2001 DODGE RAM light

INSTALLATION
(1) Install new front output seal in front case with
Installer Tool 8143-A as follows:
(a) Place new seal on tool. Garter spring on seal
goes toward interior of case.
(b) Start seal in bore with light taps from ham-
mer (Fig. 101). Once seal is started, continue tap-
ping seal into bore until installer tool seats against
case.
(2) Install companion flange seal on front shaft
(Fig. 102).
(3) Install companion flange on front shaft (Fig.
103). Then install and tighten flange nut to 176-271
N´m (130-200 ft. lbs.) torque.(4) Install propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - INSTALLATION)
SHIFT LEVER
REMOVAL
(1) Shift transfer case into 2H.
(2) Remove transfer case shifter knob cap.
(3) Remove nut holding shifter knob to shift lever.
(4) Remove shifter knob.
(5) Remove the shift boot from the shifter bezel.
(6) Remove the bolts securing the shifter mecha-
nism to the floor pan along the driver's side of the
transmission tunnel (Fig. 104).
(7) Raise and support the vehicle.
(8) Loosen adjusting trunnion lock bolt and slide
shift rod out of trunnion. If rod lacks enough travel
to come out of trunnion, push trunnion out of shift
lever.
(9) Remove the nuts holding the shifter mecha-
nism to the underside of the floor pan.
(10) Separate shift lever mechanism from the vehi-
cle.
Fig. 101 Front Output Seal Installation
1 - INSTALLER 8143-A
2 - TRANSFER CASE
Fig. 102 Installing Flange Seal On Front Shaft
1 - FRONT OUTPUT SHAFT
2 - FLANGE SEAL
Fig. 103 Installing Companion Flange On Front
Shaft
1 - COMPANION FLANGE
21 - 852 TRANSFER CASE - NV231HDBR/BE
FRONT OUTPUT SHAFT SEAL (Continued)

(b) Start seal in bore with light taps from ham-
mer (Fig. 49). Once seal is started, continue tap-
ping seal into bore until installer tool bottoms
against case.(c) Remove installer and verify that seal is
recessed the proper amount (Fig. 50). Seal should
be 2.03 to 2.5 mm (0.080 to 0.100 in.) below top
edge of seal bore in front case. This is correct final
seal position.
CAUTION: Be sure the front output seal is seated
below the top edge of the case bore as shown. The
seal could loosen, or become cocked if not seated
to recommended depth.
(9) Remove seal from front bearing retainer with
suitable pry tool.
Fig. 47 Seating Input Shaft Bearing
1 - SNAP-RING
2 - INPUT SHAFT BEARING
Fig. 48 Front Output Shaft Bearing Installation
1 - HANDLE C-4171
2 - REMOVER/INSTALLER 6953
Fig. 49 Front Output Seal Installation
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 6888
Fig. 50 Checking Front Output Seal Installation
Depth
1 - CORRECT SEAL DEPTH IS 2.03-2.5 mm (0.080-0.100 in.)
BELOW TOP EDGE OF BORE
2 - FRONT CASE SHAFT BORE
3 - FRONT OUTPUT SEAL
21 - 870 TRANSFER CASE - NV241LDBR/BE
TRANSFER CASE - NV241LD (Continued)

(5) Using Installer 6953, remove front output shaft
bearing.
(6) Start front shaft output bearing in case (Fig.
44). Then seat bearing with Handle C-4171 and
Installer 6953.
(7) Install front output bearing retaining ring.(8)
Install new front output seal in front case with
Installer Tool 6888 (Fig. 45) and Tool Handle C-4171 as
follows:
(a) Place new seal on tool.Garter spring on
seal goes toward interior of case.
(b) Start seal in bore with light taps from ham-
mer (Fig. 46). Once seal is started, continue tap-
ping seal into bore until installer tool bottoms
against case.
(c) Remove installer and verify that seal is
recessed the proper amount. Seal should be 2.03 to
2.5 mm (0.080 to 0.100 in.) below top edge of seal
bore in front case. This is correct final seal posi-
tion.
CAUTION: Be sure the front output seal is seated
below the top edge of the case bore as shown. The
seal could loosen, or become cocked if not seated
to recommended depth.
Fig. 43 Seating Input Shaft Bearing
1 - SNAP-RING
2 - INPUT SHAFT BEARING
Fig. 44 Front Output Bearing Installation
1 - HANDLE C-4171
2 - REMOVER/INSTALLER 6953
Fig. 45 Front Output Seal Installation
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 6888
Fig. 46 Checking Front Output Seal Installation Depth
1 - CORRECT SEAL DEPTH IS 2.03-2.5 mm (0.080-0.100 in.)
BELOW TOP EDGE OF BORE
2 - FRONT CASE SHAFT BORE
3 - FRONT OUTPUT SEAL
BR/BETRANSFER CASE - NV241HD 21 - 905
TRANSFER CASE - NV241HD (Continued)

DIAGNOSIS AND TESTING ± WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not
always seal water tight under all conditions. At
times, side glass or door seals will allow water to
enter the passenger compartment during high pres-
sure washing or hard driving rain (severe) condi-
tions. Overcompensating on door or glass
adjustments to stop a water leak that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After completing
a repair, water test vehicle to verify leak has stopped
before returning vehicle to use.
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 Group 0,
Lubrication and Maintenance, General Information
section.
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.
23 - 2 BODYBR/BE
BODY (Continued)

SLAM BUMPER
REMOVAL
(1) Open tailgate.
(2) Remove screw holding slam bumper to cargo
box (Fig. 8).
(3) Separate slam bumper from vehicle.
INSTALLATION
(1) Position slam bumper on vehicle.
(2) Install screw holding slam bumper to cargo
box.
(3) Close tailgate and verify operation.
TAILGATE
REMOVAL
(1) Open tailgate.
(2) Disconnect tailgate marker light harness, if
equipped.
(3) Remove tailgate check cables (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
CHECK CABLE - REMOVAL).
(4) Close tailgate until the notch in the right hand
collar aligns with the pivot pin.
(5) Slip tailgate hinge collar from pivot pins.
(6) Slide tailgate to the right and separate left
hand collar from the pivot pin.
(7) 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) Install tailgate check cables (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
CHECK CABLE - INSTALLATION).
(4) Connect tailgate marker light harness, if
equipped.
Fig. 8 Tailgate Slam Bumper
1 - CARGO BOX
2 - SLAM BUMPER
3 - TAILGATE
23 - 66 DECKLID/HATCH/LIFTGATE/TAILGATEBR/BE

(3) Apply soap solution liberally to body panel sur-
face.
(4) Place decal into position on body panel (Fig. 3)
. Smooth out wrinkles by pulling lightly on edges of
decal until it lays flat on painted surface.
(5) Push air pockets from under decal to the
perimeter of the panel from the center of the decal
out.
(6) Squeegee soap solution and air bubbles from
behind decal from the center of the panel out using a
body putty applicator squeegee.
(7) Apply heat to decal to evaporate residual mois-
ture from edges of decal.
(8) Small air or water bubbles under decal can be
pierced with a pin and smoothed out.
TAPE STRIPE
REMOVAL
(1) If the panel that is being serviced is not going
to be refinished, apply a length of masking tape par-
allel to the edge of the original tape stripe to aid
installation.
(2) Warm the panel to approximately 38ÉC (100ÉF)
using a suitable heat lamp or heat gun.
(3) Peel tape stripe (Fig. 4) from body panel using
an even pressure pull.
(4) Remove adhesive residue from body panel
using a suitable adhesive removing solvent.
INSTALLATION
The painted surface of the body panel to be covered
by a tape stripe overlay must be smooth and com-pletely cured before overlay can be applied. If painted
surface is not smooth, wet sand with 600 grit wet/dry
sand paper until surface is smooth. Ripples and
feather edging will read through overlay if surface is
not properly prepared. Clean all residue from sur-
face.
Installation equipment:
²Pail filled with mild dish soap solution.
²Lint free applicator cloth or sponge.
²Body putty applicator squeegee.
²Heat gun or sun lamp.
²Razor knife.
Fig. 3 Decals
1 - TAPE STRIPE
Fig. 4 Tape Stripe Overlay
1 - CAB/DOOR TAPE STRIPE
2 - HOOD TAPE STRIPE
23 - 88 EXTERIORBR/BE
BODY STRIPES AND DECALS (Continued)

(1) Spread replacement tape stripe overlay across
a smooth flat work surface, finish side down.
(2) Peel paper backing away from overlay exposing
adhesive back of overlay.
(3) Apply soap solution liberally to adhesive back
of overlay.
(4) Apply soap solution liberally to body panel sur-
face.
(5) Place overlay into position on body panel.
Smooth out wrinkles by pulling lightly on edges of
overlay until it lays flat on painted surface.
(6) Push air pockets from under overlay to the
perimeter of the panel from the center of the overlay
out.
(7) Squeegee soap solution and air bubbles from
behind overlay from the center of the panel out using
a body putty applicator squeegee (Fig. 5).
CAUTION: Do not cut into painted surface of body
panel when trimming overlay to size.
(8) Trim overlay to size using a razor knife. Leave
at least 13 mm (0.5 in.) for edges of doors and open-
ings.
CAUTION: Do not overheat overlay when perform-
ing step 9.
(9) Apply heat to overlay to evaporate residual
moisture from edges of overlay and to allow overlay
to be stretched into concave surfaces.
(10) Edge turn overlay around doors or fenders.
(11) Install exterior trim if necessary.
(12) Small air or water bubbles under overlay can
be pierced with a pin and smoothed out.
EXTERIOR NAME PLATES
REMOVAL
NOTE: Exterior nameplates are attached to body
panels with adhesive tape.
(1) Apply a length of masking tape on the body,
parallel to the top edge of the nameplate to use as a
guide, if necessary.(2) If temperature is below 21ÉC (70ÉF) warm
emblem with a heat lamp or gun. Do not exceed 52ÉC
(120ÉF) when heating emblem.
(3) Insert a plastic trim stick or a hard wood
wedge behind the emblem to separate the adhesive
backing from the body.
(4) Clean adhesive residue from body with
MOPARž Super Clean solvent or equivalent.
INSTALLATION
(1) Remove protective cover from adhesive tape on
back of emblem.
(2) Position emblem properly on body (Fig. 6).
(3) Press emblem firmly to body with palm of
hand.
(4) If temperature is below 21ÉC (70ÉF) warm
emblem with a heat lamp or gun to assure adhesion.
Do not exceed 52ÉC (120ÉF) when heating emblem.
Fig. 5 Tape Stripe Application
1 - SQUEEGEE
2 - CARRIER
3 - BODY PANEL
4 - TAPE STRIPE
BR/BEEXTERIOR 23 - 89
TAPE STRIPE (Continued)

HOOD
REMOVAL
(1) Disconnect the under hood lamp wire connec-
tor.
(2) Disconnect the air temperature sensor wire
connector, if equipped.
(3) Mark all bolt and hinge attachment locations
with a grease pencil or equivalent to provide refer-
ence marks for installation.
(4) Remove top nuts attaching hood to hinge and
loosen bottom nuts until they can be removed by
hand (Fig. 2).
(5) With assistance of a helper at the opposite side
of the vehicle to support the hood, remove the bottom
nuts. Separate the hood from the vehicle.
INSTALLATION
(1) With assistance of a helper, position hood on
vehicle loosely install bottom nuts.Align all marks, install top nuts and tighten bot-
tom nuts. The hood should be aligned to 5 mm (0.2
in.) gap to the front fenders and flush across the top
surfaces along fenders.
(2) Connect the air temperature sensor wire con-
nector, if equipped.
(3) Connect the under hood lamp wire connector.
ADJUSTMENT
(1) Loosen the hinge arm-to-hood panel bolts at
each side of the vehicle.
(2) Loosen the hood latch screws.
(3) Close the hood. Adjust the fore/aft position.
(4) Raise the hood. Tighten the hinge arm-to-hood
panel bolts.
(5) Tighten the latch screws.
(6) Lower the hood. Inspect clearance between the
hood and the cowl cover.
LATCH
REMOVAL
(1) Remove bolts attaching hood latch to radiator
closure panel crossmember (Fig. 3).
(2) Separate hood latch from crossmember.
(3) Disconnect release cable from hood latch.
INSTALLATION
(1) Connect release cable to hood latch.
(2) Position hood latch on crossmember.
(3) Install bolts attaching hood latch to radiator
closure panel crossmember.
ADJUSTMENT
(1) Loosen the hood latch screws.
(2) Move the latch to the correct location and
lightly tighten the screws.
(3) Close the hood slowly and observe the latching
operation.
(4) As necessary, re-adjust the latch position and
tighten the screws.
Fig. 2 Hood
1 - HOOD
2 - HOOD HINGE
3 - FENDER
23 - 100 HOODBR/BE