1993 DODGE TRUCK Service Repair Manual

23
- 26
BODY COMPONENTS

• (2) Install the spacer and replacement striker on
the B-pillar.
(3) Adjust the door latch striker to engage com­
pletely when the door is closed. When closed, the
door should be flush with the adjacent body panels. IOCK
KNOB
OUTSIDE HANDLE GROMMET
B-PILLAR DOOR
LATCH
OUTSIDE
HANDLE-TO- LATCH ROD
SCREW INSIDE
HANDLE
LOCK MOTOR-TO- ACTUATOR LATCH ROD
LOCK
MOTOR
J9123-601

Fig.
10
Striker,
Lock
Motor,
Door
Handle, Latch &
Rods
POWER
DOOR LOCK MOTOR

REMOVAL

(1) Raise the window glass to the completely closed
position.
(2) Remove the door trim panel and the waterdam.
(3) Disconnect wire harness connector from the
lock motor.
(4) Disconnect the lock motor latch rod from the
motor (Fig. 10).
(5) Remove the screws and the motor from the
door.

INSTALLATION
(1) Position the motor in door inner panel.
(2) Connect the lock motor latch rod to the motor.
(3) Install the lock motor screws. Tighten the
screws to 11 N#m (95 in. lbs.) torque. (4) Connect the lock motor connector to the door
harness connector.
(5) Test and verify that the lock motor and latch
lock operate correctly.
(6) Install the door waterdam and the trim panel.
If necessary, refer to the installation procedure. DOOR INSIDE HANDLE

REMOVAL

(1) Raise the window glass to the closed position.
(2) Remove the door trim panel and the waterdam.
(3) Remove the handle latch rod from the inside
handle actuator (Fig. 10).
(4) Remove the screws from the reinforcement
plate. Remove inside handle (and seal) from the door inner panel.

INSTALLATION
(1) Position the seal and inside handle on the door
inner panel.
(2) Connect the handle latch rod to the handle ac­
tuator. (3) Position the reinforcement plate at the inside of
the door inner panel. Attach the inside handle to the door panel. Tighten the screws to 15 N#m (130 in.
lbs.) torque.
(4) If necessary, adjust to eliminate excess handle
travel.
(5) Install the door waterdam and the trim panel.
If necessary, refer to the installation procedure. DOOR
INNER PANEL
REINFORCEMENT PLATE INSIDE
LATCH
RELEASE HANDLE SCREW DOOR
OUTER PANEL
INSIDE LATCH
RELEASE HANDLE DOOR
INNER PANEL

J9123-394

Fig.
11
Door
Inside
Handle Removal/Installation DOOR OUTSIDE HANDLE

REMOVAL
(1) Raise the window glass to the closed position.
(2) Remove the door trim panel and the waterdam. (3) Remove the door handle nuts from the inside of
the door. (4) Disconnect handle latch rod from latch.
(5) Remove handle from door outer panel.

•

BODY
COMPONENTS
23 - 27
INSTALLATION
(1)
Apply silicone spray lubricant to the handle in­
ternal moving parts.
(2) Install the handle on the door outer panel.
(3) Tighten the handle nuts to 7 N*m (65 in. lbs.)
torque. (4) Connect the handle latch rod to the latch.
(5) Test and verify the handle operates correctly.

(6)
Install the door waterdam and the trim panel.

OUTSIDE HANDLE LATCH
ROD
RELEASE

ADJUSTMENT

(1) Locate the 4-mm (5/32-in) diameter Allen-head
adjustment screw inside the door panel face slot near
the latch (Fig. 12).
(2) Loosen the door latch adjustment screw.
(3) Push upward on the latch lever to remove all
the slack from the handle latch rod.
(4) Tighten adjustment screw.
(5) Test and verify proper operation.
INNER

RELEASE

HANDLE-TO
LATCH
ROD

LOCK

KNOB

TO-LATCH
ROD
POWER
LOCK
MOTOR-TO-LATCH
ROD
DOOR

LATCH
LOCK

/CYLINDER-TO LATCH
ROD
SCREW
DOOR
OUTER
PANEL
DOOR

LATCH

DOOR

INNER
OUTER
PANEL

RELEASE

HANDLE-TO LATCH
ROD
ADJUSTMENT

SCREW
SLOT
LEFT
DOOR LATCH OUTER
RELEASE
HANDLE-TO-
LATCH ROD ADJUSTMENT
SCREW
ACCESS
SLOT
J9123-384

Fig.
12
Door
Latch &
Rods

DOOR
LATCH
REMOVAL
(1) Raise the window glass to the closed position.
(2) Remove the door trim panel and the waterdam.
(3) Disconnect the:
• Outside handle latch rod
• Key lock cylinder latch rod
• Inside handle latch rod
• Lock knob latch rod
• Lock motor latch rod (4) Remove the door latch screws from the door in­
ner panel face.
(5) Remove the door latch from the door.

INSTALLATION
(1) Install the latch striker, if removed.
(2) Insert the door latch. Position it at the door in­
ner panel face and connect the rods to it. (3) Install the latch screws in the door panel face
(Fig. 12). Tighten the screws to 9 Nnn (7 ft-lbs)
torque.
(4) Test and verify that the latch operates cor­
rectly. (5) Install the door waterdam and the trim panel.
If necessary, refer to the installation procedure.

WINDOW
GLASS
AND
DOOR
WEATHERSTRIP
SEALS

WINDOW
GLASS
BELTLINE WEATHERSTRIP

SEALS

REMOVAL
The window glass beltline weatherstrip seals can
be removed according to the following procedure. (1) Open the window glass.
(2) Pry the inner and outer beltline weatherstrip
seals from the door panels with a small putty knife.
(3) Remove the beltline seals from the door (Fig.

13).
INSTALLATION
Position the beltline weatherstrip seals on the door
panels. Force them downward until the retainers are seated in the panel slots.

WEATHERSTRIP
GLASS

DOOR

INNER
PANEL

DOOR

OUTER
PANEL

REGULATOR
(MANUAL)
J9123-398

Fig. 13 Beltline Weatherstrip Seals

DOOR
WEATHERSTRIP
SEAL

REMOVAL
(1) Start at the lower ends and pull outward on the
seal. Separate it from the door opening panel flanges
(Fig. 14). (2) Continue around the edge of the seal and pull
outward on the seal to separate it from the flanges.
(3) Remove the seal from the door opening.

INSTALLATION
(1) Position the weatherstrip seal in the door open­
ing.

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.