2006 DODGE RAM SRT-10 Service Repair Manual

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Page 2193 of 5267

DODGE RAM SRT-10 2006 Service Repair Manual 8. Remove the air cleaner and support bracket (1 - if
required) (Refer to 9 - ENGINE/AIR INTAKE SYS-
TEM/AIR CLEANER ELEMENT - REMOVAL).
9. Remove the integrated power module (Refer to 8 -
ELECTRICAL/

Page 2194 of 5267

DODGE RAM SRT-10 2006 Service Repair Manual 11. Remove the upper radiator crossmember (4). (Refer to 23 - BODY/EXTERIOR/UPPER RADIATOR CROSS-
MEMBER - REMOVAL).
12. Remove the headlamp unit (5) (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR

Page 2195 of 5267

DODGE RAM SRT-10 2006 Service Repair Manual 13. Remove the front cab mount to the Front End Sheet Metal bracket (FESM) bolt (2).
14. Remove the bolts (5) attaching the lower radiator crossmember (6) to the hydroform fender rail (1).
CAUTION: Do

Page 2196 of 5267

DODGE RAM SRT-10 2006 Service Repair Manual 15. Using a reciprocating saw or equivalent, cut the fender rail and shotgun at a straight and square section of the
hydroform and remove.
16. Smooth and square the cut edges.
17. Using the damaged st

15. Using a reciprocating saw or equivalent, cut the fender rail and shotgun at a straight and square section of the
hydroform and remove.
16. Smooth and square the cut edges.
17. Using the damaged structure as a reference cut the service part at the same location as the first cut. Smooth
and square the cut edges.
NOTE: The repair structure should butt up to the remaining structure and provide the same overall vehicle
geometry.
18. Fabricate 51 mm (2.0 in.) long repair inserts using scrap from the old structure or the replacement part. It will
be necessary to split the inserts on each of their four sides to fit into the hydroform.
19. Remove any paint or e-coat from the inserts and also to the interior and exterior of the hydroforms.
20. Cut plug weld holes as described below.
On the upper rail, cut one 13 mm (0.5 in.) hole on each side of the rail, 25 mm (1.0 in.) from the butt joint of
the tubes.
On the lower rail, cut one 13 mm (0.5 in.) hole on the top and bottom sides of therail25mm(1.0in.)fromthe
butt joint of the tube.
On the lower rail, cut two 13 mm (0.5 in.) holes on the inner and outer sides oftherail25mm(1.0in.)from
the butt joint of the tube.
CAUTION: Shield the surrounding area and components from exposure to the welding spatter and heat.
21. Install the insert 1” into the replacement part and tack into place witha weld. (Refer to 13 - FRAME &
BUMPERS/FRAME - SPECIFICATIONS - WELDING)
22. Insert the service part into place and using the appropriate measuringequipment, verify the front end sheet
metal bracket’s location in all three (X,Y, and Z) planes of space.
23. Complete all 360° plug welds.
NOTE: Before the final welding, use three dimensional measuring equipment to ensure the part is in the
correct location. Verify that tap plate extrusion at the bottom of the vertical post lines up with the isolator
and hole in the frame perch mount. Also ensure the lower radiator closure tube is bolted into the forward
shotgun ends.
24. Complete welding by making a 360° butt weld around the fender rails.
25. Metal finish the exposed welds on the hydroforms.
26. Dress the welded area and apply corrosion resistant coatings inside and out.
a. Inside the rail, inject a creeping wax based rust inhibitor compound to the inside of the hydroforms ensuring
100% coverage including the mating face between the fender rail sections and insert such that corrosion
protection is restored in the internal cavity.
b. Apply a durable top coat to the outside of the repair area.

Page 2197 of 5267

DODGE RAM SRT-10 2006 Service Repair Manual 27. Install the front cab mount bolt (2) if previously removed and tighten to81Nꞏm(60ft.lbs.).
28. Install the lower radiator crossmember (6) bolts (5) and tighten to 28 Nꞏm ( 2 1 f t . l b s . )

Page 2198 of 5267

DODGE RAM SRT-10 2006 Service Repair Manual 30. Install the upper radiator crossmember (4) (Refer to 23 - BODY/EXTERIOR/UPPER RADIATOR CROSSMEM-
BER - INSTALLATION).
31. Install the wire harness and ground if previously removed and install the

Page 2199 of 5267

DODGE RAM SRT-10 2006 Service Repair Manual 33. Install the air cleaner bracket and air cleaner (1),
if previously removed (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER ELEMENT -
INSTALLATION).
34. Install the radiator assembly (4) (Refer

Page 2200 of 5267

DODGE RAM SRT-10 2006 Service Repair Manual 35. Install the A/C lines, if previously removed. Refer
to the Heating and Air Conditioning section of the
manual for the recommended procedures.
36. Install the A/C condenser, if previously removed
(

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