bumper DODGE RAM 2003 Service Manual PDF

Adhesion Promoter/Surface Modifier:
Adhesion Promoters/Surface Modifiers are required
for certain plastics. All three categories may have
plastics that require the use of adhesion promoter/
surface modifiers. Always follow repair material man-
ufacturer's plastic identification and repair
procedures.
SAFETY PRECAUTION AND WARNINGS
WARNING:
²EYE PROTECTION SHOULD BE USED WHEN
SERVICING COMPONENTS. PERSONAL INJURY
CAN RESULT.
²USE AN OSHA APPROVED BREATHING MASK
WHEN MIXING EPOXY, GRINDING, AND SPRAYING
PAINT OR SOLVENTS IN A CONFINED AREA. PER-
SONAL INJURY CAN RESULT.²AVOID PROLONGED SKIN CONTACT WITH
RESIN, PETROLEUM, OR ALCOHOL BASED SOL-
VENTS. PERSONAL INJURY CAN RESULT.
²DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT PROPERLY SUPPORTED ON
SAFETY STANDS. PERSONAL INJURY CAN
RESULT.
NOTE:
²When holes must be drilled or cut in body pan-
els, verify locations of internal body components
and electrical wiring. Damage to vehicle can result.
²Do not use abrasive chemicals or compounds
on undamaged painted surfaces around repair
areas. Damage to finish can result.
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES
CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION
ASA ACRYLONITRILE STYRENE
ACRYLITELURAN S CONSOLES, GRILLES
ABS ACRYLONITRILE
BUTADIENE STYRENETERLURAN9A9PILLARS, CONSOLES,
GRILLES
ABS/PC ABS/PC ALLOY PULSE, PROLOY,
BAYBLENDDOORS, INSTRUMENT
PANELS
ABS/PVC ABS/PV ALLOY PROLOY, PULSE, LUSTRAN,
CYCLOVINDOOR PANELS, GRILLES,
TRIM
BMC BULK MOLDING
COMPOUNDBMC FENDER EXTENSIONS
EMA EHTYLENE METHYL
ACRYLATE/IONOMERSURLYN, EMA, IONOMER BUMPER GUARDS, PADS
METTON METTON METTON GRILLES, KICK PANELS,
RUNNING BOARDS
MPPO MODIFIED
POLYPHENYLENE OXIDEMPPO SPOILER ASSEMBLY
PA POLYAMID ZYTEL, VYDYNE, PA,
MINLONFENDERS, QUARTER PANELS
PET THERMOPLASTIC
POLYESTERRYNITE TRIM
PBT/PPO PBT/PPO ALLOY GERMAX CLADDINGS
PBTP POLYBUTYLENE
THEREPTHALATEPBT, PBTP, POCAN, VALOX WHEEL COVERS, FENDERS,
GRILLES
PBTP/EEBC POLYBUTYLENE
THEREPTHALATE/EEBC
ALLOYBEXLOY,9M9, PBTP/EEBC FASCIAS, ROCKER PANEL,
MOLDINGS
PC POLYCARBONATE LEXAN, MERLON, CALIBRE,
MAKROLON PCTAIL LIGHT LENSES, IP TRIM,
VALANCE PANELS
23 - 4 BODYDR
BODY (Continued)

CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION
PC/ABS PC/ABS ALLOY GERMAX, BAY BLENDS,
PULSEDOORS, INSTRUMENT
PANELS
PPO POLYPHENYLENE OXIDE AZDEL, HOSTALEN,
MARLEX, PRFAX, NORYL,
GTX, PPOINTERIOR TRIM, DOOR
PANELS, SPLASH SHIELDS,
STEERING COLUMN SHROUD
PPO/PA POLYPHENYLENE/
POLYAMIDPPO/PA, GTX 910 FENDERS, QUARTER PANELS
PR/FV FIBERGLASS REINFORCED
PLASTICFIBERGLASS, FV, PR/FV BODY PANELS
PS POLYSTYRENE LUSTREX, STYRON, PS DOOR PANELS, DASH
PANELS
RTM RESIN TRANSFER
MOLDING COMPOUNDRTM BODY PANELS
SMC SHEET MOLDED
COMPOUNDSMC BODY PANELS
TMC TRANSFER MOLDING
COMPOUNDTMC GRILLES
UP UNSATURATED
POLYESTER
(THERMOSETTING)SMC, BMC, TMC, ZMC, IMC,
XSMC, UPGRILLE OPENING PANEL,
LIFTGATES, FLARESIDE
FENDERS, FENDER
EXTENSIONS
EEBC ETHER/ESTER BLOCKED
CO-POLYMEREEBC BUMPERS
EEBC/PBTP EEBC/POLYBUTYLENE
TEREPTHALATEEEBC, PBTP, BEXLOY BUMPER, ROCKER PANELS
EMPP ETHYLENE MODIFIED
POLYPROPYLENEEMPP BUMPER COVERS
EPDM ETHYLENE/
PROPROPYLENE DIENE
MONOMEREPDM, NORDEL, VISTALON BUMPERS
EPM ETHYLENE/
PROPROPYLENE CO-
POLYMEREPM FENDERS
MPU FOAM POLYURETHANE MPU SPOILERS
PE POLYETHYLENE ALATHON, DYLAN,
LUPOLEN, MARLEX-
PP POLYPROPYLENE
(BLENDS)NORYL, AZDEL, MARLOX,
DYLON, PRAVEXINNER FENDER, SPOILERS,
KICK PANELS
PP/EPDM PP/EPDM ALLOY PP/EPDM SPOILERS, GRILLES
PUR POLYURETHANE COLONELS, PUR, PU FASCIAS, BUMPERS
PUR/PC PUR/PC ALLOY TEXIN BUMPERS
PVC POLYVINYL CHLORIDE APEX, GEON, VINYLITE BODY MOLDINGS, WIRE
INSULATION, STEERING
WHEELS
RIM REACTION INJECTED
MOLDED POLYURETHANERIM, BAYFLEX FRONT FASCIAS, MODULAR
WINDOWS
RRIM REINFORCED REACTION
INJECTED MOLDEDPUR, RRIM FASCIAS, BODY PANELS,
BODY TRIMS
DRBODY 23 - 5
BODY (Continued)

CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION
TPE THERMO POLYETHYLENE TPE, HYTREL, BEXLOY-V FASCIAS, BUMPERS,
CLADDINGS
TPO THERMOPOLYOLEFIN POLYTROPE, RENFLEX,
SANTOPRENE, VISAFLEX,
ETA, APEX, TPO, SHIELDS,
CLADDINGSBUMPERS, END CAPS,
TELCAR, RUBBER, STRIPS,
SIGHT, INTERIOR B POST
TPP THERMO-
POLYPROPYLENETPP BUMPERS
TPU THERMOPOLYURETHANE,
POLYESTERTPU, HYTREL, TEXIN,
ESTANEBUMPERS, BODY SIDE,
MOLDINGS, FENDERS,
FASCIAS
PANEL SECTIONING
If it is required to section a large panel for a plas-
tic repair, it will be necessary to reinforce the panel
(Fig. 1). To bond two plastic panels together, a rein-
forcement must overlap both panels. The panels
must be ªV'dº at a 20 degree angle. The area to be
reinforced should be washed, then sanded. Be sure to
wipe off any excess soap and water when finished.
Lightly sand or abrade the plastic with an abrasive
pad or sandpaper. Blow off any dust with compressed
air or wipe with a clean dry rag.
When bonding plastic panels, Follow repair mate-
rial manufacturers recommendations. Be sure that
enough adhesive has been applied to allow squeeze
out and to fill the full bond line. Once the pieces
have been brought together, do not move them until
the adhesive is cured. The assembly can be held
together with clamps, rivets, etc. A faster cure can be
obtained by heating with a heat lamp or heat gun.
After the parts have been bonded and have had timeto cure, rough sand the seam and apply the final
adhesive filler to the area being repaired. Smooth the
filler with a spreader, wooden tongue depressor, or
squeegee. For fine texturing, a small amount of
water can be applied to the filler surface while
smoothing. The cured filler can be sanded as neces-
sary and, as a final step, cleanup can be done with
soapy water. Wipe the surface clean with a dry cloth
allowing time for the panel to dry before moving on
with the repair.
PANEL REINFORCEMENT
Structural repair procedures for rigid panels with
large cracks and holes will require a reinforcement
backing. Reinforcements can be made with several
applications of glass cloth saturated with structural
adhesive. Semi-rigid or flexible repair materials
should be used for semi-rigid or flexible backing rein-
forcement (Fig. 2) and (Fig. 3). Open meshed fiber-
glass dry wall tape can be used to form a
reinforcement. The dry wall tape allows the resin to
penetrate through and make a good bond between
the panel and the adhesive. Structurally, the more
dry wall tape used, the stronger the repair.
Another kind of repair that can be done to repair
large cracks and holes is to use a scrap piece of sim-
ilar plastic and bond with structural adhesive. The
reinforcement should cover the entire break and
should have a generous amount of overlap on either
side of the cracked or broken area.
When repairing plastic, the damaged area is first
ªV'dº out, or beveled. Large bonding areas are desir-
able when repairing plastic because small repairs are
less likely to hold permanently. Beveling the area
around a crack at a 20 degree angle will increase the
bonding surface for a repair (Fig. 4). It is recom-
mended that sharp edges be avoided because the
joint may show through after the panel is refinished.
Fig. 1 PANEL SECTIONING
1 - EXISTING PANEL
2 - NEW PANEL
3 - PANEL ADHESIVE
4 - BONDING STRIP
23 - 6 BODYDR
BODY (Continued)

INSTALLATION
(1) Install the splash shield and position the front
edge into the support bracket on the bumper.
(2) Install the five inner screws.
(3) Install the three screws at the fender.
(4) Install the electrical connector push pin fas-
tener.
REAR WHEELHOUSE SPLASH
SHIELD
REMOVAL
(1) Remove the screws and remove the shield. (Fig.
11 )
INSTALLATION
(1) Install the splash shield and install the screws.
SIDE VIEW MIRROR
REMOVAL
(1) Remove the door trim panel. (Refer to 23 -
BODY/DOOR - FRONT/TRIM PANEL - REMOVAL)
(2) Disconnect the electrical connector and remove
the nuts. (Fig. 12)
(3) Squeeze the electrical connector tabs and
remove the mirror. (Fig. 13)
INSTALLATION
(1) Install the mirror onto the door and engage the
electrical connector tabs. (Fig. 13)
(2) Install the nuts and tighten to 7 N´m (60 in.
lbs.).(3) Install the door trim panel. (Refer to 23 -
BODY/DOOR - FRONT/TRIM PANEL - INSTALLA-
TION)
Fig. 11 REAR SPLASH SHIELD
1 - CARGO BOX
2 - SCREWS (3)
3 - SPLASH SHIELD
Fig. 12 SIDE VIEW MIRROR
1 - MIRROR
2 - NUTS (3)
3 - ELECTRICAL CONNECTOR
Fig. 13 MIRROR ELECTRICAL CONNECTOR
1 - DOOR
2 - MIRROR STUDS
3 - CONNECTOR TABS
4 - ELECTRICAL CONNECTOR
DREXTERIOR 23 - 41
FRONT WHEELHOUSE SPLASH SHIELD (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 Tailgate to outer box
(Up/Down surface only)Ð 0.0   1.5
Parallel within 1.0
2 Cab Back to box front 31.0   5.0
Parallel within 3.0Ð
3 Fuel door to outer box 5.0   1.5
Parallel within 1.00.0   1.5
4 Cab to box side 31.0   5.0
Parallel within 3.04.0   2.5 (Standard Cab)
O/F 5.0   2.5 (Quad Cab)
5 Cab to box character line alignment Ð Up/Down 0.0   3.0
6 Tailgate to outer box 5.0   2.0
Parallel within 1.0U/F 1.5   1.5
7 Bumper to outer box 24.75   5.0 (F/A)
23.75   5.0 (C/C)
Parallel within 5.0Ð
8 Tailgate to outer box character line
adjustmentÐ Up/Down 0.0   1.5
9 Bumper to tailgate 30.25   3.0
Parallel within 4.0Ð
Fig. 3 GAP & FLUSH - PICKUP BOX
23 - 98 BODY STRUCTUREDR
GAP AND FLUSH (Continued)

NOTE: Removal of the front bumper on the V-10 is
required, failure to do so could result in damage to
the condenser assembly and the bumper.
(3) Remove the front bumper assembly from the
vehicle(Refer to 13 - FRAME & BUMPERS/
BUMPERS/FRONT BUMPER - REMOVAL).
(4) Remove hood latch bolts and set hood latch
assembly aside(Refer to 23 - BODY/HOOD/LATCH -
REMOVAL).
(5) Remove a/c lines from condenser(Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
DISCHARGE LINE - REMOVAL) and (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
SUCTION LINE - REMOVAL). Install plugs or tape
over all open connections (Fig. 7).
(6) Remove two bolts from top of condenser shroud
assembly (Fig. 8).
(7) Lift condenser and shift assembly to passenger
side of vehicle and remove from vehicle.
(8) With condenser and shroud on a clean flat
work area remove condenser retainer screws and sep-
arate condenser from shroud.
INSTALLATION
INSTALLATION - 3.7, 4.7 and 5.7L ENGINES
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION - REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS)
(1) Install the condenser lower dowel pins to the
bottom of the support rail.
(2) Position the condenser until both of the con-
denser studs are installed through the holes in the
upper support rail. Tighten the mounting nuts to 5.3
N´m (47 in. lbs.).
(3) Remove the tape or plugs from the refrigerant
line fittings on the condenser outlet and the liquid
line. Install the liquid line or the liquid line jumper
to the condenser outlet. (Refer to 24 - HEATING &
Fig. 7 CONDENSER LINES
1 - Discharge line to condenser
2 - Mounting nut
3 - Mounting nut
4 - Liquid line
5 - A/C condenser shroud
6 - A/C condenser
Fig. 8 A/C CONDENSER
1 -A/C shroud mounting bolt
2 - Hood latch bolt
3 - Hood latch assembly
4 - Hood latch bolt
5 - A/C shroud mounting bolt
6 - A/C discharge line
7 - A/C liquid line
8 - Condenser to shroud mounting bolts (5)
9 - A/C condenser
10 - Condenser to shroud mounting bolts (5)
DRPLUMBING 24 - 41
A/C CONDENSER (Continued)

AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE - A/C LINE COUPLERS)
(4) Remove the tape or plugs from the refrigerant
line fittings on the condenser inlet and the discharge
line. Connect the discharge line to the condenser
inlet. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE - A/C
LINE COUPLERS)
(5) Connect the battery negative cable.
(6) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
NOTE: If the condenser is replaced, add 30 millili-
ters (1 fluid ounce) of refrigerant oil to the refriger-
ant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT OIL - DESCRIPTION)
INSTALLATION - 5.9L DIESEL ENGINE
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)(Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION - REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS)
(1) On diesel engine models:
(a) Install the driver side condenser mounting
brackets over the two studs on the charge air
cooler.
(b) Install the two screws that secure the brack-
ets on the passenger side end of the condenser to
the charge air cooler. Tighten the mounting screws
to 10.5 N´m (95 in. lbs.).
(c) Install the two nuts that secure the driver
side end of the condenser to the studs on the
charge air cooler. Tighten the mounting nuts to
10.5 N´m (95 in. lbs.).
(2) Remove the plugs or tape from the refrigerant
line fittings on the liquid line and the condenser out-
let. Connect the liquid line to the condenser outlet.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE - A/C LINE
COUPLERS)(3) Install a new gasket and the discharge line
block fitting over the stud on the condenser inlet.
Tighten the mounting nut to 20 N´m (180 in. lbs.).
(4) Check that all of the condenser and radiator
air seals are in their proper locations.
(5) Connect the battery negative cable.
(6) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
NOTE: If the condenser is replaced, add 30 millili-
ters (1 fluid ounce) of refrigerant oil to the refriger-
ant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT OIL - DESCRIPTION)
INSTALLATION - 8.0L Engine
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION(Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) AND (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
(1) If the condenser was removed from the shroud,
install it and tighten the mounting screws.
(2) Install the condenser and shroud in the vehicle.
Make sure the lower mounting flanges are positioned
correctly before installing the two mounting screws
to the radiator brace. Tighten the screws to spec.
(3) Remove and plugs or tape installed over the
condenser connections and the a/c lines.
(4) Install the lines to the condenser(Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
DISCHARGE LINE - INSTALLATION) and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
SUCTION LINE - INSTALLATION).
(5) Install the hood latch assembly(Refer to 23 -
BODY/HOOD/LATCH - INSTALLATION).
(6) Install the front bumper assembly(Refer to 13 -
FRAME & BUMPERS/BUMPERS/FRONT BUMPER
- INSTALLATION).
(7) Evacuate the a/c system(Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE).
24 - 42 PLUMBINGDR
A/C CONDENSER (Continued)

AIRBAG CONTROL MODULE -
INSTALLATION......................8O-12
AIRBAG CONTROL MODULE -
OPERATION.........................8O-10
AIRBAG CONTROL MODULE -
OPERATION, SIDE IMPACT.............8O-54
AIRBAG CONTROL MODULE - REMOVAL . . 8O-11
AIRBAG INDICATOR - DESCRIPTION......8J-18
AIRBAG INDICATOR - OPERATION.......8J-18
AIRBAG ON/OFF SWITCH -
DESCRIPTION, PASSENGER............8O-38
AIRBAG ON/OFF SWITCH -
INSTALLATION, PASSENGER...........8O-39
AIRBAG ON/OFF SWITCH - OPERATION,
PASSENGER........................8O-38
AIRBAG ON/OFF SWITCH - REMOVAL,
PASSENGER........................8O-39
AJAR INDICATOR - DESCRIPTION, DOOR . . 8J-23
AJAR INDICATOR - OPERATION, DOOR . . . 8J-23
AJAR SWITCH - DESCRIPTION, DOOR....8L-25
AJAR SWITCH - OPERATION, DOOR......8L-25
ALIGNMENT - DESCRIPTION, WHEEL.......2-1
ALIGNMENT - OPERATION, WHEEL........2-2
ALIGNMENT - SPECIAL TOOLS,
HEADLAMP..........................8L-7
ALIGNMENT LINK/COIL SUSPENSION -
STANDARD PROCEDURE.................2-5
ALIGNMENT, SPECIAL TOOLS - WHEEL.....2-7
ALIGNMENT, SPECIFICATIONS............2-6
ALUMINUM THREAD REPAIR -
STANDARD PROCEDURE . . 21-156,21-337,21-495
AMBIENT TEMP SENSOR - DESCRIPTION . 8M-10
AMBIENT TEMP SENSOR - OPERATION . . 8M-10
AMBIENT TEMPERATURE SENSOR -
DIAGNOSIS AND TESTING.............8M-11
AMBIENT TEMPERATURE SENSOR
CIRCUIT - DIAGNOSIS AND TESTING....8M-11
AMPLIFIER - DESCRIPTION.............8A-3
AMPLIFIER - INSTALLATION.............8A-4
AMPLIFIER - OPERATION...............8A-3
AMPLIFIER - REMOVAL................8A-3
ANCHOR - DESCRIPTION, CHILD
RESTRAINT.........................8O-14
ANCHOR - INSTALLATION, CHILD
RESTRAINT.........................8O-17
ANCHOR - OPERATION, CHILD
RESTRAINT.........................8O-16
ANCHOR - REMOVAL, CHILD RESTRAINT . 8O-16
ANCHOR & RIGHT OUTBOARD -
INSTALLATION, CENTER...............8O-45
ANCHOR & RIGHT OUTBOARD -
REMOVAL, CENTER...................8O-43
ANTENNA BODY & CABLE -
DESCRIPTION........................8A-4
ANTENNA BODY & CABLE -
INSTALLATION.......................8A-6
ANTENNA BODY & CABLE - OPERATION . . . 8A-4
ANTENNA BODY & CABLE - REMOVAL.....8A-6
ANTENNA BODY AND CABLE -
DIAGNOSIS AND TESTING..............8A-4
ANTENNA CABLE - INSTALLATION,
INSTRUMENT PANEL..................8A-7
ANTENNA CABLE - REMOVAL,
INSTRUMENT PANEL..................8A-6
ANTILOCK - DIAGNOSIS AND TESTING,
REAR WHEEL........................5-42
ANTILOCK BRAKE - DESCRIPTION,
CONTROLLER........................8E-3
ANTILOCK BRAKE - INSTALLATION,
CONTROLLER........................8E-3
ANTILOCK BRAKE - OPERATION,
CONTROLLER........................8E-3
ANTILOCK BRAKE - REMOVAL,
CONTROLLER........................8E-3
A-PILLAR TRIM/GRAB HANDLE -
INSTALLATION.......................23-64
A-PILLAR TRIM/GRAB HANDLE -
REMOVAL..........................23-64
A-PILLAR WEATHERSTRIP RETAINER -
INSTALLATION
.......................23-91
A-PILLAR WEATHERSTRIP RETAINER -
REMOVAL
..........................23-91
APPLICATION TABLE, SPECIFICATIONS -
A/C
................................24-7
AREA LEAKS - DIAGNOSIS AND
TESTING, REAR SEAL
........9-135,9-204,9-64
ARM / ADJUSTER ASSEMBLY -
DESCRIPTION, ROCKER
...............9-124ARM / ADJUSTER ASSEMBLY -
INSTALLATION, ROCKER..........9-124,9-249
ARM / ADJUSTER ASSEMBLY -
REMOVAL, ROCKER.............9-124,9-249
ARM / ADJUSTER ASSY - CLEANING,
ROCKER............................9-310
ARM / ADJUSTER ASSY - DESCRIPTION,
ROCKER............................9-310
ARM / ADJUSTER ASSY - INSPECTION,
ROCKER............................9-311
ARM / ADJUSTER ASSY -
INSTALLATION, ROCKER.....9-198,9-312,9-379
ARM / ADJUSTER ASSY - REMOVAL,
ROCKER.................9-198,9-310,9-379
ARM - DESCRIPTION, ROCKER......9-30,9-36
ARM - DESCRIPTION, WIPER...........8R-18
ARM - INSTALLATION, LOWER
SUSPENSION.........................2-35
ARM - INSTALLATION, PITMAN.........19-36
ARM - INSTALLATION, ROCKER..........9-30
ARM - INSTALLATION, UPPER CONTROL . . . 2-27
ARM - INSTALLATION, WIPER..........8R-19
ARM - OPERATION, WIPER............8R-18
ARM - REMOVAL, LOWER SUSPENSION . . . 2-35
ARM - REMOVAL, PITMAN.............19-35
ARM - REMOVAL, ROCKER..........9-30,9-36
ARM - REMOVAL, UPPER CONTROL......2-27
ARM - REMOVAL, WIPER..............8R-18
ARM BUSHINGS - 2WD (LD) -
INSTALLATION, LOWER CONTROL..........2-14
ARM BUSHINGS - 2WD (LD) -
REMOVAL, LOWER CONTROL............2-12
ARM BUSHINGS - 4WD (LD) -
INSTALLATION, LOWER CONTROL........2-13
ARM BUSHINGS - 4WD (LD) -
REMOVAL, LOWER CONTROL............2-12
ARMREST / SEAT BACK - INSTALLATION,
CENTER............................23-78
ARMREST / SEAT BACK - REMOVAL,
CENTER............................23-77
ASD AND FUEL PUMP RELAYS -
DIAGNOSIS AND TESTING...............8I-7
ASD SENSE - PCM INPUT - OPERATION....8I-6
ASH RECEIVER - INSTALLATION.........23-52
ASH RECEIVER - REMOVAL............23-51
AUDIO - DESCRIPTION.................8A-1
AUDIO - DIAGNOSIS AND TESTING.......8A-2
AUDIO - OPERATION...................8A-1
AUTOMATIC DAY / NIGHT MIRROR -
DESCRIPTION.......................8N-12
AUTOMATIC DAY / NIGHT MIRROR -
DIAGNOSIS AND TESTING.............8N-12
AUTOMATIC DAY / NIGHT MIRROR -
OPERATION.........................8N-12
AUTOMATIC DAY / NIGHT MIRROR -
REMOVAL..........................8N-13
AUTOMATIC LOCKING RETRACTOR -
DESCRIPTION.......................8O-13
AUTOMATIC LOCKING RETRACTOR -
OPERATION.........................8O-14
AUTOMATIC TRANSMISSION -
45RFE/545RFE - DESCRIPTION.........21-489
AUTOMATIC TRANSMISSION -
45RFE/545RFE - OPERATION...........21-490
AUTOMATIC TRANSMISSION - 46RE -
DESCRIPTION......................21-131
AUTOMATIC TRANSMISSION - 46RE -
OPERATION........................21-133
AUTOMATIC TRANSMISSION - 48RE -
DESCRIPTION......................21-312
AUTOMATIC TRANSMISSION - 48RE -
OPERATION........................21-314
AUTOMATIC TRANSMISSION -
DIAGNOSIS AND TESTING......21-139,21-320,
21-491
AUTOMATIC TRANSMISSION FLUID -
DESCRIPTION.........................0-4
AUTOMATIC TRANSMISSION FLUID -
OPERATION...........................0-5
AUXILIARY SPRING BUMPERS (3500) -
INSTALLATION
........................2-40
AUXILIARY SPRING BUMPERS (3500) -
REMOVAL
...........................2-40
AXLE - 10 1/2 AA - ADJUSTMENTS,
REAR
..............................3-104
AXLE - 10 1/2 AA - DESCRIPTION, REAR
. . 3-100
AXLE - 10 1/2 AA - DIAGNOSIS AND
TESTING, REAR
......................3-100AXLE - 10 1/2 AA - INSTALLATION,
REAR..............................3-103
AXLE - 10 1/2 AA - OPERATION, REAR . . . 3-100
AXLE - 10 1/2 AA - REMOVAL, REAR.....3-103
AXLE - 10 1/2 AA - SPECIAL TOOLS,
REAR..............................3-108
AXLE - 10 1/2 AA - SPECIFICATIONS,
REAR..............................3-108
AXLE - 11 1/2 AA - ADJUSTMENTS,
REAR..............................3-131
AXLE - 11 1/2 AA - DESCRIPTION, REAR . . 3-127
AXLE - 11 1/2 AA - DIAGNOSIS AND
TESTING, REAR......................3-127
AXLE - 11 1/2 AA - INSTALLATION,
REAR..............................3-130
AXLE - 11 1/2 AA - OPERATION, REAR . . . 3-127
AXLE - 11 1/2 AA - REMOVAL, REAR.....3-130
AXLE - 11 1/2 AA - SPECIAL TOOLS,
REAR..............................3-135
AXLE - 11 1/2 AA - SPECIFICATIONS,
REAR..............................3-135
AXLE - 9 1/4 - ADJUSTMENTS, REAR.....3-74
AXLE - 9 1/4 - DESCRIPTION, REAR......3-69
AXLE - 9 1/4 - DIAGNOSIS AND
TESTING, REAR.......................3-69
AXLE - 9 1/4 - INSTALLATION, REAR......3-74
AXLE - 9 1/4 - OPERATION, REAR........3-69
AXLE - 9 1/4 - REMOVAL, REAR..........3-74
AXLE - 9 1/4 - SPECIAL TOOLS, REAR.....3-80
AXLE - 9 1/4 - SPECIFICATIONS, REAR......3-79
AXLE - 9 1/4 AA - ADJUSTMENTS,
FRONT..............................3-49
AXLE - 9 1/4 AA - DESCRIPTION, FRONT . . . 3-45
AXLE - 9 1/4 AA - DIAGNOSIS AND
TESTING, FRONT......................3-45
AXLE - 9 1/4 AA - INSTALLATION,
FRONT..............................3-48
AXLE - 9 1/4 AA - OPERATION, FRONT....3-45
AXLE - 9 1/4 AA - REMOVAL, FRONT......3-48
AXLE - 9 1/4 AA - SPECIAL TOOLS,
FRONT..............................3-53
AXLE - 9 1/4 AA - SPECIFICATIONS,
FRONT..............................3-53
AXLE - C205F - ADJUSTMENTS, FRONT....3-21
AXLE - C205F - DESCRIPTION, FRONT.....3-18
AXLE - C205F - DIAGNOSIS AND
TESTING, FRONT......................3-18
AXLE - C205F - INSTALLATION, FRONT....3-21
AXLE - C205F - OPERATION, FRONT......3-18
AXLE - C205F - REMOVAL, FRONT........3-21
AXLE - C205F - SPECIAL TOOLS, FRONT . . . 3-30
AXLE - C205F - SPECIFICATIONS, FRONT . . . 3-29
AXLE - DESCRIPTION...................0-4
AXLE BEARINGS - INSTALLATION . . 3-112,3-139,
3-34,3-84
AXLE BEARINGS - REMOVAL . . 3-112,3-138,3-33,
3-84
AXLE SHAFT SEALS - INSTALLATION . 3-33,3-58,
3-84
AXLE SHAFT SEALS - REMOVAL . 3-33,3-58,3-84
AXLE SHAFTS - ASSEMBLY.............3-58
AXLE SHAFTS - DISASSEMBLY...........3-56
AXLE SHAFTS - INSTALLATION....3-111,3-138,
3-33,3-58,3-83
AXLE SHAFTS - REMOVAL
....3-111,3-138,3-33,
3-56,3-83
BACK - INSTALLATION, CENTER
ARMREST / SEAT
....................23-78
BACK - REAR - INSTALLATION, SEAT
.....23-84
BACK - REAR - REMOVAL, SEAT
........23-84
BACK - REMOVAL, CENTER ARMREST /
SEAT
..............................23-77
BACK CUSHION / COVER - FRONT -
INSTALLATION, SEAT
.................23-83
BACK CUSHION / COVER - FRONT -
REMOVAL, SEAT
.....................23-83
BACK CUSHION / COVER - REAR -
INSTALLATION, SEAT
.................23-85
BACK CUSHION / COVER - REAR -
REMOVAL, SEAT
.....................23-85
BACK HINGE - INSTALLATION, CENTER
SEAT
..............................23-80
BACK HINGE - REMOVAL, CENTER SEAT
. . 23-79
BACK INERTIA HINGE COVER -
INSTALLATION, CENTER SEAT
..........23-78
BACK INERTIA HINGE COVER -
REMOVAL, CENTER SEAT
..............23-78
2 INDEXDR
Description Group-Page Description Group-Page Description Group-Page

BRAKE SYSTEM - DIAGNOSIS AND
TESTING, BASE........................5-2
BRAKE TRANSMISSION SHIFT
INTERLOCK - ADJUSTMENTS . . . 21-195,21-376,
21-540
BRAKE TRANSMISSION SHIFT
INTERLOCK - DIAGNOSIS AND
TESTING..............21-195,21-375,21-540
BRAKE TRANSMISSION SHIFT
INTERLOCK SYSTEM - DESCRIPTION . . . 21-194,
21-375,21-540
BRAKE TRANSMISSION SHIFT
INTERLOCK SYSTEM - OPERATION.....21-194,
21-375,21-540
BRAKE/PARK BRAKE INDICATOR -
DESCRIPTION.......................8J-18
BRAKE/PARK BRAKE INDICATOR -
OPERATION.........................8J-19
BRAKES - ABS - DESCRIPTION...........5-39
BRAKES - ABS - OPERATION............5-39
BRAKES, SPECIAL TOOLS - BASE.........5-5
BREAK-IN - STANDARD PROCEDURE,
A/C COMPRESSOR CLUTCH............24-10
BREATHER - INSTALLATION,
CRANKCASE........................9-292
BREATHER - REMOVAL, CRANKCASE.....9-291
BUCKLE - INSTALLATION, FRONT
OUTBOARD SEAT BELT................8O-34
BUCKLE - REMOVAL, FRONT OUTBOARD
SEAT BELT .........................8O-33
BUILT-IN INDICATOR TEST - STANDARD
PROCEDURE........................8F-10
BUMPER - INSTALLATION, FRONT........13-2
BUMPER - INSTALLATION, JOUNCE.......2-40
BUMPER - INSTALLATION, REAR.........13-4
BUMPER - REMOVAL, FRONT............13-2
BUMPER - REMOVAL, JOUNCE...........2-40
BUMPER - REMOVAL, REAR.............13-4
BUMPERS (3500) - INSTALLATION,
AUXILIARY SPRING....................2-40
BUMPERS (3500) - REMOVAL,
AUXILIARY SPRING....................2-40
BURNT FLUID - DIAGNOSIS AND
TESTING, CAUSES OF....21-201,21-381,21-541
BUSHING - INSTALLATION.............19-18
BUSHING - INSTALLATION,
DISTRIBUTOR.......................9-258
BUSHING - INSTALLATION, EXTENSION
HOUSING..........................21-200
BUSHING - INSTALLATION, TORSION
BAR CROSS MEMBER..................2-14
BUSHING - REMOVAL.................19-18
BUSHING - REMOVAL, DISTRIBUTOR.....9-258
BUSHING - REMOVAL, EXTENSION
HOUSING..........................21-200
BUSHING - REMOVAL, TORSION BAR
CROSSMEMBER......................2-12
BUSHING AND SEAL - INSTALLATION,
EXTENSION HOUSING..........21-616,21-682
BUSHING AND SEAL - REMOVAL,
EXTENSION HOUSING..........21-616,21-682
BUSHINGS - 2WD (LD) - INSTALLATION,
LOWER CONTROL ARM................2-14
BUSHINGS - 2WD (LD) - REMOVAL,
LOWER CONTROL ARM................2-12
BUSHINGS - 4WD (LD) - INSTALLATION,
LOWER CONTROL ARM
................2-13
BUSHINGS - 4WD (LD) - REMOVAL,
LOWER CONTROL ARM
................2-12
BUSHINGS - INSTALLATION
.............2-39
BUSHINGS - REMOVAL
.................2-39
BUZZ, SQUEAK & RATTLE - STANDARD
PROCEDURE
........................23-11
BYPASS - DESCRIPTION, WATER PUMP
. . . 7-64
BYPASS - OPERATION, WATER PUMP
.....7-65
BYPASS HOSE WITH AIR CONDITIONING
- INSTALLATION, WATER PUMP
..........7-70
BYPASS HOSE WITH AIR CONDITIONING
- REMOVAL, WATER PUMP
..............7-68
BYPASS HOSE WITHOUT AIR
CONDITIONING - INSTALLATION,
WATER PUMP
........................7-70
BYPASS HOSE WITHOUT AIR
CONDITIONING - REMOVAL, WATER
PUMP
..............................7-69
C205F - ADJUSTMENTS, FRONT AXLE
.....3-21
C205F - DESCRIPTION, FRONT AXLE
......3-18C205F - DIAGNOSIS AND TESTING,
FRONT AXLE.........................3-18
C205F - INSTALLATION, FRONT AXLE.....3-21
C205F - OPERATION, FRONT AXLE........3-18
C205F - REMOVAL, FRONT AXLE.........3-21
C205F - SPECIAL TOOLS, FRONT AXLE....3-30
C205F - SPECIFICATIONS, FRONT AXLE....3-29
CAB - INSTALLATION, QUAD...........8O-32
CAB - INSTALLATION, STANDARD.......8O-31
CAB - REMOVAL, QUAD...............8O-29
CAB - REMOVAL, STANDARD...........8O-28
CAB BACK PANEL TRIM -
INSTALLATION, REAR.................23-70
CAB BACK PANEL TRIM - REMOVAL,
REAR..............................23-70
CAB CLEARANCE LAMP - INSTALLATION . . 8L-10
CAB CLEARANCE LAMP - REMOVAL.....8L-10
CABLE - ADJUSTMENTS, THROTTLE
VALVE ......................21-255,21-432
CABLE - DESCRIPTION.................8P-3
CABLE - DESCRIPTION, ANTENNA BODY . . . 8A-4
CABLE - DESCRIPTION, SPARK PLUG.....8I-33
CABLE - DESCRIPTION, THROTTLE
VALVE ......................21-254,21-432
CABLE - DIAGNOSIS AND TESTING,
ANTENNA BODY......................8A-4
CABLE - DIAGNOSIS AND TESTING,
GEARSHIFT............21-209,21-389,21-544
CABLE - INSTALLATION..................8P-6
CABLE - INSTALLATION, ANTENNA BODY . . 8A-6
CABLE - INSTALLATION, CHECK.........23-15
CABLE - INSTALLATION, FRONT
PARKING BRAKE......................5-32
CABLE - INSTALLATION, GEARSHIFT....21-210,
21-390,21-545
CABLE - INSTALLATION, INSTRUMENT
PANEL ANTENNA......................8A-7
CABLE - INSTALLATION, LEFT REAR......5-33
CABLE - INSTALLATION, REAR PARK
BRAKE..............................5-32
CABLE - INSTALLATION, RIGHT REAR.....5-32
CABLE - INSTALLATION, SPARK PLUG....8I-35
CABLE - INSTALLATION, THROTTLE
CONTROL.....................14-51,14-96
CABLE - OPERATION...................8P-3
CABLE - OPERATION, ANTENNA BODY.....8A-4
CABLE - OPERATION, SPARK PLUG.......8I-33
CABLE - REMOVAL....................8P-3
CABLE - REMOVAL, ANTENNA BODY......8A-6
CABLE - REMOVAL, CHECK.............23-15
CABLE - REMOVAL, FRONT PARKING
BRAKE..............................5-31
CABLE - REMOVAL, GEARSHIFT . 21-209,21-389,
21-544
CABLE - REMOVAL, INSTRUMENT PANEL
ANTENNA...........................8A-6
CABLE - REMOVAL, LEFT REAR..........5-32
CABLE - REMOVAL, REAR PARK BRAKE . . . 5-31
CABLE - REMOVAL, RIGHT REAR.........5-31
CABLE - REMOVAL, SPARK PLUG........8I-34
CABLE - REMOVAL, THROTTLE
CONTROL.....................14-49,14-94
CABLE, ADJUSTMENTS - GEARSHIFT . . . 21-211,
21-391,21-546
CABLE ORDER, 8.0L V-10 ENGINE -
SPARK PLUG.........................8I-5
CABLE RESISTANCE, SPECIFICATIONS -
SPARK PLUG.........................8I-5
CABLE ROUTING, 5.7L V-8 ENGINE -
FIRING ORDER........................8I-4
CABLE/HANDLE ASSEMBLY -
INSTALLATION, LATCH RELEASE........23-47
CABLE/HANDLE ASSEMBLY - REMOVAL,
LATCH RELEASE.....................23-47
CABLES - DESCRIPTION, BATTERY.......8F-14
CABLES - DIAGNOSIS AND TESTING,
BATTERY...........................8F-15
CABLES - DIAGNOSIS AND TESTING,
SPARK PLUG........................8I-33
CABLES - INSTALLATION, BATTERY......8F-17
CABLES - OPERATION, BATTERY........8F-14
CABLES - REMOVAL, BATTERY
..........8F-16
CALIBRATION - STANDARD PROCEDURE,
COMPASS
...........................8M-3
CALIPER ADAPTER MOUNT -
INSTALLATION, DISC BRAKE
............5-17
CALIPERS - DESCRIPTION, DISC BRAKE
. . . 5-11
CALIPERS - OPERATION, DISC BRAKE
.....5-12CAM BORE REPAIR - STANDARD
PROCEDURE........................9-315
CAMBER AND CASTER ADJUSTMENT -
STANDARD PROCEDURE.................2-4
CAMBER, CASTER AND TOE
ADJUSTMENT - STANDARD
PROCEDURE..........................2-4
CAM/OVERDRIVE PISTON RETAINER -
ASSEMBLY, OVERRUNNING CLUTCH....21-239,
21-416
CAM/OVERDRIVE PISTON RETAINER -
CLEANING, OVERRUNNING CLUTCH....21-238,
21-416
CAM/OVERDRIVE PISTON RETAINER -
DESCRIPTION, OVERRUNNING CLUTCH . 21-237,
21-415
CAM/OVERDRIVE PISTON RETAINER -
DISASSEMBLY, OVERRUNNING
CLUTCH.....................21-238,21-415
CAM/OVERDRIVE PISTON RETAINER -
INSPECTION, OVERRUNNING CLUTCH . . 21-238,
21-416
CAM/OVERDRIVE PISTON RETAINER -
OPERATION, OVERRUNNING CLUTCH . . . 21-237,
21-415
CAMSHAFT - INSTALLATION . 9-201,9-250,9-320,
9-381
CAMSHAFT - REMOVAL.....9-200,9-250,9-317,
9-380
CAMSHAFT BEARINGS - INSTALLATION . . 9-320,
9-381
CAMSHAFT BEARINGS - REMOVAL . 9-317,9-380
CAMSHAFT CORE HOLE PLUG -
INSTALLATION.......................9-201
CAMSHAFT CORE HOLE PLUG -
REMOVAL............................9-200
CAMSHAFT POSITION SENSOR -
DESCRIPTION.......................14-82
CAMSHAFT POSITION SENSOR -
DESCRIPTION.........................8I-8
CAMSHAFT POSITION SENSOR -
INSTALLATION.......................14-83
CAMSHAFT POSITION SENSOR -
INSTALLATION.......................8I-14
CAMSHAFT POSITION SENSOR -
OPERATION.........................14-82
CAMSHAFT POSITION SENSOR -
OPERATION..........................8I-8
CAMSHAFT POSITION SENSOR -
REMOVAL..........................14-83
CAMSHAFT POSITION SENSOR -
REMOVAL...........................8I-11
CAMSHAFT(S) - DESCRIPTION.......9-24,9-34
CAMSHAFT(S) - INSTALLATION......9-25,9-35
CAMSHAFT(S) - LEFT - DESCRIPTION....9-113
CAMSHAFT(S) - LEFT - INSTALLATION....9-114
CAMSHAFT(S) - LEFT - REMOVAL.......9-113
CAMSHAFT(S) - REMOVAL..........9-24,9-34
CAMSHAFT(S) - RIGHT - DESCRIPTION . . . 9-117
CAMSHAFT(S) - RIGHT - INSTALLATION . . 9-118
CAMSHAFT(S) - RIGHT - REMOVAL......9-117
CANISTER - DESCRIPTION, VAPOR......25-22
CANISTER - INSTALLATION, VAPOR......25-23
CANISTER - OPERATION, VAPOR........25-22
CANISTER - REMOVAL, VAPOR..........25-22
CAP - 5.9L V-8 - DIAGNOSIS AND
TESTING, DISTRIBUTOR...............8I-18
CAP - DESCRIPTION, FUEL FILLER.......25-13
CAP - DESCRIPTION, RADIATOR
PRESSURE..........................7-60
CAP - DIAGNOSIS AND TESTING,
RADIATOR...........................7-61
CAP - OPERATION, FUEL FILLER........25-13
CAP - OPERATION, RADIATOR
PRESSURE..........................7-61
CAPACITIES, SPECIFICATIONS - FLUID......0-5
CAPACITOR - DESCRIPTION, IGNITION
COIL...............................8I-33
CAPACITOR - INSTALLATION, IGNITION
COIL...............................8I-33
CAPACITOR - OPERATION, IGNITION
COIL
...............................8I-33
CAPACITOR - REMOVAL, IGNITION COIL
. . . 8I-33
CAPACITY - SPECIFICATIONS, CHARGE
. . . 24-35
CAP-TO-FILLER NECK SEAL -
DIAGNOSIS AND TESTING, RADIATOR
.....7-61
CARDAN UNIVERSAL JOINTS -
ASSEMBLY, SINGLE
.....................3-9
DRINDEX 5
Description Group-Page Description Group-Page Description Group-Page