1993 DODGE TRUCK Service Repair Manual

23-10 BODY COMPONENTS

(5) Press the moulding onto the panel with a roller
(or use hand pressure) to ensure complete adhesion.
QUARTER PANEL

MOLDING
FRONT

FENDER

REAR

MOLDING
FRONT

FENDER
FRONT

MOLDING
REAR

CARGO
DOOR
FRONT
^WHEEWOUSE
~SST
MSSNG
W^|S$E

SIDE
OPENING
SIDE
PANEL
MOLDING
PANEL
REAR
MOLDING

MOLDING

QUARTER PANEL

MOLDING
OPENING

MOLDING

ADHESIVE-BACKED
MOLDING

NUT QUARTER
PANEL

MOLDING

EXTENDED
CAB
STANDARD
CAB
10.5
MMlyx

CHARACTER

UNE
J9123-603

Fig.
25 Ram Truck
Body
Side
Mouldings

REMOVAL—WHEEL
LIP MOULDINGS (1) Remove the screws from the moulding (Fig. 25).
(2) Soften the wheel lip moulding tape adhesive
with a heat gun.
(3) Peel the moulding and tape from the wheel-
house. Apply additional heat to any location where
the moulding adhesive remains.
INSTALLATION—WHEEL LIP MOULDINGS (1) Remove the backing from the double sided

tape.

(2) Align the moulding with the screws holes in
the fender panel. Install the screws into the fender
panel. Tighten the screws to 3 N*m (24 in. lbs.)
torque.
(3) Press the moulding onto the wheelhouse with a
roller (or use hand pressure).

NAMEPLATES

REMOVAL
(1) Soften the nameplate/badge tape adhesive

(Figs.
26 and 27) with a heat gun. (2) Lift one edge of the nameplate with a putty
knife (or a similar thin-blade tool). Peel the mould­
ing and tape from the panel. Apply additional heat to any location where the tape remains.
(3) Remove the residual tape adhesive from the
panel with 3M All Purpose Cleaner or an equivalent. INSTALLATION
(1) Clean the painted panel surface with a com­
mercial wax and silicone removal solution. Wipe the
surface with a clean cloth and allow it to dry.
(2) Use masking tape to indicate the upper posi­
tion for the nameplate on the panel (Figs. 26 and 27).
(3) Remove the backing from the nameplate. Align
the nameplate with the alignment reference tape. Po­ sition the nameplate on the panel. (4) Verify that the nameplate is properly aligned.
Remove the alignment reference tape. (5) Press the nameplate onto the panel with a
roller (or use hand pressure).
DOOR

OPENING
B-PILLAR

NAMEPLATE
J9123-356

Fig.
26 Ram Truck Nameplates
SIDE

WINDOW
B-PILLAR

NAMEPLATE
DOOR
OPENING
FRONT

FENDER

NAMEPLATE

J9123-357

Fig.
27
Ramcharger
Nameplates

TAILGATE
AND
CARGO
BOM
DECALS
The raised letters on the tailgate are covered with
a durable, weather-resistant decal. The cargo box
side panel decal also is a durable, weather-resistant
decal.

REMOVAL
(1) Soften the decal adhesive with a heat gun.
(2) Lift one edge of the decal with a putty knife.
Slowly peel the decal from the panel.

•

BODY COMPONENTS
23 - 11 (3) Apply additional heat to any location where the
decal remains adhered to the panel.
(4) Remove the extra adhesive from the panel with
a cloth saturated with an adhesive remover.

INSTALLATION
(1) Clean the panel surface with a commercial wax
and silicone removal solution. Wipe the surface with
a clean cloth. (2) Remove the backing from the decal. Position it
on the panel.
(3) Verify that the decal is properly aligned.
(4) Press the decal onto the panel with a roller to
ensure complete adhesion.
Fig.
28
Tailgate
&
Cargo
Box
Decals

TMILGA
TE/HA
TCHGA
TE
APPLIQUE
REMOVAL

(1) Open the tailgate/hatchgate.
(2) If applicable, remove the hatchgate trim panel.
(3) Remove the applique screws (Figs. 29 and 30).
(4) Pry the applique from the tailgate/hatchgate to
separate the corner studs from the retainers. (5) Remove the applique from the tailgate/hatch­

gate.

INSTALLATION
(1) Position the applique on the tailgate/hatchgate
with the corner studs mated with the retainers.
(2) Install the applique screws in the tailgate/
hatchgate (Figs. 29 and 30). Tighten the screws to 2 N-m (20 in. lbs.) torque. (3) If applicable, install the hatchgate trim panel.
(4) Close the tailgate/hatchgate.

ROOF
MOULDING

REMOVAL
(1) Remove the moulding end caps.
(2) Pry the moulding from the drip rail. Remove
the moulding from the roof edge.
RETAINER
APPLIQUE
J9123-538

Fig.
29
Tailgate
Applique

Fig.
30 Hatchgate Applique
INSTALLATION

(1) Position the roof moulding with retainers at
the roof drip rail. (2) Force the moulding onto the drip rail until it is
seated against the roof edge.
(3) Install the moulding end caps.

CAB/BODY
AND
CARGO
BOX
STRIPES
GENERAL
INFORMATION
The cab/body and cargo box stripes are durable,
weather-resistant tape stripes with pressure-sensitive
backing (Figs. 32 and 33). The tape stripe is pro­ tected by a carrier until installed on a body panel.
The carrier also is an installation alignment aid.

23
- 12
BODY COMPONENTS

•

Fig.
31
Roof
Moulding
REMOVAL

(1) Remove exterior trim as necessary to clear cap­
tured edges of the tape stripe being removed
(2) Remove tape stripe using a suitable heat gun
or lamp. This will soften the adhesive backing.
(3) Clean adhesive residue from body finish using
a suitable adhesive remover.

INSTALLATION

INSTALLATION EQUIPMENT

• Bucket filled with a mild dish soap solution.
• Lint free applicator cloth or sponge. • Body putty applicator squeegee.
• Heat gun or sun lamp.
• Razor knife.
The painted surface of the body panel to be covered
by a tape stripe must be smooth and completely cured before the stripe can be applied. If the painted surface is not smooth, wet sand with 600 grit wet/dry
sand paper until surface is smooth.
Ripples and feather edges will read through the
stripe if surface is not properly prepared. (1) With backing still in place, position stripe
across panel to receive the stripe. Apply masking at
top of stripe to hold it in position. (2) Mark outside edge of panel on stripe with
grease pencil. (3) Trim stripe to within 17 mm (0.750 in.) of out­
line marks.
(4) Spread stripe across a smooth flat work surface,
stripe side down. (5) Peel paper backing away from stripe exposing
adhesive backing of stripe.
(6) Apply soap solution liberally to adhesive back­
ing of stripe. (7) Apply soap solution to body panel surface.
(8) Place stripe into position on body panel.
Smooth out wrinkles by pulling lightly on edges of
tape stripe until it lays flat on panel surface. (9) Push air pockets from under tape stripe to the
perimeter of the panel from the center of the tape stripe out. (10) Remove air bubbles from under tape stripe us­
ing a body putty squeegee (Fig 34).

CAUTION:
Do nut cut
Into
painted surface
of body

when trimming
tape
stripe
to
size.

(11) Trim tape stripe to size using a razor knife.
Leave at least 13 mm (0.5 in.) for edges of doors and openings.

CAUTION;
Do not overheat
tape
stripe
when
per­

forming
step
12.
(12) Apply heat to tape stripe to evaporate residual
moisture from edges of tape stripe. This will also al­
low tape stripe to be stretched into concave surfaces.
(13) Edge turn tape stripe around doors or fenders
(Fig 35). (14) Install exterior trim if necessary. Small air or
water bubbles under tape stripe can be pierced with a pin and smoothed out.

TAILGATE
CARGO BOX
CAB
AND FENDER TAPE SIDE TAPE DOOR TAPE TAPE
STRIPE STRIPE STRIPE STRIPE

J9123-532

Fig.
32 Cab &
Cargo
Box Upper Stripes

FUEL FILLER DOOR AND NOZZLE/TUBES
DOOR
REMOVAL
(1) Open the fuel filler door.
(2) Remove the screws from the cargo box side
outer panel. (3) Remove the door from the panel.

INSTALLATION
(1) Position the fuel filler door on the cargo box
side outer panel.
(2) Install the door screws in the cargo box side
outer panel. Tighten the screws to 4 Nnn (35 in. lbs.)
torque.

•

BODY COMPONENTS
23 - 13

AM.
TAPE
STRIPE

WHEELHOUSE
LIP
CARGO BOX

LOWER

REAR,
SIDE PANEL
BUMPER
— •
SECONDARY

COLOR

DOOR

PANEL
FRONT /

FENDER
SCREW

J9123-555
FUEL

FILLER

DOOR
SIDE
OUTER
PANEL

J9123-342
Fig. 33 Cab & Cargo Box Stripes With Two-Tom
Paint
TAPE
STRIPE

FLANGE
J9123-593

Fig. 35
Tape
Stripe installation On Door Flange
(3) Close the fuel filler door. Fig. 36 Fuel Filler Door
NOZZLE/TUBES

REMOVAL
(1) Remove the fuel filler door (Fig. 36).

(2)
Remove the cap from the nozzle (Fig. 37).
(3) Loosen the clamps and separate the hose from
the tube.
(4) Remove the screws that attach the housing and
nozzle to the cargo box panel.
The fuel cap tether is also attached to the

cargo
box panel
with
one of the
screws,

(5) Remove the housing and nozzle/tube from the
cargo box panel.

INSTALLATION
(1) Position the fuel filler housing and nozzle/tube,
and the fuel cap tether at the opening in the cargo
box panel.

(2)
Install the housing, nozzle and tether screws in
the panel. Tighten the screws to 2 N»m (20 in. lbs.)
torque.
(3) Attach the hose to the tube with the clamp.
Tighten the fuel hose clamp screw to 2 N*m (20 in. lbs.) torque. Tighten the vent hose clamp screw to 1 N#m (12 in. lbs.) torque.
(4) Install the cap on the nozzle (Fig. 37),
(5) Install the fuel filler door.

OUTSIDE MIRRORS
STANDARD (NON-REMOTE) MANUAL MIRROR

REMOVAL
(1) Remove the screws from the mirror base.

(2)
Remove the mirror and base from the door out­
side panel. (3) If necessary, separate the mirror from the base.

23
- 14
BODY
COMPONENTS

HOUSING
U-NUT
CARGO BOX
FWD HOSE CLAMP
J9123-551

Fig.
37
Fuel
Filler
Housing
& Nozzle/Tubes
INSTALLATION

(1) If necessary, clean the door panel-mirror base
contact surface.
(2) If separated, attach the mirror to the base.
Tighten the stud-nut to 11 N-m (95 in. lbs.) torque. (3) Position the mirror base on the door outside panel
with its screw holes aligned with the panel holes.
(4) Install the mirror base screws. Tighten the
screws to 4 N-m (35 in. lbs.) torque.
LOCKWASHER OUTSIDE REINFORCEMENT
PLATE
61/2 x 9 IN.
MIRROR
MANUAL MIRROR MANUAL
OR
POWER

J9123-332
Fig.
38 Standard&6X9 Wide-View Mirrors
6X9
WIDE-VIEW
MIRROR

REMOVAL
(1) Remove the mirror cover screw. Separate the
mirror cover from the base.
(2) Remove the mirror base nuts from the rein­
forcement plate studs.
(3) Remove the mirror and the base from the door
outside panel. (2) Position the mirror base on the door outside panel
with the studs inserted in the mirror base holes.
(3) Install the mirror base nuts. Tighten the nuts
to 11 N-m (95 in. lbs.) torque.
(4) Position the cover over the mirror base. (5) Install the cover screw. Tighten the screw to 2
N-m (17 in. lbs.) torque.

LOW PROFILE OUTSIDE MIRROR

REMOVAL
(1) Remove the bolts that attach the support
braces to the door outer panel. (2) Remove the mirror and braces from the door
outer panel.

INSTALLATION
(1) Position the mirror and braces on the door
outer panel with the brace holes aligned with the nut
inserts.
(2) Install the mirror brace bolts in the nut inserts.
Tighten the bolts to 11 N-m (95 in. lbs.) torque.
WASHER
Fig.
39 Low
Profile
Mirror

CAB

SERVICE
INFORMATION
The cab is attached to the vehicle frame structure
with bolts (Figs. 40 and 41). If necessary, the cab can
be removed for repair or service access. Refer to the
procedure within Group 13—Frame.

TAILGATE REMOVAL
(1) Open the tailgate.
(2) Separate the tailgate check arms from the pins.
Separate the check arms from the tailgate (Fig. 42).
• Single wheel vehicles: On the right side, remove
the tailgate hinge-half from the slot in cargo box
INSTALLATION

(1) If necessary, clean the door panel-mirror base
contact surface.

•

BODY
COMPONENTS
23 - 15

BOLT

Fig.
40 Cab/Body Front-End Holddowns hinge-half. On the left side, remove the tailgate
hinge-half from the cargo box hinge-half by moving
the tailgate to the right.
• Dual wheel vehicles: On the right side, remove the
rivet. Remove the tailgate hinge-half from the slot in cargo box hinge-half. On the left side, pull the tail­
gate clearance/ID lamp wire harness outward from
the cargo box and disconnect the connectors (Fig. 43). (3) Remove the tailgate from the cargo box.

INSTALLATION
(1) Position the tailgate at the cargo box. CAB FRONT DOWN HOLD CAB REAR DOWN HOLD

J9113-18

Fig.
41 Cab Holddowns—Typical
• Single rear wheel: On the left side, insert the tail­
gate hinge-half into the cargo box hinge-half. Move
the tailgate to the left. On the right side, insert the
tailgate hinge-half into the slot in cargo box hinge-

half.

• Dual rear wheel: On the left side, connect the tail­
gate clearance/ID lamp wire harness connectors. In­
sert the wire harness in the cargo box. Insert the
tailgate hinge-half into the cargo box hinge-half.
Move the tailgate to the left. On the right side, in­ stall the rivet in the tailgate hinge-halves.
(2) Install the check arms onto the pins.
Note that the tailgate end of the check arms
are identified as to which side faces the tailgate.
Fig.
42
Tailgate
Removal/Installation

23 - 16
BODY COMPONENTS

(3) Test the handle and latches for correct opera­
tion. If necessary, adjust the strikers to eliminate
tailgate looseness and noise.
(4) Close the tailgate.
CONNECTOR
TO
LT
TAIL.
STOP,
TURN
& B/UP
LAMPS

HOUSING
CLEARANCE
AND
ID

LAMPS

J9123-570

Fig.
43
Tailgate
Clearance/ID
Lamps
&
Wire
Harness
STRIKER
ADJUSTMENT

(1) Remove the striker from the cargo box inner
panel.
(2) As necessary, add or remove spacers. (3) Install the striker in the cargo box inner panel.
Tighten the striker to 23 N-m (200 in. lbs.) torque.
TAILGATE DISASSEMBLY
(1)
Remove the screws that attach the lock and
latch release handle to the tailgate inside panel.
(2) Lower the lock and handle. Remove from the
tailgate opening.
(3) Disconnect the clips that attach the lock latch
rods to the lock arms. (4) Remove the bolts, the latch and the rod from
each end of the tailgate.
(5) Separate the clip and rod from each latch.
TAILGATE
ASSEMBLY
(1) Lubricate the latches, the handle and lock, and
the rod ends before assembly. (2) Install the rod and clip on each latch.
(3) At each end of the tailgate, insert the rod into
the opening. Position the latch on the end of the tail­
gate.
Install the bolts. Tighten them to 23 N-m (200
in. lbs) torque.
(4) Connect the lock latch rods to the lock arms.
Retain them with the clips.
(5) Insert the handle and lock in the tailgate open­
ing.
(6) Install the lock and handle screws in the tail­
gate inner panel. Tighten the screws to 11 N-m (95
in. lbs.) torque.
(7) Test the handle and latches for correct opera­
tion. Adjust the strikers to eliminate tailgate loose­ ness and noise.

HATCHGATE AND COMPONENTS
SUPPORT
ROD

REMOVAL

WARNING:
DO NOT
DISCONNECT
A
SUPPORT ROD
WITH
THE
HATCHGATE CLOSED.
THE
SUP­
PORT
ROD
PISTONS
ARE
OPERATED
BY
HIGH
PRESSURE
GAS.
THIS COULD CAUSE DAMAGE
AND/OR PERSONAL INJURY
IF
THEY
ARE RE­
MOVED WHILE
THE
PISTONS
ARE
COMPRESSED.
Fig.
44
Tailgate
Disassembly/Assembly

•

BODY
COMPONENTS
23 - 17 (1) Open and support the hatchgate.
(2) Remove the support rod upper bolt from the
rear pillar (Fig. 45).
(3) Remove the support rod lower screw from the
hatchgate (Fig. 46). (4) Remove the support rod from the hatchgate.

INSTALLATION
(1) Position the upper end of the support rod at the
roof panel. Install the nut and bolt. Tighten them to 23 N'm (200 in. lbs.) torque.
(2) Position the lower end of the support rod at the
hatchgate. Install the nut and screw. Tighten them
to 23 N-m (200 in. lbs.) torque.
(3) Test the support rod and hatchgate for correct
operation.

ROOF PANEL REAR

Fig.
45 Hatchgate

HATCHGATE
HINGE

REMOVAL
(1) Open and support the hatchgate.
(2) Remove the hinge roof panel screws.
(3) Remove the hinge hatchgate screws.
(4) Remove the hinge from the hatchgate and roof
panel.

INSTALLATION
(1) Position the hinge on the hatchgate.
(2) Install the hinge hatchgate screws. Tighten the
screws to 23 N*m (200 in. lbs.) torque.
(3) Position the hinge on the roof panel.
(4) Install the hinge roof panel screws. Tighten the
screws to 23 N»m (200 in. lbs.) torque.
(5) Test the hatchgate and hinge operation. If nec­
essary, add spacer(s) for hinge adjustment.
AUXILIARY RETAINER
SCREW
NUT
HATCHGATE
J9123-387
Fig.
46 Hatchgate
Support
Rod &
Hinge
Removal/
Installation
HATCHGATE

REMOVAL
(1) Open and support the hatchgate.
(2) Remove the hinge roof panel screws.

WARNING:
DO NOT
DISCONNECT
THE
SUPPORT
RODS
WITH
THE
HATCHGATE CLOSED.
THE
SUP­
PORT
ROD
PISTONS
ARE
OPERATED
BY
HIGH

PRESSURE
GAS.
THIS COULD CAUSE DAMAGE
AND/OR PERSONAL INJURY
IF
THEY
ARE RE­
MOVED WHILE
THE
PISTONS
ARE
COMPRESSED.

(3) Remove support rod upper bolts from the rear
pillar.
(4) Remove hatchgate and support rods from the
vehicle.

INSTALLATION
(1) Position and support the hatchgate in the vehi­
cle opening. (2) Align the support rod bolt holes. Install the
nuts and bolts. Tighten the bolts to 23 N*m (200 in.
lbs.) torque.
(3) Install the hinge roof panel screws. Tighten
screws to 23 N«m (200 in. lbs.) torque. (4) Test the hatchgate and hinge operation. If nec­
essary, add spacer(s) for hinge adjustment.

LATCH
STRIKER
REMOVAL/INSTALLATION
(1) Raise the hatchgate.