1998 DODGE RAM 1500 Door

VISUAL INSPECTION BEFORE WATER LEAK TESTS
Verify that floor and body plugs are in place, body
drains are clear, and body components are properly
aligned and sealed. If component alignment or seal-
ing is necessary, refer to the appropriate section of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the conditions causing a water leak have
been determined, simulate the conditions as closely
as possible.
²If a leak occurs with the vehicle parked in a
steady light rain, flood the leak area with an open-
ended garden hose.
²If a leak occurs while driving at highway speeds
in a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water. Direct the
spray in a direction comparable to actual conditions.
²If a leak occurs when the vehicle is parked on an
incline, hoist the end or side of the vehicle to simu-
late this condition. This method can be used when
the leak occurs when the vehicle accelerates, stops or
turns. If the leak occurs on acceleration, hoist the
front of the vehicle. If the leak occurs when braking,
hoist the back of the vehicle. If the leak occurs on left
turns, hoist the left side of the vehicle. If the leak
occurs on right turns, hoist the right side of the vehi-
cle. For hoisting recommendations (Refer to LUBRI-
CATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE).
WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water
test and watch for water tracks or droplets forming
on the inside of the vehicle. If necessary, remove inte-
rior trim covers or panels to gain visual access to the
leak area. If the hose cannot be positioned without
being held, have someone help do the water test.
Some water leaks must be tested for a considerable
length of time to become apparent. When a leak
appears, find the highest point of the water track or
drop. The highest point usually will show the point of
entry. After leak point has been found, repair the
leak and water test to verify that the leak has
stopped.
Locating the entry point of water that is leaking
into a cavity between panels can be difficult. The
trapped water may splash or run from the cavity,
often at a distance from the entry point. Most water
leaks of this type become apparent after accelerating,
stopping, turning, or when on an incline.MIRROR INSPECTION METHOD
When a leak point area is visually obstructed, use
a suitable mirror to gain visual access. A mirror can
also be used to deflect light to a limited-access area
to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can
be detected without water testing. Position the vehi-
cle in a brightly lit area. From inside the darkened
luggage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage
compartment. If light is visible through a normally
sealed location, water could enter through the open-
ing.
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compart-
ment cannot be detected by water testing, pressurize
the passenger compartment and soap test exterior of
the vehicle. To pressurize the passenger compart-
ment, close all doors and windows, start engine, and
set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to ensure adequate voltage to the blower.
With interior pressurized, apply dish detergent solu-
tion to suspected leak area on the exterior of the
vehicle. Apply detergent solution with spray device or
soft bristle brush. If soap bubbles occur at a body
seam, joint, seal or gasket, the leak entry point could
be at that location.
DIAGNOSIS AND TESTING - WIND NOISE
Wind noise is the result of most air leaks. Air leaks
can be caused by poor sealing, improper body compo-
nent alignment, body seam porosity, or missing plugs
in the engine compartment or door hinge pillar areas.
All body sealing points should be airtight in normal
driving conditions. Moving sealing surfaces will not
always seal airtight under all conditions. At times,
side glass or door seals will allow wind noise to be
noticed in the passenger compartment during high
cross winds. Over compensating on door or glass
adjustments to stop wind noise that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After a repair pro-
cedure has been performed, test vehicle to verify
noise has stopped before returning vehicle to use.
VISUAL INSPECTION BEFORE TESTS
Verify that floor and body plugs are in place and
body components are aligned and sealed. If compo-
nent alignment or sealing is necessary, refer to the
appropriate section of this group for proper proce-
dures.
23 - 2 BODYDR
BODY (Continued)

ROAD TESTING WIND NOISE
(1) Drive the vehicle to verify the general location
of the wind noise.
(2) Apply 50 mm (2 in.) masking tape in 150 mm
(6 in.) lengths along weatherstrips, weld seams or
moldings. After each length is applied, drive the vehi-
cle. If noise goes away after a piece of tape is applied,
remove tape, locate, and repair defect.
POSSIBLE CAUSE OF WIND NOISE
²Moldings standing away from body surface can
catch wind and whistle.
²Gaps in sealed areas behind overhanging body
flanges can cause wind-rushing sounds.
²Misaligned movable components.
²Missing or improperly installed plugs in pillars.
²Weld burn through holes.
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY LUBRICATION
All mechanisms and linkages should be lubricated
when necessary. This will maintain ease of operation
and provide protection against rust and excessive
wear. The weatherstrip seals should be lubricated to
prolong their life as well as to improve door sealing.
All applicable exterior and interior vehicle operat-
ing mechanisms should be inspected and cleaned.
Pivot/sliding contact areas on the mechanisms should
then be lubricated.
(1) When necessary, lubricate the operating mech-
anisms with the specified lubricants.
(2) Apply silicone lubricant to a cloth and wipe it
on door seals to avoid over-spray that can soil pas-
senger's clothing.
(3) Before applying lubricant, the component
should be wiped clean. After lubrication, any excess
lubricant should be removed.
(4) The hood latch, latch release mechanism, latch
striker, and safety latch should be lubricated period-
ically.
(5) The door lock cylinders should be lubricated
twice each year (preferably autumn and spring).
²Spray a small amount of lock cylinder lubricant
directly into the lock cylinder.
²Apply a small amount to the key and insert it
into the lock cylinder.
²Rotate it to the locked position and then back to
the unlocked position several times.
²Remove the key. Wipe the lubricant from it with
a clean cloth to avoid soiling of clothing.
STANDARD PROCEDURE - HEAT STAKING
(1) Remove trim panel.(2) Bend or move the trim panel components at
the heat staked joints. Observe the heat staked loca-
tions and/or component seams for looseness.
(3) Heat stake the components.
(a) If the heat staked or component seam loca-
tion is loose, hold the two components tightly
together and using a soldering gun with a flat tip,
melt the material securing the components
together. Do not over heat the affected area, dam-
age to the exterior of the trim panel may occur.
(b) If the heat staked material is broken or miss-
ing, use a hot glue gun to apply new material to
the area to be repaired. The panels that are being
heat staked must be held together while the apply-
ing the glue. Once the new material is in place, it
may be necessary to use a soldering gun to melt
the newly applied material. Do not over heat the
affected area, damage to the exterior of the trim
panel may occur.
(4) Allow the repaired area to cool and verify the
repair.
(5) Install trim panel.
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR
There are many different types of plastics used in
today's automotive environment. We group plastics in
three different categories: Rigid, Semi-Rigid, and
Flexible. Any of these plastics may require the use of
an adhesion promoter for repair. These types of plas-
tic are used extensively on DaimlerChrysler Motors
vehicles. Always follow repair material manufactur-
er's plastic identification and repair procedures.
Rigid Plastics:
Examples of rigid plastic use: Fascias, Hoods,
Doors, and other Body Panels, which include SMC,
ABS, and Polycarbonates.
Semi-Rigid Plastics:
Examples of semi-rigid plastic use: Interior Panels,
Under Hood Panels, and other Body Trim Panels.
Flexible Plastics:
Examples of flexible plastic use: Fascias, Body
Moldings, and upper and lower Fascia Covers.
Repair Procedure:
The repair procedure for all three categories of
plastics is basically the same. The one difference is
the material used for the repair. The materials must
be specific for each substrate, rigid repair material
for rigid plastic repair, semi-rigid repair material for
semi-rigid plastic repair and flexible repair material
for flexible plastic repair.
DRBODY 23 - 3
BODY (Continued)

Adhesion Promoter/Surface Modifier:
Adhesion Promoters/Surface Modifiers are required
for certain plastics. All three categories may have
plastics that require the use of adhesion promoter/
surface modifiers. Always follow repair material man-
ufacturer's plastic identification and repair
procedures.
SAFETY PRECAUTION AND WARNINGS
WARNING:
²EYE PROTECTION SHOULD BE USED WHEN
SERVICING COMPONENTS. PERSONAL INJURY
CAN RESULT.
²USE AN OSHA APPROVED BREATHING MASK
WHEN MIXING EPOXY, GRINDING, AND SPRAYING
PAINT OR SOLVENTS IN A CONFINED AREA. PER-
SONAL INJURY CAN RESULT.²AVOID PROLONGED SKIN CONTACT WITH
RESIN, PETROLEUM, OR ALCOHOL BASED SOL-
VENTS. PERSONAL INJURY CAN RESULT.
²DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT PROPERLY SUPPORTED ON
SAFETY STANDS. PERSONAL INJURY CAN
RESULT.
NOTE:
²When holes must be drilled or cut in body pan-
els, verify locations of internal body components
and electrical wiring. Damage to vehicle can result.
²Do not use abrasive chemicals or compounds
on undamaged painted surfaces around repair
areas. Damage to finish can result.
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES
CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION
ASA ACRYLONITRILE STYRENE
ACRYLITELURAN S CONSOLES, GRILLES
ABS ACRYLONITRILE
BUTADIENE STYRENETERLURAN9A9PILLARS, CONSOLES,
GRILLES
ABS/PC ABS/PC ALLOY PULSE, PROLOY, BAYBLEND DOORS, INSTRUMENT
PANELS
ABS/PVC ABS/PV ALLOY PROLOY, PULSE, LUSTRAN,
CYCLOVINDOOR PANELS, GRILLES,
TRIM
BMC BULK MOLDING
COMPOUNDBMC FENDER EXTENSIONS
EMA EHTYLENE METHYL
ACRYLATE/IONOMERSURLYN, EMA, IONOMER BUMPER GUARDS, PADS
METTON METTON METTON GRILLES, KICK PANELS,
RUNNING BOARDS
MPPO MODIFIED
POLYPHENYLENE OXIDEMPPO SPOILER ASSEMBLY
PA POLYAMID ZYTEL, VYDYNE, PA,
MINLONFENDERS, QUARTER
PANELS
PET THERMOPLASTIC
POLYESTERRYNITE TRIM
PBT/PPO PBT/PPO ALLOY GERMAX CLADDINGS
PBTP POLYBUTYLENE
THEREPTHALATEPBT, PBTP, POCAN, VALOX WHEEL COVERS, FENDERS,
GRILLES
PBTP/EEBC POLYBUTYLENE
THEREPTHALATE/EEBC
ALLOYBEXLOY,9M9, PBTP/EEBC FASCIAS, ROCKER PANEL,
MOLDINGS
PC POLYCARBONATE LEXAN, MERLON, CALIBRE,
MAKROLON PCTAIL LIGHT LENSES, IP TRIM,
VALANCE PANELS
23 - 4 BODYDR
BODY (Continued)

CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION
PC/ABS PC/ABS ALLOY GERMAX, BAY BLENDS,
PULSEDOORS, INSTRUMENT
PANELS
PPO POLYPHENYLENE OXIDE AZDEL, HOSTALEN,
MARLEX, PRFAX, NORYL,
GTX, PPOINTERIOR TRIM, DOOR
PANELS, SPLASH SHIELDS,
STEERING COLUMN
SHROUD
PPO/PA POLYPHENYLENE/
POLYAMIDPPO/PA, GTX 910 FENDERS, QUARTER
PANELS
PR/FV FIBERGLASS REINFORCED
PLASTICFIBERGLASS, FV, PR/FV BODY PANELS
PS POLYSTYRENE LUSTREX, STYRON, PS DOOR PANELS, DASH
PANELS
RTM RESIN TRANSFER
MOLDING COMPOUNDRTM BODY PANELS
SMC SHEET MOLDED
COMPOUNDSMC BODY PANELS
TMC TRANSFER MOLDING
COMPOUNDTMC GRILLES
UP UNSATURATED
POLYESTER
(THERMOSETTING)SMC, BMC, TMC, ZMC, IMC,
XSMC, UPGRILLE OPENING PANEL,
LIFTGATES, FLARESIDE
FENDERS, FENDER
EXTENSIONS
EEBC ETHER/ESTER BLOCKED
CO-POLYMEREEBC BUMPERS
EEBC/PBTP EEBC/POLYBUTYLENE
TEREPTHALATEEEBC, PBTP, BEXLOY BUMPER, ROCKER PANELS
EMPP ETHYLENE MODIFIED
POLYPROPYLENEEMPP BUMPER COVERS
EPDM ETHYLENE/
PROPROPYLENE DIENE
MONOMEREPDM, NORDEL, VISTALON BUMPERS
EPM ETHYLENE/
PROPROPYLENE CO-
POLYMEREPM FENDERS
MPU FOAM POLYURETHANE MPU SPOILERS
PE POLYETHYLENE ALATHON, DYLAN,
LUPOLEN, MARLEX-
PP POLYPROPYLENE
(BLENDS)NORYL, AZDEL, MARLOX,
DYLON, PRAVEXINNER FENDER, SPOILERS,
KICK PANELS
PP/EPDM PP/EPDM ALLOY PP/EPDM SPOILERS, GRILLES
PUR POLYURETHANE COLONELS, PUR, PU FASCIAS, BUMPERS
PUR/PC PUR/PC ALLOY TEXIN BUMPERS
PVC POLYVINYL CHLORIDE APEX, GEON, VINYLITE BODY MOLDINGS, WIRE
INSULATION, STEERING
WHEELS
RIM REACTION INJECTED
MOLDED POLYURETHANERIM, BAYFLEX FRONT FASCIAS, MODULAR
WINDOWS
DRBODY 23 - 5
BODY (Continued)

²Panel repair for both flexible and rigid panels
are basically the same. The primary difference
between flexible panel repair and rigid panel repair
is in the adhesive materials used (Fig. 5).
²The technician should first decide what needs to
be done when working on any type of body panel.
One should determine if it is possible to return the
damage part to its original strength and appearance
without exceeding the value of the replacement part.
²When plastic repairs are required, it is recom-
mended that the part be left on the vehicle when
every possible. That will save time, and the panel
will remain stationary during the repair. Misalign-ment can cause stress in the repair areas and can
result in future failure.
VISUAL INSPECTION
Composite materials can mask the severity of an
accident. Adhesive bond lines, interior structure of
the doors, and steel structures need to be inspected
carefully to get a true damage assessment. Close
inspection may require partial removal of interior
trim or inner panels.
Identify the type of repair: Puncture or Crack -
Damage that has penetrated completely through the
panel. Damage is confined to one general area; a
panel section is not required. However, a backer
panel, open fiberglass tape, or matted material must
be bonded from behind (Fig. 7) (Fig. 6).
PANEL SURFACE PREPARATION
If a body panel has been punctured, cracked, or
crushed, the damaged area must be removed from
the panel to achieve a successful repair. All spider
web cracks leading away from a damaged area must
be stopped or removed. To stop a running crack in a
panel, drilla6mm(0.250 in.) hole at the end of the
crack farthest away from the damage. If spider web
cracks can not be stopped, the panel would require
replacement. The surfaces around the damaged area
Fig. 2 SOFTENED EDGES
1 - SOFTENED EDGES
2 - PANEL ADHESIVE
3 - BONDING STRIP
Fig. 3 PANEL REINFORCEMENT
1 - PANEL ADHESIVE
2 - REINFORCEMENT
Fig. 4 BEVELING ANGLE - 20 DEGREE
Fig. 5 FIBERGLASS TAPE
Fig. 6 DAMAGE COMPONENT
1 - PUNCTURE
DRBODY 23 - 7
BODY (Continued)

STANDARD PROCEDURE - BUZZ, SQUEAK &
RATTLE
Buzz, Squeak & Rattles (BSR) may be caused by
any one or more of the following and may be cor-
rected as indicated:
²Loose fasteners should be tightened to specifica-
tions.
²Damaged or missing clips should be replaced.
²Damaged trim panels should be replaced.²Incorrectly installed trim panels should be rein-
stalled properly.
Many BSR complaints such as loose trim, can be
serviced using the MopartParts BSR Noise Reduc-
tion Kit. This kit contains various tapes including
foam, flock and anti-squeak used to eliminate noises
caused by metal, plastic and vinyl components. Long
life lubricants and greases can also be used on a vari-
ety of components. Refer to the Buzz, Squeak & Rat-
tle Kit table for material contents and usage.
BUZZ, SQUEAK & RATTLE KIT
ITEM FEATURES APPLICATIONS SERVICE TEMP
Itch And Squeak
TapeAn abrasion resistant material
thin enough to conform to most
irregular surfaces. Stops most
itches and squeaks.Between metal and metal,
metal and plastic, metal and
vinyl, vinyl and plastic. Interior.
Examples: Trim panels and
bezels.-40É to 225É
Fahrenheit
(-40É to 107É
Celsius)
Black Nylon Flock Nylon Flock with an aggressive
acrylic adhesive. Provides for
cushioning and compression fit,
also isolates components.
Water-resistant.Between metal and metal,
metal and plastic, vinyl and
plastic.
Examples: Pull cups, bezels,
clips, ducts, top cover to glass,
cowl panel.-40É to 180É
Fahrenheit
(-40É to 82É Celsius)
High Density
Urethane FoamTear resistant, highly resilient
and durable.Between metal and metal,
metal and plastic. Water-
resistant.
Examples: I/P, heavy metal
rattles, isolating brackets.-40É to 180É
Fahrenheit
(-40É to 82É Celsius)
Open Cell Foam
TapeSoft foam conforms to irregular
surfaces.Wire harness and connector
wrap.
Examples: Seals, gasket,
wiring, heat ducts.-40É to 180É
Fahrenheit
(-40É to 82É Celsius)
Closed Cell Low
Density Foam TapeSoft, conformable. Water-
resistant.Wherever bulk is needed.
Prevents closing flutters and
rattles when applied to door
watershield.
Examples: Door, I/P.-40É to 180É
Fahrenheit
(-40É to 82É Celsius)
NYETGrease 880 Long life. Suspensions.
Examples: Strut busings, sway
bars.-40É to 390É
Fahrenheit
(-40É to 200É
Celsius)
KrytoxTOil Long life. Will not dry out or
harm plastics or rubber.When access is not possible, oil
will migrate to condition. Vinyl,
rubber, plastic, metal.
Examples: Convertible top
bushings, pull cups trim panel
inserts.-30É to 400É
Fahrenheit
(-34É to 205É
Celsius)
KrytoxTGrease Long life. Will not dry out or
harm plastics or rubber.Vinyl, rubber, plastic, metal,
glass.
Examples: Weather-strips,
backlite and windshield
moldings.-30É to 400É
Fahrenheit
(-34É to 205É
Celsius)
DRBODY 23 - 11
BODY (Continued)

SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
Description N´m Ft. Lbs. In. Lbs.
A-pillar trim/grab handle bolts 6 Ð 55
Body Isolator/cab bolts 81 60 Ð
Cargo box bolts 108 80 Ð
Cargo box tie down/cleat bolts 34 25 Ð
Center seat assembly nuts*25 18 Ð
Center seat cushion/hinge bolts*20 15 Ð
Center seat back hinge to storage bin bolts*25 18 Ð
Center seat back free pivot hinge bolt*25 18 Ð
Center seat back inertia hinge pivot bolt*10 Ð 89
Center seat inertia hinge to seat back bolts*25 18 Ð
Fender bolts - front lower 9 Ð 80
Fender bolts - lower inside 17 13 Ð
Fender to hinge support bolts 11 8 Ð
Fender to upper fender rail bolts 9 Ð 80
Footmans loop bolts 12 9 Ð
Front center seat nuts*25 18 Ð
Front door glass lift plate nuts 10 Ð 89
Front door hinge to a-pillar nuts 28 21 Ð
Front door hinge to door nuts/bolts 28 21 Ð
Front door inside handle bolt 9 Ð 80
Front door latch adjustment screw 3 Ð 30
Front door latch assembly bolts 10 Ð 89
Front door latch striker bolts 28 21 Ð
Front door latch striker bolts 28 21 Ð
Front door regulator bolts 10 Ð 89
Front door regulator stabilizer nuts 10 Ð 89
Front door remote handle actuator nuts 10 Ð 89
Front door run channel screws 10 Ð 89
Front seat assembly front bolts*28 30 Ð
Front seat assembly rear bolts*40 30 Ð
Front seat track nuts*25 18 Ð
Fuel fill door bolts 9 Ð 80
Hood hinge to fender rail bolts 20 15 Ð
Hood latch bolts 11 8 Ð
Hood latch striker/safety catch bolts 11 8 Ð
Hood hinge to hood nuts 23 17 Ð
Instrument panel center bracket bolts 12 9 Ð
Instrument panel column support bolts 14 10 Ð
Instrument panel side mounting bolts 12 9 Ð
23 - 12 BODYDR
BODY (Continued)

Description N´m Ft. Lbs. In. Lbs.
Instrument panel top bolts 12 9 Ð
Load floor nuts 25 18 Ð
Load floor/rear seat bolts 40 30 Ð
Lower seat belt anchor bolt - quad cab 40 30 Ð
Overhead/b-pillar grab handle bolts 6 Ð 55
Radiator and condenser to radiator crossmember bolts 8 Ð 75
Radiator upper crossmember bolts 28 21 Ð
Rear door glass lift plate nuts 10 Ð 89
Rear door glass run channels 10 Ð 89
Rear door hinge to b-pillar bolts 28 21 Ð
Rear door hinge to door bolts/nuts 28 21 Ð
Rear door inside handle bolt 9 Ð 80
Rear door latch adjustment screw 3 Ð 30
Rear door latch bolts 10 Ð 89
Rear door latch striker bolts 28 21 Ð
Rear door regulator bolts 10 Ð 89
Rear door regulator stabilizer nuts 10 Ð 89
Rear door remote handle actuator nuts 10 Ð 89
Rear fender bottom screws 7 Ð 60
Rear fender nuts 7 Ð 60
Rear fender support bracket bolts 11 8 Ð
Rear seat assembly bolts*40 30 Ð
Rear seat back hinge bolts*25 18 Ð
Rear seat cushion hinge bolts*32 24 Ð
Rear shoulder belt anchor bolts 40 30 Ð
Rear view mirror set screw 1 Ð 15
Shifter knob nut 27 20 Ð
Side view mirror nuts 7 Ð 60
Tailgate check cable bolt 23 17 Ð
Tailgate hinge/pivot screws 34 25 Ð
Tailgate latch bolts 23 17 Ð
Tailgate latch striker 34 25 Ð
Tailgate release handle nuts 7 Ð 60
NOTE: *Seat fasteners should be discarded and
replaced with new fasteners during assembly.
DRBODY 23 - 13
BODY (Continued)