2002 DODGE RAM Service Repair Manual

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Page 2049 of 2255

DODGE RAM 2002 Service Repair Manual (4) Install cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
LATCH STRIKER - LOWER
REMOVAL
(1) Using a grease pencil or equivalent, mark the
position of the lower s

Page 2050 of 2255

DODGE RAM 2002 Service Repair Manual SHUTFACE HANDLE
REMOVAL
(1) Remove cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(2) Peel back waterdam.
(3) Disengage upper and lower latch release rods
from shutface

Page 2051 of 2255

DODGE RAM 2002 Service Repair Manual 2(4) Pull the trim panel outward to disengage the
spring clips.
(5) Separate the trim panel from the cargo door.
(6) Disengage the cargo door release cable from
the inside release handle (Fig. 18).
IN

Page 2052 of 2255

DODGE RAM 2002 Service Repair Manual VENT WINDOW
REMOVAL
(1) Remove cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(2) Remove the screws attaching the latch to the
cargo door (Fig. 19).
(3) Remove the bolts

Page 2053 of 2255

DODGE RAM 2002 Service Repair Manual EXTERIOR
TABLE OF CONTENTS
page page
EXTERIOR
DESCRIPTION.........................86
OPERATION...........................86
BODY SIDE MOLDINGS
REMOVAL.............................86
INSTALLATION......

EXTERIOR
TABLE OF CONTENTS
page page
EXTERIOR
DESCRIPTION.........................86
OPERATION...........................86
BODY SIDE MOLDINGS
REMOVAL.............................86
INSTALLATION.........................87
BODY STRIPES AND DECALS
REMOVAL.............................87
INSTALLATION.........................87
TAPE STRIPE
REMOVAL.............................88
INSTALLATION.........................89
EXTERIOR NAME PLATES
REMOVAL.............................89
INSTALLATION.........................89
COWL GRILLE
REMOVAL.............................90
INSTALLATION.........................90
ROOF JOINT MOLDING
REMOVAL.............................91
INSTALLATION.........................91
GRILLE
REMOVAL.............................91
INSTALLATION.........................91
GRILLE FRAME
REMOVAL.............................91
INSTALLATION.........................92
FRONT END SPLASH SHIELDS
REMOVAL.............................92
INSTALLATION.........................92LEFT FRONT FENDER
REMOVAL.............................93
INSTALLATION.........................93
RIGHT FRONT FENDER
REMOVAL.............................94
INSTALLATION.........................94
FUEL FILL DOOR
REMOVAL.............................95
INSTALLATION.........................95
REAR FENDER
REMOVAL.............................95
INSTALLATION.........................95
REAR SPLASH SHIELD
REMOVAL.............................96
INSTALLATION.........................96
REAR WHEELHOUSE LINER
REMOVAL.............................96
INSTALLATION.........................96
CARGO BOX
REMOVAL.............................97
INSTALLATION.........................97
SIDE VIEW MIRROR
REMOVAL.............................97
INSTALLATION.........................98
SIDE VIEW MIRROR - LOW MOUNTED
REMOVAL.............................98
INSTALLATION.........................98
SIDE VIEW MIRROR GLASS
REMOVAL.............................98
INSTALLATION.........................98
EXTERIOR
DESCRIPTION
Exterior sheet metal components make up the
exterior of the vehicle. Some exterior metal systems
are welded assemblies, such as doors and hoods.
Some exterior trim items are made of composite.
OPERATION
The exterior is finished in various metal stampings
and composite moldings. These assemblies give the
vehicle a finished appearance and protect the occu-
pants from the elements. Some components are part
of the energy absorbing system used to protect the
occupants in collisions. The exterior sheet metal is
repairable and adjustable for fit and finish. Welded
and bonded component systems are adjustable as asystem. Trim components made of composite are
stamped with the type of material used.
DaimlerChrysler uses various fasteners to retain
trim items. At times, it is not possible to remove trim
items without damaging the fastener. If it is not pos-
sible to remove an item without damaging a compo-
nent, cut or break the fasteners and use new ones
when installing the component.BODY SIDE MOLDINGS
REMOVAL
(1) Warm the effected stick-on molding and body
metal to approximately 38ÉC (100ÉF) using a suitable
heat lamp or heat gun.
(2) Pull stick-on molding from painted surface
(Fig. 1) and (Fig. 2).
23 - 86 EXTERIORBR/BE

Page 2054 of 2255

DODGE RAM 2002 Service Repair Manual INSTALLATION
(1) Clean body surface with MOPARtSuper Kleen
solvent or equivalent. Wipe surface dry with lint free
cloth.
(2) Apply a length of masking tape on the body,
parallel to the top edge of the

Page 2055 of 2255

DODGE RAM 2002 Service Repair Manual (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 edge

Page 2056 of 2255

DODGE RAM 2002 Service Repair Manual 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 san

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.
(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
MOPARtSuper 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)

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