INSTRUMENT PANEL LOWER SURROUND
REMOVAL
WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering
wheel, steering column, seat belt tensioner, or instrument panel component diagnosis or service. Discon-
nect 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 accidentalairbag deployment and possible
personal injury or death.
1. Disconnect and isolate the negative battery cable.
2. Using a trim stick C-4755 or equivalent, from the
notch on the bottom, remove the right instrument
panel side cover.
3. Remove the right side cowl trim panel (Refer to 23
- BODY/INTERIOR/COWL TRIM - REMOVAL).
4. Remove the glove box (Refer to 23 - BODY/IN-
STRUMENT PANEL/GLOVE BOX - REMOVAL).
5. Remove the cup holder or storage bin (depending
on application) (Refer to 23 - BODY/INSTRUMENT
PANEL/CUPHOLDER-REMOVAL)or(Referto23
- BODY/INSTRUMENT PANEL/STORAGE BIN -
REMOVAL).
6. Remove the ash receiver (Refer to 23 - BODY/IN-
STRUMENT PANEL/ASH RECEIVER -
REMOVAL).
7. Remove the steering column opening cover (Refer
to 23 - BODY/INSTRUMENT PANEL/STEERING
COLUMN OPENING COVER - REMOVAL).
8. Remove the twenty one screws (1) that secure the instrument panel lower surround (2) to the instrument panel
and support.
9. Disconnect the wire harness connector for the 12V power outlet (3) and remove the instrument panel lower sur-
round.
INSTALLATION
1. Position the instrument panel lower surround (2) to
the instrument panel and connect the wire harness
connector for the 12V power outlet (3).
2. Install the instrument panel lower surround onto the
instrument panel and install the twenty one screws
(1). Tighten the screws to 2.2 Nꞏm (20 in. lbs.).
3. Install the steering column opening cover (Refer to
23 - BODY/INSTRUMENT PANEL/STEERING
COLUMN OPENING COVER - INSTALLATION).
4. Install the ash receiver (Refer to 23 - BODY/IN-
STRUMENT PANEL/ASH RECEIVER - INSTALLA-
TION).
5. Install the cup holder or storage bin (depending on
application) (Refer to 23 - BODY/INSTRUMENT
PANEL/CUP HOLDER - INSTALLATION) or (Refer
to 23 - BODY/INSTRUMENT PANEL/STORAGE
BIN - INSTALLATION).
6. Install the glove box (Refer to 23 - BODY/INSTRU-
MENT PANEL/GLOVE BOX - INSTALLATION).
STORAGE BIN
REMOVAL
WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering
wheel, steering column, seat belt tensioner, or instrument panel component diagnosis or service. Discon-
nect 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 accidentalairbag deployment and possible
personal injury or death.
NOTE: A storage bin replaces the cup holder in
the instrument panel when the vehicle is equipped
with a floor console.
1. Remove the instrument panel center bezel (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRU-
MENT PANEL CENTER BEZEL - REMOVAL).
2. Removethefloorconsole(Referto23-BODY/IN-
TERIOR/FLOOR CONSOLE - REMOVAL).
3. Remove the four screws (1) that secure the stor-
age bin (2) to the instrument panel and remove the
bin.
INSTALLATION
NOTE: A storage bin replaces the cup holder in
the instrument panel when the vehicle is equipped
with a floor console.
1. Position the storage bin (2) into the instrument
panel.
2. Install the four screws (1) that secure the storage
bin to the instrument panel. Tighten the screws to
2.2 Nꞏm (20 in. lbs.).
3. Install the floor console (Refer to 23 - BODY/INTE-
RIOR/FLOOR CONSOLE - INSTALLATION).
4. Install the instrument panel center bezel (Refer to
23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL CENTER BEZEL - INSTALLATION).
SEATS
WARNING
WARNINGS - RESTRAINT SYSTEM
WARNING: To avoid personal injury or death, during and following any seat beltorchildrestraintanchor
service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors
for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any
belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle
or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child
restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to
repair a seat belt or child restraint component. Always replace damaged orineffective seat belt and child
restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler
Mopar
Parts Catalog.
WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental
restraint system before attempting any steering wheel, steering column,airbag, seat belt tensioner, impact
sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative
(ground) cable, then wait two minutes for the system capacitor to discharge before performing further diag-
nosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the
proper precautions could result in accidental airbag deployment.
WARNING: To avoid personal injury or death on vehicles equipped with airbags, before performing any
welding operations disconnect and isolate the battery negative (ground)cable and disconnect all wire har-
ness connectors from the Occupant Restraint Controller (ORC). Failure totake the proper precautions could
result in accidental airbag deployment and other possible damage to the supplemental restraint system cir-
cuits and components.
WARNING: To avoid personal injury or death, do not attempt to dismantle an airbag unit or tamper with its
inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures
exceeding 93° C (200° F). An airbag inflator unit may contain sodium azide and potassium nitrate. These
materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce
harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible com-
pounds. An airbag inflator unit may also contain a gas canister pressurizedtoover2500psi.
WARNING: To avoid personal injury or death, when handling a seat belt tensioner retractor, proper care
should be exercised to keep fingers out from under the retractor cover and away from the seat belt webbing
where it exits from the retractor cover.
WARNING: To avoid personal injury or death, replace all restraint system components only with parts spec-
ified in the DaimlerChrysler Mopar
Parts Catalog. Substitute parts may appear interchangeable, but internal
differences may result in inferior occupant protection.
WARNING: To avoid personal injury or death, the fasteners, screws, and bolts originally used for the
restraint system components must never be replaced with any substitutes.These fasteners have special
coatings and are specifically designed for the restraint system. Any timea new fastener is needed, replace
it with the correct fasteners provided in the service package or specifiedin the DaimlerChrysler Mopar
Parts Catalog.
WARNING: To avoid personal injury or death, when a steering column has an airbag unit attached, never
place the column on the floor or any other surface with the steering wheel orairbag unit face down.
STRUCTURAL ADHESIVE LOCATIONS
SPECIFICATIONS
INDEX
DESCRIPTION FIGURE
FLOOR PAN AND SEAT MOUNTING FRONT CROSSMEMBER 34
FRONT FENDER 35
FLOOR PAN 36
INNER WHEELHOUSE TO INNER BOX SIDE PANEL 37
INNER BOX SIDE PANEL TO OUTER BOX SIDE PANEL 38
INNER WHEELHOUSE, CROSSMEMBERS AND CROSSMEMBER END SUPPORT
BRACKET TO INNER BOX SIDE PANEL39
INNER BOX SIDE PANEL TO OUTER BOX SIDE PANEL 40
INNER DOOR PANEL TO OUTER DOOR PANEL - FRONT DOOR (QUAD CAB) 41
INNER DOOR PANEL TO OUTER DOOR PANEL - FRONT DOOR (STANDARD CAB) 42
INNER DOOR PANEL TO OUTER DOOR PANEL - REAR DOOR (QUAD CAB) 43
SILL RAIL - STD CAB 44
SILL RAIL - QUAD CAB 45
Fig. 33 C-PILLAR/ROOF MEGA CAB
Fig. 36 FLOOR PAN
Fig. 37 INNER WHEELHOUSE
Fig. 38 INNER BOX SIDE PANEL
Fig. 39 INNER WHEELHOUSE
DESCRIPTION FIGURE
OUTER BODY SIDE APERTURE TO INNER BODY SIDE APERTURE TO FLOOR SILL 98
REAR FLOOR CROSSMEMBER AND CAB BACK REINFORCEMENT TO CAB BACK
PANEL TO INNER BODY SIDE APERTURE99
CAB BACK REINFORCEMENT TO CAB BACK PANEL 100
CENTER SHOULDER BELT REINFORCEMENT AND TAPPING PLATES TO CAB BACK
REINFORCEMENT101
A-PILLAR REINFORCEMENT TO COWL SIDE PANEL TO OUTER BODY SIDE
APERTURE/APERTURE EXTENSION TO COWL SIDE PANEL102
B-PILLAR REINFORCEMENT TO OUTER ROOF PANEL TO OUTER BODY SIDE
APERTURE103
FRONT ROOF HEADER TO OUTER ROOF PANEL/ROOF BOW TO INNER BODY SIDE
APERTURE/FRONT ROOF HEADER TO A-PILLAR REINFORCEMENT104
INNER BODY SIDE APERTURE TO REAR ROOF HEADER AND OUTER BODY SIDE
APERTURE TO OUTER ROOF PANEL105
FRONT CROSSMEMBER, WHEELHOUSE CROSSMEMBER AND BRACKET SUPPORT
CROSSMEMBER TO BOX FLOOR PAN106
LONG CROSSMEMBER AND FLOOR BOX CROSS SILL TO BOX FLOOR PAN 107
TAPPING PLATES AND SUPPORT BRACKETS TO REAR CROSS BOX SILL, FRONT
WHEELHOUSE, LONG AND BRACKET SUPPORT CROSSMEMBERS108
STAKE POCKET REINFORCEMENTS AND TIE DOWN REINFORCEMENTS TO INNER
BOX SIDE PANEL109
OUTER BOX SIDE REINFORCEMENT BRACES NUT PLATES TO OUTER BOX SIDE
PANEL MOUNTING11 0
OUTER WHEELHOUSE TO OUTER BOX SIDE PANEL 111
WELD NUT STRIKER CAGE NUT, OUTER BOX SIDE PANEL AND NUT PLATE TO BOX
SIDE TAILGATE REINFORCEMENT11 2
FRONT BOX PANEL TO FRONT INNER STAKE POCKET REINFORCEMENT TO FRONT
BOX SIDE PANEL11 3
FRONT CROSSMEMBER TO FRONT BOX SIDE PANEL AND BOX FLOOR PANEL TO
BOX FRONT PANEL11 4
BOX FLOOR PANEL AND INNER WHEELHOUSE PANEL TO INNER BOX SIDE PANEL 115
FRONT CROSSMEMBER AND END SUPPORT BRACKET TO LONG CROSSMEMBER
TO INNER BOX SIDE PANEL/STAKE POCKET REINFORCEMENT AND BOX FLOOR
SILL TO OUTER TAILGATE PILLAR TO INNER TAILGATE PILLAR11 6
STAKE POCKET REINFORCEMENT AND BOX FLOOR SILL CROSSMEMBER TO
INNER TAILGATE PILLAR11 7
INNER TAILGATE PILLAR PANEL TO INNER BOX SIDE PANEL TO TIE DOWN
MOUNTING REINFORCEMENT11 8
BOX FLOOR SILL CROSSMEMBER TO INNER BOX SIDE PANEL 119
INNER TAILGATE PILLAR TO TAILGATE BOX SIDE REINFORCEMENT TO OUTER
TAILGATE PILLAR120
BOX SIDE PANEL AND OUTER TAILGATE PILLAR TO OUTER BOX SIDE PANEL 121
FRONT BOX PANEL TO OUTER BOX SIDE PANEL 122
INNER BOX SIDE PANEL AND INNER TAILGATE PILLAR TO OUTER BOX SIDE PANEL 123
OUTER WHEELHOUSE PANEL TO INNER WHEELHOUSE PANEL 124
FRONT CROSSMEMBER, LONG CROSSMEMBER, AND WHEELHOUSE
CROSSMEMBER TO FLOOR PAN125
WHEELHOUSE CROSSMEMBER, LONG CROSSMEMBER AND REAR CROSS BOX
SILL TO BOX FLOOR PAN126
DESCRIPTION FIGURE
FRONT AND CENTER STAKE POCKET REINFORCEMENTS AND TIE DOWN
MOUNTING REINFORCEMENT TO INNER BOX SIDE PANEL127
OUTER FRONT AND CENTER STAKE POCKET REINFORCEMENT AND OUTER TIE
DOWN MOUNTING REINFORCEMENT TO INNER BOX SIDE PANEL128
OUTER WHEELHOUSE AND OUTER BRACE MOUNTING REINFORCEMENT TO
OUTER BOX SIDE PANEL129
TAILGATE BOX SIDE PIVOT REINFORCEMENT TO OUTER BOX SIDE PANEL 130
FRONT BOX SIDE PANEL TO FRONT CROSSMEMBER TO INNER BOX SIDE PANEL 131
FRONT BOX SIDE PANEL TO BOX FRONT PANEL TO INNER BOX SIDE PANEL/
FRONT STAKE POCKET REINFORCEMENT TO FRONT BOX SIDE PANEL TO BOX
FRONT PANEL132
BOX FRONT PANEL TO BOX FLOOR PANEL 133
BOX FLOOR PANEL TO INNER BOX SIDE PANEL 134
LONG CROSSMEMBERS TO CROSSMEMBER END SUPPORT BRACKETS TO INNER
BOX SIDE PANEL135
INNER WHEELHOUSE PANEL TO INNER BOX SIDE PANEL 136
TAILGATE PILLAR OUTER PANEL TO TAILGATE PILLAR INNER PANEL TO INNER BOX
SIDE PANEL137
REAR SILL CROSS BOX TO TAILGATE PILLAR OUTER PANEL AND INNER BOX SIDE
PA N E L138
OUTER BOX SIDE PANEL TO BOX FRONT PANEL AND BOX FRONT SIDE PANEL 139
STAKE POCKET REINFORCEMENTS TO INNER BOX SIDE PANEL TO OUTER BOX
SIDE PANEL140
TAILGATE PIVOT REINFORCEMENT AND INNER TAILGATE PILLAR TO INNER BOX
SIDE PANEL TO OUTER BOX SIDE PANEL141
INNER WHEELHOUSE TO OUTER WHEELHOUSE/TAILGATE PIVOT
REINFORCEMENT TO OUTER TAILGATEPILLAR TO INNER TAILGATE PILLAR142
OUTER TAILGATE PILLAR TO OUTER BOX SIDE PANEL 143
INNER DOOR PANEL TO OUTER DOOR PANEL - FRONT DOOR (QUAD CAB) 144
INNER DOOR PANEL TO OUTER DOOR PANEL - FRONT DOOR (STANDARD CAB) 145
INNER DOOR PANEL TO OUTER DOOR PANEL - REAR DOOR (QUAD CAB) 146
MEGA CAB
FRONT FLOOR PAN (1 OF 3) - MEGA CAB 147
FRONT FLOOR PAN (2 OF 3) - MEGA CAB 148
FRONT FLOOR PAN (3 OF 3) - MEGA CAB 149
FLOOR PAN ASSEMBLY - COMPLETE - MEGA CAB 150
SILL ASSEMBLY (1 OF 3) - MEGA CAB 151
SILL ASSEMBLY (2 OF 3) - MEGA CAB 152
SILL ASSEMBLY (3 OF 3) - MEGA CAB 153
LADDER (1 OF 2) - MEGA CAB 154
LADDER (2 OF 2) - MEGA CAB 155
MISCELLANEOUS UNDERBODY (1 OF 8) - MEGA CAB 156
MISCELLANEOUS UNDERBODY (2 OF 8) - MEGA CAB 157
MISCELLANEOUS UNDERBODY (3 OF 8) - MEGA CAB 158
MISCELLANEOUS UNDERBODY (4 OF 8) - MEGA CAB 159
MISCELLANEOUS UNDERBODY (5 OF 8) - MEGA CAB 160
MISCELLANEOUS UNDERBODY (6 OF 8) - MEGA CAB 161