2002 DODGE RAM Service Repair Manual

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Page 2041 of 2255

DODGE RAM 2002 Service Repair Manual LOCK CYLINDER
REMOVAL
(1) Remove outside door handle (Refer to 23 -
BODY/DOOR - FRONT/EXTERIOR HANDLE -
REMOVAL).
(2) Remove clip securing lock cylinder to outside
door handle (Fig. 14).
(3) Pull lock

Page 2042 of 2255

DODGE RAM 2002 Service Repair Manual INSTALLATION
(1) Position flag cover on door.
(2) Install nuts attaching mirror flag cover to door
frame.
(3) Install flag door seal.
(4) Install door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRI

Page 2043 of 2255

DODGE RAM 2002 Service Repair Manual (3) Position trim panel on door.
(4) Engage clips around perimeter of trim panel,
attaching trim panel to door.
(5) Install screws attaching pull cup to door.
(6) Install screw attaching trim panel to

Page 2044 of 2255

DODGE RAM 2002 Service Repair Manual DOOR - CARGO
TABLE OF CONTENTS
page page
AIR EXHAUSTER
REMOVAL.............................77
INSTALLATION.........................77
CHECK
REMOVAL.............................78
INSTALLATION.........

DOOR - CARGO
TABLE OF CONTENTS
page page
AIR EXHAUSTER
REMOVAL.............................77
INSTALLATION.........................77
CHECK
REMOVAL.............................78
INSTALLATION.........................78
DOOR
REMOVAL.............................78
INSTALLATION.........................78
ADJUSTMENTS
ADJUSTMENT - CARGO DOOR..........78
EXHAUST VENT
REMOVAL.............................79
INSTALLATION.........................79
HINGE
REMOVAL.............................79
INSTALLATION.........................80
INSIDE HANDLE ACTUATOR
REMOVAL.............................80
INSTALLATION.........................80
LATCH - LOWER
REMOVAL.............................80
INSTALLATION.........................80
LATCH - UPPER
REMOVAL.............................81INSTALLATION.........................81
LATCH STRIKER - LOWER
REMOVAL.............................82
INSTALLATION.........................82
LATCH STRIKER - UPPER
REMOVAL.............................82
INSTALLATION.........................82
RELEASE CABLE
REMOVAL.............................82
INSTALLATION.........................82
SHUTFACE HANDLE
REMOVAL.............................83
INSTALLATION.........................83
TRIM PANEL
REMOVAL.............................83
INSTALLATION.........................84
VENT WINDOW
REMOVAL.............................85
INSTALLATION.........................85
WATERDAM
REMOVAL.............................85
INSTALLATION.........................85
AIR EXHAUSTER
REMOVAL
(1) Remove cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(2) Peel back waterdam.
(3) Remove push-in fastener attaching air
exhauster to cargo door inner panel (Fig. 1).
(4) Separate air exhauster from cargo door.
INSTALLATION
(1) Position air exhauster in cargo door.
(2) Engage air exhauster upper tabs with cargo
door inner panel.
(3) Install push-in fastener attaching air exhauster
to cargo door inner panel (Fig. 1).
(4) Reposition waterdam.
(5) Install cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
Fig. 1 Cargo Door Air Exhauster
1 - CARGO DOOR
2 - PUSHÐIN FASTENER
3 - DOOR EXHAUSTER
4-TAB
BR/BEDOOR - CARGO 23 - 77

Page 2045 of 2255

DODGE RAM 2002 Service Repair Manual CHECK
REMOVAL
(1) Remove cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(2) Remove the bolts attaching the door check to
the cab C-pillar.
(3) Remove the nuts attaching

CHECK
REMOVAL
(1) Remove cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(2) Remove the bolts attaching the door check to
the cab C-pillar.
(3) Remove the nuts attaching the door check to
the cargo door (Fig. 2).
(4) Remove the door check through the access hole
in the cargo door.
INSTALLATION
(1) Position the door check in the cargo door
through the access hole.
(2) Install the nuts attaching the door check to the
cargo door (Fig. 2).
(3) Install the bolts attaching the door check to the
cab C-pillar.
(4) Install cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
DOOR
REMOVAL
(1) Using a grease pencil or equivalent, mark the
position of the hinge on the door.
(2) Remove the cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(3) Remove the cargo door check strap from the
cab C-pillar (Refer to 23 - BODY/DOOR - CARGO/
CHECK - REMOVAL).(4) Using the access hole in the cargo door inner
panel, disengage the speaker wire from the speaker
and route the wire through the door.
(5) Support the cargo door on a suitable device.
(6) Remove the bolts attaching the hinges to the
cargo door (Fig. 3).
INSTALLATION
(1) Support the cargo door on a suitable device.
(2) Using the alignment marks, position the door
at the hinge.
(3) Install the bolts attaching the hinges to the
cargo door (Fig. 3). Tighten the bolts to 28 N´m (21
ft. lbs.) torque.
(4) Route the speaker wire through the door and
using the access hole in the cargo door inner panel,
engage the speaker wire at the speaker.
(5) Install the cargo door check strap at the cab
C-pillar (Refer to 23 - BODY/DOOR - CARGO/
CHECK - INSTALLATION).
(6) Install the cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
ADJUSTMENTS
ADJUSTMENT - CARGO DOOR
CARGO DOOR FORE/AFT AND UP/DOWN
(1) As applicable, remove the C-pillar trim to
access the bolts attaching the cargo door to the C-pil-
lar.
(2) Support the door with a padded floor jack.
(3) Loosen the applicable C-pillar to hinge bolts
and move the door to the correct position.If neces-
Fig. 2 Door Check
1 - CARGO DOOR
2 - DOOR CHECK
3 - CARGO DOOR INNER PANEL
Fig. 3 Cargo Door
1 - CARGO DOOR
2 - CARGO DOOR HINGE
23 - 78 DOOR - CARGOBR/BE

Page 2046 of 2255

DODGE RAM 2002 Service Repair Manual sary, loosen the other C-pillar to hinge bolts and
move the door to the correct position.
(4) Tighten the bolts to 28 N´m (21 ft. lbs.) torque.
(5) If necessary, loosen the bolts attaching the
lower

Page 2047 of 2255

DODGE RAM 2002 Service Repair Manual INSTALLATION
(1) Position hinge on vehicle.
(2) Install bolts attaching hinge to C-pillar (Fig. 6).
Tighten bolts to 28 N´m (21 ft. lbs.) torque.
(3) Install quarter trim panel (Refer to 23 - BODY/
I

INSTALLATION
(1) Position hinge on vehicle.
(2) Install bolts attaching hinge to C-pillar (Fig. 6).
Tighten bolts to 28 N´m (21 ft. lbs.) torque.
(3) Install quarter trim panel (Refer to 23 - BODY/
INTERIOR/QUARTER TRIM PANEL - INSTALLA-
TION).
(4) Install cargo door (Refer to 23 - BODY/DOOR -
CARGO/DOOR - INSTALLATION).
INSIDE HANDLE ACTUATOR
REMOVAL
NOTE: The cargo door inside handle actuator is
heat staked to the trim panel (Fig. 7).
(1) Remove cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(2) Disengage release cable from inside handle.
(3) Using a small file, drummel tool or die grinder,
remove the melted material securing the handle to
the trim panel.
(4) Separate the handle from the trim panel.
INSTALLATION
(1) Position the handle in the trim panel.
(2) Using a soldering gun, and using the additional
studs, heat stake the handle to the trim panel.
(3) Engage release cable to inside handle.
(4) Install cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
LATCH - LOWER
REMOVAL
(1) Remove cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(2) Peel back waterdam to access air exhauster.
(3) Remove cargo door air exhauster (Refer to 23 -
BODY/DOOR - CARGO/AIR EXHAUSTER - REMOV-
AL).
(4) Disengage lower latch to shutface handle rod at
shutface handle (Fig. 8).
(5) Remove nuts attaching lower latch to cargo
door.
(6) Separate lower latch and latch rod from cargo
door.
INSTALLATION
(1) If installing a new replacement latch:
(a) Engage latch rod to latch rod retaining clip
in lower latch. Ensure ªwhiteº latch installation
pin is in the position closest to the latch release
lever (Fig. 9).
(2) If the latch was not replaced and the existing
latch is to be installed:
(a) Slide ªwhiteº latch installation pin to the
position closest to the latch release lever.
(3) Position lower latch and latch rod in cargo
door.
(4) Install nuts attaching lower latch to cargo door.
Tighten nuts to 12 N´m (9 ft. lbs.) torque (Fig. 8).
(5) Engage latch rod to latch rod retaining clip in
lower latch.
Fig. 7 Heat Staked Locations
1 - RELEASE CABLE
2 - HEAT STAKED LOCATIONS
3 - CARGO DOOR TRIM PANEL
4 - HEAT STAKED LOCATIONS
Fig. 8 Cargo Door Lower Latch
1 - LOWER LATCH TO HANDLE ROD
2 - LOWER CARGO DOOR LATCH
3 - CARGO DOOR
23 - 80 DOOR - CARGOBR/BE
HINGE (Continued)

Page 2048 of 2255

DODGE RAM 2002 Service Repair Manual CAUTION: When engaging lower latch release rod
to shutface handle, ensure lower latch rod is
pushed all the way down before engaging to the
handle.
(6) Engage lower latch rod to shutface handle
(7) Cy

CAUTION: When engaging lower latch release rod
to shutface handle, ensure lower latch rod is
pushed all the way down before engaging to the
handle.
(6) Engage lower latch rod to shutface handle
(7) Cycle the shutface handle and verify latch
operation.
(8) Install cargo door air exhauster (Refer to 23 -
BODY/DOOR - CARGO/AIR EXHAUSTER -
INSTALLATION).
(9) Reposition waterdam.
(10) Install cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
LATCH - UPPER
REMOVAL
(1) Remove cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(2) Using a grease pencil or equivalent, mark the
position of the bolts.
(3) Disengage upper latch release rod from shut-
face handle.
(4) Remove the bolts attaching upper latch to
cargo door (Fig. 10).
(5) Separate upper latch and latch rod from cargo
door.
INSTALLATION
(1) The new replacement latch is supplied with an
alignment set screw located in the lower mountinghole of the upper cargo door latch. If a new is latch is
being installed, use the following procedure:
(a) Verify alignment set screw is fully seated in
latch.
(b) Engage latch rod to latch.
(c) Position latch in cargo door with alignment
set screw located in the lower hole.
(d) Align bolt with reference mark.
(e) Install upper bolt. Tighten bolt to 23 N´m (17
ft. lbs.) torque.
(f) Engage latch rod to shutface handle.
(g) Remove alignment set screw from lower hole.
(h) Align lower bolt with reference mark.
(i) Install bolt in lower hole. Tighten bolt to 23
N´m (17 ft. lbs.) torque.
CAUTION: When engaging upper latch release rod
to shutface handle, ensure the latch rod is pushed
all the way up before engaging into the shutface
handle.
(2) If the latch was not replaced and the existing
latch is to be installed:
(a) Engage latch rod to latch.
(b) Position upper latch and latch rod in cargo
door.
(c) Align bolts with reference marks.
(d) Install the bolts attaching upper latch to
cargo door (Fig. 10). Tighten the bolts to 23 N´m
(17 ft. lbs.) torque.
(e) Engage upper latch release rod to shutface
handle.
(3) Cycle the shutface handle and verify latch
operation.
Fig. 9 Cargo Door Lower Latch Installation Pin
1 - LATCH ROD RETAINING CLIP
2 - SLOT
3 - CARGO DOOR LOWER LATCH
4 - INSTALLATION PIN
5 - LATCH RELEASE LEVER
Fig. 10 Cargo Door Upper Latch
1 - CARGO DOOR
2 - UPPER CARGO DOOR LATCH
3 - UPPER LATCH TO HANDLE ROD
4 - ALIGNMENT SET SCREW
BR/BEDOOR - CARGO 23 - 81
LATCH - LOWER (Continued)

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