Page 2305 of 2627
PATCHED PANEL SURFACING
After patch panel is installed, the patch area can
be finished using the same methods as finishing
other types of body panels. If mesh material is
exposed in the patched area, grind surface down, and
apply a coat of high quality rigid plastic body filler.
Prime, block sand, and paint as required.
Fig. 12 INSTALL SCREWS
1 - PATCH
2 - GAP
Fig. 13 GRIND SURFACE
1 - PATCH
2 - GAP
3 - DISC GRINDER
Fig. 14 COVER GAPS WITH MESH
1 - GROUND DOWN AREA
2 - PATCH
3 - MESH
Fig. 15 COVER MESH WITH ADHESIVE
1 - ADHESIVE
2 - MESH
3 - PATCH
4 - SPREADER
23 - 10 BODYDR
BODY (Continued)
Page 2306 of 2627

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)
Page 2307 of 2627

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)
Page 2308 of 2627

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)
Page 2309 of 2627
SPECIAL TOOLS
BODY
Trim Stick C-4755
Torx Bit Set C-4794-B
REMOVER, MOLDINGS C-4829-A
23 - 14 BODYDR
BODY (Continued)
Page 2310 of 2627

TAILGATE
TABLE OF CONTENTS
page page
CHECK CABLE
REMOVAL.............................15
INSTALLATION.........................15
COVER
REMOVAL.............................16
INSTALLATION.........................16
HINGE
REMOVAL.............................16
INSTALLATION.........................16
LATCH
REMOVAL.............................16INSTALLATION.........................16
LATCH STRIKER
REMOVAL.............................16
INSTALLATION.........................17
RELEASE HANDLE/LATCH REMOTE
REMOVAL.............................17
INSTALLATION.........................17
TAILGATE
REMOVAL.............................17
INSTALLATION.........................17
CHECK CABLE
REMOVAL
(1) Open tailgate.
(2) Pry lock tab outward to clear stud head on
cargo box (Fig. 1).
(3) Push cable end forward until stud head is in
clearance hole portion of cable end.
(4) Separate cable end from stud.
(5) Remove screw attaching cable to tailgate. (Fig.
2)
(6) Separate check cable from tailgate.
INSTALLATION
(1) Position check cable on tailgate.
(2) Install bolt attaching small end of cable to tail-
gate.
(3) Tighten tailgate check cable bolt to 23 N´m (17
ft. lbs.).
(4) Position large end of cable onto stud head and
slide downward to secure lock tab.
Fig. 1 Tailgate Check
1 - TAILGATE STRIKER
2 - SCREW DRIVER
3 - TAILGATE CHECK CABLE
4 - LOCK TAB
Fig. 2 LATCH HANDLE - LATCH
1 - EXTERIOR HANDLE
2 - CONTROL ASSEMBLY
3 - NUTS (2)
4 - TAILGATE
5-LATCH
6 - CHECK CABLE
7 - CHECK/LATCH BOLT
8 - LATCH BOLT
DRTAILGATE 23 - 15
Page 2311 of 2627

COVER
REMOVAL
(1) Open the tailgate.
(2) Remove the eight screws and remove tailgate
liner, if equipped.
(3) Remove the bolts and remove the cover. (Fig. 3)
INSTALLATION
(1) Install the cover and install the bolts and
tighten by hand.
(2) Install the liner and install the screws, if
equipped.
HINGE
REMOVAL
(1) Remove the tailgate. (Refer to 23 - BODY/
TAILGATE/TAILGATE - REMOVAL)
(2) Remove the two screws and remove the hinge/
pivot. (Fig. 4)
INSTALLATION
(1) Install the hinge/pivot and install the screws.
(2) Tighten the screws to 34 N´m (25 ft. lbs.).
(3) Install the tailgate. (Refer to 23 - BODY/TAIL-
GATE/TAILGATE - INSTALLATION)
LATCH
REMOVAL
(1) Remove the cover. (Refer to 23 - BODY/TAIL-
GATE/COVER - REMOVAL)
(2) Using a grease pencil or equivalent, mark the
actuator rod for installation.
(3) Disconnect the actuator rod at the control
assembly. (Fig. 3)
(4) Remove the latch bolt and the check cable bolt.
(Fig. 5)
(5) Remove the latch and actuator rod assembly.
INSTALLATION
(1) Install the latch and actuator rod assembly.
(2) Install the latch and the check cable bolts and
tighten to 23 N´m (17 ft. lbs.).
(3) Connect the actuator rod to the control assem-
bly line up the marks made during removal.
(4) Install the cover. (Refer to 23 - BODY/TAIL-
GATE/COVER - INSTALLATION)
LATCH STRIKER
REMOVAL
(1) Open tailgate.
(2) Using a grease pencil or equivalent, mark out-
line of striker on cargo box jamb to aid installation.
(3) Using a Torx drive wrench, remove striker and
washer from cargo box.
Fig. 3 TAILGATE ASSEMBLY
1 - LATCH ASSEMBLY
2 - CONTROL ASSEMBLY
3 - ACTUATOR ROD (2)
4 - COVER
5 - BOLTS (10)
Fig. 4 TAILGATE HINGE
1 - HINGE/PIVOT
2 - TAILGATE PILLAR
3 - CLIP/BUSHING
4 - BOLTS (2)
23 - 16 TAILGATEDR
Page 2312 of 2627

INSTALLATION
(1) Position striker and washer on jamb using
alignment outline as reference and install with Torx
drive wrench.
(2) Tighten the striker to 34 N´m (25 ft. lbs.).
RELEASE HANDLE/LATCH
REMOTE
REMOVAL
(1) Remove the tailgate cover. (Refer to 23 - BODY/
TAILGATE/COVER - REMOVAL)
(2) Using a grease pencil or equivalent, mark the
latch actuator rods for ease of installation.
(3) Disconnect the latch actuator rods. (Fig. 3)
(4) Remove the control assembly nuts and remove
the control assembly and the exterior handle. (Fig. 5)
INSTALLATION
(1) Install the handle and the control assembly.
(2) Install the nuts and tighten to 7 N´m (60 in.
lbs.).
(3) Connect the actuator rods using the marks
made during removal.
(4) Install the cover. (Refer to 23 - BODY/TAIL-
GATE/COVER - INSTALLATION)
TAILGATE
REMOVAL
(1) Open the tailgate.
(2) Disconnect the tailgate check cables (Fig. 6).
(Refer to 23 - BODY/TAILGATE/CHECK CABLE -
REMOVAL)
(3) Close tailgate until the notch in the right hand
collar aligns with the pivot pin.
(4) Slip tailgate hinge collar from pivot pins.
(5) Slide tailgate to the right and separate left
hand collar from the pivot pin.
(6) Separate tailgate from vehicle.
INSTALLATION
(1) Position tailgate collar on left hand pivot pin
and slide tailgate to the left.
(2) Raise tailgate until the notch in the right hand
collar aligns with the pivot pin.
(3) Connect the tailgate check cables. (Refer to 23 -
BODY/TAILGATE/CHECK CABLE - INSTALLA-
TION)
Fig. 5 LATCH HANDLE - LATCH
1 - EXTERIOR HANDLE
2 - CONTROL ASSEMBLY
3 - NUTS (2)
4 - TAILGATE
5-LATCH
6 - CHECK CABLE
7 - CHECK/LATCH BOLT
8 - LATCH BOLT
Fig. 6 TAILGATE ASSEMBLY
1 - LATCH STRIKER
2 - CHECK CABLE BOLT
3 - CHECK CABLE
4 - TAILGATE
5 - HINGE BUSHING
DRTAILGATE 23 - 17
LATCH STRIKER (Continued)