tailgate DODGE RAM SRT-10 2006 Service User Guide

TA I L G AT E
REMOVAL
1. Open the tailgate (4).
2. Disconnect the tailgate check cables (3) from the
cable bolts (2) locate below each tailgate striker (1)
(Refer to 23 - BODY/TAILGATE/CHECK CABLE -
REMOVAL).
3. Partially close the tailgate so that the notch in the
right side tailgate pivot aligns with the flats on the
right side tailgate hinge.
4. Lift the tailgate upward and disconnect the tailgate
pivot from the right side tailgate hinge.
5. Carefully slide the tailgate to the right and discon-
nect it from the left side tailgate hinge and remove
the tailgate.
6. If required, remove the bushing (5) from each tail-
gate hinge.
INSTALLATION
1. If removed, install the bushing (5) onto each tail-
gate hinge.
2. Position the tailgate (4) onto the left side tailgate
hinge.
3. Partially close the tailgate so that the notch in the
right side tailgate pivot aligns with the flats on the
right side tailgate hinge.
4. Lower the tailgate onto the right side tailgate hinge.
5. Connect the tailgate check cables (3) to the cable
bolts (2) located below each tailgate striker (1)
(Refer to 23 - BODY/TAILGATE/CHECK CABLE -
INSTALLATION).

CARGO BOX
REMOVAL
NOTE: Long cargo box shown in illustration. Short
cargo box similar.
1. Remove the screws (1) that secure the fuel filler (2)
to the cargo box (3).
2. Remove the fuel filler from the cargo box and posi-
tionitoutoftheway.
3. If necessary, remove the fuel filler door from the
cargo box (Refer to 23 - BODY/EXTERIOR/FUEL
FILL DOOR - REMOVAL).
4. Disconnect the tail lamp wire harness from the
underbody wire harness (Refer to 8 - ELECTRI-
CAL/CONNECTOR/GROUND/SPLICE LOCATION
- DESCRIPTION).
5. If necessary, remove the tail lamp units and wire
harness from the cargo box (Refer to 8 - ELECTRI-
CAL/LAMPS/LIGHTING - EXTERIOR/TAIL LAMP
UNIT - REMOVAL).
6. If necessary, remove the tailgate (Refer to 23 -
BODY/TAILGATE/TAILGATE - REMOVAL).
7. If necessary, remove the rear bumper (Refer to 13
- FRAME & BUMPERS/BUMPERS/REAR
BUMPER - REMOVAL).
8. Remove the bolts (3) that secure the cargo box (1)
to the frame (2) (six short box, eight long box) and
remove the cargo box.
INSTALLATION
NOTE: Long cargo box shown in illustration. Short
cargo box similar.
1. Position the cargo box (1) onto the frame (2) and
loosely install the bolts (3) (six short box, eight long
box).
2. Align the cargo box to the cab and tighten the bolts
to 108 Nꞏm (80 ft. lbs.).
3. If removed, install tail lamp units and wire harness
onto the cargo box (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/TAIL LAMP UNIT -
INSTALLATION).
4. Connect the tail lamp wire harness to the under-
body wire harness (Refer to 8 - ELECTRICAL/

CONNECTOR/GROUND/SPLICE LOCATION - DESCRIPTION).
5. If removed, install the tailgate (Refer to 23 - BODY/TAILGATE/TAILGATE- INSTALLATION).
6. If removed, install the rear bumper (Refer to 13 - FRAME & BUMPERS/BUMPERS/REAR BUMPER - INSTAL-
LATION).
7. If removed, install the fuel filler door (Refer to 23 -
BODY/EXTERIOR/FUEL FILL DOOR - INSTALLA-
TION).
8. Position the fuel filler (2) to the cargo box (3).
9. Install the screws (1) that secure the fuel filler to
the cargo box. Tighten the screws to 2.2 Nꞏm (20
in. lbs.).

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)— 0.0 ± 1.5
Parallel within 1.0
2 Cab Back to box front 31.0 ± 5.0
Parallel within 3.0—
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 — 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 5.0—
8 Tailgate to outer box character line
adjustment— Up/Down 0.0 ± 1.5
9 Bumper to tailgate 30.25 ± 3.0
Parallel within 4.0—
Fig. 3 GAP & FLUSH - PICKUP BOX

NOTE:
All measurements are in mm. O/F = Over Flush. U/F = Under Flush.
DIMENSION DESCRIPTION GAP FLUSH
2 Hood To Grille 1.5 ± 1.0 U/F 0.5 ± 1.75
3 Fender To Hood 6.0 ± 2.0
Parallel Within 1.0U/F 3.2 ± 1.5
(Under flush from front of
hood to start of hockey
stick area only.)
4 Fender To Hood
(Up/Down Surface Only)6.0 ± 2.0
Parallel Within 2.00.0 ± 1.5
5 Front Door To Windshield — O/F 20.5 ± 1.5
(Base of windshield)
O/F 9.0 ± 1.5
(Top of windshield)
6 Front Door To Roof — O/F 6.0 ± 1.5
Parallel within 1.5
7 Rear Door To Roof — O/F 0.0 ± 1.5
8 Rear Door To Quarter Panel 5.0 ± 1.5
Parallel Within 1.50.0 ± 1.5
9 Fuel Door To Outer Box 5.0 ± 1.5
Parallel Within 1.50.0 ± 1.5
10 Rear Door To Quarter Character Line
Alignment— Up/Down 0.0 ± 1.5
11 Rear Door To Front Door 5.0 ± 1.5
Parallel Within 1.50.0 ± 1.5
12 Rear Door To Front Door Character
Line Alignment— Up/Down 0.0 ± 1.5
13 Front Door To Fender 5.0 ± 1.5
Parallel Within 1.5U/F 0.5 ± 1.5
14 Front Door To Fender Character Line
Alignment— Up/Down 0.0 ± 1.5
15 Bumper To Fender 16.0 ± 4.0
Side To Side 3.0O/F 6.5 ± 5.0 (SLT)
O/F 14.5 ± 5.0 (SPORT)
16 Bumper To Headlamp 16.0 ± 4.0 —
17 Tailgate To Outer Box Character Line
Alignment— 0.0 ± 1.5
18 Cab Back To Box Front 31.0 ± 5.0
Parallel Within 1.5—
19 Cab To Box Side 30.5 ± 5.0
Parallel Within 3.0O/F 5.25 ± 3.5
20 Cab To Box Character Line Alignment — Up/Down 0.0 ± 3.0
21 Tailgate To Outer Box 5.0 ± 2.0
Parallel Within 1.5U/F 1.5 ± 1.5
Side to side within 2.0
22 Bumper To Outer Box 24.0 ± 5.0 (F/A)
25.0 ± 5.0 (C/C)
Parallel Within 5.0—
23 Tailgate To Outer Box Character Line
Alignment— Up/Down 0.0 ± 1.5
24 Bumper To Tailgate 30.0 ± 3.0
Parallel Within 4.0—

DESCRIPTION FIGURE
OUTER BODY SIDE APERTURE TO INNER BODY SIDE APERTURE TO FLOOR SILL 98
REAR FLOOR CROSSMEMBER AND CAB BACK REINFORCEMENT TO CAB BACK
PANEL TO INNER BODY SIDE APERTURE99
CAB BACK REINFORCEMENT TO CAB BACK PANEL 100
CENTER SHOULDER BELT REINFORCEMENT AND TAPPING PLATES TO CAB BACK
REINFORCEMENT101
A-PILLAR REINFORCEMENT TO COWL SIDE PANEL TO OUTER BODY SIDE
APERTURE/APERTURE EXTENSION TO COWL SIDE PANEL102
B-PILLAR REINFORCEMENT TO OUTER ROOF PANEL TO OUTER BODY SIDE
APERTURE103
FRONT ROOF HEADER TO OUTER ROOF PANEL/ROOF BOW TO INNER BODY SIDE
APERTURE/FRONT ROOF HEADER TO A-PILLAR REINFORCEMENT104
INNER BODY SIDE APERTURE TO REAR ROOF HEADER AND OUTER BODY SIDE
APERTURE TO OUTER ROOF PANEL105
FRONT CROSSMEMBER, WHEELHOUSE CROSSMEMBER AND BRACKET SUPPORT
CROSSMEMBER TO BOX FLOOR PAN106
LONG CROSSMEMBER AND FLOOR BOX CROSS SILL TO BOX FLOOR PAN 107
TAPPING PLATES AND SUPPORT BRACKETS TO REAR CROSS BOX SILL, FRONT
WHEELHOUSE, LONG AND BRACKET SUPPORT CROSSMEMBERS108
STAKE POCKET REINFORCEMENTS AND TIE DOWN REINFORCEMENTS TO INNER
BOX SIDE PANEL109
OUTER BOX SIDE REINFORCEMENT BRACES NUT PLATES TO OUTER BOX SIDE
PANEL MOUNTING11 0
OUTER WHEELHOUSE TO OUTER BOX SIDE PANEL 111
WELD NUT STRIKER CAGE NUT, OUTER BOX SIDE PANEL AND NUT PLATE TO BOX
SIDE TAILGATE REINFORCEMENT11 2
FRONT BOX PANEL TO FRONT INNER STAKE POCKET REINFORCEMENT TO FRONT
BOX SIDE PANEL11 3
FRONT CROSSMEMBER TO FRONT BOX SIDE PANEL AND BOX FLOOR PANEL TO
BOX FRONT PANEL11 4
BOX FLOOR PANEL AND INNER WHEELHOUSE PANEL TO INNER BOX SIDE PANEL 115
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 PILLAR11 6
STAKE POCKET REINFORCEMENT AND BOX FLOOR SILL CROSSMEMBER TO
INNER TAILGATE PILLAR11 7
INNER TAILGATE PILLAR PANEL TO INNER BOX SIDE PANEL TO TIE DOWN
MOUNTING REINFORCEMENT11 8
BOX FLOOR SILL CROSSMEMBER TO INNER BOX SIDE PANEL 119
INNER TAILGATE PILLAR TO TAILGATE BOX SIDE REINFORCEMENT TO OUTER
TAILGATE PILLAR120
BOX SIDE PANEL AND OUTER TAILGATE PILLAR TO OUTER BOX SIDE PANEL 121
FRONT BOX PANEL TO OUTER BOX SIDE PANEL 122
INNER BOX SIDE PANEL AND INNER TAILGATE PILLAR TO OUTER BOX SIDE PANEL 123
OUTER WHEELHOUSE PANEL TO INNER WHEELHOUSE PANEL 124
FRONT CROSSMEMBER, LONG CROSSMEMBER, AND WHEELHOUSE
CROSSMEMBER TO FLOOR PAN125
WHEELHOUSE CROSSMEMBER, LONG CROSSMEMBER AND REAR CROSS BOX
SILL TO BOX FLOOR PAN126

DESCRIPTION FIGURE
FRONT AND CENTER STAKE POCKET REINFORCEMENTS AND TIE DOWN
MOUNTING REINFORCEMENT TO INNER BOX SIDE PANEL127
OUTER FRONT AND CENTER STAKE POCKET REINFORCEMENT AND OUTER TIE
DOWN MOUNTING REINFORCEMENT TO INNER BOX SIDE PANEL128
OUTER WHEELHOUSE AND OUTER BRACE MOUNTING REINFORCEMENT TO
OUTER BOX SIDE PANEL129
TAILGATE BOX SIDE PIVOT REINFORCEMENT TO OUTER BOX SIDE PANEL 130
FRONT BOX SIDE PANEL TO FRONT CROSSMEMBER TO INNER BOX SIDE PANEL 131
FRONT BOX SIDE PANEL TO BOX FRONT PANEL TO INNER BOX SIDE PANEL/
FRONT STAKE POCKET REINFORCEMENT TO FRONT BOX SIDE PANEL TO BOX
FRONT PANEL132
BOX FRONT PANEL TO BOX FLOOR PANEL 133
BOX FLOOR PANEL TO INNER BOX SIDE PANEL 134
LONG CROSSMEMBERS TO CROSSMEMBER END SUPPORT BRACKETS TO INNER
BOX SIDE PANEL135
INNER WHEELHOUSE PANEL TO INNER BOX SIDE PANEL 136
TAILGATE PILLAR OUTER PANEL TO TAILGATE PILLAR INNER PANEL TO INNER BOX
SIDE PANEL137
REAR SILL CROSS BOX TO TAILGATE PILLAR OUTER PANEL AND INNER BOX SIDE
PA N E L138
OUTER BOX SIDE PANEL TO BOX FRONT PANEL AND BOX FRONT SIDE PANEL 139
STAKE POCKET REINFORCEMENTS TO INNER BOX SIDE PANEL TO OUTER BOX
SIDE PANEL140
TAILGATE PIVOT REINFORCEMENT AND INNER TAILGATE PILLAR TO INNER BOX
SIDE PANEL TO OUTER BOX SIDE PANEL141
INNER WHEELHOUSE TO OUTER WHEELHOUSE/TAILGATE PIVOT
REINFORCEMENT TO OUTER TAILGATEPILLAR TO INNER TAILGATE PILLAR142
OUTER TAILGATE PILLAR TO OUTER BOX SIDE PANEL 143
INNER DOOR PANEL TO OUTER DOOR PANEL - FRONT DOOR (QUAD CAB) 144
INNER DOOR PANEL TO OUTER DOOR PANEL - FRONT DOOR (STANDARD CAB) 145
INNER DOOR PANEL TO OUTER DOOR PANEL - REAR DOOR (QUAD CAB) 146
MEGA CAB
FRONT FLOOR PAN (1 OF 3) - MEGA CAB 147
FRONT FLOOR PAN (2 OF 3) - MEGA CAB 148
FRONT FLOOR PAN (3 OF 3) - MEGA CAB 149
FLOOR PAN ASSEMBLY - COMPLETE - MEGA CAB 150
SILL ASSEMBLY (1 OF 3) - MEGA CAB 151
SILL ASSEMBLY (2 OF 3) - MEGA CAB 152
SILL ASSEMBLY (3 OF 3) - MEGA CAB 153
LADDER (1 OF 2) - MEGA CAB 154
LADDER (2 OF 2) - MEGA CAB 155
MISCELLANEOUS UNDERBODY (1 OF 8) - MEGA CAB 156
MISCELLANEOUS UNDERBODY (2 OF 8) - MEGA CAB 157
MISCELLANEOUS UNDERBODY (3 OF 8) - MEGA CAB 158
MISCELLANEOUS UNDERBODY (4 OF 8) - MEGA CAB 159
MISCELLANEOUS UNDERBODY (5 OF 8) - MEGA CAB 160
MISCELLANEOUS UNDERBODY (6 OF 8) - MEGA CAB 161

Fig. 118 INNER TAILGATE PILLAR PANEL - SHORT CARGO BOX ONLY
Fig. 119 BOX FLOOR SILL CROSSMEMBER - SHORT CARGO BOX ONLY

Fig. 120 INNER TAILGATE PILLAR - SHORT CARGO BOX ONLY
Fig. 121 BOX SIDE PANEL - SHORT CARGO BOX ONLY

Fig. 129 OUTER WHEELHOUSE - LONG CARGO BOX ONLY
Fig. 130 TAILGATE BOX SIDE PIVOT REINFORCEMENT - LONG CARGO BOX ONLY