2002 DODGE RAM service

STANDARD PROCEDURE - MATCH MOUNTING
Wheels and tires are match mounted at the factory.
This means that the high spot of the tire is matched
to the low spot on the wheel rim. Each are marked
with a bright colored temporary label on the out-
board surface for alignment. The wheel is also
marked permanently on the inside of the rim in the
tire well. This permanent mark may be a paint dot
or line, a permanent label or a stamped impression
such as an X. An optional location mark is a small
spherical indentation on the vertical face of the out-
board flange on some non styled base steel wheels.
The tire must be removed to locate the permanent
mark on the inside of the wheel.
Before dismounting a tire from its wheel, a refer-
ence mark should be placed on the tire at the valve
stem location. This reference will ensure that it is
remounted in the original position on the wheel.
(1) Remove the tire and wheel assembly from the
vehicle and mount on a service dynamic balance
machine.
(2) Measure the total runout on the center of the
tire tread rib with a dial indicator. Record the indi-
cator reading. Mark the tire to indicate the high spot.
Place a mark on the tire at the valve stem location
(Fig. 6).
(3) Break down the tire and remount it 180
degrees on the rim (Fig. 7).
(4) Measure the total indicator runout again. Mark
the tire to indicate the high spot.
(5) If runout is still excessive, the following proce-
dures must be done.
²If the high spot is within 101.6 mm (4.0 in.) of
the first spot and is still excessive, replace the tire.
²If the high spot is within 101.6 mm (4.0 in.) of
the first spot on the wheel, the wheel may be out of
specifications. Refer to Wheel and Tire Runout.
²If the high spot is NOT within 101.6 mm (4.0
in.) of either high spot, draw an arrow on the tread
Fig. 5 Dual Wheel Tire Rotation Pattern
1 - FRONT
Fig. 6 First Measurement On Tire
1 - REFERENCE MARK
2 - 1ST MEASUREMENT
HIGH SPOT MARK TIRE AND RIM
3 - WHEEL
4 - VALVE STEM
Fig. 7 Remount Tire 180 Degrees
1 - VALVE STEM
2 - REFERENCE MARK
BR/BETIRES/WHEELS 22 - 3
TIRES/WHEELS (Continued)

from second high spot to first. Break down the tire
and remount it 90 degrees on rim in that direction
(Fig. 8). This procedure will normally reduce the
runout to an acceptable amount, if not replace the
rim.STANDARD PROCEDURE - TIRE AND WHEEL
BALANCE
It is recommended that a two plane service
dynamic balancer be used when a tire and wheel
assembly require balancing. Refer to balancer opera-
tion instructions for proper cone mounting proce-
dures. Typically use front cone mounting method for
steel wheels. For aluminum wheel use back cone
mounting method without cone spring.
NOTE: Static should be used only when a two plane
balancer is not available.
NOTE: Cast aluminum and forged aluminum wheels
require coated balance weights and special align-
ment equipment.
Wheel balancing can be accomplished with either
on or off vehicle equipment. When using on-vehicle
balancing equipment, remove the opposite wheel/tire.
Off-vehicle balancing is recommended.
For static balancing, find the location of the heavy
spot causing the imbalance. Counter balance wheel
directly opposite the heavy spot. Determine weight
required to counter balance the area of imbalance.
Place half of this weight on theinnerrim flange and
the other half on theouterrim flange (Fig. 9).
For dynamic balancing, the balancing equipment is
designed to locate the amount of weight to be applied
to both the inner and outer rim flange (Fig. 10).
Fig. 8 Remount Tire 90 Degrees In Direction of
Arrow
1 - 2ND HIGH SPOT ON TIRE
2 - 1ST HIGH SPOT ON TIRE
22 - 4 TIRES/WHEELSBR/BE
TIRES/WHEELS (Continued)

DIAGNOSIS AND TESTING
WHEEL INSPECTION
Inspect wheels for:
²Excessive run out
²Dents or cracks
²Damaged wheel lug nut holes
²Air Leaks from any area or surface of the rim
NOTE: Do not attempt to repair a wheel by hammer-
ing, heating or welding.
If a wheel is damaged an original equipment
replacement wheel should be used. When obtaining
replacement wheels, they should be equivalent in
load carrying capacity. The diameter, width, offset,
pilot hole and bolt circle of the wheel should be the
same as the original wheel.
WARNING: FAILURE TO USE EQUIVALENT REPLACE-
MENT WHEELS MAY ADVERSELY AFFECT THE
SAFETY AND HANDLING OF THE VEHICLE. USED
WHEELS ARE NOT RECOMMENDED. THE SERVICE
HISTORY OF THE WHEEL MAY HAVE INCLUDED
SEVERE TREATMENT OR VERY HIGH MILEAGE. THE
RIM COULD FAIL WITHOUT WARNING.
STANDARD PROCEDURE - DUAL REAR WHEEL
INSTALLATION
Dual rear wheels use a special heavy duty lug nut
wrench. It is recommended to remove and install dual
rear wheels only when the proper wrench is available.
The wrench is also use to remove wheel center caps for
more information refer to Owner's Manual.
The tires on both wheels must be completely raised
off the ground when tightening the lug nuts. This
will ensure correct wheel centering and maximum
wheel clamping.
A two piece flat face lug nut with right-hand
threads is used for retaining the wheels on the hubs
(Fig. 20).The dual rear wheel lug nuts should be tightened
according to the following procedure:
²Place two drops of oil to the interface of the nut/
washer (Fig. 20) before installing on the wheel stud.
NOTE: Do not use more then two drops of oil on
the nut/washer, since the center caps attach in this
area.
²Tighten the wheel lug nuts in the numbered
sequential pattern until they are snug tight. Then
tighten lug nut to specified torque following same
number sequence, (Refer to 22 - TIRES/WHEELS/
WHEELS - SPECIFICATIONS).
²Tighten lug nuts in same numbered sequence a
second time to the specified torque. This will ensure
that the wheels are thoroughly mated.
²Check lug nut specified torque after 100 miles
(160 kilometers). Also after 500 miles (800 kilome-
ters) of vehicle operation.
NOTE: Wheel lug nuts should be tightened to spec-
ified torque at every maintenance interval thereafter.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Lug Nut
BR2500 (8 Stud Wheel)180 135 Ð
Lug Nut
BR3500 (8 Stud Dual
Wheel)195 145 Ð
Fig. 20 Oil Location
1 - PLACE TWO DROPS OF OIL HERE
BR/BETIRES/WHEELS 22 - 11
WHEELS (Continued)

(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.
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)

²Glove Box- The hinged bin-type glove box in
the passenger side of the instrument panel features a
recessed paddle-operated latch handle. Three molded
hook formations on the lower edge of the glove box
door are engaged with and pivot on three hinge pins
integral to the lower edge of the instrument panel
support structure. The glove box door also serves as
the passenger side knee blocker. A honeycomb struc-
ture between the inner and outer glove box door pan-
els helps to absorb the impact load and distribute it
to the instrument panel structure.
²Steering Column Opening Cover- The steer-
ing column opening cover serves as the driver side
knee blocker. This molded plastic cover has an inte-
gral ribbed plastic liner concealed behind it, for
increased strength and integrity. The steering column
opening cover transfers impact loads to the instru-
ment panel structural support.
²Top Cover- The instrument panel top cover or
base trim is the molded, grained, and color impreg-
nated plastic outer skin of the instrument panel
structural support.
Hard wired circuitry connects the electrical compo-
nents on the instrument panel to each other through
the electrical system of the vehicle. These hard wired
circuits are integral to several wire harnesses, which
are routed throughout the vehicle and retained by
many different methods. These circuits may be con-
nected to each other, to the vehicle electrical system
and to the instrument panel components through the
use of a combination of soldered splices, splice block
connectors and many different types of wire harness
terminal connectors and insulators. Refer to the
appropriate wiring information. The wiring informa-
tion includes complete circuit diagrams, proper wire
and connector repair procedures, further details on
wire harness routing and retention, as well as pin-
out and location views for the various wire harness
connectors, splices, and grounds.
OPERATION
The instrument panel serves as the command cen-
ter of the vehicle, which necessarily makes it a very
complex unit. The instrument panel is designed to
house the controls and monitors for standard and
optional powertrains, climate control systems, audio
systems, safety systems, and many other comfort or
convenience items. When the components of the
instrument panel structural support are properly
assembled and secured in the vehicle they provide
superior instrument panel stiffness and integrity to
help reduce buzzes, squeaks, and rattles. This type of
construction also provides improved energy absorp-
tion which, in conjunction with the dual airbags and
seat belts, helps to improve occupant protection.The instrument panel is also designed so that all of
the various controls can be safely reached and the
monitors can be easily viewed by the vehicle operator
when driving, while still allowing relative ease of
access to each of these items for service. Modular
instrument panel construction allows all of the
gauges and controls to be serviced from the front of
the panel. In addition, most of the instrument panel
electrical components can be accessed without com-
plete instrument panel removal. However, if neces-
sary, the instrument panel can be removed from the
vehicle as an assembly.
The steering column opening cover with its inte-
gral knee blocker located on the driver side of the
instrument panel works in conjunction with the air-
bag system in a frontal vehicle impact to keep the
driver properly positioned for an airbag deployment.
In addition, removal of this component provides
access to the steering column mounts, the steering
column wiring, the Junction Block (JB) (removal of a
snap-fit fuse access panel on the left end of the
instrument panel allows access to the fuses and cir-
cuit breakers), the Central Timer Module (CTM), the
Infinity speaker filter choke and relay unit, much of
the instrument panel wiring, and the gear selector
indicator cable (automatic transmission).
In a frontal collision, the glove box door on the pas-
senger side of the instrument panel provides the
same function for the front seat passenger as the
knee blocker does for the driver. The glove box door
also incorporates a recessed latch handle. Removal of
the glove box provides access to the passenger airbag,
the glove box lamp and switch, the radio antenna
coaxial cable, the heating and air conditioning vac-
uum harness connector, and additional instrument
panel wiring.
Removal of the instrument panel cluster bezel
allows access to the headlamp switch, instrument
cluster, radio, passenger airbag on-off switch, heated
seat switches (if equipped), and the heating and air
conditioning control. Removal of the instrument clus-
ter allows access to the cluster illumination and indi-
cator bulbs, and more of the instrument panel
wiring. Complete instrument panel removal is
required for service of most components internal to
the heating and air conditioning system housing,
including the heater core and the evaporator.
See the owner's manual in the vehicle glove box for
more information on the features, use and operation
of all of the components and systems mounted on or
in the instrument panel.
23 - 106 INSTRUMENT PANEL SYSTEMBR/BE
INSTRUMENT PANEL SYSTEM (Continued)

ASH RECEIVER
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Open the instrument panel ash receiver.
(3) From the open position, close the ash receiver
slightly and pull it straight back far enough to disen-
gage it from the pivot pins in the lower instrument
panel.
(4) Remove the three screws that secure the ash
receiver flame shield to the lower instrument panel
(Fig. 1).
(5) Pull the ash receiver flame shield out from the
instrument panel far enough to disengage the two
retaining tabs on the top of the shield from the
mounting holes in the instrument panel.(6) Lower the flame shield from the instrument
panel far enough to access the ash receiver lamp and
hood.
(7) Squeeze the ash receiver lamp and hood
bracket to disengage the unit from the mounting hole
in the flame shield.
(8) Remove the ash receiver flame shield from the
instrument panel.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Position the ash receiver flame shield to the
instrument panel (Fig. 1).
(2) Squeeze the ash receiver lamp and hood
bracket and engage the unit to the mounting hole in
the flame shield.
(3) Insert the two retaining tabs on the top of the
ash receiver flame shield into the mounting holes in
the instrument panel, then push the shield forward
to engage the tabs with the instrument panel.
(4) Install and tighten the three screws that secure
the ash receiver flame shield to the instrument
panel. Tighten the screws to 2 N´m (20 in. lbs.).
(5) Align the pivot receptacles on each side of the
ash receiver with the pivot pins in the lower instru-
ment panel.
(6) Push the ash receiver forward onto the pivot
pins in the instrument panel until the open ash
receiver snaps into place.
(7) Reconnect the battery negative cable.
Fig. 1 Instrument Panel Ash Receiver Remove/
Install
1 - SCREW
2 - ASH RECEIVER
3 - FLAME SHIELD
BR/BEINSTRUMENT PANEL SYSTEM 23 - 107

CLUSTER BEZEL
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) If the vehicle is equipped with an automatic
transmission, turn the ignition switch to the Off posi-
tion (not Lock), set the parking brake, and place the
automatic transmission gear selector lever in the
Low position.
(3) If the vehicle is so equipped, set the tilt steer-
ing column in its lowest position.
(4) Using a trim stick or another suitable wide
flat-bladed tool, gently pry around the perimeter of
the cluster bezel to disengage the snap clips from
their receptacles in the instrument panel (Fig. 2).
(5) Remove the cluster bezel from the instrument
panel.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Position the cluster bezel to the instrument
panel (Fig. 2).
(2) Align the snap clips on the cluster bezel with
the receptacles in the instrument panel.
(3) Press firmly on the cluster bezel over each of
the snap clip locations until each of the snap clips is
fully engaged in its receptacle.
(4) Reconnect the battery negative cable.
CUBBY BIN
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cluster bezel from the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - REMOVAL).
(3) Remove the three screws that secure the cubby
bin to the instrument panel (Fig. 3).
(4) Remove the cubby bin from the instrument
panel.
Fig. 2 Cluster Bezel Remove/Install
1 - CLUSTER BEZEL
23 - 108 INSTRUMENT PANEL SYSTEMBR/BE

INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Position the cubby bin to the instrument panel
(Fig. 3).
(2) Install and tighten the three screws that secure
the cubby bin to the instrument panel. Tighten the
screws to 2 N´m (20 in. lbs.).
(3) Install the cluster bezel onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - INSTALLATION).
(4) Reconnect the battery negative cable.
CUP HOLDER
REMOVAL
Vehicles equipped with an automatic transmission
have a lighted fold-down cup holder installed on the
instrument panel just inboard of the glove box. Vehi-
cles equipped with a manual transmission have a
lighted storage bin installed on the instrument panel
in place of the fold-down cup holder.WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cluster bezel from the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - REMOVAL).
(3) Unlatch and fold the cup holder down from the
instrument panel to its open position.
(4) Remove the six screws that secure the cup
holder to the instrument panel (Fig. 4).
(5) Pull the cup holder away from the instrument
panel far enough to access the illumination lamp and
hood unit.
(6) Disengage the illumination lamp and hood
retainer clip from the back of the instrument panel
cup holder unit.
(7) Remove the cup holder unit from the instru-
ment panel.
Fig. 3 Instrument Panel Cubby Bin Remove/Install
1 - SCREW (3)
2 - CUBBY BIN
Fig. 4 Instrument Panel Cup Holder
1 - SCREW
2 - INSTRUMENT PANEL
3 - CUP HOLDER
BR/BEINSTRUMENT PANEL SYSTEM 23 - 109
CUBBY BIN (Continued)