DODGE TRUCK 1993 Service Repair Manual

23
- 28
BODY COMPONENTS

• (2) Start at the upper, rear corner of the door open­
ing. Move forward and downward around the edge of
the door opening. Force the seal inward against the
panel. Seat the flange in the seal slot.
Seal positioning at the corners is critical. The
seal must be seated at each corner. Avoid puck­
ering and stretching the seal at the corners.
(3) When correctly installed, the seal ends will
meet at the door lower centerline.
(4) Inspect the fit of the door in the door opening.
If not correct, adjust the door fit so the seal is not damaged when the door is closed. Refer to the door adjustment procedure.
BUTYL
DOOR
Fig.
14
Cab/Body-To-Door
Weatherstrip
Seat

•

IODY
COMPONENTS 23 - 29
FIXED
GLASS

1NDE1

page

Cab
Rear Window
30
Hatchgate Window Glass—Ramcharger
........ 32

Mirror Support Bracket
29

Quarter Vent Window-Club
Cab 30
page

Quarter Window
Glass
. 32
Rearview
Mirror
.......................... 29

Service
Information
29

Windshield
Glass
29

SERVICE
INFORMATION Do not use a putty knife, a razor blade, or steel
wool to remove foreign material from glass. Glass surfaces are best cleaned with the use of a commer­
cial glass cleaner.

REARVIEW
MIRROR
REMOVAL (1) Loosen the mirror base setscrew.

(2)
Slide the mirror base upward and off the sup­
port bracket.
INSTALLATION (1) Position the mirror base at the support bracket.
Slide it downward onto the support bracket.

CAUTION:
Do not
over-tighten
the mirror
base
set-

screw.
Windshield
glass
chipping and/or breakage
could
result.

(2)
Tighten the setscrew securely.

MIRROR
SUPPORT BRACKET
REPLACEMENT (1) To replace the mirror support bracket follow
the directions provided in the repair kit. Fig. 1 Rearview Mirror Bracket.
WINDSHIELD
GLASS

REMOVAL (1) Remove the wiper arms. Place a cover over the
upper cowl area. If necessary, refer to Group 8—Elec­
trical for the wiper arm removal procedure.
(2) Remove the interior rearview mirror.
(3) Remove the locking strip retainer from the
windshield glass weatherstrip seal (Fig. 2).
(4) Position an assistant outside the vehicle to re­
ceive the windshield glass.

(5)
Starting at either inside, upper corner, gently
push the glass outward. Separate it from the weath­ erstrip seal. Continue until the glass is completely separated from the seal (Fig. 3).
(6) The assistant now can remove the glass from
outside the vehicle.
(7) Remove the weatherstrip seal from the wind­
shield opening. (8) Remove the residual sealant from the wind­
shield opening flange.
(9) Clean the windshield opening flange and
groove with an appropriate cleaning solution.
INSTALLATION (1) Apply a 3-mm (1/8-in) diameter bead of syn­
thetic rubber-based sealant to the windshield open­ ing flange and groove.
(2) Install the weatherstrip seal on the flange. Ver­
ify that it is completely seated around the edge of the
windshield opening.
(3) With the aid of an assistant, insert one corner
of the windshield glass into the weatherstrip seal groove. (4) Use a trim stick to force the seal lip over the
glass around the edge of the seal. If necessary, use mineral spirits as a lubricant
to aid locking strip installation.
(5)
Start at the lower, center area of the weather­
strip seal. Install the locking strip in the weather­
strip seal with Tool L-4567, or an equivalent (Fig. 4). (6) Install the locking strip end cap over the ends
of the locking strip. (7) Test the windshield for water leaks. (8) Install the wiper arms. If necessary, refer to
Group 8—Electrical for the installation procedure.

23
- 30
BODY COMPONENTS

• (9) If necessary, install the rearview mirror sup­
port bracket on the windshield glass. (10) Install the rearview mirror. If necessary, refer
to the installation procedure.
Fig.
2 Windshield
Glass
Fig.
3 Windshield
Glass
Removal
QUARTER WENT WINDOW-CLUB CAB

REMOVAL

(1) Remove the vent window latch screws from the
cab quarter panel.
(2) Remove the hinge screws from the cab side, in­
ner panel.
(3) Remove the vent window from the cab.
(4) If necessary, remove the latch and hinge from
the glass.

INSTALLATION
(1) If removed, install the latch and hinge on the

glass.
Fig.
4
Weatherstrip
Seal Locking
Strip Retainer

Installation

(2) Position the vent window in the cab. Install the
screws. Tighten the nuts to 3 N#m (24 in. lbs.)
torque. (3) Attach the latch to the quarter panel. Tighten
the screws to 3 N«m (24 in. lbs.) torque. (4) Test the vent window for water leaks.
WEATHERSTRIP
SEAL

REMOVAL
(1) Remove the vent window. If necessary, refer to
the removal procedure. (2) Pull the seal away from the flange. (3) Clean the flange as necessary.

INSTALLATION
(1) Position the seal at the window opening.
(2) Mate the seal with the front flange.
(3) Move upward and mate the seal with the top
flange. (4) Mate the seal with the rear flange.
(5) Mate the seal with the bottom flange.
CAB REAR WINDOW
SERVICE
INFORMATION
The rear window glass is attached to the window
frame with urethane adhesive (Figs. 6 and 7). The
urethane adhesive seals the window frame and the
glass.
The window weatherstrip seal attaches the
window frame to the window opening flange.

REMOVAL-STANDARD
GLASS
(1) As applicable, remove the window reveal moul­
ding/retainer.

•

BODY
COMPONENTS 23 - 31

WEATHERSTRIP
SEAL
VENT

GLASS

AND
FRAME

SCREW

RIVET-NUT
RETAINER

J9123-340

Fig.
5 Vent Window Removal/installation
(2)
Separate the seal lip from the glass at one cor­
ner with a trim stick. Carefully push the glass out of
the seal (Fig. 8).
(3) Force the glass out of the weatherstrip seal. Re­
move it from the seal and the window opening.
(4) Remove the weatherstrip seal from the window
opening.

INSTALLATION
(1) Clean the seal channels and the window
flanges in the cab.
(2) Install the seal on the window glass or frame.
(3) Apply a 6-mm (1/4-in) diameter bead of sealant
to the window flange.
(4) Install the glass according to the following in­
structions:
• Moisten a length of 6-mm (1/4-in) diameter cord
with a soap and water solution • Verify that the cord is long enough to go around
the edge of the seal. • Insert the cord into the window flange in the seal (Fig. 9)
• Position the window and seal in the opening with
the free ends of the cord inside the vehicle
• Pull on the cord ends. Pull the seal channel lip over the window flange. (5) Test the window for water leaks.
(6) As applicable, install the window reveal moul­
ding or retainer. (7) Clean the vehicle, as necessary.

SLIDING
WENT
GLASS

REMOVAL
(1) Remove the complete rear window from the cab
opening. If necessary, refer to the removal procedure. (2) Place the frame and glass on a clean, padded
area. (3) Loosen the screws located on the bottom of the
frame.
CAB

BACK

PANEL WEATHERSTRIP

SEAL

SLIDING
GLASS

AND FRAME
RETAINER Fig.
6 Cab Rear
Windows

CAB

PANEL WEATHERSTRIP SEAL
WITH

MOULDING
WEATHERSTRIP
SEAL

RETAINER FIXED

WINDOW
GLASS

WEATHERSTRIP SEAL

'
WITH
MOULDING
CAB

BACK

PANEL
RETAINER

CAP

RETAINER
WINDOW

LOWER WEATHERSTRIP

SEAL

UPPER FIXED

GLASS

J9123-339

CAB

BACK

PANEL
FIXED

WINDOW
GLASS

SLIDING
GLASS

AND FRAME

J9123-338
Fig.
7 Rear Window
Glass/Frame—Removal/Installation

PU866

Fig.
8 Rear Window
Removal—
Typical

(4) Carefully spread the frame apart.
(5) Remove the sliding vent glass from the frame
track.

23
- 32
BODY COMPONENTS

•

Fig.
9 Window
installation
Cord—Typical

INSTALLATION
(1) Position the sliding vent glass in the frame
track.
(2) Tighten all the screws at the bottom of the
frame, (3) Test for correct travel. Check the latch opera­
tion for the sliding vent glass.
(4) Install rear window in the cab opening. If nec­
essary, refer to the installation procedure.
(5) Verify that the drain holes are not restricted.
HATCHGATE WINDOW GLASS-RAMCHARGER

REMOVAL (1) Use a trim stick to separate the glass seal lip
from the hatchgate flanges. Push the window glass and seal outward from the top.
(2) Remove the seal and glass from the hatchgate.
(3) Remove the retainer strip from the weather­
strip seal.
(4) Remove the seal from the window glass.
(5) Clean the seal channels and window opening
flanges.
INSTALLATION (1) Install the seal on the window glass.
(2) Apply mineral spirits to the retainer strip
channel in the weatherstrip seal. (3) Install the retainer strip in the seal channel.
(4) Install the hatchgate window glass according to
the following instructions: • Moisten a length of 6-mm (1/4-in) diameter cord
with a soap and water solution;
• Verify that the cord is long enough to go all the
way around the edge of the weatherstrip seal
• Insert the cord into the window flange in the seal • Position the glass in the window opening with the
free ends of the cord inside the vehicle • Pull on the cords to pull the seal channel lip over
the window flange
(5) After installation, release any curls from the
seal outer lip.
(6) Test the hatchgate window for water leaks.
(7) Clean the glass.
HATCHGATE RETAINER WEATHERSTRIP

Fig.
10 Hatchgate Window
Glass
&
Seal

QUARTER WINDOW GLASS

REMOVAL (1) Remove the quarter window glass interior trim
panel (Fig. 11).
Fig.
11
Quarter
Window
Interior
Trim
Panel

(2) Remove the quarter window exterior mouldings
(Fig. 12).
(3) Use an electric knife (Tool 4386 or an equiva­
lent) to cut the butyl tape.
(4) Remove the glass from the opening by applying
even pressure to the inside of the glass.

•

BODY
COMPONENTS
23 - 33
Fig. 12 Quarter Window Exterior
Mouldings

INSTALLATION (1) Remove the residual butyl tape from the win­
dow opening. If the original glass will be installed,
remove all the residual butyl tape from the glass. (2) Apply primer to the glass and allow 10 minutes
for it to dry. Avoid contact with the primed surface.
(3) Inspect the quarter window spacers for correct
installation (Fig. 13). (4) Apply butyl tape to the entire edge of the win­
dow flange (Fig. 14).

SECTION
A-A
SECTION
B-B
Fig.
14
Butyl
Tape
Installation

(5) Remove excess tape and butt the tape-ends
firmly together. (6) Install the quarter window glass on the butyl
tape (Fig. 15)
(7) Force the glass against the butyl tape to obtain
a good seal (Fig. 15). (8) Test the quarter window glass for water leaks.
(9) If leakage occurs, additional sealing will be re­
quired. Use an appropriate windshield sealer (Fig.
16).

(10) Install the exterior mouldings.
(11) Install the interior trim panel.
(12) Clean the glass.

•

BODY
COMPONENTS
23 - 35
CAB/BODY
INTERIOR COMPONENTS

INDEX

page

Carpets
and
Floor Mats
51
Floor Console
and
Rear Storage Tray
.........
50

Front Seats
38
Headliners
48

Instrument
Panel
35
page

Interior
Trim
Panels
. 42

Rear
Seats
41

Shoulder
Belts/Lap Belt/Buckles
45

Spare
Tire
Carrier
45

INSTRUMENT
PANEL INSTRUMENT CLUSTER BEZEL

REMOVAL
(1) Remove
the
bezel screws.
(2) Remove
the
bezel from
the
instrument panel.

INSTALLATION
(1) Position
the
bezel
on the
instrument panel.
(2) Install
the
bezel screws. Tighten
the
screws
to

2
Nnn (17 in. lbs.)
torque.
INSTRUMENT
PANEL

EDGE
TRIM
4WD
INDICATOR COVER 4WD)
INSTRUMENT CLUSTER
BEZEL
SCREW

Fig.
11nstrument
Cluster
Bezel
Removal/Installation
INSTRUMENT CLUSTER AND/OR
IP

COMPONENT

REMOVAL
(1) Remove
the
instrument cluster bezel screws
(Fig.
1).
Remove
the
bezel from
the
instrument
panel.
(2)
As
applicable, remove
the
instrument cluster
or

other
IP
component screws
(Fig. 2).

(3) Disconnect
the
wire harness connector(s) from
the
IP
cluster
or
component. Refer
to
Group 8—Elec­
trical
for
additional information. (4)
If
applicable, disconnect
the
shift position indi­
cator from
the
steering column
(Fig. 3).

(5) Remove
the IP
cluster
or
component from
the

instrument panel.
INSTALLATION

(1) Position
the IP
cluster
or
component
at the in­

strument panel. Connect
the
wire harness connec­

tors).

(2) Install
the
cluster
or
component
in the
instru­
ment panel
(Fig. 2).

(3)
If
applicable, connect
the
shift position indica­
tor
to the
steering column
(Fig. 3).

(4) Install
the IP
cluster
or
component screws.
Tighten
the
screws
to 2 N#m (17 in. lbs.)
torque. (5) Position
the
bezel
on the
instrument panel.
(6) Install
the
bezel screws. Tighten
the
screws
to

2
Nnn (17 in. lbs.)
torque.
INSTRUMENT
PANEL
LAMP

ACC

SWITCH
BEZEL

HEADLAMP SWITCH
HEADLAMP SWITCH
AND POWER MIRROR
CONTROL
BEZEL
SCREW

INSTRUMENT
J9123351
CLUSTER
J9123-351

Fig.
2
Instrument
Cluster
Removal/Installation
A/T SHIFT POSITION (PRNDL) INDICATOR

REMOVAL
(1) Disconnect
the
shift position (PRNDL) indicator
cable from
the
steering column.
(2) Remove
the
indicator screws from
the
rear
of

the instrument cluster. (3) Remove
the
indicator from
the
instrument clus­
ter.

23
- 36
BODY COMPONENTS

SCREW

INSTRUMENT

CLUSTER (REAR)

SHIFT

INDICATOR

STEERING COLUMN
J9123-539

Fig.
3 A/T Shift Position Indicator

INSTALLATION
(1) Position the shift position (PRNDL) indicator
on the instrument cluster.
(2) Install the indicator screws in the rear of the
instrument cluster. Tighten the screws to 2 N»m (17
in. lbs.) torque.
(3) Connect the indicator wire to the steering col­
umn.
ASH
RECEIVER
TRAY
AND
HOUSING

REMOVAL
(1) Disconnect the wire harness connector from the
cigarette lighter. Remove the ash receiver tray from
the housing. (2) Remove the housing screws from the instru­
ment panel. (3) Disconnect the wire harness connector from the

lamp.
Remove the housing from the instrument
panel.

INSTALLATION
(1) Position the ash receiver tray housing at the
instrument panel. Connect the wire harness connec­
tor to the lamp.
(2) Install the housing screws in the instrument
panel. Tighten the screws to 2 N«m (17 in. lbs.)
torque. (3) Position the ash receiver tray in the housing.
Connect the wire harness connector to the cigarette
lighter.

GLOVE
BOX

REMOVAL
(1) Remove the glove box door hinge screws from
the instrument panel (Fig. 5).
(2) Remove the glove box from the instrument
panel.
INSTRUMENT

PANEL

SCREW
LAMP

HOOD

PANEL
ASH

TRAY

'
HOUSING
-
LIGHTER

ELEMENT

SCREW
LIGHTER

CLAMP

ASH

TRAY

HOUSING
LIGHTER

SHELL
ASH

RECEIVER
TRAY

J9123-346

Fig.
4 Ash Receiver
Tray
&
Housing

INSTALLATION
(1) Position the glove box at the instrument panel.
(2) Install the door hinge screws. Tighten the
screws to 3 N»m (24 in. lbs.) torque.

INSTRUMENT
PANEL
STRIKER
SCREW
BUMPER
GLOVE BOX
DOOR
LAMP

SWITCH

LAMP

LENSE
SCREW
HINGE
NAME
PLATE

J9123-345
Fig.
5
Glove
Box

LOCK
CYLINDER
AND
LATCH
REMOVAL
(1) Remove the glove box latch screws from the
door panel. (2) Separate the latch from the lock cylinder.
(3) Remove the lock cylinder and the latch from
the door panel.

LOCK
CYLINDER
AND
LATCH
INSTALLATION
(1) Insert the lock cylinder in the door panel hole.
Engage it with the latch. (2) Install the latch screws in the door panel.
Tighten the screws to 2 N»m (17 in. lbs.) torque.

BODY
COMPONENTS
23 - 37

DOOR
LATCH STRIKER ADJUSTMENT

(1) Insert a small pry bar in the latch striker slot.
(2) Pry on the striker as necessary to obtain cor­
rect adjustment.

INSTRUMENT PANEL
(UP)

REMOVAL
(1) Remove the I/P screws from the dash panel
(Fig. 6). (2) Remove the steering column cover inserts from
the I/P (Fig. 7). (3) Remove the I/P reinforcement bracket screws
from the brace. (4) Remove the hood and parking brake release
handle brackets from the I/P (Fig. 8).
(5) If equipped, remove the hand throttle bracket
from the I/P (Fig. 9).
(6) Remove the I/P screws from the each cowl
panel.
(7) Pull the I/P outward from the dash panel for
clearance and disconnect the:
• Wire harness connectors
• Window defogger tubes
• Speedometer cable
• Heat/vent tube
• PRNDL cable
• Temperature control cable Refer to the applicable service information groups
for additional information.
(8) Remove the I/P from the dash panel.
(9) If necessary, remove the reinforcement brackets
from the inside of the panel (Fig. 10).

INSTALLATION
(1) If applicable, install the reinforcement brackets
at the inside of the I/P (Fig. 10). Tighten the bracket
screws to 23 N#m (200 in. lbs.) torque. Tighten the
reinforcement bracket I/P screws to 3 N*m (24 in. lbs.) torque.
(2) Position the I/P at the dash panel. (3) Connect the:
• Wire harness connectors
• Window defog tubes
• Speedometer cable
• Heat/vent tube
• PRNDL cable
• Temperature control cable
to the I/P. Refer to the applicable service informa­
tion groups for additional information. (4) Install the I/P screws. Tighten the IP cowl
screws to 23 N-m (200 in. lbs.) torque. Tighten the IP
dash panel screws and reinforcement bracket screws
to 4 N»m (35 in. lbs.) torque.
(5) Install the steering column cover inserts on the
17P (Fig. 7). Tighten the screws to 2 N*m (17 in. lbs.)
torque.
(6) Install the hood and parking brake release han­ dle brackets on the I/P (Fig. 8). Tighten the screws to
3 N*m (30 in. lbs.) torque. (7) If equipped, install the hand throttle bracket on
the I/P (Fig. 9). Tighten the locknut to 2 N*m (17 in. lbs.) torque. Tighten the screw to 3 N*m (24 in. lbs.)
torque.

SCREW
PLENUM SCREW BRACE PLENUM
Fig.
6 Instrument
Panel
INSTRUMENT LOWER UPPER
irt

PANEL COVER COVER
J9123-350

Fig.
7 Steering
Column
Cover
Inserts
Removal/
Installation

DASH
PANEL INSULATION
MAT

REMOVAL
(1) Remove the instrument panel from the dash
panel. If necessary, refer to the removal procedure. (2) Remove the defroster duct from the dash panel. (3) Remove the heater/A/C unit from the dash
panel. If necessary, refer to the removal procedure in Group 24.