2002 DODGE RAM lock

SEATS
TABLE OF CONTENTS
page page
SEATS
DESCRIPTION........................131
OPERATION..........................131
CENTER CONSOLE LID
REMOVAL............................131
INSTALLATION........................132
CENTER SEAT ARMREST/CONSOLE
REMOVAL............................132
INSTALLATION........................132
CENTER SEAT ARMREST/LATCH COVER
REMOVAL............................132
INSTALLATION........................132
LUMBAR SUPPORT
REMOVAL............................132
INSTALLATION........................133
SEAT - BENCH SEAT
REMOVAL............................133
INSTALLATION........................133
SEAT - SPLIT BENCH
REMOVAL............................133
INSTALLATION........................134
SEAT BACK - BENCH SEAT
REMOVAL............................135
INSTALLATION........................135
SEAT BACK - SPLIT BENCH
REMOVAL............................135
INSTALLATION........................136
SEAT BACK COVER
REMOVAL............................137
INSTALLATION........................137
SEAT BACK COVER - SPLIT BENCH
REMOVAL............................137
INSTALLATION........................137SEAT BACK RECLINER
REMOVAL............................138
INSTALLATION........................138
SEAT CUSHION
REMOVAL............................138
INSTALLATION........................138
SEAT CUSHION COVER
REMOVAL............................139
INSTALLATION........................139
SEAT CUSHION COVER - SPLIT BENCH
REMOVAL............................139
INSTALLATION........................140
SEAT RISER
REMOVAL............................141
INSTALLATION........................141
SEAT TRACK
REMOVAL............................141
INSTALLATION........................141
SEAT TRACK - SPLIT BENCH
REMOVAL............................142
INSTALLATION........................142
EASY ENTRY SEAT TRACK
REMOVAL............................143
INSTALLATION........................143
SEAT TRACK ADJUSTER
REMOVAL............................143
INSTALLATION........................143
STANCHION COVER
REMOVAL............................143
INSTALLATION........................143
REAR SEAT
REMOVAL............................144
INSTALLATION........................144
SEATS
DESCRIPTION
Seat modules are made up of a seat frame, seat
cushion, seat back cushion, a covering material, and
the electrical components used for power operation, if
equipped. Some seat systems also contain seat belt
components and supplemental restraint systems.
OPERATION
Seat assemblies transport the occupants in comfort
and safety. Seat assemblies also help position occupants
correctly in the event of airbag deployment. Seat cush-
ions, coverings, and electrical components are service-
able. Refer to the appropriate group in this manual.
CENTER CONSOLE LID
REMOVAL
(1) Open console lid.
(2) Using a small flat blade screwdriver, disengage
locking tabs located under the console lid trim bezel.
(3) Separate bezel from lid.
(4) Move driver and passenger seat to full forward
position.
(5) Using a small drift and hammer, tap out con-
sole lid hinge pin.
(6) Separate lid from console.
BR/BESEATS 23 - 131

REAR SEAT
REMOVAL
(1) Move front seat track to full forward position.
(2) Turn release handle on underside of rear seat
(Fig. 29) to disengage seat cushion and move seat to
the stowed position.
(3) Remove side support bracket screws and lift
seat to disengage from cab (Fig. 30) .
INSTALLATION
(1) Position seat in vehicle.
(2) Align seatback hooks with loops on cab rear
panel (Fig. 31).
(3) Align side support alignment tabs, and lower
seat into place.
(4) Install side support bracket screws. Tighten the
screws to 28 N´m (21 ft. lbs.) torque.
(5) Turn release handle to disengage seat from
stowed position and push seat cushion downward to
lock into place.
Fig. 29 Rear Seat Release Handle
1 - SEAT CUSHION
2 - RELEASE HANDLE
3 - ALIGNMENT TAB
Fig. 30 Rear Seat Removal/Installation
1 - REAR SEAT
2 - BUMPER
3-TAB
Fig. 31 Rear Seat Removal/Installation
1 - REAR SEAT
2 - BUMPER
3-TAB
23 - 144 SEATSBR/BE

(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)

INSTALLATION
WARNING: Allow the urethane at least 24 hours to
cure before returning the vehicle to use.
CAUTION: Roll down the left and right front door
glass and open the rear glass slider (if available)
before installing windshield to avoid pressurizing
the passenger compartment if a door is slammed
before urethane is cured. Water leaks can result.
The windshield fence should be cleaned of most of its
old urethane bonding material. A small amount of old
urethane, approximately 1-2 mm in height, shouldremain on the fence. Do not grind off or completely
remove all old urethane from the fence, the paint finish
and bonding strength will be adversely affected.
(1) Place replacement windshield into windshield
opening and position glass in the center of the open-
ing against the support spacers. Mark the outside
surface of the glass at the support spacers with a
grease pencil or pieces of masking tape and ink pen
to use as a reference for installation. Remove replace-
ment windshield from windshield opening (Fig. 9).
(2) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart (Fig. 10).
(3) Clean inside of windshield with MOPAR Glass
Cleaner and lint-free cloth.
(4) Apply clear glass primer 25 mm (1 in.) wide
around perimeter of windshield and wipe with a new
clean and dry lint- free cloth.
(5) Apply the molding to the windshield:
(a) Press the upper corners of the molding onto
the windshield.
(b) Press the header section onto the windshield.
(c)
Press the A-Pillar sections onto the windshield.
(6) Apply black-out primer onto the glass using the
windshield molding as a guide. The primer should be
15 mm (5/8 in.) wide on the top and sides of the glass
and 25 mm (1 in.) on the bottom of windshield. Allow
at least three minutes drying time.
(7) Locatenewsupport spacers on support brack-
ets and adjust to lowest height.
(8)
Position one 5 mm (3/16 in.) soft spacer (p/n
55028214) at the bottom of the windshield fence (Fig. 11).
(9) Apply a 13mm (1/2 in.) high and 10mm (3/8 in.)
wide bead of urethane around the perimeter of wind-
shield. At the bottom, apply the bead 7 mm (1/4 in.)
inboard from the glass edge. On the three sides
where the molding is on the glass, follow the edge of
molding. The urethane bead should be shaped in a
triangular cross-section, this can be achieved by
notching the tip of the applicator (Fig. 12).
(10) With the aid of a helper, position the wind-
shield over the windshield opening. Align the refer-
ence marks at the bottom of the windshield to the
support spacers.
(11)
Slowly lower windshield glass to the fence open-
ing guiding the lower corners into proper position.
Beginning at the bottom and continuing to the top, push
glass onto fence along the A-Pillars. Push windshield
inward to the fence at the bottom corners (Fig. 13).
(12) Push windshield upward, snug with roof and
ratchet up the adjustable support brackets. Discard
tab from support spacer.
(13) Using clean water, lightly mist the support
spacers.
Fig. 7 Windshield Moldings
1 - WINDSHIELD
2 - WINDSHIELD MOLDING
Fig. 8 Cut Urethane Around Windshield
1 - WINDSHIELD
2 - COLD KNIFE
23 - 148 STATIONARY GLASSBR/BE
WINDSHIELD (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)

QUARTER WINDOW
REMOVAL
(1) Remove quarter trim panel.
(2) Remove the latch retaining screws from the cab
rear side panel (Fig. 14) .
(3) Remove the frame/hinge retaining nuts from
the B-pillar.
(4) Remove the window glass from the cab.
(5) If necessary, remove the latch from the glass.
INSTALLATION
(1) If removed, install the latch to the glass.
Tighten the screw to 6 N´m (60 in. lbs.) torque.
(2) Center the window glass at the opening, insert
the hinge studs in the B-pillar holes, and install the
retaining nuts. Tighten the nuts to 8 N´m (70 in. lbs.)
torque.
(3) Attach the latch to the rear side panel with the
screws. Tighten the screws with the latch in the lock
position and pushing rearward on the latch. Tighten
the screws to 8 N´m (70 in. lbs.) torque.(4) Test the vent window for water leaks.
(5) Install quarter trim panel.
Fig. 14 Vent WindowÐClub Cab
1 - QUARTER GLASS
2-LATCH
23 - 150 STATIONARY GLASSBR/BE

A/C Diagnosis
Condition Possible Causes Correction
2. Faulty a/c low
pressure switch.2. (Refer to Controls/A/C Low Pressure Switch/Diagnosis
and Testing) in this group. Test the a/c low pressure
switch and replace, if required.
3. Faulty Powertrain
Control Module (PCM).3. (Refer to Appropriate Diagnostic Information) for testing
the PCM. Test the PCM and replace, if required.
EQUAL PRESSURES,
BUT THE
COMPRESSOR CLUTCH
DOES NOT ENGAGE.1. No refrigerant in the
refrigerant system.1. (Refer to Plumbing/Diagnosis and Testing - Refrigerant
System Leaks) in this group. Test the refrigerant system
for leaks. Repair, evacuate and charge the refrigerant
system, if required.
2. Faulty fuse. 2. Check the fuses in the Power Distribution Center and
the junction block. Repair the shorted circuit or
component and replace the fuses, if required.
3. Faulty a/c compressor
clutch coil.3. (Refer to Controls/A/C Compressor Clutch Coil/
Diagnosis and Testing) in this group. Test the compressor
clutch coil and replace, if required.
4. Faulty a/c compressor
clutch relay.4. (Refer to Controls/A/C Compressor Clutch Relay/
Diagnosis and Testing) in this group. Test the compressor
clutch relay and relay circuits. Repair the circuits or
replace the relay, if required.
5. Improperly installed or
faulty a/c low pressure
switch.5. (Refer to Controls/A/C Low Pressure Switch/Diagnosis
and Testing) in this group. Test the a/c low pressure
switch and tighten or replace, if required.
6. Faulty a/c high
pressure switch.6. (Refer to Controls/A/C High Pressure Switch/Diagnosis
and Testing) in this group. Test the a/c high pressure
switch and replace, if required.
7. Faulty Powertrain
Control Module (PCM).7. (Refer to Appropriate Diagnostic Information) for testing
the PCM. Test the PCM and replace, if required.
8. Faulty a/c heater
control.8. (Refer to Controls/A/C Heater Control/Diagnosis and
Testing) in this group. Test the a/c heater control and
replace, if required.
NORMAL PRESSURES,
BUT A/C
PERFORMANCE TEST
AIR TEMPERATURES AT
CENTER PANEL
OUTLET ARE TOO
HIGH.1. Excessive refrigerant
oil in system.1. (Refer to Plumbing/Refrigerant Oil/Standard Procedure
- Refrigerant Oil Level) in this group. Recover the
refrigerant from the refrigerant system and inspect the
refrigerant oil content. Restore the refrigerant oil to the
proper level, if required.
2. Blend door actuator
inoperative or faulty.2. Check the Blend Door Actuator operation. Replace as
required.
3. Blend door
inoperative, obstructed or
sealing improperly.3. (Refer to Distribution/Blend Door/Removal/Installation)
in this group. Inspect the blend door for proper operation
and sealing and correct, if required.
LOW SIDE PRESSURE
IS NORMAL OR
SLIGHTLY LOW, AND
HIGH SIDE PRESSURE
IS TOO LOW.1. Low refrigerant system
charge.1. (Refer to Plumbing/Diagnosis and Testing - Refrigerant
System Leaks) in this group. Test the refrigerant system
for leaks. Repair, evacuate and charge the refrigerant
system, if required.
24 - 4 HEATING & AIR CONDITIONINGBR/BE
HEATING & AIR CONDITIONING (Continued)

Item Description Notes
Blower Motor hardwired to
control headresistor block
Cooling Fan viscous fan
Clutch
Control relay PCM
Draw 2 - 3.9 amps @
12V  0.5V @ 70É
FItem Description Notes
Gap 0.0169- 0.0319
DRB IIIT
Reads TPS, RPM, A/C
switch test
Actuators clutch relay
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
A/C COMPRESSOR
CLUTCH PLATE NUT14.4 10.5 12.7
A/C COMPRESOR LINE
MANIFOLD FASTENER22 16 195
A/C COMPRESSOR TO
MOUNTING BRACKET
BOLTS24 17.7 212
ACCUMULATOR
RETAINING BAND4.5 3.3 40
BLOWER MOTOR
SCREWS2.2 1.6 20
CHECK VALVE AND
NIPPLE UNIT (DIESEL)24 18 212
CONDENSER MOUNTING
SCREWS/NUTS10.5 7.7 93
DISCHARGE LINE TO
CONDENSER FASTENER20 14.8 177
DOOR ACTUATOR
SCREWS2.2 1.6 19.5
HVAC HOUSING SCREWS 2.2 1.6 19.5
HVAC HOUSING TO DASH
PANEL NUTS (ENGINE
SIDE)7 5.2 62
HVAC HOUSING TO DASH
PANEL NUTS
(PASSENGER
COMPARTMENT SIDE)4.5 3.3 40
24 - 8 HEATING & AIR CONDITIONINGBR/BE
HEATING & AIR CONDITIONING (Continued)