1998 DODGE RAM 1500 page 39

INSTRUMENT PANEL
TABLE OF CONTENTS
page page
CLUSTER BEZEL
REMOVAL.............................49
INSTALLATION.........................49
ASH RECEIVER
REMOVAL.............................50
INSTALLATION.........................51
CUP HOLDER
REMOVAL.............................51
INSTALLATION.........................51
GLOVE BOX
REMOVAL.............................52
INSTALLATION.........................52
GLOVE BOX LATCH
REMOVAL.............................52
INSTALLATION.........................52
INSTRUMENT PANEL ASSEMBLY
REMOVAL.............................52
INSTALLATION.........................55
INSTRUMENT PANEL HEADLAMP SWITCH
BEZEL
REMOVAL.............................56
INSTALLATION.........................56INSTRUMENT PANEL CENTER BEZEL
REMOVAL.............................57
INSTALLATION.........................57
INSTRUMENT PANEL DRIVER SIDE BEZEL
REMOVAL.............................58
INSTALLATION.........................58
INSTRUMENT PANEL TOP COVER
REMOVAL.............................58
INSTALLATION.........................59
INSTRUMENT PANEL LOWER SURROUND
REMOVAL.............................59
INSTALLATION.........................59
STEERING COLUMN OPENING COVER
REMOVAL.............................60
INSTALLATION.........................60
STEERING COLUMN OPENING SUPPORT
BRACKET
REMOVAL.............................60
INSTALLATION.........................60
STORAGE BIN
REMOVAL.............................61
INSTALLATION.........................61
CLUSTER BEZEL
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Remove the headlamp switch bezel. (Refer to
23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL SWITCH BEZEL - REMOVAL)
(2) Remove the center bezel. (Refer to 23 - BODY/
INSTRUMENT PANEL/INSTRUMENT PANEL
CENTER BEZEL - REMOVAL)(3) Remove the two top screws. (Fig. 1)
(4) Using a trim stick C-4755 or equivalent, sepa-
rate the two lower clips.
(5) Disengage the two top attachment bosses and
remove the bezel.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Position the cluster bezel over the cluster and
seat the outer bosses over the posts on the left and
right sides.
DRINSTRUMENT PANEL 23 - 49

INTERIOR
TABLE OF CONTENTS
page page
INTERIOR
CAUTION.............................62
4WD FLOOR SHIFT BOOT
REMOVAL.............................62
INSTALLATION.........................62
A-PILLAR TRIM/GRAB HANDLE
REMOVAL.............................63
INSTALLATION.........................63
B-PILLAR LOWER TRIM
REMOVAL.............................63
INSTALLATION.........................64
B-PILLAR UPPER TRIM
REMOVAL.............................64
INSTALLATION.........................64
CARPETS AND FLOOR MATS
REMOVAL.............................65
INSTALLATION.........................65
COAT HOOK
REMOVAL.............................66
INSTALLATION.........................66
COWL TRIM
REMOVAL.............................66
INSTALLATION.........................66
C-PILLAR LOWER TRIM
REMOVAL.............................66
INSTALLATION.........................67
C-PILLAR UPPER TRIM
REMOVAL.............................67
INSTALLATION.........................67
FLOOR CONSOLE
REMOVAL.............................67
INSTALLATION.........................67
HEADLINER
REMOVAL.............................68INSTALLATION.........................68
B-PILLAR GRAB HANDLE
REMOVAL.............................68
INSTALLATION.........................68
REAR CAB BACK PANEL TRIM
REMOVAL.............................68
INSTALLATION.........................69
REAR VIEW MIRROR
REMOVAL.............................69
INSTALLATION
INSTALLATION.......................70
INSTALLATION - REAR VIEW MIRROR
SUPPORT BRACKET...................70
SUN VISOR
REMOVAL.............................70
INSTALLATION.........................70
SUN VISOR SUPPORT
REMOVAL.............................70
INSTALLATION.........................71
BODY VENT
REMOVAL.............................71
INSTALLATION.........................71
REAR DOOR SILL TRIM COVER
REMOVAL.............................71
INSTALLATION.........................71
LOAD FLOOR
REMOVAL.............................71
INSTALLATION.........................72
LOAD FLOOR SUPPORT CYLINDER
REMOVAL.............................72
INSTALLATION.........................72
INTERIOR
CAUTION
CAUTION:: Do not attempt to remove interior trim
panels/moldings without first removing the neces-
sary adjacent panels. To avoid damaging the pan-
els, ensure that all the screws and clips are
removed before attempting to remove an interior
trim panel/molding. Trim panels are somewhat flex-
ible but can be damaged if handled improperly.
4WD FLOOR SHIFT BOOT
REMOVAL
(1) Using a small pry bar or equivalent, remove
the insert, the nut and remove the shifter knob. (Fig.
2)
(2) Using a trim stick C-4755 or equivalent, pry up
the boot from the console. (Fig. 1)
INSTALLATION
(1) Position the shift boot over the shifter lever
fully seat onto the console.
23 - 62 INTERIORDR

PAINT
TABLE OF CONTENTS
page page
PAINT
SPECIFICATIONS - PAINT CODES..........73
PAINT CODE
DESCRIPTION.........................73
BASECOAT/CLEARCOAT FINISH
DESCRIPTION.........................73PAINT TOUCH-UP
DESCRIPTION.........................74
STANDARD PROCEDURE - PAINT TOUCH-UP . 74
FINESSE SANDING/BUFFING & POLISHING
DESCRIPTION.........................74
PAINT
SPECIFICATIONS - PAINT CODES
NOTE: Because of late model changes to the avail-
able paint colors (Refer to VEHICLE DATA/VEHICLE
INFORMATION/VEHICLE CERTIFICATION LABEL -
DESCRIPTION) or (Refer to VEHICLE DATA/VEHI-
CLE INFORMATION/BODY CODE PLATE - DESCRIP-
TION) for the correct paint codes for each vehicle.
(Refer to 23 - BODY/PAINT/PAINT CODE - DESCRIP-
TION)
EXTERIOR COLORS
EXTERIOR COLOR DAIMLERCHRYSLER
CODE
Deep Molten Red
PearlcoatBR8
Flame Red Clearcoat PR4
Light Almond Pearl
Metallic ClearcoatZKJ
Atlantic Blue Pearlcoat ZBJ
Patriot Blue Pearlcoat WBT/WB7
Graphite Metallic
ClearcoatZDR
Bright Silver Metallic
ClearcoatWSB/WS2
Black Clearcoat DX8
Bright White Clearcoat GW7
Timberline Green AGW
INTERIOR COLORS
INTERIOR COLOR DAIMLERCHRYSLER
CODE
Taupe L5
Dark Slate Gray DV
PAINT CODE
DESCRIPTION
Exterior vehicle body colors are identified on the
Vehicle Certification Label (Refer to VEHICLE
DATA/VEHICLE INFORMATION/VEHICLE CERTI-
FICATION LABEL - DESCRIPTION) or the Body
Code Plate (Refer to VEHICLE DATA/VEHICLE
INFORMATION/BODY CODE PLATE - DESCRIP-
TION). The first digit of the paint code listed on the
vehicle indicates the sequence of application, i.e.: P =
primary coat, Q = secondary coat. The color names
provided in the Paint and Trim Code Description
chart are the color names used on most repair prod-
uct containers. (Refer to 23 - BODY/PAINT - SPECI-
FICATIONS)
BASECOAT/CLEARCOAT
FINISH
DESCRIPTION
The original equipment finish is a multi step pro-
cess that involves cleaning, applying electro de-posi-
tion (E-coat), anti-chip primer, basecoat, and
clearcoat steps.
On most vehicles a two-part paint application
(basecoat/clearcoat) is used. Color paint that is
applied to primer is called basecoat. The clear coat
protects the basecoat from ultraviolet light and pro-
vides a durable high-gloss finish.
DRPAINT 23 - 73

SEATS
TABLE OF CONTENTS
page page
CENTER SEAT
REMOVAL.............................75
INSTALLATION.........................76
CENTER ARMREST / SEAT BACK
REMOVAL.............................76
INSTALLATION.........................77
CENTER SEAT BACK INERTIA HINGE COVER
REMOVAL.............................77
INSTALLATION.........................77
CENTER SEAT BACK HINGE
REMOVAL.............................78
INSTALLATION.........................79
CENTER SEAT BACK LID
REMOVAL.............................79
INSTALLATION.........................79
CENTER SEAT CUSHION
REMOVAL.............................79
INSTALLATION.........................79
CENTER SEAT CUSHION COVER
REMOVAL.............................79
INSTALLATION.........................79
UNDER SEAT STORAGE BIN LID
REMOVAL.............................80
INSTALLATION.........................80
UNDER SEAT STORAGE BIN
REMOVAL.............................80
INSTALLATION.........................80
UNDER SEAT STORAGE BIN COVERING
REMOVAL.............................80
INSTALLATION.........................80
UNDER SEAT STORAGE BIN LATCH
REMOVAL.............................80
INSTALLATION.........................80
HEADREST
REMOVAL.............................80
INSTALLATION.........................80
HEADREST SLEEVE
REMOVAL.............................81INSTALLATION.........................81
SEAT - FRONT
REMOVAL.............................81
INSTALLATION.........................81
LUMBAR SUPPORT HANDLE/BEZEL
REMOVAL.............................82
INSTALLATION.........................82
SEAT BACK CUSHION / COVER - FRONT
REMOVAL.............................82
INSTALLATION.........................82
SEAT CUSHION / COVER - FRONT
REMOVAL.............................83
INSTALLATION.........................83
SEAT TRACK
REMOVAL.............................83
INSTALLATION.........................83
SEAT - REAR
REMOVAL.............................83
INSTALLATION.........................83
SEAT BACK - REAR
REMOVAL.............................83
INSTALLATION.........................83
SEAT BACK CUSHION / COVER - REAR
REMOVAL.............................84
INSTALLATION.........................84
SEAT CUSHION / COVER - REAR
REMOVAL.............................84
INSTALLATION.........................84
SEAT CUSHION FRAME - REAR
REMOVAL.............................85
INSTALLATION.........................85
SEAT BACK REAR - FOOTMANS LOOP
BRACKETS
REMOVAL.............................85
INSTALLATION.........................85
CENTER SEAT
REMOVAL
NOTE: Do not reuse the seat fasteners, always
replace with new ones.
(1) Remove and discard the front bolts. (Fig. 1)(2) Position the seats forward, remove the rear
bolts and discard.
(3) Disconnect the 12v power supply electrical con-
nector, if equipped. (Fig. 2)
(4) Fold the seat backs forward and roll the seat
assembly back in the vehicle.
(5) Remove the nuts attaching the center seat to
the drivers seat and the passenger seat and discard.
(Fig. 3)
DRSEATS 23 - 75

STATIONARY GLASS
TABLE OF CONTENTS
page page
BACKLITE
REMOVAL.............................86
INSTALLATION.........................86
BACKLITE VENT GLASS
REMOVAL.............................87
INSTALLATION.........................87WINDSHIELD
WARNING
WINDSHIELD SAFETY PRECAUTIONS.....88
REMOVAL.............................88
INSTALLATION.........................88
BACKLITE
REMOVAL
It is difficult to salvage the backlite during the
removal operation. The backlite is part of the struc-
tural support for the roof. The urethane bonding
used to secure the glass to the fence is difficult to cut
or clean from any surface. Since the molding is set in
urethane, it is unlikely it would be salvaged. Before
removing the backlite, check the availability from the
parts supplier.
The backlite is attached to the window frame with
urethane adhesive. The urethane adhesive is applied
cold and seals the surface area between the window
opening and the glass. The primer adheres the ure-
thane adhesive to the backlite.
(1) Roll down door glass.
(2) Remove headliner. (Refer to 23 - BODY/INTE-
RIOR/HEADLINER - REMOVAL).
(3) On standard cab models remove the upper
b-pillar trim. (Refer to 23 - BODY/INTERIOR/B-PIL-
LAR UPPER TRIM - REMOVAL)
(4) On quad cab models remove the upper c-pillar
trim. (Refer to 23 - BODY/INTERIOR/C-PILLAR
UPPER TRIM - REMOVAL)
(5) Bend backlite retaining tabs (Fig. 1) inward
against glass.
(6) Disconnect the rear window defogger electrical
connector, if equipped.
(7) Using a suitable pneumatic knife from inside
the vehicle, cut urethane holding backlite frame to
opening fence.
(8) Separate glass from vehicle.
INSTALLATION
(1) Clean urethane adhesive from around backlite
opening fence.
(2) If necessary, apply black-out primer to outer
edge of replacement backlite frame.(3) If black-out primer was pre-applied on backlite,
clean bonding surface with Isopropyl alcohol and
clean lint free cloth. Allow 3 minutes for drying time.
(4) Apply black-out primer to backlite opening
fence.
(5) Apply a 13 mm (0.5 in.) bead of urethane
around the perimeter of the window frame bonding
surface (Fig. 2).
(6) Set glass on lower fence and move glass for-
ward into opening (Fig. 3).
(7) Firmly push glass against rear window glass
opening fence.
(8) Bend tabs around edges of backlite opening
fence to retain glass.
(9) Clean excess urethane from exterior with
MOPARt, Super Clean or equivalent.
(10) Allow urethane to cure at least 24 hours (full
cure is 72 hours).
(11) Water test to verify repair before returning
vehicle to service.
(12) Connect the rear window defogger electrical
connector, if equipped.
Fig. 1 Backlite Tabs
1 - BACKLITE
2-TAB
23 - 86 STATIONARY GLASSDR

WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page page
A-PILLAR WEATHERSTRIP RETAINER
REMOVAL.............................91
INSTALLATION.........................91
DRIP RAIL WEATHERSTRIP
REMOVAL.............................91
INSTALLATION.........................91
DOOR OPENING SEAL
REMOVAL.............................92
INSTALLATION.........................92
DRIP RAIL WEATHERSTRIP RETAINER
REMOVAL.............................92
INSTALLATION.........................92
FRONT DOOR GLASS RUN WEATHERSTRIP
REMOVAL.............................92
INSTALLATION.........................92FRONT DOOR OUTER BELT MOLDING
REMOVAL.............................92
INSTALLATION.........................93
FRONT DOOR INNER BELT MOLDING
REMOVAL.............................93
INSTALLATION.........................93
REAR DOOR GLASS RUN WEATHERSTRIP
REMOVAL.............................93
INSTALLATION.........................93
REAR DOOR OUTER BELT MOLDING
REMOVAL.............................93
INSTALLATION.........................94
REAR DOOR INNER BELT MOLDING
REMOVAL.............................94
INSTALLATION.........................94
A-PILLAR WEATHERSTRIP
RETAINER
REMOVAL
(1) Remove the drip rail weatherstrip retainer.
(Refer to 23 - BODY/WEATHERSTRIP/SEALS/DRIP
RAIL WEATHERSTRIP - REMOVAL)
(2) Remove the five screws and remove the weath-
erstip retainer. (Fig. 1)
INSTALLATION
(1) Install the weatherstip retainer and install the
screws.
(2) Install the drip rail weatherstrip retainer.
(Refer to 23 - BODY/WEATHERSTRIP/SEALS/DRIP
RAIL WEATHERSTRIP - INSTALLATION)
DRIP RAIL WEATHERSTRIP
REMOVAL
(1) Open the doors and separate the weatherstrip
from the drip rail and a-pillar retainers. (Fig. 1)
INSTALLATION
(1) Position the weatherstrip onto the drip rail and
a-pillar retainers and seat fully.
Fig. 1 DOOR OPENING WEATHERSTRIPS/SEALS
1 - DRIP RAIL WEATHERSTRIP RETAINER
2 - SCREWS (7)
3 - DRIP RAIL WEATHERSTRIP
4 - CAB
5 - REAR DOOR OPENING SEAL
6 - FRONT DOOR OPENING SEAL
7 - A-PILLAR WEATHERSTRIP RETAINER
8 - SCREWS (5)
9 - CORNER SEAL
DRWEATHERSTRIP/SEALS 23 - 91

BODY STRUCTURE
TABLE OF CONTENTS
page page
GAP AND FLUSH
SPECIFICATIONS.......................95
OPENING DIMENSIONS
SPECIFICATIONS - BODY OPENING
DIMENSIONS.........................99
SEALER LOCATIONS
SPECIFICATIONS......................102STRUCTURAL ADHESIVE LOCATIONS
SPECIFICATIONS......................112
WELD LOCATIONS
SPECIFICATIONS......................120
GAP AND FLUSH
SPECIFICATIONS
GAP & FLUSH DIMENSIONS INDEX
DESCRIPTION FIGURE
STANDARD CAB 1
QUAD CAB 2
PICKUP BOX 3
DRBODY STRUCTURE 23 - 95

HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION
DESCRIPTION - ENGINE COOLING
SYSTEM REQUIREMENTS...............1
DESCRIPTION - HEATER AND AIR
CONDITIONER........................1
OPERATION - HEATER AND AIR
CONDITIONER........................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C
PERFORMANCE.......................3DIAGNOSIS AND TESTING - HEATER
PERFORMANCE TEST..................6
SPECIFICATIONS - A/C SYSTEM............7
CONTROLS.............................9
DISTRIBUTION..........................26
PLUMBING.............................41
HEATING & AIR
CONDITIONING
DESCRIPTION
DESCRIPTION - ENGINE COOLING SYSTEM
REQUIREMENTS
To maintain the performance level of the heating,
ventilation and air conditioning (HVAC) system, the
engine cooling system must be properly maintained.
The use of a bug screen is not recommended. Any
obstructions in front of the radiator or A/C condenser
will reduce the performance of the A/C and engine
cooling systems.
The engine cooling system includes the radiator,
thermostat, radiator hoses and the engine coolant
pump. Refer to Cooling for more information before
opening or attempting any service to the engine cool-
ing system.
DESCRIPTION - HEATER AND AIR
CONDITIONER
A manually controlled single zone type heating-air
conditioning system or a manually controlled dual
zone type heating-air conditioning system is available
on this model.
All vehicles are equipped with a common heater,
ventilation and air conditioning (HVAC) housing (Fig.
1). The system combines air conditioning, heating,
and ventilating capabilities in a single unit housing
mounted within the passenger compartment under
the instrument panel. The HVAC housing includes:
²Blower motor
²Blower motor resistor block²Heater core
²Evaporator coil
²Blend door and actuator
²Defrost door and actuator
²Mode door and actuator
²Recirculation door and actuator
Based upon the system and mode selected, condi-
tioned air can exit the HVAC housing through one or
a combination of the three main housing outlets:
defrost, panel or floor. The defrost outlet is located on
the top of the housing, the panel outlet is located on
the face of the housing and the floor outlet is located
on the bottom of the housing. Once the conditioned
air exits the unit housing, it is further directed
through molded plastic ducts to the various outlets in
the vehicle interior. These outlets and their locations
are as follows:
²Defroster Outlet- A single large defroster out-
let is located in the center of the instrument panel
top cover, near the base of the windshield.
²Side Window Demister Outlets- There are
two side window demister outlets, one is located at
each outboard end of the instrument panel top cover,
near the belt line at the A-pillars.
²Panel Outlets- There are four panel outlets in
the instrument panel, one located near each outboard
end of the instrument panel facing the rear of the
vehicle and two located near the top of the instru-
ment panel center bezel.
²Front Floor Outlets- There are two front floor
outlets, one located above each side of the floor panel
center tunnel near the dash panel.
OPERATION - HEATER AND AIR CONDITIONER
The heating and air conditioning systems pulls
outside (ambient) air through the cowl opening at the
base of the windshield, then into the plenum cham-
DRHEATING & AIR CONDITIONING 24 - 1