1993 DODGE TRUCK Service Repair Manual

23
- 2
BODY COMPONENTS
•

EXPORT
LABEL
VEHICLE ORIGIN

LABEL
NATIONAL
SAFETY MARK
(CANADA) B-PILLAR

GLASS

EXHAUST
GAS

WARNING DECAL
UNLEADED/DIESEL FUEL LABEL
(U.S.)

EXHAUST EMISSION STANDARDS-CALIF.
(MODELS
30 AND 60)
EXHAUST

EMISSION

STADARDS-CALIF. (RAMCHARGER) UNLEADED/DIESEL
FUEL LABEL (CANADA)

J9123-408

Fig.
2
Exterior
Labels
&
Decals
ARM

BRACKET
NOISE
CERTIFICATION
LABEL

UOVER
10,000
LBS)5 SNOW
PLOW
TRANSMISSION
CAUTION HEADLINER
LABEL

TRANSFER
CASE
SHIFT
LABEL
(4WD)

SUN
VISOR
REAR

VIEW

MIRROR SCREW
*
BRACKET

J9123-410

Fig.
3
Sunvisor
Rear
Labels
GRILLE INSTALLATION
(1) Position
the
grille
at the
radiator support panel
and extension panel. Install
the
screws
(Fig. 6).

(2) Tighten
the
extension panel screws
to 2 N»m

(17
in. lbs.)
torque. Tighten
the
radiator support
panel screws
to 3 Nnn (21 in. lbs.)
torque. (3) Install
the
headlamp bezels
and the
screws
(Fig.
5).
Tighten
the
screws
to 2 Nnn (17 in. lbs.)

torque. (4) Remove
the
support
and
lower
the
hood.
GRILLE EMTENSION PANEL REMOVAL (1) Raise
and
support
the
hood.
(2) Remove
the
grille.
If
necessary, refer
to the re­

moval procedure. (3) Remove
the
screws from
the
fender panels
and

the support bracket
(Fig. 7).
EXTERNAL
NOISE
CERTIFICATION
LABEL

(OVER
10,000
LBS.)
VEHICLE
HANDLING
LABEL

(RAMCHARGER)

J9123-599

Fig.
4
Sunvisor
Front
Labels

SCREW

ANCHOR
HEADIAMP

BEZEL
•
GRILLE

J9123-600
Fig.
5
Headlamp
Bezel
&
Grille

GRILLE RADIATOR
SUPPORT PANEL

NUT

PUSH-IN
NUT

SCREW
NUT
SCREW SUPPORT

BRACKET

J9123-328
Fig.
6
Grille,
Radiator
Support Panel
&
Extension

Panel

(4) Remove
the
extension panel.

•
BODY
COMPONENTS
23 - 3
GRILLE
EXTENSION
PANEL
INSTALLATION

(1) Position the grille extension panel at the fender
panels and the support bracket. (2) Install the panel screws. Tighten the screws to
23 N*m (200 in. lbs.) torque.
(3) Install the grille. If necessary, refer to the in­
stallation procedure. (4) Remove the support and close the hood.
U-NUT
RADIATOR GRILLE

Fig. 7 Grille Extension Panel
GRILLE EXTENSION PANEL SUPPORT BRACKET

(WITH
DIESEL ENGINE ONLY)

REMOWAL
(1) Remove the grille.
(2) Remove the extension panel.
(3) Remove support bracket-to-grille opening panel
screw. (4) Remove the support bracket-to-radiator support
panel screw (Fig. 8). (5) Remove the support bracket from the vehicle.

INSTALLATION
(1) Position the support bracket at the grille open­
ing panel (GOP) and radiator support panel. (2) Install the support bracket-to-radiator support
panel screw. Tighten the screw to 11 N*m (95 in. lbs.) torque.
(3) Install the support bracket-to-grille opening
panel (GOP) screw. Tighten the screw to 23 N-m (200 in. lbs.) torque.
(4) Install the grille extension panel.
(5) Install the grille.
SCREW
U-NUT
RADIATOR

Fig. 8 Grille Extension Panel Support Bracket—Diesel Engine only
GRILLE OPENING PANEL
(GOP) AND
RADIATOR

SUPPORT
PANEL

REMOVAL
(1) Raise and support the hood. Remove the bat­
tery. (2) Remove the grille.
(3) Remove the extension panel.
(4) If equipped, remove the extension panel sup­
port bracket.
(5) Remove the headlamps from the headlamp re­
ceptacles in the GOP.
(6) Drain the engine coolant from the radiator in a
clean container for reuse. Remove the radiator from
the GOP. If necessary, refer to Group 7—Cooling System for the procedure.
(7) Remove the battery and tray from the GOP.
(8) Remove the horns from the GOP.
(9) Remove the screws, hood latch and the rein­
forcement plate from the radiator support panel. (10) Detach the latch release cable from the clip on
the radiator support panel.
(11) Remove the screws that attach the splash
shields to the GOP (Fig. 9). (12) Remove the cab/body front holddowns from
the front crossmember (Fig. 10). (13) Remove the screws that attach the fenders to
the GOP.
(14) Remove the screws that attach the fenders to
the radiator support panel.
(15) Remove the screws that attach the splash
shield to the right fender inner support panel.
(16) Repeat step (15) for the left fender panel.
(17) Move both fender panels outward at the front.
Remove the GOP and the radiator support panel
from the vehicle.

23
- 4
BODY
COMPONENTS

• INSTALLATION
(1) If necessary, install U-nuts at the GOP lower
flange. (2) Move both fender panels outward at the front.
Position the GOP on the frame rails (Fig. 10).
(3) Move both fender panels inward at the front.
Install the screws to attach the fender splash shields
to the fender inner support panels. Tighten the
screws to 11 N#m (95 in. lbs.) torque.
(4) Install the cab/body front holddown bolts at the
GOP to the front crossmember. Tighten the nuts to
68 Nnn (50 ft. lbs.) torque.
(5) Install the screws at the fenders to the GOP
and radiator support panel. Tighten the screws to 11
N»m (95 in. lbs.) torque. Tighten the radiator support
panel screws to 23 Nnn (200 in. lbs.) torque.
(6) Align the holes and install the splash shield
screws. Tighten the screws to 11 N»m (95 in. lbs.)
torque.
(7) Install the horns on the GOP.
(8) Attach the battery tray to the GOP. If neces­
sary, refer to the installation procedure. Tighten the
screws to 11 Nnn (95 in. lbs.) torque.
(9) Install the radiator on the GOP. Refill the en­
gine with coolant. If necessary, refer to Group 7—Cooling System for the procedures. (10) Attach the hood release cable to the clip on
the radiator support panel.
(11) Adjust the hood latch cable.
(12) Position the shield and the hood latch on the
radiator support panel. Install the screws. Tighten
the screws to 23 Nnn (200 in. lbs.) torque.
(13) Test the hood latch and the release cable for
proper operation.
(14) Install the headlamps in the headlamp recep­

tacles.

(15) Install the extension panel support bracket (if
equipped). Install the grille extension panel and the
grille.
(16) Install the battery and the holddown bracket.
Tighten the holddown rod nuts to 2 Nnn (20 in. lbs.) torque.
(17) Remove the support and close the hood.
(18) If necessary, adjust the headlamp beams.

HOOD
LATCH

REMOVAL
(1) Open and support the hood.
(2) Remove the hood latch and screws from the ra­
diator support panel (Fig. 11). (3) Disconnect release cable from the hood latch.
INSTALLATION If a replacement hood latch is being installed,
lubricate it thoroughly.
SCREW

U-NUT
BUMPER INNER FENDER
SUPPORT PANEL
PANEL
SPLASH

SHIELD

SCREW

U-NUT
REINFORCEMENT PANEL
(4WD
ONLY)
GRILLE
PANEL
J9123-567

Fig.
9
Grille
Opening
Panel
(GOP) & Radiator
Support
Panel

BOLT

(RAMCHARGER)
WASHER
GRILLE OPENING AND RADIATOR SUPPORT PANEL INSULATOR

BOLT

WITH
INSULATOR
(MODELS
30
AND
60)

FRAME
RAIL
WASHER NUT
SPACER

WASHER
(4
FOR ADI)
INSULATOR
^

BOLT
RETAINER
.
FRAME

— "
"
CROSSMEMBER
J9113-19

Fig.
10
Cab/Body
Front
Holddowns

(1) Position the hood latch on the radiator support
panel. Install the screws. Tighten the screws to 23 Nnn (200 in. lbs.) torque. (2) Connect latch release cable to the hood latch. (3) Adjust the hood latch cable.
(4) Test the hood latch and release cable for proper
operation.

•

BODY
COMPONENTS
23 - 5
(5)
If
necessary, align
the
hood,
the
latch,
and the

striker. Refer
to
Fore/Aft
And
Latch/Striker Adjust­
ment.
BOLT

CABLE

SHIELD

RADIATOR

GRILL SUPPORT

RB1346

Fig.
11
Hood
Latch
&
Release
Cable

HOOD
INSIDE
RELEASE
CABLE
REMOWAL
(1) Open
and
support
the
hood.
(2) Disconnect release cable from
the
hood latch.
(3) Detach
the
release cable from
the
clip
in the

engine compartment
(Fig. 12).

(4)
Separate
the
release cable grommet from
the

dash panel hole.
(5) From inside
the
vehicle, remove
the
screws.
Re­

move
the
release cable handle bracket from
the
bot­
tom
of the
instrument panel.
(6) Route
the
hood release cable through
the
dash
panel hole. Remove
it via the
inside
of the
vehicle.
INSTALLATION (1) Route
the
hood release cable through
the
hole
in
the
dash panel.
(2) Position
the
release cable handle
at the
bottom
of
the
instrument panel. Install
the
screws. Tighten
the screws
to 11 Nem (95 in. lbs.)
torque.
(3) Install
the
cable grommet
in the
dash panel
hole
(Fig. 12).

(4)
Attach
the
cable
to the
rear clip
in the
engine
compartment. (5) Route
the
cable under
the
radiator support
panel flange. Attach
it to the
clip
and
then connect
it

to
the
hood latch.
(6) Adjust
the
latch cable.
(7) Test
the
hood latch release cable
for
proper
op­

eration.
RELEASE

CABLE

HANDLE

BRACKET

HOOD
LATCH
RADIATOR
BAFFLE PANEL
J9123-376

Fig.
12
Release
Cable Removal/Installation
LOCATOR
CLIP

HOOD
LATCH

RELEASE
CABLE

BRACKET
INSTRUMENT

PANEL
LOWER
REINFORCEMENT
BRACKET

RWAL BRAKE
TEST CONNECTOR
J9123-360

Fig.
13
Release
Cable Handle Bracket
&
RWAL

Brake
Test
Connector
HOOD

POSITION ADJUSTMENT The hood hinge bolt holes
are
oversize
and
elon­
gated
for
ease
of
adjustment
(Fig. 15).
Loosen
the

hinge bolts
at the
fender
for
up/down adjustment.
Loosen
the
hinge bolts
at the
hood
for
front/back
ad­

justment.
REMOVAL (1) Raise
and
support
the
hood
at the
full-open
po­

sition. (2)
If
equipped, disconnect
the
underhood lamp
wire connector
(Fig. 16).

(3) With
the aid of an
assistant, remove
the
hinge
arm-to-hood bolts. Remove
the
hood from vehicle.

23
- 6
BODY
COMPONENTS

•

INSTRUMENT
PANEL

COWL

PANEL

REGULATOR
BRACKET
J9123-437

Fig.
14 Release Cable Handle Bracket &
Diesel
Engine
Speed
Control Regulator Bracket (4) If a replacement hood is being installed, trans­
fer the underhood lamp and the insulator panel (Fig.
17).
(5) Test the hood hinges for correct operation.
(6) Lubricate the hood hinges with engine oil.

INSTALLATION
(1) With the aid of an assistant, position the hood
on the vehicle. Align the hood bolt holes with the
hinge arm holes. Install and finger-tighten the bolts. (2) Align the hood, the latch, and the striker.

HINGE
REPLACEMENT

REMOVAL
If both hinges are being replaced, remove the
hood and both hinges as a unit. If only one
hinge is being replaced, use the following proce­ dure. (1) Raise and support the hood at the full-open po­
sition. (2) Mark the position of the hinge bolts. Loosen
the bolts (Fig. 15). (3) Support the hood at the side being removed.
Remove the bolts and hinge from the hood and
fender panel.

INSTALLATION
(1) Position the replacement hinge against the
fender panel. Install and finger-tighten the bolts. (2) Align the hood bolt holes with the marks.
(3) Tighten the hinge bolts to 23 N-m (200 in. lbs.)
torque.
LATCH STRIKER
LATCH SAFETY SUPPORT HOOD

STRIKER
LATCH PANEL HINGE
J9123-375

Fig.
16
Underhood
Lamp
INSTALLATION

(1) Position the striker on the hood.
(2) Install and tighten the screws.
HOOD SUPPORT ROD

REMOVAL
(1) Raise and support the hood.
(2) Drill out the support rod rivet from the radia­
tor support panel. (3) Remove the support rod from the radiator sup­
port panel.

INSTALLATION
(1) Position the support rod on the radiator support
panel. (2) Install the rivet to attach the rod to the panel.

REMOVAL
(1) Raise and support the hood.
(2) Remove the screws and the latch striker from
the hood.

•

BODY COMPONENTS
23 - 7

Fig.
17
Hood
Insulator
Panel
BLOWER MOTOR HOUSING INSULATION

PANEL-DIESEL
ENGINE ONLY
REMOVAL
(1) Remove the insulation panel screws from the
dash panel (Fig. 18).
(2) Remove the insulation panel from the blower
motor housing and the dash panel.

INSTALLATION
(1) Position the insulation panel over the blower
motor housing. (2) Install the insulation panel screws. Tighten the
screws to 1 N#m (12 in. lbs.) torque.

COWL GRILLE
REMOVAL
(1) Remove the windshield wiper arms. If neces­
sary, refer to the procedure in Group 8—Electrical. (2) Raise and support the hood.
(3) Remove the cowl grille screws (Fig. 19).
Ramcharger vehicles have extra screws lo­
cated at the rear of the cowl grille under the
seal.
(4) Disengage the rear of the grille from the wind­
shield weatherstrip seal. (5) Detach windshield washer hoses from the noz­
zles and the clips.
(6) Separate the grille from the cowl. Remove it
from the cowl upper panel.
DASH
TAB

ENGINE) SCREW
J9123-385
Fig.
18
Blower
Motor
Housing
Insulation
Panel
INSTALLATION

(1) Position the grille on the cowl upper panel and
under the windshield weatherstrip seal. Align the screw holes.
(2) Attach windshield washer hoses to the nozzles
and the clips.
(3) Install the grille screws. Tighten the front
screws to 1 N»m (12 in. lbs.) torque. (4) Remove the support and close the hood.
(5) Install the windshield wiper arms.

SCREW WEATHERSTRIP
Fig.
19
Cowl
Grille
Removal/Installation

BATTERY TRAY
REMOVAL
(1) Remove the nuts, holddown strap and support
bracket from the holddown rods.

23
- 8
BODY COMPONENTS

• (2) Disconnect the cables. Remove the battery from
the tray.
(3) Remove the bolts that attach the battery tray
to the fender inner panel and the radiator baffle
panel.
(4) Remove the screws that attach the rear brace
to the tray and to the inner fender panel. (5) Remove the battery tray from the vehicle.
(6) If necessary, remove the holddown rods from
the battery tray.
INSTALLATION (1) If removed, install the holddown rods on the
battery tray. (2) Position the battery tray against the radiator
baffle panel and the fender inner panel.
(3) Attach the battery tray to the radiator baffle
panel and the fender inner panel. Tighten the bolts
to 11 N«m (95 in. lbs.) torque.
(4) Position the rear brace at the tray and at the
fender inner panel. Install the brace screws in the
tray and the fender inner panel. Tighten the screws
to 11 N*m (95 in. lbs.) torque.
(5) Install the battery in the tray.
(6) Position the holddown strap and the support
bracket over the holddown rods.
(7) Install the nuts on the holddown rods. Tighten
the nuts to 2 N»m (20 in. lbs.) torque.
(8) Connect the cables to the battery.
HOLDDOWN

STRAP

REAR

BRACE
NUT

SUPPORT
'BRACKET
BATTERY
SCREW

U-NUT

SUPPORT BRACKET
NUT-
J9123-355
WASHER^—

BOLT-^
FWD
U-NUT

LEFT

FRONT

FENDER

NUT

BOLT RADIATOR
BAFFLE PANEL
Fig. 20
Battery
Tray
Removal/Installation

FRONT
FENDERS
(3) Remove the grille extension panel.
(4) Remove the battery and tray for left fender re­
moval only. (5) Remove the screws that attach the fender and
inner panel (Fig. 21) to the radiator support panel.
SCREW

U-NUT
BUMPER INNER FENDER
SUPPORT PANEL PANEL SPLASH
SHIELD
SCREW

U-NUT
REINFORCEMENT PANEL

(4WD
ONLY)
GRILLE
PANEL
J9123-567

Fig. 21 Front Fender-To-Grille/Radiator Support Panels Hardware (6) Remove the screw and nut that attach the top
of the fender (Fig. 22) to the cowl.
-SCREW

NUT
SPACER CAB

STUD
\ HOLDDOWN BRACKET
COWL
SIDE

PANEL
FENDER PANEL SPACER
GRILLE PANEL
V
SPACER SCREW
SCREW
J9123-566

Fig.
22 Front
Fender-To-Cowl/Dash
Panel Hardware (7) Remove the screws that attach the bottom of
the fender and inner panel to the dash panel. REMOWAL
(1) Raise and support the hood.
(2) Remove the grille.

•

BODY
COMPONENTS
23 - 9 (8) Remove the fender and the inner panel from
the cab/body.
(9) Remove the screws that attach the fender inner
panel to the fender panel. Remove the inner panel from the fender outer panel (Fig. 23).
INSTALLATION (1) Position the fender inner panel liner on the
outer panel. Install the screws. Tighten them to 23
N-m (200 in. lbs.) torque.
(2) Position the fender with inner panel on the cab/
body.
(3) Install the screws that attach the fender to the
radiator support panel. Tighten the screws to 23 N-m (200 in. lbs.) torque.
(4) Install the screws that attaches the fender and
inner panel to the dash panel. Tighten the screws to
23 N-m (200 in. lbs.) torque.

(5)
Install the screw and nut that attaches the top
of the fender to the cowl. Tighten the screw and nut
to 23 N-m (200 in. lbs.) torque. (6) If removed, install the battery and tray.
Tighten the battery tray bolts to 11 N-m (95 in. lbs.)
torque. Tighten the support bracket-to-fender inner panel bolt to 23 N-m (200 in. lbs.) torque.
(7) Install the grille extension panel and the grille.
(8) Remove the support and close the hood.
FENDER
PANEL
GRILLE
EXTENSION PANEL

J9123-565

Fig.
23 Front Fender Outer Panel

SPLASH
SHIELDS—FRONT
FENDER
REMOVAL (1) Remove the plastic clip that attach the splash
shield to the frame rail. (2) Remove the pushnuts and the screws that at­
tach the splash shield to the frame rail. (3) Remove the push retainers that attach the
splash shield to the fender inner panel. (4) Remove the splash shield from the frame rail
and the fender inner panel. INSTALLATION
(1) Position the splash shield on the frame rail and
the fender inner panel.
(2) Install the retainers to attach the shield to the
fender inner panel and to the frame rail. (3) Install the frame rail-to-shield screws and
pushnuts.
RIGHT
FRONT
FENDER CLIP RETAINER
CLIP RETAINER
FRAME LEFT
FRONT
FENDER

SPLASH
SHIELD
FRAME RAIL
RIGHT SIDE
SCREW
LEFT
FRONT
FENDER
SPLASH
SHIELD

J9123-327

Fig.
24
Splash
Shields—Front
Fender
BODY
MOULDINGS, NAMEPLATES AND
DECALS

BODY SIDE (VINYL) MOULDING
REPLACEMENT
Vinyl mouldings are attached to outer panels by

tape.

Wheel lip mouldings are attached by screws and

tape.
Ensure that the method of moulding attachment is
known before attempting removal (Fig. 25).

REMOVAL—MOULDINGS
ATTACHED WITH ADHESIVE TAPE
(1) Soften the body side moulding tape adhesive
(Fig. 25 with a heat gun. (2) Lift one edge of the moulding with a putty
knife and peel the moulding and tape from the panel.
Apply heat to any location where the moulding tape remains adhered to a panel.
(3) Remove the residual tape adhesive from the
panel with 3M All Purpose Cleaner or an equivalent.

INSTALLATION
—
MOULDINGS
ATTACHED WITH ADHESIVE

TAPE

(1) Clean the panel surface with a commercial wax
and silicone removal solution. Wipe the surface with
a clean cloth and allow it to dry.
(2) To ensure proper vertical alignment, use mask­
ing tape as an alignment reference.
(3) Remove the backing from the double-sided

tape.
Align the moulding with the alignment refer­
ence tape. Position it on the panel.
(4) Verify that the moulding is properly aligned.
Remove the alignment reference tape.