roof DODGE RAM 2003 Service Owner's Manual

(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 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.
(6) Locatenewsupport spacers on support brack-
ets and adjust to lowest height. (Fig. 5)
(7) Position seven new foam spacers on the inside
surface of the windshield, flush with the lower and
side edges. (Fig. 7)
(8) Position three new foam spacers on the inside
surface of the windshield, at a minimum distance of
3 mm (0.12 in.) from the top edge of the windshield.
(Fig. 7)
(9) Apply a 13 mm (1/2 in.) high and 10 mm (3/8
in.) wide bead of urethane around the perimeter of
windshield. At the top, apply the bead 7 mm (1/4 in.)
inboard from the glass edge. On the other three sides
apply the bead 14 mm (0.55 in.) inboard from the
glass edge. The urethane bead should be shaped in a
triangular cross-section, this can be achieved by
notching the tip of the applicator (Fig. 8).
(10) Install the a-pillar trim. (Refer to 23 - BODY/
INTERIOR/A-PILLAR TRIM - INSTALLATION)
(11) 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.
(12) Slowly lower windshield glass to the fence
opening guiding the lower corners into proper posi-
tion. 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. 9).
(13) Push windshield upward, setting the wind-
shield to roof gap to 1.5 mm (0.06 in.) to 3 mm (0.12
in.) and ratchet up the adjustable support brackets.
(14) Using clean water, lightly mist the support
spacers.
(15) Clean excess urethane from exterior with
MOPARtSuper Clean or equivalent.
(16) Install cowl grill. (Refer to 23 - BODY/EXTE-
RIOR/COWL GRILLE - INSTALLATION).
(17) Install rear view mirror support bracket.
(Refer to 23 - BODY/INTERIOR/REAR VIEW MIR-
ROR - INSTALLATION).(18) Install rear view mirror. (Refer to 23 - BODY/
INTERIOR/REAR VIEW MIRROR - INSTALLA-
TION).
(19) Install the a-pillar weatherstrip retainer.
(Refer to 23 - BODY/WEATHERSTRIP/SEALS/A-
PILLAR WEATHERSTRIP RETAINER - INSTALLA-
TION)
(20) After urethane has cured, remove tape strips
and water test windshield to verify repair.
Fig. 5 CENTER WINDSHIELD AND MARK AT
SUPPORT
1 - WINDSHIELD
2 - INDEX MARKS
3 - SUPPORT SPACERS
Fig. 6 WORK SURFACE SET UP
1 - WINDSHIELD AND MOLDINGS
2 - URETHANE BEAD AROUND GLASS 7mm (0.3 in.) FROM
EDGE
3 - BLOCKS
DRSTATIONARY GLASS 23 - 89
WINDSHIELD (Continued)

NOTE:
All measurements are in mm. O/F = Over Flush
U/F = Under Flush
DIMENSION DESCRIPTION GAP FLUSH
*
1Bumper to grille 19.0   3.0 Ð
*
2Hood to grille 1.5   1.0
Parallel within 2.0U/F 0.75   1.75
*
3Fender to hood 6.0   2.0
Parallel within 1.0U/F 3.2   1.5
(Underflush from front of hood to
start of hockey stick area only)
*
4Fender to hood
(Up/Down surface only)6.0   1.5
Parallel within 1.00.0   1.5
*
5Front door to windshield Ð O/F 20.5   1.5
(Base of windshield)
O/F 9.0   1.5
(Top of windshield)
*
6Roof to front door Ð U/F 6.0   1.5
Parallel within 1.5
7 Quarter to front door 5.0   1.5
Parallel within 1.00.0   1.5
8 Front door to quarter character
line alignmentÐ Up/Down 0.0   1.5
*
9Front door to fender character
line alignmentÐ Up/Down 0.0   1.5
*
10Front door to fender 5.0   1.5
Parallel within 1.00.0   1.5
*
11Bumper to fender 19.0   3.0
Parallel within 3.0O/F 5.0   5.0 (SLT)
O/F 14.0   5.0 (SPORT)
*
12Bumper to headlamp 19.0   4.0 Ð
* ALL MODELS
Fig. 1 GAP & FLUSH - STANDARD CAB
23 - 96 BODY STRUCTUREDR
GAP AND FLUSH (Continued)

NOTE:
All measurements are in mm.
O/F = Over Flush
U/F = Under Flush
DIMENSION DESCRIPTION GAP FLUSH
1 Roof to rear door Ð U/F 6.0   1.5
Parallel within 1.5
2 Quarter to rear door 5.0   1.5
Parallel within 2.00.0   1.5
3 Rear door to quarter character line
alignmentÐ Up/Down 0.0   1.5
4 Rear door to front door character line
alignmentÐ Up/Down 0.0   1.5
5 Rear door to front door 5.0   1.5
Parallel within 2.00.0   1.5
Fig. 2 GAP & FLUSH - QUAD CAB
DRBODY STRUCTURE 23 - 97
GAP AND FLUSH (Continued)

SEALER LOCATIONS
SPECIFICATIONS
INDEX
DESCRIPTION FIGURE
LOWER WINDSHIELD PILLAR, LOWER PLENUM AND COWL BAR 9
DASH PANEL, LOWER PLENUM AND COWL SIDE PANEL 10
LOWER DASH PANEL, LOWER COWL SIDE AND FLOOR PAN SUPPORT 11
ROOF PANEL, OUTER BODY SIDE APERTURE AND BACKLITE 12
CAB BACK, BODY SIDE APERTURE - REAR AND BACKLITE LOWER CORNER 13
LOWER DASH PANEL AND FLOOR PAN 14
FLOOR PAN AND BODY SIDE APERTURE 15
FRONT FLOOR PAN AND REAR PAN 16
FLOOR PAN TO CAB BACK 17
PICKUP BOX 18
Fig. 9 LOWER WINDSHIELD PILLAR
DRBODY STRUCTURE 23 - 103

Fig. 12 ROOF PANEL
23 - 106 BODY STRUCTUREDR
SEALER LOCATIONS (Continued)

DESCRIPTION FIGURE
STORAGE BIN TO RIGHT AND LEFT REAR FLOOR CROSSMEMBER TO REAR
FLOOR PAN54
RIGHT REAR FRONT SEAT MOUNTING CROSSMEMBER TO LEFT REAR FRONT
SEAT MOUNTING CROSSMEMBER TO REAR FLOOR PAN55
FRONT SEAT MOUNTING FRONT CROSSMEMBER AND STORAGE BIN TO FLOOR
SILL TO FRONT AND REAR FLOOR PAN56
FRONT SEAT MOUNTING FRONT CROSSMEMBER TO UNDERBODY SUPPORT TO
FRONT FLOOR PAN57
A-PILLAR REINFORCEMENT TO INNER BODY SIDE APERTURE TO OUTER BODY
SIDE APERTURE58
A-PILLAR REINFORCEMENT TO FRONT APERTURE EXTENSION TO INNER BODY
SIDE APERTURE TO OUTER BODY SIDE APERTURE59
INNER BODY SIDE APERTURE TO OUTER BODY SIDE APERTURE 60
SHOULDER BELT REINFORCEMENT TO INNER BODY SIDE APERTURE TO OUTER
BODY SIDE APERTURE61
FRONT PILLAR TAPPING PLATES TO INNER BODY SIDE APERTURE TO OUTER
BODY SIDE APERTURE62
INNER BODY SIDE APERTURE TO OUTER BODY SIDE APERTURE 63
C-PILLAR BAFFLE AND OUTER BODY SIDE APERTURE TO INNER BODY SIDE
APERTURE64
A-PILLER REINFORCEMENT TO INNER BODY SIDE APERTURE TO OUTER BODY
SIDE APERTURE65
FRONT EXTENSION PLATE TO INNER BODY SIDE APERTURE TO OUTER BODY
SIDE APERTURE TO A-PILLAR REINFORCEMENT66
OUTER BODY SIDE APERTURE TO INNER BODY SIDE APERTURE 67
B-PILLAR REINFORCEMENT TO INNER BODY SIDE APERTURE TO OUTER BODY
SIDE APERTURE68
UPPER B-PILLAR TAPPING PLATE AND LOWER B-PILLAR TAPPING PLATE TO
OUTER BODY SIDE APERTURE69
UPPER A-PILLAR TAPPING PLATE AND LOWER A-PILLAR TAPPING PLATE TO INNER
BODY SIDE APERTURE70
SEAT BELT MOUNTING PLATES AND REINFORCEMENTS TO INNER BODY SIDE
APERTURE71
OUTER BODY SIDE APERTURE TO INNER BODY SIDE APERTURE 72
C-PILLAR REINFORCEMENTS AND SHOULDER BELT MOUNTING REINFORCEMENT
TO INNER BODY SIDE APERTURE TO OUTER BODY SIDE APERTURE73
SEAT BELT RETRACTOR PLATE TO FLOOR SILL TO INNER BODY SIDE APERTURE
TO OUTER BODY SIDE APERTURE74
FLOOR SILL TO INNER BODY SIDE APERTURE TO OUTER BODY SIDE APERTURE 75
BACK REINFORCEMENT AND CAB BACK PANEL TO REAR FLOOR CROSSMEMBER
AND INNER BODY SIDE APERTURE TO OUTER BODY SIDE APERTURE76
CAB BACK REINFORCEMENT TO CAB BACK PANEL (CHILD TETHERS) 77
COWL SIDE PANEL TO INNER BODY SIDE APERTURE TO OUTER BODY SIDE
APERTURE78
OUTER ROOF PANEL TO OUTER BODY SIDE APERTURE 79
ROOF HEADER TO OUTER ROOF PANEL TO A-PILLAR REINFORCEMENT TO INNER
BODY SIDE APERTURE TO OUTER BODY SIDE APERTURE80
DRBODY STRUCTURE 23 - 123
WELD LOCATIONS (Continued)

DESCRIPTION FIGURE
REAR ROOF HEADER TO OUTER ROOF PANEL TO INNER BODY SIDE APERTURE
TO OUTER BODY SIDE APERTURE81
OUTER BODY SIDE APERTURE TO CAB BACK PANEL TO FLOOR SILL, INNER BODY
SIDE APERTURE TO FLOOR SILL82
OUTER BODY SIDE APERTURE TO INNER BODY SIDE APERTURE TO FLOOR SILL 83
REAR FLOOR CROSSMEMBER AND CAB BACK REINFORCEMENT TO CAB BACK
PANEL TO INNER BODY SIDE APERTURE84
CAB BACK REINFORCEMENT TO CAB BACK PANEL 85
CENTER SHOULDER BELT REINFORCEMENT AND TAPPING PLATES TO CAB BACK
REINFORCEMENT86
A-PILLAR REINFORCEMENT TO COWL SIDE PANEL TO OUTER BODY SIDE
APERTURE/APERTURE EXTENSION TO COWL SIDE PANEL87
B-PILLAR REINFORCEMENT TO OUTER ROOF PANEL TO OUTER BODY SIDE
APERTURE88
FRONT ROOF HEADER TO OUTER ROOF PANEL/ROOF BOW TO INNER BODY SIDE
APERTURE/FRONT ROOF HEADER TO A-PILLAR REINFORCEMENT89
INNER BODY SIDE APERTURE TO REAR ROOF HEADER AND OUTER BODY SIDE
APERTURE TO OUTER ROOF PANEL90
FRONT CROSSMEMBER, WHEELHOUSE CROSSMEMBER AND BRACKET SUPPORT
CROSSMEMBER TO BOX FLOOR PAN91
LONG CROSSMEMBER AND FLOOR BOX CROSS SILL TO BOX FLOOR PAN 92
TAPPING PLATES AND SUPPORT BRACKETS TO REAR CROSS BOX SILL, FRONT
WHEELHOUSE, LONG AND BRACKET SUPPORT CROSSMEMBERS93
STAKE POCKET REINFORCEMENTS AND TIE DOWN REINFORCEMENTS TO INNER
BOX SIDE PANEL94
OUTER BOX SIDE REINFORCEMENT BRACES NUT PLATES TO OUTER BOX SIDE
PANEL MOUNTING95
OUTER WHEELHOUSE TO OUTER BOX SIDE PANEL 96
WELD NUT STRIKER CAGE NUT, OUTER BOX SIDE PANEL AND NUT PLATE TO BOX
SIDE TAILGATE REINFORCEMENT97
FRONT BOX PANEL TO FRONT INNER STAKE POCKET REINFORCEMENT TO FRONT
BOX SIDE PANEL98
FRONT CROSSMEMBER TO FRONT BOX SIDE PANEL AND BOX FLOOR PANEL TO
BOX FRONT PANEL99
BOX FLOOR PANEL AND INNER WHEELHOUSE PANEL TO INNER BOX SIDE PANEL 100
FRONT CROSSMEMBER AND END SUPPORT BRACKET TO LONG CROSSMEMBER
TO INNER BOX SIDE PANEL/STAKE POCKET REINFORCEMENT AND BOX FLOOR
SILL TO OUTER TAILGATE PILLAR TO INNER TAILGATE PILLAR101
STAKE POCKET REINFORCEMENT AND BOX FLOOR SILL CROSSMEMBER TO
INNER TAILGATE PILLAR102
INNER TAILGATE PILLAR PANEL TO INNER BOX SIDE PANEL TO TIE DOWN
MOUNTING REINFORCEMENT103
BOX FLOOR SILL CROSSMEMBER TO INNER BOX SIDE PANEL 104
INNER TAILGATE PILLAR TO TAILGATE BOX SIDE REINFORCEMENT TO OUTER
TAILGATE PILLAR105
BOX SIDE PANEL AND OUTER TAILGATE PILLAR TO OUTER BOX SIDE PANEL 106
FRONT BOX PANEL TO OUTER BOX SIDE PANEL 107
23 - 124 BODY STRUCTUREDR
WELD LOCATIONS (Continued)

Fig. 78 COWL SIDE PANEL - STANDARD CAB
Fig. 79 OUTER ROOF PANEL - STANDARD CAB
23 - 162 BODY STRUCTUREDR
WELD LOCATIONS (Continued)

Fig. 80 FRONT ROOF HEADER - STANDARD CAB
Fig. 81 REAR ROOF HEADER - STANDARD CAB
DRBODY STRUCTURE 23 - 163
WELD LOCATIONS (Continued)

Fig. 89 FRONT ROOF HEADER- QUAD CAB
DRBODY STRUCTURE 23 - 171
WELD LOCATIONS (Continued)