2002 DODGE RAM power

INSTALLATION
(1) Position door latch/lock in door.
(2) Install screws attaching door latch to door end
panel. Tighten screws to 10 N´m (89 in. lbs.) torque.
(3) Connect power door lock/latch connector, if
equipped.(4) Engage clips attaching lock and latch rods to
door latch.
(5) Install the door waterdam (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION).
ADJUSTMENTS
ADJUSTMENT - FRONT DOOR LATCH
(1) Insert a 4-mm (5/32-in) hex-wrench through
the elongated hole in the door end frame near the
latch striker opening (Fig. 12).
(2) Loosen torx head screw on the side of the latch
linkage.
(3) Lift upward on outside door handle and release
it.
(4) Tighten torx head screw on latch.
(5) Verify latch operation.
LATCH STRIKER
REMOVAL
(1) Mark outline of striker base on B-pillar with a
grease pencil or equivalent to aid installation.
(2) Remove screws attaching striker to B-pillar
(Fig. 13).
(3) Separate striker from vehicle.
INSTALLATION
(1) Position striker on vehicle and align with refer-
ence marks.
(2) Install screws attaching striker to B-pillar.
Tighten screws to 28 N´m (21 ft. lbs.) torque. (Fig.
13) .
Fig. 10 Power Lock/Latch Connector
1 - INSIDE HANDLE - TO - LATCH ROD
2 - LOCK KNOB - TO - LATCH ROD
3 - POWER LATCH CONNECTOR
4 - LOCK CYLINDER - TO - LATCH ROD
5 - OUTSIDE HANDLE - TO - LATCH ROD
Fig. 11 Front Door Latch
1 - OUTSIDE HANDLE - TO - LATCH ROD
2-LATCH
3 - INSIDE HANDLE - TO - LATCH ROD
4 - LOCK CYLINDER - TO - LATCH ROD
5 - LOCK KNOB - TO - LATCH ROD
Fig. 12 DOOR LATCH ADJUSTMENT
1 - HEX WRENCH
BR/BEDOOR - FRONT 23 - 73
LATCH (Continued)

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/TRIM PANEL - INSTALLATION)
TRIM PANEL
REMOVAL
(1) Roll window down.
(2) Remove window crank (Fig. 16), if equipped.
(3) Remove screw attaching trim panel to outside
mirror frame.
(4) Remove screws attaching pull cup to door (Fig.
17).
(5) Using a trim panel removal tool, disengage
clips around perimeter of trim panel, attaching trim
panel to door.
(6) While holding bottom of trim panel away from
door, simultaneously lift upward and inboard.
(7) Disengage power mirror switch connector, if
equipped.
(8) Disengage power window/lock switch connec-
tors from switch panel, if equipped (Fig. 18).
(9) Separate trim panel from door.
INSTALLATION
NOTE: When replacing door trim panel, installer
must replace the X-mas tree style pin 6506878aa.
(1) Engage power mirror switch connector, if
equipped.
(2) Engage power window/lock switch connectors to
switch panel, if equipped.
Fig. 16 Window CrankÐTypical
1 - WINDOW CRANK REMOVAL TOOL
2 - WINDOW CRANK
Fig. 17 Door Trim Panel
1 - SCREW
2 - SCREW
3 - TRIM PANEL
4 - DOOR LOCK BUTTON
5 - POWER WINDOW HARNESS
6 - POWER MIRROR HARNESS
7 - POWER MIRROR
8 - POWER MIRROR CONTROL
Fig. 18 Power Window/Lock Switch Panel
1 - ELECTRICAL CONNECTOR
2 - POWER WINDOW/LOCK SWITCH PANEL
3 - WIRE HARNESS
BR/BEDOOR - FRONT 23 - 75
SIDE VIEW MIRROR FLAG (Continued)

(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 outside
mirror frame.
(7) Install window crank, if equipped.
WATERDAM
REMOVAL
(1) Remove door trim panel (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL).
(2) Peel waterdam away from adhesive around
perimeter of inner door panel (Fig. 19).
INSTALLATION
(1) Position and align water dam with adhesive
around perimeter of inner door panel.
(2) Press water dam onto inner door panel to
secure.
(3) Install door trim panel (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - INSTALLATION).
WINDOW REGULATOR
REMOVAL
(1) Remove the door waterdam (Refer to 23 -
BODY/DOOR - FRONT/WATERDAM - REMOVAL).
(2) Remove nuts attaching door glass to window
regulator.(3) Remove glass from door or move glass to full
up position and secure glass to door with tape.
(4) Disengage power window motor wire connector
from door harness, if equipped.
(5) Remove bolts attaching window regulator to
inner door panel.
(6) Separate window regulator from door panel
(Fig. 20).
(7) Extract window regulator through access hole
in inner door panel.
INSTALLATION
(1) Position window regulator in door through
access hole.
(2) Install bolts attaching window regulator to
inner door panel.
(3) Engage power window motor wire connector to
door harness, if equipped.
(4) Install glass in lift plate.
(5) Install the door waterdam (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION).
Fig. 19 Door Water Dam
1 - WATER DAM
2 - DOOR
Fig. 20 Door Glass Window Regulator
1 - DOOR ASSEMBLY
2 - WINDOW REGULATOR ASSEMBLY
3 - DOOR GLASS ASSEMBLY
4 - WINDOW REGULATOR
23 - 76 DOOR - FRONTBR/BE
TRIM PANEL (Continued)

LEFT FRONT FENDER
REMOVAL
(1) Remove front bumper (Refer to 13 - FRAMES
& BUMPERS/BUMPERS/FRONT BUMPER -
REMOVAL).
(2) Remove air cleaner from wheelhouse (DIESEL
ONLY).
(3) Remove coolant overflow bottle (V-10 ONLY).
(4) Remove battery tray (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/TRAY - REMOVAL).
(5) Remove screws attaching power distribution
center to left wheelhouse (Fig. 14).
(6) Disengage wire harness tie-downs from wheel-
house.
(7) Disconnect wiring harness to headlamp connec-
tor.
(8) Disconnect wiring harness to airbag sensor and
remove airbag sensor from wheelhouse.
(9) Remove bolts attaching anti-lock brake control-
ler to wheelhouse (Fig. 14), if equipped.
(10) Disengage windshield washer tubing tie-
downs from wheelhouse (Fig. 14).
(11) Remove bolts attaching front fender to cowl
reinforcement (Fig. 15).
(12) Remove bolts attaching front fender to radia-
tor closure panel (Fig. 16).
(13) Remove bolts attaching bottom of front fender
to rocker panel lower flange.
(14) Open left door.
(15) Remove bolt attaching front fender to hinge
pillar mounting bracket.
(16) Remove bolts attaching top of fender to radia-
tor closure panel.
(17) Separate left front fender from vehicle.
INSTALLATION
(1) Position left front fender on vehicle.
(2) Install bolts attaching top of fender to radiator
closure panel.
(3) Install bolt attaching front fender to hinge pil-
lar mounting bracket.
(4) Install bolts attaching bottom of front fender to
rocker panel lower flange.
(5) Install bolts attaching front fender to radiator
closure panel.
(6) Install bolts attaching front fender to cowl rein-
forcement.
(7) Secure windshield washer tubing tie-downs to
wheelhouse.
(8) Install anti-lock brake controller to wheel-
house, if equipped.
(9) Install airbag sensor to wheelhouse and con-
nect wiring harness to airbag sensor.
(10) Connect wiring harness to headlamp connec-
tor.
Fig. 14 Left Front Fender Access Components
1 - ABS CONTROLLER
2 - POWER DISTRIBUTION CENTER
3 - BATTERY
4 - FENDER
5 - WINDSHIELD WASHER RESERVOIR
6 - BRAKE MASTER CYLINDER
Fig. 15 Fender to Cowl ReinforcementÐTypical
1 - BOLT
2 - FENDER
3 - FENDERÐTOÐCOWL REINFORCEMENT
BR/BEEXTERIOR 23 - 93

(11) Secure wire harness tie-downs to wheelhouse.
(12) Install power distribution center to wheel-
house.
(13) Install battery tray (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/TRAY - INSTALLATION).
(14) Install coolant overflow bottle (V-10 ONLY).
(15) Install air cleaner (DIESEL ONLY).
(16) Install front bumper (Refer to 13 - FRAMES
& BUMPERS/BUMPERS/FRONT BUMPER -
INSTALLATION).
RIGHT FRONT FENDER
REMOVAL
(1) Remove front bumper (Refer to 13 - FRAMES
& BUMPERS/BUMPERS/FRONT BUMPER -
REMOVAL).
(2) Disconnect and isolate battery negative cable.
(3) Remove auxiliary battery and tray on right
side, if equipped.
(4) Disengage wire harness tie-downs from wheel-
house.
(5) Disconnect wiring harness to headlamp connec-
tor.
(6) Disconnect wiring harness to airbag sensor and
remove airbag sensor from wheelhouse.
(7) Remove front wheelhouse liner (Fig. 13) (Refer
to 23 - BODY/EXTERIOR/FRONT END SPLASH
SHIELDS - REMOVAL).
(8) Disengage air conditioning tubing from inner
fender clips.
(9) Remove bolts attaching front fender to cowl
reinforcement (Fig. 15).
(10) Remove bolts attaching front fender to radia-
tor closure panel.(11) Remove bolts attaching bottom of front fender
to rocker panel lower flange (Fig. 17).
(12) Open right door.
(13) Remove bolt attaching front fender to hinge
pillar mounting bracket (Fig. 17).
(14) Remove bolts attaching top of fender to radia-
tor closure panel (Fig. 17).
(15) Separate right front fender from vehicle.
INSTALLATION
(1) Position fender on vehicle.
(2) Install bolts attaching top of fender to radiator
closure panel.
(3) Install bolt attaching front fender to hinge pil-
lar mounting bracket.
(4) Install bolts attaching bottom of front fender to
rocker panel lower flange.
(5) Install bolts attaching front fender to radiator
closure panel.
(6) Install bolts attaching front fender to cowl rein-
forcement.
(7) Secure air conditioning tubing to inner fender
clips.
(8) Install front wheelhouse liner (Refer to 23 -
BODY/EXTERIOR/FRONT END SPLASH SHIELDS
- INSTALLATION).
(9) Install airbag sensor and connect wiring har-
ness to airbag sensor.
(10) Connect wiring harness to headlamp connec-
tor.
(11) Secure wire harness tie-downs to wheelhouse.
(12) Install auxiliary battery tray and battery on
right side, if equipped.
(13) Connect battery negative cable.
(14) Install front bumper (Refer to 13 - FRAMES
& BUMPERS/BUMPERS/FRONT BUMPER -
INSTALLATION).
Fig. 16 Left Fender to Radiator Closure Panel
Fasteners
1 - LEFT FENDER
2 - RADIATOR CLOSURE PANEL
Fig. 17 Right Front Fender
1 - RADIATOR CLOSURE PANEL
2 - RIGHT FENDER
23 - 94 EXTERIORBR/BE
LEFT FRONT FENDER (Continued)

CARGO BOX
REMOVAL
CAUTION: The bolts attaching the cargo box to the
frame are specially coated to provide a locking action.
These bolts are not reusable and must be replaced
each time the cargo box is removed or replaced.
(1) Open fuel fill door.
(2) Remove screws attaching fuel fill neck adaptor
to cargo box side wall.
(3) Separate fuel fill neck from cargo box.
(4) Disengage tail lamp wire connector from main
body harness at left rear frame rail.
(5) Remove bolts attaching cargo box to frame rails
(Fig. 22).
(6) Using a suitable lifting device, separate cargo
box from vehicle.
INSTALLATION
(1) Using a suitable lifting device, position cargo
box on vehicle.
(2) Installnewbolts attaching cargo box to frame
rails. Tighten bolts to 54 N´m (40 ft. lbs.) torque.
(3) Engage tail lamp wire connector to main body
harness at left rear frame rail.
(4) Install fuel fill neck.
SIDE VIEW MIRROR
REMOVAL
(1) Remove door trim panel (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL).
(2) Remove mirror flag door seal (Fig. 23).
(3) Disengage power mirror wire connector from
door harness, if equipped (Fig. 24).
(4) Remove nuts attaching sideview mirror to door
frame (Fig. 25).
(5) Separate harness grommet form door frame, if
equipped.
(6) Separate sideview mirror from vehicle.
Fig. 22 Cargo Box
1 - CARGO BOX
2 - FRAME
3 - BOLT
4 - AXLE
5 - BOLT
Fig. 23 Mirror Flag Door Seal
1 - MIRROR
2 - MIRROR FLAG SEAL
Fig. 24 Sideview MirrorÐPower
1 - POWER MIRROR
2 - NUT
3 - CONNECTOR
BR/BEEXTERIOR 23 - 97

INSTALLATION
(1) Position sideview mirror on door.
(2) Install harness grommet in door frame, if
equipped.
(3) Install nuts attaching sideview mirror to door
(Fig. 25).
(4) Engage power mirror wire connector to har-
ness, if equipped (Fig. 24).
(5) Install mirror flag door seal (Fig. 23).
(6) Install door trim panel (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - INSTALLATION).
SIDE VIEW MIRROR - LOW
MOUNTED
REMOVAL
(1) Remove bolts attaching lower support legs to
outer door panel.
(2) Remove bolts attaching upper support arms to
outer door panel (Fig. 26).
(3) Separate mirror from door.
INSTALLATION
(1) Position mirror on door.
(2) Place insulation washers between support
frame and door panel
(3) Install bolts attaching upper support arms to
outer door panel.
(4) Install bolts attaching lower support legs to
outer door panel.
SIDE VIEW MIRROR GLASS
REMOVAL
WARNING: ALWAYS WEAR EYE AND HAND PRO-
TECTION WHEN SERVICING THE MIRROR ASSEM-
BLY. FAILURE TO OBSERVE THESE WARNINGS
MAY RESULT IN PERSONAL INJURY FROM BRO-
KEN GLASS.
(1) Carefully pull/pry the broken glass holder from
the mirror assembly.
(2) Disconnect the heated mirror electrical connec-
tors from the terminals on the mirror glass holder, if
equipped.
INSTALLATION
CAUTION: It is important to make sure the motor is
square to the glass holder (attaching fingers) prior
to glass holder attachment, otherwise the glass
holder could be installed incorrectly causing poor
retention and possible repeat failure.
(1) Position the new mirror glass holder to the
mirror assembly.
NOTE: Position the mirror glass holder so that the
moisture drain hole on the mirror glass holder
assembly is facing downward.
(2) Align the mirror glass holder's attaching fin-
gers to the mirror motor housing.
Fig. 25 Sideview Mirror
1 - MIRROR
2 - NUT
3 - DOOR
Fig. 26 Low Mounted Side View Mirror
1 - FLAG COVER
2 - MIRROR
3 - WASHER
4 - NUTSERT
5 - WASHER
6 - NUTSERT
23 - 98 EXTERIORBR/BE
SIDE VIEW MIRROR (Continued)

INSTRUMENT PANEL SYSTEM
TABLE OF CONTENTS
page page
INSTRUMENT PANEL SYSTEM
DESCRIPTION........................105
OPERATION..........................106
ASH RECEIVER
REMOVAL............................107
INSTALLATION........................107
CLUSTER BEZEL
REMOVAL............................108
INSTALLATION........................108
CUBBY BIN
REMOVAL............................108
INSTALLATION........................109
CUP HOLDER
REMOVAL............................109
INSTALLATION........................110
GLOVE BOX
REMOVAL
REMOVAL..........................110
DISASSEMBLY - GLOVE BOX...........110
ASSEMBLY - GLOVE BOX................111INSTALLATION........................111
GLOVE BOX LATCH STRIKER
REMOVAL............................111
INSTALLATION........................112
GLOVE BOX OPENING UPPER TRIM
REMOVAL............................112
INSTALLATION........................112
INSTRUMENT PANEL TOP COVER
REMOVAL............................113
INSTALLATION........................113
STEERING COLUMN OPENING COVER
REMOVAL............................113
INSTALLATION........................114
STORAGE BIN
REMOVAL............................114
INSTALLATION........................114
INSTRUMENT PANEL ASSEMBLY
REMOVAL............................115
INSTALLATION........................117
INSTRUMENT PANEL SYSTEM
DESCRIPTION
The instrument panel is located at the front of the
passenger compartment. This instrument panel is
molded from a blend of various plastics that are
mechanically attached to the vehicle. Colors are
molded into the plastic components to minimize
appearance degradation from scratches or abrasions.
The panel components are internally ribbed and riv-
eted to steel reinforcements for additional structural
integrity and dimensional stability. The instrument
panel surface components are designed to deform
upon impact without breaking. This type of construc-
tion provides improved energy absorption which, in
conjunction with the dual airbags and seat belts,
helps to improve occupant protection.
The top of the instrument panel is secured to the
top of the dash panel near the base of the windshield
using screws. An end bracket integral to each end of
the instrument panel structure is secured to each
cowl side inner panel with a screw. A stamped metal
bracket supports the center of the instrument panel
by securing it to the top of the floor panel transmis-
sion tunnel below the instrument panel with screws.
The instrument cluster, radio, heater-air conditioner
control, passenger airbag, glove box, electrical junc-tion block, Central Timer Module (CTM), accessory
switches, ash receiver, cigar lighter, accessory power
outlet, park brake release handle, inside hood release
handle, as well as numerous other components are
secured to and supported by this unit.
The instrument panel for this vehicle includes the
following major features:
²Cluster Bezel- This molded plastic bezel is
secured with snap clips to the instrument panel sup-
porting structure. It trims out the edges of the head-
lamp switch, instrument cluster, radio, heater-air
conditioner controls, passenger airbag on-off switch,
and the heated seat switches on vehicles so equipped.
On vehicles without the heated seat option, a small
storage cubby bin is provided in the cluster bezel.
This bezel also incorporates three completely adjust-
able panel outlets for the climate control system, and
fills the opening between the instrument cluster and
the top of the steering column where it passes
through the instrument panel.
²Cup Holder/Storage Bin- Vehicles equipped
with an automatic transmission feature a latching
fold-down, adjustable cup holder located on the lower
instrument panel between the glove box and the ash
receiver. Vehicles equipped with a manual transmis-
sion have a lighted storage bin on the instrument
panel in place of the cup holder.
BR/BEINSTRUMENT PANEL SYSTEM 23 - 105