2002 DODGE RAM mirror

INTERIOR
TABLE OF CONTENTS
page page
INTERIOR
CAUTION............................118
A-PILLAR GRAB HANDLE
REMOVAL............................119
INSTALLATION........................119
A-PILLAR TRIM
REMOVAL............................119
INSTALLATION........................119
COWL TRIM COVER
REMOVAL............................119
INSTALLATION........................120
B-PILLAR TRIM
REMOVAL............................120
INSTALLATION........................120
REAR CLOSURE PANEL TRIM
REMOVAL............................120
INSTALLATION........................121
REAR FLOOR STOWAGE TRAY
REMOVAL............................121
INSTALLATION........................121
DOOR SILL TRIM
REMOVAL............................121
INSTALLATION........................121
SHIFT BOOT - MANUAL TRANSMISSION
REMOVAL............................122
INSTALLATION........................122
4WD FLOOR SHIFT BOOT
REMOVAL............................122
INSTALLATION........................122
CENTER CONSOLE
REMOVAL............................122INSTALLATION........................122
CARPETS AND FLOOR MATS
REMOVAL............................123
INSTALLATION........................123
ASSIST HANDLE
REMOVAL............................124
INSTALLATION........................124
COAT HOOK
REMOVAL............................124
INSTALLATION........................125
HEADLINER
REMOVAL............................125
INSTALLATION........................125
BODY VENT
REMOVAL............................126
INSTALLATION........................126
REAR VIEW MIRROR
REMOVAL............................126
INSTALLATION
INSTALLATION......................126
INSTALLATION - REARVIEW MIRROR
SUPPORT BRACKET..................126
SUN VISOR
REMOVAL............................127
INSTALLATION........................127
QUARTER TRIM PANEL
REMOVAL............................128
INSTALLATION........................128
C-PILLAR TRIM
REMOVAL............................128
INSTALLATION........................128
INTERIOR
CAUTION
CAUTION: Do not attempt to remove interior trim
panels/moldings without first removing the neces-sary adjacent panels. To avoid damaging the pan-
els, ensure that all the screws and clips are
removed before attempting to remove an interior
trim panel/molding. Trim panels are somewhat flex-
ible but can be damaged if handled improperly.
23 - 118 INTERIORBR/BE

BODY VENT
REMOVAL
(1) Open door.
(2) Pull outward at top of vent to disengage clips
attaching vent to door jamb (Fig. 16).
(3) Separate vent from door jamb.
INSTALLATION
(1) Position vent from in jamb.
(2) Press vent inward to engage clips.
REAR VIEW MIRROR
REMOVAL
(1) If equipped, disconnect mirror harness wire
connector (Fig. 17).
(2) Loosen the mirror base setscrew (Fig. 18).
(3) Slide the mirror base upward and off the
bracket.
INSTALLATION
INSTALLATION
(1) Position the mirror base at the bracket and
slide it downward onto the support bracket.
(2) Tighten the setscrew 1 N´m (15 in. lbs.) torque.(3) If equipped, connect mirror harness wire con-
nector.
INSTALLATION - REARVIEW MIRROR
SUPPORT BRACKET
(1) Mark the position for the mirror bracket on the
outside of the windshield glass with a wax pencil.
(2) Clean the bracket contact area on the glass.
Use a mild powdered cleanser on a cloth saturated
with isopropyl (rubbing) alcohol. Finally, clean the
glass with a paper towel dampened with alcohol.
Fig. 16 Body Vent
1 - BÐPILLAR
2 - DOOR STRIKER
3 - BODY VENT
Fig. 17 Rearview Mirror Connector
1 - CONNECTOR
2 - MIRROR
3 - SCREW
Fig. 18 Rearview Mirror
1 - REARVIEW MIRROR
2 - WINDSHIELD GLASS
3 - SUPPORT BRACKET
4 - SCREW
23 - 126 INTERIORBR/BE

(3) Sand the surface on the support bracket with
fine grit-sandpaper. Wipe the bracket surface clean
with a paper towel.
(4) Apply accelerator to the surface on the bracket
according to the following instructions:
(a) Crush the vial to saturate the felt applicator.
(b) Remove the paper sleeve.
(c) Apply accelerator to the contact surface on
the bracket.
(d) Allow the accelerator to dry for five minutes.
(e) Do not touch the bracket contact surface
after the accelerator has been applied.
(5) Apply adhesive accelerator to the bracket con-
tact surface on the windshield glass. Allow the accel-
erator to dry for one minute. Do not touch the glass
contact surface after the accelerator has been
applied.
(6) Install the bracket according to the following
instructions:
(a) Apply one drop of adhesive at the center of
the bracket contact-surface on the windshield
glass.
(b) Apply an even coat of adhesive to the contact
surface on the bracket.
(c) Align the bracket with the marked position
on the windshield glass.
(d) Press and hold the bracket in place for at
least one minute.
NOTE: Verify that the mirror support bracket is cor-
rectly aligned, because the adhesive will cure rap-
idly.
(7) Allow the adhesive to cure for 8-10 minutes.
Remove any excess adhesive with an alcohol-damp-
ened cloth.
(8) Allow the adhesive to cure for an additional
8-10 minutes before installing the mirror.SUN VISOR
REMOVAL
(1) Remove screws attaching sunvisor to roof (Fig.
19).
(2) If equipped, disengage lighted vanity mirror
connector.
(3) Separate sunvisor from roof.
(4) Remove screw attaching sun visor hook to roof.
(5) Separate sunvisor hook from roof.
INSTALLATION
(1) Position sunvisor hook on roof.
(2) Install screw attaching sunvisor hook to roof.
(3) Position sunvisor on roof.
(4) If equipped, engage lighted vanity mirror con-
nector.
(5) Install screws attaching sunvisor to roof (Fig.
19).
Fig. 19 Sunvisor
1 - BODY
2 - CLIP
3 - SUNVISOR
BR/BEINTERIOR 23 - 127
REAR VIEW MIRROR (Continued)

(7) Latch vent glass panels
(8) Insert upper ends of vent glass panels into
upper run channel.
NOTE: Aggressive clamp pressure is required to
lock lower run channel into place.
(9) Position lower run channel on backlite frame
lower rail and roll lower run channel onto backlite
frame rail.
(10) Fill the ends of the run channel with Mopar
GEN II Silicone Rubber Adhesive Sealant or equiva-
lent.
(11) Verify window and latch/keeper operation.(12) Install rear closure panel trim. (Refer to 23 -
BODY/INTERIOR/REAR CLOSURE PANEL TRIM -
INSTALLATION).
WINDSHIELD
DESCRIPTION
The windshield is attached to the window frame
with urethane adhesive. The urethane adhesive is
applied cold and seals the surface area between the
window opening and the glass. The primer adheres
the urethane adhesive to the windshield.
It is difficult to salvage a windshield during the
removal operation. The windshield is part of the struc-
tural support for the roof. The urethane bonding used to
secure the windshield to the fence is difficult to cut or
clean from any surface. If the moldings are set in ure-
thane, it would also be unlikely they could be salvaged.
Before removing the windshield, check the availability
of the windshield and moldings from the parts supplier.
REMOVAL
(1)Remove inside rear view mirror. (Refer to 23 -
BODY/INTERIOR/REAR VIEW MIRROR - REMOVAL).
(2) Remove cowl grill. (Refer to 23 - BODY/EXTE-
RIOR/COWL GRILLE - REMOVAL).
(3) With doors open, remove windshield molding
(Fig. 7). Pull outward on molding beginning at the
bottom of A-pillars using pliers.
(4) Cut urethane bonding from around windshield
using a suitable sharp cold knife (C-4849). A pneu-
matic cutting device can be used but is not recom-
mended (Fig. 8).
(5) Separate windshield from vehicle.
Fig. 4 Lower Run Channel
1 - SLIDING BACKLITE
2 - LOWER RUN CHANNEL
3 - CAB BACK PANEL
Fig. 5 Lower Run Channel Removal
1 - LATCH/KEEPER
2 - BACK LITE
3 - LOWER RUN CHANNEL
4 - SLIDE OUTWARD
Fig. 6 Glass Panel Installation
1 - INSERT A 0.5mm DIA. BEAD OF PUMPABLE GRADE BUTYL
ALONG THE ENTIRE LENGTH OF THE LOWER RUN WINDOW
CHANNEL
BR/BESTATIONARY GLASS 23 - 147
BACKLITE VENT GLASS (Continued)

(14) Clean excess urethane from exterior with
MOPARtSuper Clean or equivalent.
(15) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)
masking tape spaced 250 mm (10 in.) apart to hold
molding in place until urethane cures.
(16) Install cowl grill. (Refer to 23 - BODY/EXTE-
RIOR/COWL GRILLE - INSTALLATION).
(17) Install rear view mirror support bracket.
(Refer to 23 - BODY/INTERIOR/REAR VIEW MIR-
ROR - INSTALLATION).
(18)
Install rear view mirror. (Refer to 23 - BODY/IN-
TERIOR/REAR VIEW MIRROR - INSTALLATION).
(19) After urethane has cured, remove tape strips
and water test windshield to verify repair.
Fig. 9 Center Windshield and Mark at Support
1 - WINDSHIELD
2 - INDEX MARKS
3 - SUPPORT SPACERS
Fig. 10 Work Surface Set up
1 - WINDSHIELD AND MOULDINGS
2 - URETHANE BEAD AROUND GLASS 7mm (.3 in.) FROM
EDGE
3 - BLOCKS
Fig. 11 Position Urethane Compression Spacer
1 - URETHANE COMPRESSION SPACER
2 - FENCE
Fig. 12 Applicator Tip
1 - APPLICATOR TIP
Fig. 13 Lower Windshield Into Position
1 - COMPRESSION SPACER
2 - WINDSHIELD
3 - ADJUSTABLE SUPPORT SPACERS
BR/BESTATIONARY GLASS 23 - 149
WINDSHIELD (Continued)

INSTALLATION
(1) Press door glass run weatherstrip into channel
around window opening (Fig. 4).
(2) Install inner door belt weatherstrip. (Refer to
23 - BODY/WEATHERSTRIP/SEALS/FDR INNER
BELT WEATHERSTRIP - INSTALLATION)
FRONT DOOR INNER BELT
WEATHERSTRIP
REMOVAL
(1) Remove door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL)
(2) Lift inner door belt weatherstrip upward (Fig.
5).
(3) Separate inner door belt weatherstrip from
door.
INSTALLATION
(1) Position inner door belt weatherstrip on door.
(2) Press inner door belt weatherstrip downward
to seat.
(3) Install door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - INSTALLATION)
FRONT DOOR OUTER BELT
WEATHERSTRIP
REMOVAL
(1) Roll door glass down.
(2) Remove mirror. (Refer to 23 - BODY/EXTERI-
OR/SIDE VIEW MIRROR - REMOVAL)
(3) Using a hook tool inserted into the end of the
belt weatherstrip, lift upward.(4) Separate outer door belt weatherstrip from
door (Fig. 6).
INSTALLATION
(1) Position outer door belt weatherstrip on door.
(2) Press weatherstrip downward to seat.
(3) Install mirror. (Refer to 23 - BODY/EXTERI-
OR/SIDE VIEW MIRROR - INSTALLATION)
FRONT DOOR UPPER CORNER
SEAL
REMOVAL
(1) Remove the push-in fasteners attaching the
upper corner seal to the front door (Fig. 7).
(2) Separate the upper corner seal from the door.Fig. 5 Inner Door Belt Weatherstrip
1 - DOOR
2 - INNER BELTLINE WEATHERSEAL
Fig. 6 Outer Door Belt Weatherstrip
1 - OUTER BELTLINE WATHERSTRIP
2 - DOOR
Fig. 7 Upper Corner SealÐQuad Cab
1 - UPPER CORNER SEAL
2 - PUSHÐIN FASTENER
BR/BEWEATHERSTRIP/SEALS 23 - 153
FRONT DOOR GLASS RUN WEATHERSTRIP (Continued)

(1) The relay common feed terminal cavity (30) is
connected to fused battery feed. There should be bat-
tery voltage at the cavity for relay terminal 30 at all
times. If OK, go to Step 2. If not OK, repair the open
circuit to the fuse in the PDC as required.
(2) The relay normally closed terminal (87A) is not
used in this application. Go to Step 3.
(3) The relay normally open terminal cavity (87) is
connected to the compressor clutch coil. There should
be continuity between this cavity and the A/C com-
pressor clutch relay output circuit cavity of the com-
pressor clutch coil wire harness connector. If OK, go
to Step 4. If not OK, repair the open circuit as
required.
(4) The relay coil battery terminal (86) is con-
nected to the fused ignition switch output (run/start)
circuit. There should be battery voltage at the cavity
for relay terminal 86 with the ignition switch in the
On position. If OK, go to Step 5. If not OK, repair the
open circuit to the fuse in the junction block as
required.
(5) The coil ground terminal cavity (85) is switched
to ground through the Powertrain Control Module
(PCM). There should be continuity between this cav-
ity and the A/C compressor clutch relay control cir-
cuit cavity of the PCM wire harness connector C
(gray) at all times. If not OK, repair the open circuit
as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cover from the Power Distribution
Center (PDC) (Fig. 17).
(3) Refer to the label on the PDC for compressor
clutch relay identification and location.(4) Unplug the compressor clutch relay from the
PDC and remove it.
INSTALLATION
(1) Install the compressor clutch relay by aligning
the relay terminals with the cavities in the PDC and
pushing the relay firmly into place.
(2) Install the PDC cover.
(3) Connect the battery negative cable.
(4) Test the relay operation.
A/C-HEATER CONTROL
DESCRIPTION
Both the heater-only and a/c heater systems use a
combination of electrical and vacuum controls. These
controls provide the vehicle operator with a number
of setting options to help control the climate and
comfort within the vehicle. Refer to the owner's man-
ual in the vehicle glove box for more information on
the features, use, and suggested operation of these
controls.
OPERATION
The heater-only or a/c heater control panel is
located to the right of the instrument cluster on the
instrument panel. The control panel contains a rota-
ry-type temperature control knob, a rotary-type mode
control switch knob, and a rotary-type blower motor
speed switch knob. On models with the optional
heated mirror system, a momentary push button
switch and indicator lamp are located near the bot-
tom of the a/c heater control panel. Refer to Heated
Mirrors for more information on this feature.
The heater-only or a/c heater control panel cannot
be repaired. If faulty or damaged, the entire unit
must be replaced. The control knobs and the illumi-
nation lamps are available for service replacement.
DIAGNOSIS AND TESTING - A/C HEATER
CONTROL
Satisfactory heater and air conditioner perfor-
mance depends upon proper operation and adjust-
ment of all operating controls and refrigeration
system components. For circuit descriptions and dia-
grams, (Refer to Appropriate Wiring Information).
These inspections, tests, and adjustments should be
used to locate the cause of a malfunction.
Operation must be tested as described in the fol-
lowing sequence:
(1) Inspect and adjust the serpentine drive bel-
t(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE
BELTS - DIAGNOSIS AND TESTING).
(2) Start the engine and hold the idle speed at
1,300 rpm.
Fig. 17 POWER DISTRIBUTION CENTER
1 - COVER
2 - POWER DISTRIBUTION CENTER
24 - 18 CONTROLSBR/BE
A/C COMPRESSOR CLUTCH RELAY (Continued)

(3) On vehicles with air conditioning, turn the
temperature control knob to the extreme counter
clockwise (Cool) position, and set the mode control
switch knob to the Bi-Level (A/C) position. The out-
side (recirculation) air door should be open to outside
air. If not OK, (Refer to 24 - HEATING & AIR CON-
DITIONING/CONTROLS - DIAGNOSIS AND TEST-
ING - VACUUM SYSTEM).
(4) Open the vehicle windows. Test the blower
motor operation in all speeds. If not OK, (Refer to 24
- HEATING & AIR CONDITIONING/DISTRIBU-
TION/BLOWER MOTOR - DIAGNOSIS AND TEST-
ING).
(5) On vehicles with air conditioning, the compres-
sor should be running and the air conditioning sys-
tem in operation unless the ambient air temperature
is below about -1É C (30É F). If not OK, (Refer to 24 -
HEATING & AIR CONDITIONING - DIAGNOSIS
AND TESTING - A/C PERFORMANCE).
(6) Check the mode control switch operation. The
heater and air conditioner systems should respond as
described in the owner's manual in the vehicle glove
box to each mode selected. Reduce the engine speed
to normal idle. The vacuum will be high at low idle
and the vacuum actuators should respond quickly. If
not OK, (Refer to 24 - HEATING & AIR CONDI-
TIONING/CONTROLS - DIAGNOSIS AND TEST-
ING - VACUUM SYSTEM).
(7) If the vacuum tests, and the electrical compo-
nent and circuit tests reveal no problems, disassem-
ble the HVAC housing to inspect for mechanical
misalignment or binding of the mode doors (Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION/HVAC HOUSING - DISASSEMBLY)
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Reach under the instrument panel near the
driver side of the floor panel transmission tunnel andunplug the a/c heater control to HVAC housing vac-
uum harness connector.
(3) While still reaching under the instrument
panel, disengage the retainer on the a/c heater con-
trol half of the vacuum harness from the hole in the
center distribution duct (Fig. 18).
(4) Remove the cluster bezel from the instrument
panel(Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - REMOVAL).
(5) Remove the four screws that secure the a/c
heater control to the instrument panel (Fig. 19).
(6) Pull the a/c heater control assembly away from
the instrument panel far enough to access the con-
nections on the back of the control.
(7) Unplug the wire harness connector from the
back of the a/c heater control.
(8) On vehicles with heated mirrors, unplug the
heated mirror wire harness connector from the back
of the a/c heater control.
(9) Remove the a/c heater control from the instru-
ment panel.
INSTALLATION
(1) Plug the wire harness connector(s) into the
receptacle(s) on the back of the a/c heater control.
(2) Route the HVAC vacuum harness through the
hole in the reinforcement below the a/c heater control
opening of the instrument panel.
(3) Position the a/c heater control in the instru-
ment panel and secure it with four screws. Tighten
the screws to 2.2 N´m (20 in. lbs.).
Fig. 18 A/C HEATER CONTROL VACUUM HARNESS
ROUTING
1 - A/C HEATER CONTROL VACUUM HARNESS
2 - REINFORCEMENT
3 - RETAINER
4 - CENTER DISTRIBUTION DUCT
BR/BECONTROLS 24 - 19
A/C-HEATER CONTROL (Continued)