2002 DODGE RAM roof

STRUCTURAL ADHESIVE LOCATIONS
ROOF PANELS Ð REGULAR CAB
23 - 44 BODYBR/BE
BODY (Continued)

CAB REAR PANEL
ROOF PANEL
BR/BEBODY 23 - 53
BODY (Continued)

BODY GAP AND FLUSH MEASUREMENTS
REGULAR CAB
NOTE: All measurements are in MM.
REGULAR CAB
DESCRIPTION GAP FLUSH
A Grille to Fascia 19.0 +/- 3.0 N/A
B Hood to Grille 1.0 +/- 0.75 0.0 + 0.0/- 1.0
C1 Hood to Fender 6.0 +/- 1.0 1.5 +/- 1.0
C2 Hood to Fender 6.0 +/- 1.0 3.5 +/- 1.0
C3 Hood to Fender 6.0 +/-1.0 1.5 +/- 1.0
C4 Hood to Fender 6.0 +/- 1.0 1.5 +/- 1.0
D Door to Hood/Fender 5.0 +/- 1.0 0.0 +/- 1.0
E Door to Windshield Molding N/A 2.0 +/- 2.0
F Door to Roof 6.0 +/- 1.5 2.0 +/- 1.0
G Door to Quarter 5.0 +/- 1.0 0.0 +/- 1.0
H Fender/Door/Quarter Char Line U/D N/A 0.0 +/- 1.0
I Door to Sill 7.7 +/- 2.0 0.0 +/- 1.5
J Fender to Aperture 5.0 +/- 1.0 0.0 +/- 1.0
K Grille to Headlamp 6.0 +/- 3.0 N/A
L Grille to Fender 5.0 +/- 0.75 1.0 +/- 0.5
23 - 56 BODYBR/BE
BODY (Continued)

CLUB CAB
NOTE: All measurements are in MM.
CLUB CAB
DESCRIPTION GAP FLUSH
A Door to Windshield Molding N/A 2.0 +/- 2.0
B1 Door to Roof 5.0 +/- 1.5 0.0 +/- 1.0
B2 Door to Roof 5.0 +/- 1.5 1.4   1.0 CONS. W/IN 1.5
B3 Door to Roof 5.0 +/- 1.5 4.1   1.0 CONS. W/IN 1.5
C Quarter Glass to Quarter (top) 5.0 +/- 1.0 3.5 +/- 1.5
D Quarter Glass to Quarter (rear) 5.0 +/- 2.0 3.25 +/- 1.5
E Cab to Box (side view) 31.0 +/- 3.0 3.25 +/- 2.5
F Quarter Glass to Quarter (bottom) 5.0 +/- 1.5 N/A
G Quarter Glass to Quarter (front) in-line within +/- 1.0
H Door to Quarter 5.0 +/- 1.0 0.0 +/- 1.0
I Quarter Glass to Door N/A 2.0 +/- 1.5
J Door to Hood/Fender 5.0 +/- 1.0 0.0 +/- 1.0
K Grille to Headlamp 6.0 +/- 3.0 N/A
L Grille to Fender 5.0 +/- 0.75 1.0 +/- 0.5
BR/BEBODY 23 - 57
BODY (Continued)

QUAD CAB
NOTE: All measurements are in MM.
QUAD CAB
DESCRIPTION GAP FLUSH
A Door to Windshield Molding N/A 2.0 +/- 2.0
B Front Door to Roof 5.0 +/- 1.5 0.0 +/- 1.0
C Rear Door to Roof 5.0 +/- 1.0 0.0 +/- 1.0
D Rear Door Glass to Rear Door (top) 5.0 +/- 1.0 3.25 +/- 1.5
E Rear Door Glass to Rear Door (rear) 5.0 +/- 2.0 3.25 +/- 1.5
F Rear Door to Quarter 5.5 +/- 1.0 0.0 +/- 1.0
G Rear Door Glass to Rear Door (bottom) 5.0 +/- 1.5 N/A
H Front Door to Rear Door 5.0 +/- 1.0 0.0 +/- 1.0
I Rear Door Glass to Rear Door (front) in-line within +/- 1.0
Rear Door Glass to Front Door N/A 3.25 +/- 1.5
J Door to Hood/Fender 5.0 +/- 1.0 0.0 +/- 1.0
K Grille to Headlamp 6.0 +/- 3.0 N/A
L Grille to Fender 5.0 +/- 0.75 1.0 +/- 0.5
23 - 58 BODYBR/BE
BODY (Continued)

(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 striker on the sill.
(2) Remove the torx screws attaching the striker to
the sill (Fig. 11) .
(3) Separate striker from sill.
INSTALLATION
(1) Using the alignment marks, position striker on
sill.
(2) Install the torx screws attaching the striker to
the sill (Fig. 11) . Tighten screws to 28 N´m (21 ft.
lbs.) torque.
LATCH STRIKER - UPPER
REMOVAL
(1) Remove screws attaching striker trim cover to
roof.
(2) Remove bolts attaching striker to roof (Fig. 11).
(3) Separate upper striker from roof.
INSTALLATION
(1) Position upper striker on roof.
(2) Install bolts attaching striker to roof (Fig. 11) .
Tighten bolts to 23 N´m (17 ft. lbs.) torque.
(3) Install the screws attaching striker trim cover
to roof.
RELEASE CABLE
REMOVAL
(1) Remove cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(2) Disengage release cable from inside release
handle (Fig. 12).
(3) Peel back waterdam
(4) Disengage release cable from shutface door
handle (Fig. 13).
(5) Separate release cable from cargo door.
INSTALLATION
(1) Position release cable in cargo door.
(2) Engage release cable to shutface door handle.
(3) Reposition waterdam
(4) Engage release cable to inside release handle.
(5) Install cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
Fig. 11 Cargo Door Strikers
1 - UPPER STRIKER
2 - LOWER STRIKER
Fig. 12 Cargo Door Release Handle
1 - CARGO DOOR RELEASE CABLE
2 - CARGO DOOR RELEASE HANDLE
23 - 82 DOOR - CARGOBR/BE
LATCH - UPPER (Continued)

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

ROOF JOINT MOLDING
REMOVAL
(1) Warm the roof joint molding and roof panel to
approximately 38ÉC (100ÉF) using a suitable heat
lamp or heat gun.
(2) Pull molding from roof joint (Fig. 8).
INSTALLATION
(1) Remove adhesive tape residue from roof joint.
(2) If molding is to be reused, remove tape residue
from back of molding. Clean molding with MOPARt
Super Kleen solvent or equivalent. Wipe molding dry
with lint free cloth. Apply new body side molding
(two sided adhesive) tape to back of molding.
(3) Clean roof joint with MOPARtSuper Kleen sol-
vent or equivalent. Wipe dry with lint free cloth.
(4) Remove protective cover from tape on back of
molding and apply molding to roof joint.
(5) Heat roof and molding, see step one. Firmly
press molding into roof joint to assure adhesion.
GRILLE
REMOVAL
(1) Open hood.
(2) Remove bolts attaching bottom of grille to
frame (Fig. 9).
(3) Remove bolts attaching sides of grille to frame.
(4) Remove nuts attaching grille to hood (Fig. 10).
(5) Separate grille from vehicle.
INSTALLATION
(1) Position grille on vehicle.
(2) Install nuts attaching grille to hood.
(3) Install bolts attaching sides of grille to frame.
(4) Install bolts attaching bottom of grille to frame.
GRILLE FRAME
REMOVAL
(1) Remove bolts attaching guide loop for hood
safety catch release rod to grille frame.
(2) Remove grille.
Fig. 8 Roof Joint Molding
1 - ROOF
2 - JOINT MOLDING
3 - B-PILLAR
4 - ADHESIVE TAPE
Fig. 9 Grille - Sport
1 - HOOD
2 - GRILLE
3 - GRILLE FRAME
Fig. 10 Grille - SLT
1 - HOOD
2 - GRILLE FRAME
3 - GRILLE
BR/BEEXTERIOR 23 - 91