2003 DODGE RAM Service Repair Manual

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Page 2665 of 2895

DODGE RAM 2003 Service Repair Manual Fig. 7 WINDSHIELD FOAM SUPPORT SPACERS
1 - UPPER FOAM SPACERS (3)
2 - SPACER LOCATION 75 MM (2.95 IN)
3 - LOWER FOAM SPACERS (3)
4 - SIDE FOAM SPACERS (4)
Fig. 8 APPLICATOR TIP
1 - APPLICATOR TIP
Fig.

Page 2666 of 2895

DODGE RAM 2003 Service Repair Manual WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page page
A-PILLAR WEATHERSTRIP RETAINER
REMOVAL.............................91
INSTALLATION.........................91
DRIP RAIL WEATHERSTRIP
REMOVAL.............

WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page page
A-PILLAR WEATHERSTRIP RETAINER
REMOVAL.............................91
INSTALLATION.........................91
DRIP RAIL WEATHERSTRIP
REMOVAL.............................91
INSTALLATION.........................91
DOOR OPENING SEAL
REMOVAL.............................92
INSTALLATION.........................92
DRIP RAIL WEATHERSTRIP RETAINER
REMOVAL.............................92
INSTALLATION.........................92
FRONT DOOR GLASS RUN WEATHERSTRIP
REMOVAL.............................92
INSTALLATION.........................92FRONT DOOR OUTER BELT MOLDING
REMOVAL.............................93
INSTALLATION.........................93
FRONT DOOR INNER BELT MOLDING
REMOVAL.............................93
INSTALLATION.........................93
REAR DOOR GLASS RUN WEATHERSTRIP
REMOVAL.............................93
INSTALLATION.........................93
REAR DOOR OUTER BELT MOLDING
REMOVAL.............................94
INSTALLATION.........................94
REAR DOOR INNER BELT MOLDING
REMOVAL.............................94
INSTALLATION.........................94
A-PILLAR WEATHERSTRIP
RETAINER
REMOVAL
(1) Remove the drip rail weatherstrip retainer.
(Refer to 23 - BODY/WEATHERSTRIP/SEALS/DRIP
RAIL WEATHERSTRIP - REMOVAL)
(2) Remove the five screws and remove the weath-
erstip retainer. (Fig. 1)
INSTALLATION
(1) Install the weatherstip retainer and install the
screws.
(2) Install the drip rail weatherstrip retainer.
(Refer to 23 - BODY/WEATHERSTRIP/SEALS/DRIP
RAIL WEATHERSTRIP - INSTALLATION)
DRIP RAIL WEATHERSTRIP
REMOVAL
(1) Open the doors and separate the weatherstrip
from the drip rail and a-pillar retainers. (Fig. 1)
INSTALLATION
(1) Position the weatherstrip onto the drip rail and
a-pillar retainers and seat fully.
Fig. 1 DOOR OPENING WEATHERSTRIPS/SEALS
1 - DRIP RAIL WEATHERSTRIP RETAINER
2 - SCREWS (7)
3 - DRIP RAIL WEATHERSTRIP
4 - CAB
5 - REAR DOOR OPENING SEAL
6 - FRONT DOOR OPENING SEAL
7 - A-PILLAR WEATHERSTRIP RETAINER
8 - SCREWS (5)
9 - CORNER SEAL
DRWEATHERSTRIP/SEALS 23 - 91

Page 2667 of 2895

DODGE RAM 2003 Service Repair Manual DOOR OPENING SEAL
REMOVAL
FRONT DOOR SEAL
(1) Remove the cowl trim panel. (Refer to 23 -
BODY/INTERIOR/COWL TRIM - REMOVAL)
(2) Remove the lower b-pillar trim panel. (Refer to
23 - BODY/INTERIOR/B-PIL

DOOR OPENING SEAL
REMOVAL
FRONT DOOR SEAL
(1) Remove the cowl trim panel. (Refer to 23 -
BODY/INTERIOR/COWL TRIM - REMOVAL)
(2) Remove the lower b-pillar trim panel. (Refer to
23 - BODY/INTERIOR/B-PILLAR LOWER TRIM -
REMOVAL)
(3) Separate the door opening seal from the door
opening flange. (Fig. 1)
REAR DOOR SEAL
(1) Remove the lower b-pillar trim panel. (Refer to
23 - BODY/INTERIOR/B-PILLAR LOWER TRIM -
REMOVAL)
(2) Remove the lower c-pillar trim. (Refer to 23 -
BODY/INTERIOR/C-PILLAR TRIM - REMOVAL)
(3) Separate the door opening seal from the door
opening flange. (Fig. 1)
INSTALLATION
FRONT DOOR SEAL
(1) Position the seal to the bottom of the door
opening, with bulb facing outboard, starting the
installation at the center of the lower flange. Press
the seal onto the sill flange and work around the
perimeter of the door opening until fully seated.
Work in one direction, smoothing the seal to avoid
puckers or wrinkles.
(2) Install the lower b-pillar trim. (Refer to 23 -
BODY/INTERIOR/B-PILLAR LOWER TRIM -
INSTALLATION)
(3) Install the cowl trim panel. (Refer to 23 -
BODY/INTERIOR/COWL TRIM - INSTALLATION)
(4) When installing a new weatherstrip on the
front door opening, remove the tear strip starting at
the splice and moving around the front of the door to
the back of the opening.
REAR DOOR SEAL
(1) Position the seal to the bottom of the door
opening, with bulb facing outboard, starting the
installation at the center of the lower flange. Press
the seal onto the sill flange and work around the
perimeter of the door opening until fully seated.
Work in one direction, smoothing the seal to avoid
puckers or wrinkles.
(2) Install the lower c-pillar trim. (Refer to 23 -
BODY/INTERIOR/C-PILLAR TRIM - INSTALLA-
TION)(3) Install the lower b-pillar trim. (Refer to 23 -
BODY/INTERIOR/B-PILLAR LOWER TRIM -
INSTALLATION)
(4) When installing a new weatherstrip on the rear
door opening, remove the tear strip starting at the
splice and moving around the back of the door to the
front of the opening.
DRIP RAIL WEATHERSTRIP
RETAINER
REMOVAL
(1) Separate the drip rail weatherstrip from the
weatherstrip retainer. (Fig. 1)
(2) Remove the seven screws and remove the
retainer.
INSTALLATION
(1) Install the weatherstrip retainer and install
the seven screws.
(2) Position the weatherstrip over the retainer
flange and seat fully.
FRONT DOOR GLASS RUN
WEATHERSTRIP
REMOVAL
(1) Remove the door glass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - REMOVAL)
(2) Separate the weatherstrip out of the door
frame and remove through the window opening. (Fig.
2)
INSTALLATION
NOTE: A mixture of soap and water may be used to
aid installation of the weatherstrip into the corners.
(1) Position the glass run weatherstrip into the
door through the window opening.
(2) Position the weatherstrip into the upper cor-
ners and seat firmly.
(3) From back to front, seat the weatherstrip
between the corners and then down the sides firmly
(4) Install the door glass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - INSTALLATION)
23 - 92 WEATHERSTRIP/SEALSDR

Page 2668 of 2895

DODGE RAM 2003 Service Repair Manual FRONT DOOR OUTER BELT
MOLDING
REMOVAL
(1) Remove the screw and separate the belt mold-
ing from the door flange from the back to the front.
(Fig. 2)
INSTALLATION
(1) Position the belt molding onto the

Page 2669 of 2895

DODGE RAM 2003 Service Repair Manual REAR DOOR OUTER BELT
MOLDING
REMOVAL
(1) Remove the screw and separate the belt mold-
ing from the door flange from the back to the front.
(Fig. 4)
INSTALLATION
(1) Position the belt molding onto the

Page 2670 of 2895

DODGE RAM 2003 Service Repair Manual BODY STRUCTURE
TABLE OF CONTENTS
page page
GAP AND FLUSH
SPECIFICATIONS.......................95
OPENING DIMENSIONS
SPECIFICATIONS - BODY OPENING
DIMENSIONS.........................99
SEALER LOCATIONS

Page 2671 of 2895

DODGE RAM 2003 Service Repair Manual NOTE:
All measurements are in mm. O/F = Over Flush
U/F = Under Flush
DIMENSION DESCRIPTION GAP FLUSH
*
1Bumper to grille 19.0 3.0 Ð
*
2Hood to grille 1.5 1.0
Parallel within 2.0U/F 0.75 1.75

Page 2672 of 2895

DODGE RAM 2003 Service Repair Manual NOTE:
All measurements are in mm.
O/F = Over Flush
U/F = Under Flush
DIMENSION DESCRIPTION GAP FLUSH
1 Roof to rear door Ð U/F 6.0 1.5
Parallel within 1.5
2 Quarter to rear door 5.0 1.5
Paralle

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