Fig. 11 Instrument Panel Assembly Remove/Install
1 - PLASTIC NUT
2 - SCREWS3 - SCREWS
23 - 116 INSTRUMENT PANEL SYSTEMBR/BE
INSTRUMENT PANEL ASSEMBLY (Continued)

wire harness connectors from the heater-A/C housing
wire harness connectors.
(15) With the aid of an assistant, remove the tem-
porary hook and lift the instrument panel assembly
off of the roll-down bracket screws and remove it
from the vehicle.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
SEAT BELT TENSIONER, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG
SYSTEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS
THE ONLY SURE WAY TO DISABLE THE AIRBAG SYS-
TEM. FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.
(1)With the aid of an assistant, load the instrument
panel assembly onto the roll-down bracket screws on
the cowl side inner panels in the vehicle (Fig. 11).
Install a temporary hook in the center hole on top of the
instrument panel. Secure the other end of the hook to
the center hole in the top of the dash panel. The hook
should support the instrument panel in its rolled down
position about 46 cm (18 inches) from the dash panel.
(2) With the instrument panel supported in the
roll-down position, reconnect the instrument panel
wire harness connectors to the heater-A/C housing
wire harness connectors.
(3) Remove the temporary hook from the instru-
ment panel and roll the instrument panel up to its
installed position against the dash panel.
(4) Install and tighten the five screws that secure
the top of the instrument panel to the top of the dash
panel. Tighten the screws to 3.2 N´m (28 in. lbs.).
(5) Tighten the right and left instrument panel
cowl side roll-down bracket screws. Tighten the
screws to 11.9 N´m (105 in. lbs.).
(6) From under the passenger side of the instru-
ment panel, reconnect the two halves of the radio
antenna coaxial cable connector.
(7) From under the driver side of the instrument
panel, perform the following:
(a) Engage the park brake release handle link-
age rod with the park brake mechanism on the left
cowl side inner panel. (Refer to 5 - BRAKES/PARK-
ING BRAKE/RELEASE - INSTALLATION).
(b) Reconnect the instrument panel wire harness
connector to the park brake switch on the park
brake mechanism.(c) Reconnect the three connectors (one from the
body wire harness, and two from the headlamp and
dash wire harness) to the three connector recepta-
cles located closest to the dash panel on the back of
the Junction Block (JB).
(d)
Reconnect the headlamp and dash wire harness
to instrument panel wire harness bulkhead connector
and tighten the screw in the center of the connector.
Tighten the screw to 3.5 N´m (31 in. lbs.).
(e) Reconnect the instrument panel wire harness
to door wire harness connector located directly
below the instrument panel wire harness to head-
lamp and dash wire harness bulkhead connector.
(f) If the vehicle is equipped with the Infinity
sound system option, reconnect the Infinity wire
harness connector to the instrument panel wire
harness connector that is secured to the outboard
side of the instrument panel wire harness to head-
lamp and dash wire harness bulkhead connector.
(g) Reconnect the instrument panel wire harness
connector to the stop lamp switch.
(h) Reconnect the heater-A/C housing vacuum
harness connector to the heater-A/C control vac-
uum harness connector located near the left end of
the heater-A/C housing.
(8) Reinstall the steering column into the vehicle.
Be certain that the steering wheel was locked and
secured from rotation to prevent the loss of clock-
spring centering. (Refer to 19 - STEERING/COL-
UMN - INSTALLATION).
(9) If the vehicle is so equipped, reconnect the
overdrive lockout switch pigtail wire connector to the
instrument panel wire harness connector near the
instrument panel lower reinforcement.
(10) Reconnect the clockspring pigtail wire connec-
tor to the instrument panel wire harness connector
at the instrument panel lower reinforcement.
(11) Position the inside hood latch release handle
to the instrument panel lower reinforcement.
(12) Install and tighten the two screws that secure
the inside hood latch release handle to the instru-
ment panel lower reinforcement. Tighten the screws
to 2.8 N´m (25 in. lbs.).
(13) Reinstall the steering column opening cover
onto the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - INSTALLATION).
(14) Reinstall the trim onto the left and right cowl
side inner panels. (Refer to 23 - BODY/INTERIOR/
COWL TRIM COVER - INSTALLATION).
(15) Reinstall the Airbag Control Module (ACM)
and bracket onto the floor panel transmission tunnel.
(Refer to 8 - ELECTRICAL/RESTRAINTS/AIRBAG
CONTROL MODULE - INSTALLATION).
(16) Reconnect the battery negative cable.
BR/BEINSTRUMENT PANEL SYSTEM 23 - 117
INSTRUMENT PANEL ASSEMBLY (Continued)

SEATS
TABLE OF CONTENTS
page page
SEATS
DESCRIPTION........................131
OPERATION..........................131
CENTER CONSOLE LID
REMOVAL............................131
INSTALLATION........................132
CENTER SEAT ARMREST/CONSOLE
REMOVAL............................132
INSTALLATION........................132
CENTER SEAT ARMREST/LATCH COVER
REMOVAL............................132
INSTALLATION........................132
LUMBAR SUPPORT
REMOVAL............................132
INSTALLATION........................133
SEAT - BENCH SEAT
REMOVAL............................133
INSTALLATION........................133
SEAT - SPLIT BENCH
REMOVAL............................133
INSTALLATION........................134
SEAT BACK - BENCH SEAT
REMOVAL............................135
INSTALLATION........................135
SEAT BACK - SPLIT BENCH
REMOVAL............................135
INSTALLATION........................136
SEAT BACK COVER
REMOVAL............................137
INSTALLATION........................137
SEAT BACK COVER - SPLIT BENCH
REMOVAL............................137
INSTALLATION........................137SEAT BACK RECLINER
REMOVAL............................138
INSTALLATION........................138
SEAT CUSHION
REMOVAL............................138
INSTALLATION........................138
SEAT CUSHION COVER
REMOVAL............................139
INSTALLATION........................139
SEAT CUSHION COVER - SPLIT BENCH
REMOVAL............................139
INSTALLATION........................140
SEAT RISER
REMOVAL............................141
INSTALLATION........................141
SEAT TRACK
REMOVAL............................141
INSTALLATION........................141
SEAT TRACK - SPLIT BENCH
REMOVAL............................142
INSTALLATION........................142
EASY ENTRY SEAT TRACK
REMOVAL............................143
INSTALLATION........................143
SEAT TRACK ADJUSTER
REMOVAL............................143
INSTALLATION........................143
STANCHION COVER
REMOVAL............................143
INSTALLATION........................143
REAR SEAT
REMOVAL............................144
INSTALLATION........................144
SEATS
DESCRIPTION
Seat modules are made up of a seat frame, seat
cushion, seat back cushion, a covering material, and
the electrical components used for power operation, if
equipped. Some seat systems also contain seat belt
components and supplemental restraint systems.
OPERATION
Seat assemblies transport the occupants in comfort
and safety. Seat assemblies also help position occupants
correctly in the event of airbag deployment. Seat cush-
ions, coverings, and electrical components are service-
able. Refer to the appropriate group in this manual.
CENTER CONSOLE LID
REMOVAL
(1) Open console lid.
(2) Using a small flat blade screwdriver, disengage
locking tabs located under the console lid trim bezel.
(3) Separate bezel from lid.
(4) Move driver and passenger seat to full forward
position.
(5) Using a small drift and hammer, tap out con-
sole lid hinge pin.
(6) Separate lid from console.
BR/BESEATS 23 - 131

REAR SEAT
REMOVAL
(1) Move front seat track to full forward position.
(2) Turn release handle on underside of rear seat
(Fig. 29) to disengage seat cushion and move seat to
the stowed position.
(3) Remove side support bracket screws and lift
seat to disengage from cab (Fig. 30) .
INSTALLATION
(1) Position seat in vehicle.
(2) Align seatback hooks with loops on cab rear
panel (Fig. 31).
(3) Align side support alignment tabs, and lower
seat into place.
(4) Install side support bracket screws. Tighten the
screws to 28 N´m (21 ft. lbs.) torque.
(5) Turn release handle to disengage seat from
stowed position and push seat cushion downward to
lock into place.
Fig. 29 Rear Seat Release Handle
1 - SEAT CUSHION
2 - RELEASE HANDLE
3 - ALIGNMENT TAB
Fig. 30 Rear Seat Removal/Installation
1 - REAR SEAT
2 - BUMPER
3-TAB
Fig. 31 Rear Seat Removal/Installation
1 - REAR SEAT
2 - BUMPER
3-TAB
23 - 144 SEATSBR/BE

(7) Latch vent glass panels
(8) Insert upper ends of vent glass panels into
upper run channel.
NOTE: Aggressive clamp pressure is required to
lock lower run channel into place.
(9) Position lower run channel on backlite frame
lower rail and roll lower run channel onto backlite
frame rail.
(10) Fill the ends of the run channel with Mopar
GEN II Silicone Rubber Adhesive Sealant or equiva-
lent.
(11) Verify window and latch/keeper operation.(12) Install rear closure panel trim. (Refer to 23 -
BODY/INTERIOR/REAR CLOSURE PANEL TRIM -
INSTALLATION).
WINDSHIELD
DESCRIPTION
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 struc-
tural support for the roof. The urethane bonding used to
secure the windshield to the fence is difficult to cut or
clean from any surface. If the moldings are set in ure-
thane, 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 - REMOVAL).
(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.
Fig. 4 Lower Run Channel
1 - SLIDING BACKLITE
2 - LOWER RUN CHANNEL
3 - CAB BACK PANEL
Fig. 5 Lower Run Channel Removal
1 - LATCH/KEEPER
2 - BACK LITE
3 - LOWER RUN CHANNEL
4 - SLIDE OUTWARD
Fig. 6 Glass Panel Installation
1 - INSERT A 0.5mm DIA. BEAD OF PUMPABLE GRADE BUTYL
ALONG THE ENTIRE LENGTH OF THE LOWER RUN WINDOW
CHANNEL
BR/BESTATIONARY GLASS 23 - 147
BACKLITE VENT GLASS (Continued)

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, shouldremain on the fence. Do not grind off or completely
remove all old urethane from the fence, the paint finish
and bonding strength will be adversely affected.
(1) Place replacement windshield into windshield
opening and position glass in the center of the open-
ing against the support spacers. Mark the outside
surface of the glass at the support spacers with a
grease pencil or pieces of masking tape and ink pen
to use as a reference for installation. Remove replace-
ment windshield from windshield opening (Fig. 9).
(2) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart (Fig. 10).
(3) Clean inside of windshield with MOPAR Glass
Cleaner and lint-free cloth.
(4) Apply clear glass primer 25 mm (1 in.) wide
around perimeter of windshield and wipe with a new
clean and dry lint- free cloth.
(5) Apply the molding to the windshield:
(a) Press the upper corners of the molding onto
the windshield.
(b) Press the header section onto the windshield.
(c)
Press the A-Pillar sections onto the windshield.
(6) Apply black-out primer onto the glass using the
windshield molding as a guide. The primer should be
15 mm (5/8 in.) wide on the top and sides of the glass
and 25 mm (1 in.) on the bottom of windshield. Allow
at least three minutes drying time.
(7) Locatenewsupport spacers on support brack-
ets and adjust to lowest height.
(8)
Position one 5 mm (3/16 in.) soft spacer (p/n
55028214) at the bottom of the windshield fence (Fig. 11).
(9) Apply a 13mm (1/2 in.) high and 10mm (3/8 in.)
wide bead of urethane around the perimeter of wind-
shield. At the bottom, apply the bead 7 mm (1/4 in.)
inboard from the glass edge. On the three sides
where the molding is on the glass, follow the edge of
molding. The urethane bead should be shaped in a
triangular cross-section, this can be achieved by
notching the tip of the applicator (Fig. 12).
(10) With the aid of a helper, position the wind-
shield over the windshield opening. Align the refer-
ence marks at the bottom of the windshield to the
support spacers.
(11)
Slowly lower windshield glass to the fence open-
ing guiding the lower corners into proper position.
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.
Fig. 7 Windshield Moldings
1 - WINDSHIELD
2 - WINDSHIELD MOLDING
Fig. 8 Cut Urethane Around Windshield
1 - WINDSHIELD
2 - COLD KNIFE
23 - 148 STATIONARY GLASSBR/BE
WINDSHIELD (Continued)